www.packagingdigest.com GRAIN OF SALT: Sealing defeats issue of packaging spices. 50 Perfect order Coding provides trail across supply chain 26 New levels in vial filling 30 SEEDING SALES: Outdoor display pushes packets into view. 44 April 2012 REALITY CHECK: Mobile test can ensure drug authenticity. 36
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www.packagingdigest.com
GRAIN OF SALT: Sealing defeats issue of packaging spices. 50
Perfect orderCoding provides trail across supply chain 26
New levels in vial filling 30
SEEDING SALES: Outdoor display pushes packets into view. 44
April 2
012
REALITY CHECK: Mobile test can ensure drug authenticity. 36
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contents
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features
new technology
26
48
30
50
40 OUTSIDE THE BOX New system lets shipper eliminate obsolescence and waste by producing right-sized cases only when they’re needed.
44 PUSHOVER A weatherproof retail display springs to the aid of Burpee so its seed packets can be sold in outdoor garden centers.
48 BREAKING THE MOLD Dividing PET bottle manufacturing into two steps can reap signifi cant savings in shipping and inventory costs.
50 TOP SHELF Specialty-salt purveyor’s new packaging line and induction sealing helps project a high level of quality and freshness.
54 SOFT LANDING Housewares shipper TAG switches to air-pillow cushioning to reduce damage, eliminate mess and improve its environmental profi le.
APRIL 2012 volume 49 no. 4
26 COVER STORY Becton, Dickinson and Co. introduces an end-to-end supply chain bar code system on all levels of medical packaging—primary, secondary and tertiary.
30 CLEAN SWEEP New aseptic pharmaceutical fi lling operation utilizes disposable product-contact parts and a Restricted Access Barrier System (RABS).
34 STEP CHANGE Filling machine manufacturers respond to the need for quick changeovers and fl exibility in pharmaceutical operations.
36 CODE RED Mobile technology from Sproxil allows African consumers armed with smartphones to authenticate the source of their medicines.
Produced and packaged as promised. Bosch.
Production and packaging lines from Bosch achieve the agreed performance. Day after day. Year after year. High speed and low material use reduce your costs per piece and improve your equipment effi ciency. Experienced employees with extensive know-how guarantee professional service worldwide. Learn more at www.boschpackaging.com
schw
arzs
pri
nger
staffdepartments
Brand Director-Packaging
Steve Everly [email protected]
Executive OfficersChief Executive Officer Paul Miller Chief Financial Officer Fred GysiVice-President/Executive Director Stephen CorrickSr. Vice President, Events Division Mark Snell Vice President, Operations Roger Burg
Art/ProductionLead Art Director Marco AguileraAssociate Art Directors Tim Burns, Laura PappadaProduction Director Jeff TadeProduction Manager Martin Schneggenburger Senior Production Artists Jeff Polman, Derric TreeceProduction Artist William BaughmanProduction Coordinator Adrienne Davis
MarketingMarketing Manager Mary WilliamsDirector of Circulation Sandra Martin Circulation Manager Xavier Contaoi
EditorialEditorial Director John Kalkowski630-990-2364 [email protected]
Editor Lisa McTigue Pierce 630-990-7384 [email protected]
Senior Editor Jenni Spinner 630-990-7385 [email protected]
Plant Operations Editor Jack Mans630-990-4208 [email protected]
Associate Art Director Jennifer Field
Corporate Headquarters 11444 W. Olympic Blvd, Los Angeles, CA 90064310-445-4200 Fax 310-445-4299 www.ubmcanon.com
Editorial: 1200 Jorie Blvd., Suite 230, Oak Brook, IL 60523 630-990-2364 Fax 630-990-8894 e-mail: [email protected]
8 PACKAGING CONCEPTS
13 COMMENT At your service
14 NEW EQUIPMENT
20 NEW MATERIALS
24 GO GREEN Triple bottom line?
25 SPC SUSTAINABILITY Material value
57 INDUSTRY INSIGHTS
59 ON PACKAGINGDIGEST.COM
61 INFO SHOWCASE
61 MARKETPLACE
62 NEWSMAKERS
62 AD INDEX
Cover: BD Vacutainer blood collection tubes courtesy Becton, Dickinson and Co. Photo by Jennifer Field.
Vacuum Pumps and Systems
Global Distributor Network
For local distributor contact:
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APRIL 2012 PACKAGING DIGEST www.packagingdigest.com8
packagingconcepts
www.mintel.com/gnpd
New Product of the Month Launch pad
With concerns growing about potential side effects from fl uoride, researchers have been exploring alternatives. The founders
of Theodent discovered Rennou, a fl uoride alternative that blends cocoa bean extract with other minerals, and formulated a
toothpaste purported to deliver the protective qualities of fl uoride without the associated risks.
When it came time to launch the product after years of research and testing, the team decided the distinctive toothpaste,
called for special packaging. They turned to World Wide Packaging LLC (www.wwpinc.com), a fi rm that produces tubes and
other packaging for cosmetic clients. The sophisticated HDPE tube—in a rich chocolate-brown tone that evokes the toothpaste’s
signature ingredient—matches the singularity of the product formulation with a sophisticated, angular shape that’s sleek, rather
than round. The head of the one-piece tube is triangular, with dramatic hard edges; the complex cap includes a fl exible plug that,
when closed, squeezes into the tube’s orifi ce, and its pintle expands for a tight seal.
The tube is decorated with metallic screened logo and text to further underscore its premium appeal. The product—available
at Whole Foods nationwide and on the company’s website (www.theodent.com)—retails for approximately $10.
Toothpaste’s packaging reflects key ingredient in its formulation
In the U.S., The Johnson Distilling Co. has
launched the Shine On Georgia Moon brand,
an 80-proof corn whiskey with an especially rustic,
unpretentious and straightforward feel. The brand has a creative
package design that helps tie in with the product’s “moonshine-
style” positioning.
The package
consists of 750ml of the
whiskey poured into a
plain blown glass jar
with a screw-on tin-
plate cap, which has
an inner EPE wad
and is sealed with an
outer shrink sleeve.
Product information
is supplied on
two self-adhesive
paper labels,
which are printed
lithographically.
While the
packaging may
look rustic and
old fashioned, the
on-pack claim that
it is “less than 30
days old” embodies
a modern and topical
trend since it taps into
the consumer demand
for freshness.
Packaging design gives whiskey a down-home feel
14,000
12,000
10,000
8,000
6,000
4,000
2,000
0
New Products Launched Globally
Source: Mintel Global New Products Database (GNPD) 11Jun
11May
11Jul
11Aug
11Sep
11Nov
11Oct
11Dec
12Jan
11Feb
12Feb
11Mar Apr
11
FoodBeauty & Personal CareBeverageHouseholdHealthcare Healthcare
Beauty & Personal Care
BeverageHousehold
Food
Source: Mintel Global New Products Database (GNPD)
New Products Launched in the U.S.
11Jun
11Jul
11Aug
11Sep
11Nov
11Oct
11Dec
12Jan
11Feb
12FebMar
11May11
Apr11
2,000
1,800
1,600
1,400
1,200
1,000
800
600
400
200
0
FoodBeauty &Personal CareBeverageHouseholdHealthcare
Food
Beauty & Personal Care
HealthcareBeverage Household
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LX400 is Primera’s most affordable desktop label printer. It has a convenient single-cartridge ink system and up to 4.25" maximum print width. With LX400 you’ll be able to print high-ly professional full-color labels for all of your short-run products, helping you to sell more! Call Primera at 1-800-797-2772www.primeralabel.com
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Call 1-800-797-2772 (USA and Canada) or +763-475-6676 for details and sample printed labels. Email to [email protected] or visit us at www.primeralabel.com.
APRIL 2012 PACKAGING DIGEST www.packagingdigest.com10
packagingconcepts
Iconic Swedish coffee debuts in stores with a premium look
Gevalia coffees aren’t new to American consumers. While the company
was founded in far-off Sweden more than 150 years ago, the coffees
produced by Scandinavia’s largest roaster have for decades been known to
U.S.-based caffeine fans through its delivery service, which has put various
fl avors and roasts of the premium beans into U.S. homes via mail order
since 1983. It also launched a retail portal on the Web in 2009.
Last year, current Gevalia brand owner Kraft Foods decided to launch
the coffee on retail shelves. They partnered with Dale Doyle, creative
director of Landor Associates (www.landor.com), to ensure the coffee
package boasted shelf appeal and a high-quality image.
“The look we were looking to achieve was an overall premium look and
feel, but also one that told the story of the brand’s rich history, visually and
verbally,” says Doyle. “Sweden’s certainly a country full of dichotomies—
traditional and modern, old and new—and we brought that together on the
package.”
The “modern” side comes courtesy of the bright yellow background
dominating the metallized layered HDPE pouch. The tradition is evoked
by the old-world feel of the logo font, and a crown symbolizing Sweden’s
regal history (and the product’s preferential status as an official coffee of
the Swedish royal court).
Bandage package takes on role of soliciting donors
Adhesive bandages are used to mend minor cuts, scrapes
and other injuries. Recently, Help Remedies launched a
bandage package that aims to heal on a larger scale.
“help I’ve cut myself & I want to save a life” bolsters a pack
containing Help’s standard adhesive bandages with a bone
marrow donor registry kit (consisting of a pamphlet, sterile cotton
swabs and a postage-paid envelope); a rubber band bearing the
kit’s name is wrapped around the pack alerting shoppers to the
potentially life-saving contents. The idea is to engage shoppers
by inviting them to step up and help others in need.
According to Help CEO Richard Fine, “This is a simple and
smart idea: By making registration a part of what people are already doing, we think we can get more people
to register, and in doing so, help save lives.”
The package (produced by Plastic Ingenuity, www.plasticingenuity.com) is a paper-pulp clamshell
(composed of 100-percent post-industrial waste) and an overmolded border/clasp of corn-based Plastarch resin.
Energy shot packtouts health benefits
Energy shots comprise one of the hottest categories in the beverage market.With
new SKUs bursting onto shelves every month, there’s a lot of competition for the
attention and dollars of tired consumers. Steaz Energy Shot, offered by a company
best known for its line of tea beverages, promise something more than a simple jolt.
“Quick, easy energy boosts are everywhere, but most of them are a little dubious
when it comes to your health,” says Danielle Lum with Steaz. “Enter Steaz Energy
Shot: a clean, green, healthy way to get the focus and power you need to shine.”
The energy shot combines organic green tea with organic yerba mate and
guarana, giving the beverage a plant-based caffeine source. Further, the label
relates that the shot is fair-trade certifi ed, USDA organic and vegan.
The 2.5-oz PET bottle is supplied by copacker Protica (www.protica.com).
The label is a shrink sleeve manufactured by Brook & Whittle Ltd. (www.
brookandwhittle.com).
Eco-friendly cleaner adds durablefoaming trigger
PRIDEclean, a company that offers a line of
environmentally responsible cleaning products,
needed a foaming trigger for its product pack—one
durable enough to last through several container
refi lls, and endure the rigors of cleaning work.
The company turned to Global One-Pak (www.
one-pak.co.uk) to provide the device. The GOP
J-Series trigger was selected because of its anti-
clog foaming nozzle technology, which is intended
to deliver leak-free performance. Also, the trigger is
designed to endure several times the usual lifespan of
a conventional cleaning product trigger.
PRIDEClean’s consumer cleaning products
currently are available through Nugget Markets
retail locations in and around Sacramento, CA;. Its
commercial/industrial offerings are sold through Office
Depot.
A D V E R T O R I A L
Weighing in on the future of packagingInterview with Mr. Zheng Jinkang, chairman of Guangdong High Dream
Intellectualized Machinery Ltd., China
With the rapid development of the global food industry, the market’s demand for food packaging machinery is increasing rapidly. As a leading manufacturer in the quantitative weighing and packaging industries, Guangdong High Dream Intellectualized Machinery Co., Ltd. is known for its high quality, unique cultural environment and excellence in marketing and sales. It is also the largest producer in China of multi-head PC-based weighing machinery, offering support in multiple languages. Recently, Mr. Zheng Jinkang, chairman of Guangdong High Dream Intellectualized Machinery Co., Ltd., discussed the company’s status and explained his vision for its future.
Could you briefly describe High Dream’s portfolio of multi-head weighing machines, as well as the company’s recent technological innovations and breakthroughs?
Mr. Zheng: The product portfolio of High Dream consists of IP66 Waterproof Weighers, Dosing Weighers, Standard Weighers, Double Door Hopper Weighers, Stick-Shaped Weighers and Compact Weighers.. Recently, we launched the 2012 Version Standard Multi-head Weigher, which is an upgraded product based on the 2.5-generation technology. First of all, improvements are made in the appearance of the machine. Sand blasting of the round corner cabin with satin surfaces creates the beautiful appearance and high-end appeal. The weighing bucket is designed with a rounded corner, making it both fashionable and safe. Secondly, improvements have been made on the individual chutes, making it faster and easier to assemble and disassemble, improving the packaging speed. Thirdly, improvements in the electrical circuitry further enhance the machines’ reliability. Last, but not least, a software update provides more functionality, such as counting and testing the weight of materials. This product is one of our major launches in 2012.
What strengths do multi-head weighing machines made by High Dream have for overseas markets?
Mr. Zheng: Our products are exported to markets in Southeast Asia, Europe and the United States. Between 2006 and 2008, our market share in European and American markets reached a level. This was because the price of our machinery was only about one third that of similar products made in Japan. If compared with products made in Germany, our price was even lower. However, the product quality is very comparable with those from Japan and Germany. Our products are characterized by their fast weighing speed and high accuracy. As far as weighing accuracy, there is no discernable difference from similar products made in Japan, and High Dream products comply with national standards in the countries where they are sold. It is not surprising that High Dream products have an absolute advantage in terms of the price-performance ratio overseas market. At that time, 80 percent of the multi-head weighing products made by High Dream were sold in Europe and North America. Afterwards, because of the global recession in 2009, sales improved dramatically within China’s domestic market at a rate of 60 percent annually for the last three years.
According to our estimates in early 2012, there are about 12,000 High Dream multi-head weighing machines in operation around the world. Most of these machines have been in continuous operations for more than six years and continue to run well. This is evidence that products made by High Dream can stand the test of time. In addition, it is worthwhile to mention that products made by High Dream are represented by agents in more than 80 countries, who offer convenient after-sales service and prompt satisfaction.
Would you please describe the successes of High Dream’s Research and Development team and the new products planned for international markets?
Mr. Zheng: Our R&D team consists of more than 70 people working in the Mechanical and Software Departments. High Dream spends nearly $1 million each year on R&D. The high added-value of products from High Dream is obvious within the industry. However, the technological challenges we face also are very huge. The R&D teams for multi-head weighers are, therefore, very crucial. The amount invested in software development absorbs as much as 70 percent of the annual R&D cost.
High Dream independently develops and produces highly automated weighing machines that incorporate advanced technical skills and optimized integration of PC-based multi-head weighers with vertical type bagging, filling, and packaging operations, which are capable of fulfilling metering , feeding, filling, bagging, date-printing operations. High Dream plans to offer X-ray and metal detection equipment and other associated equipment and devices in the near future.
What solutions do multi-head weighing machines provide for food processors and what are their application areas?
Mr. Zheng: Multi-head weighers from High Dream use advanced computers, user-friendly computer interfaces and powerful automatic data logging functions to record and collect important data such as the total number of bags in a batch, the rate of acceptance, the average error of every single bag and other data to help solve operational and maintenance issues. In addition, China’s manufacturing industry is facing a harsh situation of labor shortage and rising labor costs. So the advantage of saving the manpower stands out prominently. More companies are asking us to provide associated equipment to upgrade the automation of their packaging lines. Multi-head weighers from High Dream are widely used in the quantitative weighing and packaging of such foods as potato chips, puffed foods, biscuits, and frozen rice dumplings. Our scales have become the first choice for many trading companies and food producers all over the world.
At present, quite a few small- and medium-sized companies are phasing out older models of cup-type weighing machines in the pursuit of precision, speed and production. They are updating their packaging lines high-tech and highly automated systems. This in turn has brought opportunities for the development of quantitative weighing and packaging markets. This has also provided High Dream with excellent opportunity for domestic and international developments. High Dream is firmly grasping this opportunity by constantly exploring and accelerating its own pace of technological innovation. In particular, we are paying attention to the development of automated machine tools, as the establishment of diversified, general-purposed, multi-functional and integrated new packaging systems requires mechatronics, which is an important direction for future development.
During the short spell of six years, High Dream today has developed into a large manufacturing enterprise that produces 2,000 units of PC-based multi-head weighing machines annually. The company plans an initial stock offering in China next year. Today, however, the people of High Dream are working hard for future innovations. We as always will stand up squarely on the profound basis and commit ourselves to creating the world’s No. 1 brand for multi-head weighing machines. I am more convinced that in years to come, High Dream will closely follow the pace of the contemporary revolution in high technologies, while actively developing state-of-the-art automated, intelligent and networking equipment for packaging applications.
APRIL 2012 PACKAGING DIGEST www.packagingdigest.com12
packagingconcepts
Building products relaunched in easy-to-use packaging
Jewson, a long-standing
supplier of sustainable timber
and building materials to U.K.
consumers, recently launched its
products in redesigned packaging.
The makeover puts the items in
containers intended to be more user-
friendly, offer greater shelf appeal
and boost sustainability.
Natalie Davenport, private label
manager at Jewson, says, “The new
packaging uses color-coding, icons
and product information to make it
easy for our customers to recognize
the quality and benefi ts of the product and choose the correct product for their job.”
RPC Containers UK Injection Moulding (www.rpc-blackburn.co.uk) manufacturers the containers, which
include 2.5- and 5-L Paintainer paint cans and 10-L pails. The packs’ enhanced label decoration is printed using
offset lithography, and each container is designed to offer durability, light weight and effective product protection on
job sites.
Beer brand pours into festival-friendly cansGermans love beer, and they also are rather fond of open-air festivals. When the two combine, however,
problems can arise. In past years, the streets of cities like Düsseldorf have been littered with broken glass
from bottles dropped by partygoers, which leads to a cleanup problem and poses a safety hazard.
In 2012, Füchschen Alt, the traditional brew
produced by Düsseldorf’s Füchschen brewery,
launched in 33-cL cans just in time for the start
of the carnival season. The sleek, striking black
aluminum cans (produced by Ball Corp., www.
ball.com) were designed with the celebratory air of
a street fest in mind. The unbreakable containers
enable people to enjoy a good German brew but
avoid the mess and danger associated with broken
bottles.
“A street carnival that is free of broken glass is a
safe carnival, and that is something very important
to me,” says Peter König, the head of Füchschen.
“That’s why I decided to produce the cans. They
also have other benefi ts: They are lightweight
and can be quickly chilled, and they simply look
fantastic.”
Particularly proud of packaging for a branded product that you’ve recently designed? We’d love to hear about it. Contact our senior editor, Jenni Spinner, at 630-990-7385 or [email protected].
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www.packagingdigest.com PACKAGING DIGEST APRIL 2012 13
John Kalkowski, Editorial Director
comment
SServices now account for nearly 80 percent of the U.S. GDP, according to a recent article in the newsletter Future Th inking. Most companies pay some level of attention to customer service. Th ey might even have a few goals and metrics built around the idea of service. While packaging is a key step in manufacturing, perhaps it’s time for those involved in the process to consider how important service is to their future.
In packaging, productivity is king. Modern packaging lines are designed for speed, reliability and repeatable high quality.
Companies rely on materials to protect the product, but also to not cause downtime. CPGs have little tolerance for downtime
due to material or machinery failures.Th e Packaging Machinery Manufacturers Institute
(PMMI) recently conducted a study on service issues and expectations in packaging. PMMI’s report concludes that 62 percent of end users are satisfi ed with services provided by North American machine builders. However, less than half of the end users are satisfi ed
with the number of “knowledgeable service technicians and their availability.”
Th e PMMI study points out that packaging machines are becoming increasingly complicated. As a result, service personnel are expected to be be skilled mechanics, system integrators and savvy computer technicians, too. Th is is happening at a time when fewer engineers are entering the
manufacturing marketplace, while veteran engineers are retiring at a faster rate than they are being replaced, the study says.
All too often, companies off er a piecemeal approach to service without organizing their eff orts to maximize the impact.
Forward-thinking original equipment manufacturers (OEMs) are beginning to realize that providing exceptional after-market services is a way to diff erentiate their off ering. A well-developed service platform not only functions as a diff erentiator, but as Future Th inking points out, it can be relatively inexpensive to implement and provide recurring revenue.
Th e basis for success in service is to really understand your company’s expertise and your customers’ requirements, and then build a service platform around your strengths and the customers’ needs. Th e services a packaging company off ers can include many elements, such as highly skilled and available technicians, operator training, easily understood documentation, preventive maintenance programs, online and remote support, extensive spare parts inventories and quick order turnaround. Most importantly, any service program must emphasize a high level of responsivenes and fl exibility to meet the mission-critical requirements of customers.
Service levels can differentiate packaging OEMs
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APRIL 2012 PACKAGING DIGEST www.packagingdigest.com14
Checkweigher The Thermo Scientifi c Versa
RxV checkweigher for track and trace applications
in the global marketplace addresses the needs of
pharmaceutical and other products that require
track-and-trace capability. The all-in-one high-speed
system can process up to 550 bottles or cartons/
min while combining code printing and verifi cation
(alpha-numeric and machine readable) with
checkweighing.
Thermo Fisher Scientifi c, 781-622-1000.
www.thermofi sher.com
Vision sensor The FQ-M vision sensor is designed to
meet the needs of pick-and-place applications. With a processing
speed of 5000 pieces/min, even with full 360-degree rotation, the
new vision sensor comes with Ethernet and EtherCAT embedded
for ease of integration into any environment, and it includes an
incremental encoder for easy tracking and calibration. The vision
sensor is easily confi gured for guidance of dynamic pick-and-
place robots using the company’s Sysmac Studio software, and
is complemented by the palm-sized TouchFinder console for local
monitoring and access to functions and settings.
Omron Industrial Automation, 866-886-6766.
www.Omron247.com
Welder The DCX Digital Power Supply Series is the company’s fi rst global series of ultrasonic welding
power supplies for automated assembly systems in the packaging, food, automotive and textiles industries.
The new series features a smaller footprint, fl exible mounting, more industrial control options and improved
diagnostic and data collection. Offered in three compact sizes and form factors (including horizontal, vertical
with side mount or rear plane mount), the series offers fl exible integration and system design.
Branson, 203-796-0400.
www.bransonultrasonics.com
new productsequipment
13,128 hrs. and still printing.
Our NEW 1000 Line printers have the longest run times in the market.
With the drastically simplifi ed maintenance requirements of our CORE system, the new 1000 Line lets you print up to an astounding 14,000 hours before preventative maintenance – the longest run times in the market, for more uptime and less cost.
Learn more at 800.843.3610, or visit www.videojet.com/moreuptime and download a FREE Technical Paper about advancements in continuous inkjet printing.
Scan this QR Code to download a FREE Technical Paper about advancements in continuous inkjet printing
©2011 Videojet Technologies Inc. All rights reserved.
T H E N E W V I D E O J E T 1 0 0 0 L I N E P R I N T E R S .
APRIL 2012 PACKAGING DIGEST www.packagingdigest.com16
new productsequipment
Vision sensor The new IV Vision
Sensor combines some of the functionality of
machine vision and traditional sensors in a single
system. The vision sensor’s standard equipment
including high-intensity illumination, high–
performance lenses and a selection of eight
different sensor heads enable sharp, clear, stable
images. The system’s camera selection includes
close, medium and long range models to suit
many application requirements. The system
complies with the IP67 enclosure rating, which is
based on IEC/JIS standards and it can be used
safely in dusty or wet environments.
Keyence, 888-539-3623.
www.keyence.com
Bottle unscramblers The company’s
new range of plastic bottle unscramblers, the
NECOSORT-S3, is more efficient in terms of the
percent of bottles discharged for every revolution of
the unscrambler’s sorting drum. This improvement in
efficiency directly relates to faster speeds for a given
size unscrambling system. The unscramblers also
feature a small footprint with a 105-in. sorting drum
and the ability to sort a wide range of bottle sizes
and styles.
Nalbach, 708-579-9100. www.nalbach.com
ID reader The DataMan advanced fi xed-mount
industrial ID reader is designed to handle difficult
ID code-reading applications, even on high-speed
lines. The new readers increase barcode read
rates and speed with a new 1DMax+ algorithm,
which incorporates groundbreaking new Hotbars
technology. For 2-D matrix and difficult-to-read
DPM (Direct Part Mark) codes, reading performance
has also been signifi cantly improved from a major
upgrade of 2DMax to the 2DMax+ algorithm. With
the ID reader, easy set up and deployment features
modular, controllable lighting options and an
intelligent tuning system.
Cognex, 508-650-3000.
www.cognex.com
Embedded computers The company
releases its two new Embedded Automation
Computers, the UNO-3072A and UNO-3074A with
Intel Atom D510 processor. Both models feature 2GB
DDR2 RAM with an integrated RAID 0/1 controller
for two 2.5-in. SATA HDD’s and an external SATA
port for additional storage. They are able to work
in temperatures ranging from 14 to 140 deg F and
feature shock/vibration absorbers for data storage
security.
Advantech, 888-576-9668.
www.advantech.com
Color label printer The CX1000 color label printer is designed for
in-house production of professional-quality product labels. The printer
is ideal for producing short- to medium-run jobs from 50 to 5,000
labels/roll in various sizes and 2400-dpi print resolution and
print speed of 16.25 ft/min. The printer prints onto many
different laser-qualifi ed label materials including pressure-
sensitive plain papers, white and clear polyesters
and more.
Primera, 800-797-2772.
www.primeralabel.com
That was then.
This is now.For 100 years we’ve been a leader in our
industry, producing superior packaging printing and converting
for global customers using the latest label packaging technologies.
Our capabilities include:
For more informationcall 585.424.3880or email us [email protected]
17www.packagingdigest.com PACKAGING DIGEST APRIL 2012 17
Laser cutter The L-350 high-speed laser
cutter’s single laser head design enables high-
quality cuts with a 210-micron spot size in a
350-mm cutting fi eld at speeds as fast as 80 m/
min. The laser cutter automates optimization of
web speed, eliminates quality issues in many
applications that require stitching cuts from two laser
sources, enables job changeovers on-the-fl y and is
recognized as operator-friendly technology due to its
intuitive operator interface and “behind-the-scenes”
sophisticated control engineering software, the
company states.
Spartanics, 847-394 5700.
www.spartanics.com
Weigher The new Dataweigh Omega
multihead weigher emphasizes sanitation and
food safety with an IP67 rating, allowing it to
withstand severe washdown procedures. Improved
polygon-shaped feed pans and weigh buckets
eliminate product build-up, while the system offers
speeds up to 90 weighments/min in single-shift
mode for IQF proteins. Other features include a
rugged load cell design that can withstand up to
150 kg of force and a tapered body for optimum
product fl ow, speed and improved performance.
Yamato, 262-512-3378.
www.yamatoamericas.com
Controller The company has extended the
functionality of its IRC5 panel-mounted controller
(PMC) to all its robots, including its largest robot
models. Previously, the PMC was only available for
models up to the IRB 1600. Featuring a new, large panel mount drive module,
PMC “Large” will bring smaller footprint functionality and simplifi ed internal cabling
benefi ts to robot models from the IRB 2400 up to the IRB 7600, the company
states. The new PMC variant also will make integrating large robots easier by
allowing machine builders and system integrators the fl exibility to create custom
enclosures to protect the electronics by the means appropriate for specifi c harsh
environments.
ABB Robotics, 248-391-9000. www.abb.com
Printer-applicator The Model 4300 Pro-
Apply label printer-applicator is an in-line unit
that merges economy with the functionality
often associated with heavier-duty labeling
equipment, the company states. The system
offers a selection of thermal-thermal-transfer
print engines. The units print 203-, 300- or 600-
dpi text barcodes and graphic images at speeds
up to 16-in./sec and will dispense labels up to 6
in. wide and 6 in. in length.
Weber Packaging Solutions, 800-843-4242.
www.weberpackaging.com Filler The company has released its new,
economical performance line of fi lling machines.
They features rigid steel frame construction,
electronic net weight fi lling, pneumatic controls,
Rice Lake touchpad weight control for high
accuracy fi lling, and single or double fi lling
positions. The machine is compact and portable—easy to position in a manufacturing facility. To
operate, the operator simply places a container
on the scale and pushes a button; the container is
tared and automatically fi lled by net weight.
Ideal Manufacturing, 608-241-1118.
www.ideal-pak.com
Go Ahead. Change Your Mind.
www.satoamerica.com
GL408/412e Printer Emulations: Performance and Connectivity without Fear, Worry or Dread.
Tired of your old thermal printers but dread having to reprogram label formats? Fear Not!
SATO’s GL408/412e series printers make switching to new technology easy! SATO’s series of on-board command language emulations
your printer solutions. It’s the most adaptive and reliable industry solution for printing barcode labels and tags, and should you need a solution platform to take your company into RFID? SATO’s GL408/412e printers have that option as well.
No Fear, Worry or Dread – make your next printer choice SATO.
For more details, visit: www.satoamerica.com/GL4
Applications Features
APRIL 2012 PACKAGING DIGEST www.packagingdigest.com18
new productsequipment
Oxygen analyzer The OpTech
O2 system has a non-invasive oxygen
analyzer capability for headspace
gas testing of pharmaceutical blisters.
The non-invasive, non-destructive
thermoformed blister package
technology is ideal for determining
oxygen headspace and ingress in
fl exible and rigid packaging, the
company states.
Mocon, 763-493-7228.
www.mocon.com
VFFS machine The Hawk
evolution VFFS machine features a
small footprint and the ability to make
a bag up to 12 in. wide and 18 in.
long. Its Kollmorgen stepper motor
is maintenance free and designed to
run for hundreds of millions of cycles
with little to no maintenance, the
company states. The VFFS machine
accommodates three bag styles: pillow
bag, typically used in the potato chip
industry; a gusseted bag; and a fl at
bottom bag, commonly used for coffee
in 1lb packages. It will run and seal just
about any structure of PE, laminated
or metalized fi lm or foil.
Sharp Packaging, 800-634-6359.
www.sharppackaging.com
Blister packaging The Z.Pack 8 blister packaging
machine for packaging silicon tube sets features a rapid
changeover design of the machine’s mold die assembly. The
quick-delivery (QD) mold change system allows for easy and
rapid changeover of mold dies by lowering complete mold die
assembly with cooling platen into the mold cowling, releasing and unlocking
mold cowling, sliding mold cowling out from under forming station, replacing the mold die
and then returning mold platen and new die to the forming station.
Zahoransky, 630-466-1901. www.zahoransky-usa.com
www.packagingdigest.com PACKAGING DIGEST APRIL 2012 19
Buck-boost transformers The company’s
power product line now includes buck-
boost transformers from Jefferson
Electric. Buck-boost transformers are
designed to maximize the performance
and life of electrical equipment, such
as air conditioners, heating elements,
277-V lighting systems and in-motor
applications. The typical use of the
transformers is to power loads with
specifi c voltage requirements that
differ from the available line voltage.
The 60 Hz single-phase buck-
boost transformers, with 50 VA to 2
kVA ratings, are encapsulated with
electrical-grade resin, featuring high-
quality electrical steel cores.
AutomationDirect, 800-633-0405.
www.automationdirect.com
Carton inspection The
company’s new Carton Inspection
Module is designed for use with a wide
array of pharmaceutical, medical and
food products. The module delivers
three main functions independent of
the cartoner: it inspects for open fl aps
on cartons, prints lot and date codes
onto cartons and provides a visual
verifi cation of the printing. The inspection
module is self-contained, with printer
and vision systems fully integrated and it
can be installed downstream from most
cartoning machines.
MGS Machine Corp., 800-790-0627.
www.mgsmachine.com
Turret rewinder The Model STACRW2-6 automatic turret rewinder for
glueless small-roll fi nishing has everything needed to automatically fi nish
small roll labels without additional unwinding equipment. Standard features
include: servo drives, touchscreen controls, cantilevered edge guided
unwind, splice table, integral slitter, glueless or coreless start, tail label roll
closure system, semi-automatic core coader, and automatic roll eject with
integral roll tray. The company’s popular Tricycle gear caster system is also
included standard.
CTC International, 973-228-2300. www.ctcint.com
APRIL 2012 PACKAGING DIGEST www.packagingdigest.com20
new productsmaterials
Pharmaceutical dosage counter
The e-Dose Counter is a
cost-effective solution that
meets regulatory recommendations for
nasal and sub-lingual spray delivery of
controlled substances, according to its
maker. The use of electronics allows the
counting display to be large and highly
visible, making it suitable for patients of
all conditions and ages. Electronics can
also provide patient comfort features
such as acoustic feedback and fl ashing
displays to inform and warn.
Aptar Pharma, 845-639-3700.
www.aptar.com/pharma
Plastic tube/can Transparent easy-open
“ring pull tube” is available as an alternative to metal
cans for dry products. The package is supplied
with the ring-pull closure in place, ready for bottom
fi lling and subsequent sealing with a tamper-evident
base plug. The container is available with customer
branding for both small and large production runs.
Visican, +44 121 359 8800.
www.visican.co.uk
Grippable large bottles New DeepGrip bottles allow the manufacture of
large size PET containers—with a deep recess for easy handling—as an alternative
to traditional extrusion blow-molded HDPE bottles with integrated handles. Developed
in partnership with Sidel, the bottles can be produced in sizes up to 7 L with a deep
recess on each side, creating an effective integral handle. End markets include dairy,
juice, edible oils, motor oils and home and personal care.
APPE Packaging, +44 1978 317 350.
www.appepackaging.com
Syringes with in-mold labels In-mold
labeling (IML) on a medical syringe barrel can foil
counterfeiters of injectable pharmaceuticals in pre-
fi lled syringes. In-mold labeling offers a number of
benefi ts to pharmaceutical brand owners interested
in protecting their intellectual property, including the
ability to create a label with special inks that will only
be revealed under special black lights. The label
can also be coded so that each syringe has its own
identity and the polymer label actually becomes a
part of the syringe barrel, making it impossible to
remove the label and replace it with a counterfeit
one, the company states. Label placement accuracy
is within +/-0.010 in.
CBW Automation, 970-229-9500.
www.cbwautomation.com
Recycle-friendly labels Three
Fasson label constructions have met the protocol
requirements of the Assn. of Post-consumer
Plastic Recyclers (APR) for the recycling of PET
thermoformed containers. The constructions are (1)
54# semi-gloss paper with AT-1 adhesive, (2) 2.0
mil clear BOPP fi lm with S2001 adhesive and (3)
2.6 mil white BOPP fi lm with S490 adhesive. The
APR protocol was designed to improve recycling
efficiencies and the quality of post-consumer
plastics. The new protocol evaluates thermoform
labels and adhesives to help advance greater
recyclability by identifying pressure-sensitive
laminates that satisfy the need to adhere and be
removed prior to recycling, the company states.
Avery Dennison, 440-534-4846.
www.averydennison.com
ESD protective packaging
Air-cushioning materials AIRplus and FOAMplus foam
padding are now available in an ESD (electrostatic
discharge) fi lm version for on-demand protective
packaging of electronic components or other products
that need shielding from static electricity. Previously,
ESD bags or ESD bubble wrap from the roll were
readily available, but there was a lack of products for
use with on-demand systems. These new materials
can be used with the company’s equipment solutions,
from single work stations to automated infeed
packaging systems.
Storopack, 513-874-0314. www.storopack.us
Refl ective designs Refl eXions gives
consumer product companies freedom to apply
highly refl ective design elements to their packaging.
Refl eXions uses patent-pending technology in
an in-line printing process to offer a cost-effective
alternative to metallized polyester, metallized transfer or
hot foil stamping. Refl ective design elements can now
be efficiently and selectively applied in a single process.
AGI-Shorewood, 203-541-8100.
www.agishorewood.com
www.packagingdigest.com PACKAGING DIGEST APRIL 2012 21
Anti-counterfeiting software New
anti-counterfeit encryption software, which keeps all
information securely encrypted in a data capacitor, is the
world’s fi rst micro database-less technology, the company
claims. When applied to products in any data capacitor
(such as 2D bar code or RFID tag), the non-mathematical
encryption has substantial marketing potential,
capabilities in gray market detection and the ability to
track and trace individual items through the supply chain.
Six Degrees Counterfeit Prevention, 818-570-1277.
www.6dcp.com
Cleanroom-made pouches
Pouches are made in the U.S. in a new ISO Class
8 cleanroom from rollstock produced at the same
facility. This vertical integration creates a domestic
supply of packaging for pharmaceutical, medical
device and diagnostic/life-science manufacturers
who are also looking for ways to reduce the number
of contaminants that come in contact with their
products.
Rollprint, 800-276-7629.
www.rollprint.com
Ovenable rollstock New Cryovac Oven Ease rollstock runs on most traditional rollstock
thermoforming equipment and allows easy changeovers. This makes it easier for food processors to offer
consumer-convenient ovenable products without incurring the expense of new equipment. The benefi ts of
ovenable material are simplifi ed preparation, faster and unattended cooking, and easier cleanup for busy
consumers. The Oven Ease rollstock material is suitable for poultry and boneless beef and pork roast
cuts, including pre-seasoned or marinated items.
Cooking temperatures can withstand 375 deg F for
a maximum of four hours. With exceptional clarity
and the same vacuum packaging properties as
the existing premade Oven Ease ovenable bag,
the ovenable fi lm ensures the product is freezer-
ready and accommodates cook-from-raw or reheat
applications. After cooking, Oven Ease rollstock offers
impressive holding time, keeping items hot in the
package long after being removed from the oven.
Sealed Air, 800-845-3456.
www.sealedair.com; www.ovenease.com
Air Cushion Conveyorfor light packaging materials
www.posimat.com1646 NW 108th Avenue, Miami (Florida) 33172 USA
Ph: (305) 477 2029 / 1-888-Posimax Fax (305) 477 8084 [email protected]
• Low cost, minimal maintenance and no product damage (in comparison to traditional conveying systems).
• Unique flexibility / high speeds.• Quick feeding batching system for
product groups to be conveyed from oneto several lanes.
• It can handle inclines and declines in limited spaces.• Product sizes: from 60 x 30 x 100 mm. up to 200 x 150 x 400 mm. trays and boxes.
*We can study customized requirements.• Product material: all types of plastic (PET, PP, HDPE, polystyrene, etc...), carton board, alluminium, etc...
Manufactured in USA by POSIMAT
POSIJET
See us in Pack Expo Las Vegas, Booth E 3810
APRIL 2012 PACKAGING DIGEST www.packagingdigest.com22
new productsmaterials
Thermal shipper As part
of the company’s Chaperon line of
thermal shipping containers, the Sentry
400 FlightSafe unit contains globally
compatible cellular technology that
enables it to communicate from virtually
any location on the globe for track-and-
trace. It transmits the information to a
server where the customer can access
the information through Vision, its secure
web-based portal, and determine the
location and condition of the container in
near-real time. The unit can also detect
lid open/close, ambient temperature,
shock, motion, vibration, pressure and
(optionally) humidity.
Intelligent Thermal Solutions,
888-465-6342.
www.intelligentthermalsolutions.
com
Polypropylene clarifi erThe Millad NX 8000 clarifi er enables
PP to be processed at signifi cantly
lower temperatures vs standard
clarifi ed PP. These cooler temperatures
allow a reduction in energy use and
associated CO2 emissions while
maintaining the brighter, cleaner
appearance of clarifi ed PP. The
product enables broader use of PP—a
low-density, easily recycled plastic—to
replace less-sustainable materials in
packaging applications.
Milliken, 864-503-2020.
www.milliken.com
Flexible packaging The company offers 10-color process printed
laminations for baking and snack food applications that help maximize a
product’s shelf-impact through eye-catching colors and high-end designs while
maintaining freshness. For one-time use packages, such as single-serve snack
bags, the company has developed seals that are strong enough to preserve
the product yet are still easy for consumers to open. For reclosable packages,
zipper solutions are available and are easy-to-open while maintaining product
freshness and quality.
Star Packaging Corp., 800-252-5414. www.starpackagingcorp.com
do it on yupoS Y N T H E T I C P A P E R
For more information, visit www.yupousa.com/clear
or call 888.873.9876
PRINT • PACKAGE • LABEL • DESIGN
Eliminate bottle-to-label color matching with YUPO® Clear.
Be at one with your package.
YUPO® Clear is the Clear In-Mold Label
substrate that resists scratching, fading
and f lagging and gives you added control
over your design. Because it has a beautiful,
clear, no label look, you can bring excitingly
unique label sizes and multi-colored bottles
to the table with confi dence that your
product will clearly shine on retail shelves
and stand out among competitors.
Scan here for an informational video.
www.packagingdigest.com PACKAGING DIGEST APRIL 2012 23
Dispensing cap Tap-The-Cap universal
dispensing bottle cap for supplements offers the ability
to add a vitamin shot to enrich mineral water. The
universal cap-capsule can be pushed on all bottles of
plain water. For a self-made vitamin mixture, a vitamin
can be packed in either a Tap-The-Cap dispensing cap
or any other brand of mineral water.
Tap-The-Cap, 818-472-2311. www.tapthecap.com
Chemical-barrier containers Baritainers, for
corrosive and difficult-to-contain
liquid chemicals, are a packaging
alternative to fl uorinated HDPE
containers that avoids the potential
failure of fl uorinated packaging while
reducing a product’s carbon footprint.
No post-manufacturing treatment is
needed at a secondary facility, so
Baritainers save greenhouse gas
emissions by shipping directly to a
packaging facility. Baritainers combine
Quoral barrier resin and a proprietary
production process. By processing
under well-defi ned conditions using
specially adapted extrusion equipment,
polyamide (PA) is stretched into thin
lamellas in a PE matrix. This creates
an integrated layered structure, where
a multitude of overlapping PA platelets
guarantee improved permeation
results, the company states.
Barrier Plastics, 949-380-1611.
www.barrierplastics.com
Microfl ute board MirriNor,
a metallized microfl ute board, is a
joint venture between Smurfi t Kappa
and Celloglas that combines Mirri Bio
Film with T-Flute. MirriNor decorative
effects are created
using the Color-Logic
metallic fi lm printing
process. The product
is targeted at brand
managers in the luxury
goods and gift pack
markets to performance
engineer packaging
while removing cost
because of the light
weight of the board as well as the ease
with which it can be printed.
Smurfi t Kappa,
954-516-2600.
www.smurfi tkappa.com
Results from Rexroth: Increase productivity, save energy, grow fasterSuccessful food and packaging operations need to maximize flexibility without sacrificing productivity or increasing costs. Innovative Rexroth drive and control technology helped Paper Machinery Corporation launch the first all servo-driven paper cup forming machine, enabling faster changeovers while cutting both energy use and machine development time. Only a technology leader like Rexroth can help its customers, and theirs, create and sustain that kind of competitive advantage.
All-servo driven PMC 2000S
Speed, time, efficiency all going up
See what Rexroth can do for you
www.BoschRexroth-us.com/packagingresultsOrder our free Results from Rexroth CD
APRIL 2012 PACKAGING DIGEST www.packagingdigest.com24
Go green Libby Bernick, vp, TerraChoice, said that consumers are interested in greener products, but their motivation is what really matters. Learn why they are interested and deliver on that, she suggests.
CollaborateMany recent successes in sustainable packaging
development have been built through partnerships between brand owners and suppliers. PepsiCo’s Knoerzer explained that creating value in the supply chain today requires shared knowledge and a coordinated strategy which usually involves exclusive features or services. Brand owners are able to rapidly move on innovation with suppliers they trust.
Knoerzer also advised attendees: Invest in what you need to know—with the right horsepower. “If you think knowledge is expensive, try ignorance.” And don’t get stuck protecting intellectual property but never getting around to using it.
Scott Vitters, general manager of the PlantBottle packaging platform at Th e Coca-Cola Co., shared a secret to their success: sharing. Th e idea was that development of the technology would accelerate (which would also drive down costs) if the supply chain could see the market for PlantBottle was bigger than Coke. So the company has decided to partner with other trusted brands—such as Heinz ketchup—to expand use of PlantBottles.
HP’s Boeller added that the size of a supplier doesn’t necessarily matter when deciding to partner with them or not. Smaller companies can sometimes act quicker, he says.
It helps, too, for packagers to try to learn about the upstream and downstream links in the supply chain. During the Q&A in “A World Without Waste” attendee Susan Collins, executive director of the Container Recycling Institute, reminded participants that packaging people know as much about the recycling business as recyclers know about packaging. Getting all stakeholders in a room talking is key to fi nding workable solutions.
Lisa McTigue Pierce, Editor
In its sixth edition, the annual Sustainability in Packaging Conference sponsored by Packaging Digest and Pira Intl. demonstrates the evolution of sustainability in the packaging segment. Held March 12-14 in Orlando, FL, the conference highlighted packaging developments and the latest advances in the science of sustainability.
In summing up the event, conference chairman John Kalkowski, editorial director of Packaging Digest, urged delegates to innovate, demonstrate and collaborate—the three major themes developed in presentations throughout the conference.
InnovateSustainability and innovation go hand-in-hand.
Attendees heard many ideas about sustainable packaging innovation during the conference.
Speaker Tony Knoerzer, vp advanced research, food packaging at PepsiCo, advised listeners to fail early and move on to the next idea.
Lars Lundquist, packaging and environment expert at Nestlé, said there is plenty of drive and innovation in sustainable packaging, but what’s lacking is direction. And it’s not about reducing packaging; it’s about optimizing. Th e risk of under-packing is higher than over-packing because of the product waste generated, he says.
Lundquist also said that Gen3 of bioplastics—those that adapt non-food sources (such as wood, agricultural waste and drought-resistant plastics/algae) for packaging applications—are still far away from commercialization. Th e holdup? Th e chemistry often uses more energy to produce the material than it saves.
In trying to sell your sustainable packaging innovation internally, Randy Boeller, packaging
engineering manager with Hewlett Packard, suggested that if two or more departments are involved in a decision (especially a contrary one, like spending more in procurement but saving more in logistics), go up the corporate organization chart to fi nd the single executive responsible for both departments to get needed changes made. He said HP recently fi xed its internal policy so that purchasing agents are no longer evaluated just on how much they save on purchase prices.
DemonstrateTh ere’s a lot more science involved in
packaging sustainability now—and that’s a good thing. Alan Blake, associate director corporate packaging development sustainability at Procter & Gamble, gave an overview of the Global Protocol on Sustainable Packaging 2.0, that provides comprehensive metrics from which users can pick and choose depending on product and project.
Life-cycle assessment was a major topic.Lundquist explained how Nestlé uses LCA at the packaging concept phase employing PIQET (Packaging Impact Quick Evaluation Tool). Th ey have super-users who train others how to use the online tool. With training, Nestle users can do an assessment in about 30 min, he says.
But are all LCA tools created equal? Tony Kingsbury, Dow executive in residence at the Haas School of Business, UC Berkeley, did a study comparing fi ve diff erent tools—COMPASS, GaBi, SimaPro, Sustainable Minds and the Walmart Packaging Scorecard—and found that results vary widely, even when the data input is the same.
Still, Ed Socci, R&D director, Advanced Research Div. at PepsiCo, suggested packagers use LCA as an improvement tool.
All the right data in the world will take you nowhere, though, if your customers think it leads you to a wrong decision. Harry Epstein, vp innovation, HAVI Global Solutions, warned, “Science doesn’t win the day when it comes to consumer perception.”
So what’s a packaging designer to do, asked an audience member, if an LCA tool tells you to make one improvement, but that isn’t the best from a consumer perception view? P&G’s Blake replied: “Communicate and educate—or don’t make the change.”
Take concentrates, for example. In the U.S., consumers expect a fi nancial incentive, according to Will Archer, manager of global sustainability at SC Johnson. Th e company recently expanded its portfolio of concentrated cleaners. Archer said companies need to communicate what the sustainable packaging savings mean to consumers.
An addendum to TRIPLE BOTTOM LINE: Innovate, demonstrate, collaborate.
Conference explores sustainability themes
During the session breaks, Packaging Digest spoke with a handful of speakers, attendees and sponsors about some of the topics and findings presented. Watch these short clips.
• Jason Foster, founder and chief reuser, Replenish, speaks about the challenges—and opportunities—for reusable packaging. www.packagingdigest.com/FosterSustPack2012
• Eben Bayer CEO and co-founder of Ecovative, tells us about recent improvements to the company’s disruptive mushroom-based cushioning, as well as the product’s expansion and next steps. www.packagingdigest.com/BayerSustPack2012
• Chandler Slavin, sustainability coordinator at Dordan Manufacturing, comments on the results of an intriguing study of various life-cycle assessment tools by the University of Berkeley. www.packagingdigest.com/SlavinSustPack2012
• Steve Massa, director of marketing at xpedx, talks about how to help customers save money, be more productive and cost competitive themselves with sustainable packaging designs and processes. www.packagingdigest.com/MassaSustPack2012
Exclusive interviews
Nearly 250 packaging professionals attended the sixth annual Sustainability in Packaging conference in Orlando, FL.
www.packagingdigest.com PACKAGING DIGEST APRIL 2012 25
sustainability
AAs a brief review of Economics 101, a free market is one where prices are determined by supply and de-mand. In the past several years, we have seen a steady rise in the price of many commodities, most notably oil, metals and the products that are in turn impacted by these price increases.
Aluminum also has seen price increases. Worth between $0.70/lb and $1.00/lb, aluminum cans are one of the most valuable packaging materials used. So why did we throw away 1.3 billion pounds of aluminum
last year? Th is is equivalent to the aluminum in more than 27 Airbus A320s, according to Alcoa. (PSI EPR Dialogue, Jan. 19, 2010)
Using an average value of $0.85 for baled used beverage containers, this represents more than $1 billion thrown in U.S. landfi lls annually. So why aren’t we recycling more of them? Isn’t that what a free market would suggest should happen, especially when we have industries clamoring for these materials? Because aluminum is such a valuable resource, this is a prime example of how the free market is not adequately addressing the value of materials.
Aluminum has been the backbone of many recycling systems, yet its recycling rates have remained
fl at below the 50 percent mark over the past fi ve years, according to EPA estimates (which do not include cans imported for recycling). Aluminum Assn. recycling rates do include growing numbers of cans imported for recycling purposes, according to the Container Recycling Institute, and show rising recycling rates over this same period from 52 percent to 58 percent.
So how can it be when some material pricing is at market highs, U.S. aluminum can recycling rates are not increasing proportionately? Where have we gone
so terribly wrong that there is a disconnect between the value of a material and our infrastructure to recapture that material?
Perhaps we have done too good a job on selling convenience and disposability. While our grandparents and great-grandparents of the Depression Era were radical savers, the current generations are so far removed from where things come from that they are also removed from the value of the materials they buy. We have encouraged a system where we blame consumers for not participating in the recycling system, yet we send signals that products are disposable—not valuable—to make it convenient
for everyone. Marketing shapes behavior and, as marketers know, consumers are Pavlovian. If consumers are rewarded, they tend to respond.
To incentivize behavior that recognizes the true value of resources, the regulatory response in some states has been container deposits. But we are still throwing away over $1 billion of cans a year so this incentive is not enough. Outside of regulation, there is a role for marketers who infl uence and shape consumer behavior to get in the game in a coordinated and meaningful way to develop eff ective recycling messaging that drives consumer behavior, such as through the SPC’s Packaging Recovery Label System (www.how2recycle.info).
Th e alternative is to continue bearing the consequences of some of the lowest recovery rates in developed countries, which equals money down the drain. Th e idealism that the free market would keep valuable materials out of landfi lls is not working, so it’s time to think about other market incentives or drivers to prize aluminum and other materials for the valuable resources they are.
Anne Johnson is the director for GreenBlue’s Sustainable Packaging Coalition. For additional information
about the Sustainable Packaging Coalition, please visit www.sustainablepackaging.org.
Market price of recycled material just doesn’t match its true value
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IN A PERFECT WORLD, there would be Perfect Order in our healthcare system, with no errors in the supply chain and ultimate patient safety.
With that goal in mind, medical device leader Becton, Dickinson and Co. (BD) implemented Perfect Order and, along the way, introduced an end-to-end supply chain packaging bar code system with its customer, Mercy Hospital, and Mercy’s supply chain company, ROi (Resource Optimization & Innovation). Th e solution—described in the illustration at right—is the fi rst known instance in the U.S. that a healthcare provider and a medical device manufacturer have used the Global Location Number (GLN) and Global Trade Item Number (GTIN) throughout both the supply chain and clinical processes.
Data synchronizationDefi ned by Strategic Marketplace Initiative
(SMI), a consortium of healthcare supply-chain executives, “Perfect Order” is an ideal in healthcare that represents true electronic order processing, from order placement to delivery and payment, without human intervention.
BD laid much of the groundwork for this eff ort decades ago by implementing bar codes on its product packages. It eventually transitioned to GS1 global standards: GTINs and GLNs. Today, the company assigns GTINs to all products at three levels of packaging—primary (product), secondary (shelf cartons) and tertiary (shipping cases). Each subsequent level connects with the prior one in a child/parent/grandparent hierarchy. Some products are too small to accommodate a bar code, though, so codes would just appear on the secondary and tertiary packs for those products.
BD has studied specifi c use cases with healthcare providers to ensure that the data imprinted in bar codes meets both clinical and supply chain needs. Th e tremendous diversity in products, package sizes and packaging materials prohibits using a one-size-fi ts-all solution to applying bar codes.
As of February 2011, BD established a voluntary data sync with Mercy/ROi keyed to the GTINs and GLNs embedded in linear Code 128 bar codes for nearly 500 products, such as syringes, catheters and specimen collection tubes. Th e data is managed through BD’s enterprise resource planning (ERP) software from SAP and shared with Mercy/ROi via electronic data interchange (EDI) and integrated into its internal IT systems. Th is sharing took place—with help from EDI partner GHX and software vendor Lawson—only after BD had reconciled all unique product IDs in its own ERP Master Data fi le.
Dennis Black, BD’s director, e-Business, and point-man in the collaborative eff ort with Mercy/ROi, explains how atypical this data-sync is in the
Using linear bar codes, unique identifi ers and global standards,
BD has SYNCHRONIZED DATA ON NEARLY 500 PRODUCTS WITH
A SINGLE CUSTOMER to eliminate product errors, ensure patient
safety, reduce stock outs, improve traceability and speed up payments.
RAISING THE BAR ON SUPPLY-CHAIN EFFICIENCY
Code 128 linear bar codes, used widely in the pharmaceutical industry, hold the GTIN data on BD’s primary packs, shelf cartons and (not shown) shipping cases.
26 APRIL 2012 PACKAGING DIGEST www.packagingdigest.comh
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Lisa McTigue Pierce, Editor
PHOTO BY JENNIFER FIELD
27 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
healthcare industry. Currently, many product manufacturer bar codes are covered up with other codes used at various points in the supply chain, which can cause errors and ineffi ciencies.
“What we were trying to do is enable the healthcare provider to get benefi ts from the bar codes that we put on product packages,” Black says. “When we studied the failure points and challenges in the supply chain, we learned that many errors and ineffi ciencies were caused by the lack of data standards.”
Th rough this successful case study with Mercy/ROi, BD is encouraging change in the industry. “It’s our hope that this becomes the norm in the healthcare industry,” Black says.
Printing processesBefore BD can share the data, it fi rst has to
be generated and then added to packages.Vijay Krishnamurthi, director, worldwide
packaging leader and manufacturing support for BD Medical-Medical Surgical Systems (the company’s largest business unit), explains that the Master Data controls the online package printing, which is how the vast majority of bar codes are added to products. Th is is done on a secure network, with all BD locations having access to the company’s ERP system.
Not all the products that ship to Mercy/ROi are produced in the U.S. (which was another reason BD went with the GS1 global product ID standard). BD has 40+ plants worldwide. Over the years, the company added some online printing capabilities, which quickly expanded as adding bar codes and other variable data become the norm. Andrew Stellon, manager, supply chain compliance at BD, says, “[Bar coding] accelerated the migration towards on-demand printing for fl exibility.”
For the most part, BD fi t the online printing technology to the existing packaging material rather than changing the substrate. “We use multiple packaging materials, though. Sometimes it was a challenge,” Krishnamurthi says. “A good example is, it’s much easier to print [on paper]
than when we use Tyvek, which we often use as a top web. Because it stretches, the equipment we use to print a bar code on Tyvek has to be able to do that job much more precisely than paper.”
Plus, nearly all products go through some sort of sterilization (gamma, EtO or steam). “Th e print should not only withstand the printing itself, but the subsequent sterilization processes,” Krishnamurthi says. “We have to ensure that, post sterilization, that we still have a useful, legible, readable code.”
Th e online printing technology used depends on the packaging material and the plant where the product is produced. However, BD typically
uses thermal transfer, some inkjet and, lately, more and more laser. “We are looking at [laser] for the future,” Krishnamurthi says. “Th is is an evolution. We started with some of the older techniques and then we continue to look for new techniques that can operate at our speeds. We’re looking to double—to one thousand parts per minute—manufacturing within BD. We have to work with the printing equipment vendor to do specifi c things Continued on page 28
Every step in the healthcare supply chain between manufacturer BD and customer Mercy uses the same bar codes to process product packages.
ILLUSTRATION COURTESY OF
BECTON, DICKINSON AND CO. (BD)
AND ROI (RESOURCE
OPTIMIZATION & INNOVATION)
to meet those high speeds.”Th e data is printed on product packages at various
stages of production, too. For fl exible packages, bar codes are typically printed using thermal transfer on the fl at web before the pack is formed. Shelf cartons are often laser-coded just before the product is loaded. And shipping labels are also printed with thermal transfer technology at the point of packing.
Codes are verifi ed to ensure readability, with equipment that varies by facility. Stellon says that plants have expanded many of their capabilities in this regard, with more inspection being done online instead of only offl ine sampling.
Additionally, says Keith Racine, director, worldwide supply chain/supply planning for BD Medical-Medical Surgical Systems, “Since we use
the bar codes in our warehouses, too, there’s further verifi cation of readability as [packages] move through our supply chain.”
The payoffBecause BD introduced product bar coding
and the GS1 standards over a long period (literally decades), it’s too hard to say how much it all cost. But Mercy/ROi paid its own way: It did not receive subsidies from BD or other suppliers.
Th e customer has realized several returns on its investment, though:• 30 percent reduction in days payable outstanding.• 73 percent reduction in errors on purchase orders.• Improved sourcing by use of a bar code to
determine the right product and to reorder.• Fewer stock outs due to the simplicity off ered to
nursing staff for scanning bar codes at the bedside.
Black says BD is planning to collaborate similarly with other customers, too. “It is our hope that GTIN and data standards are adopted throughout the healthcare supply chain,” Black says.
Given the benefi t of experience and time, what might BD do diff erently in implementing bar codes?
“We would work closer with the operations on what the [bar code] verifi cation process should be, and what controls were needed to ensure that they were verifying codes correctly,” Stellon says. “We did have some struggles up front. But before we went live, we were monitoring the compliance to our standards.”BD uses a variety of online printing technologies in its plants, such as thermal transfer coding on fl exible webs.
GHX, 800-968-7449.www.ghx.com
GS1 US, 937-435-3870.www.gs1us.org
Lawson, 800-477-1357.www.lawson.com
SAP, 877-727-1127, x11010.www.sap.com
Strategic Marketplace Initiative (SMI),
781-378-1107.www.smisupplychain.com
0 More information is available:
“What we were trying to do is enable the healthcare provider to get
benefi ts from bar codes that we put on product packages.”— DENNIS BLACK,
BD’s e-Business director
Looking for end-to-end supply chain solutions similar to this one from BD and Mercy/ROi that you can use? Consider attending the GS1 Connect Conference. Scheduled for June 4-7, 2012, at the Aria Resort and Casino in Las Vegas, the event shares best practices about how to use GS1 standards across a variety of markets.
In addition to sector-specifi c content for apparel, consumer packaged goods, foodservice, fresh foods, general merchandise, grocery and healthcare, GS1
Connect will present innovations supporting supply-chain processes for product and location identifi cation; inventory effi ciency; traceability and safety; business-to-consumer (B2C) communication; trading-partner collaboration; and data quality/management/synchronization.
GS1 US, 937-435-3870.www.gs1connectevent.org
GS1 event helps connect packagers with solutions for their supply chains
28 APRIL 2012 PACKAGING DIGEST www.packagingdigest.com
30 APRIL 2012 PACKAGING DIGEST www.packagingdigest.comp
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Vetter Development Services USA Inc. has installed a FIRST-OF-ITS-KIND
VIAL FILLER that incorporates aseptic fi lling, stopper insertion and capping in a single system to produce pharmaceutical product for clinical trials.
Jack Mans, Plant Operations Editor
A new vial filling system at Vetter´s U.S. site—called Vetter Development Services USA Inc.(VDS), Chicago—is one of the most advanced aseptic clinical manufacturing operations in the world. Th e heart of the operation is a MHI 2020B vial filler from Bosch Packaging Technology Inc.—the first of its kind specifically developed for aseptic clinical manufacturing—that allows for highly automated vial filling and closing, particularly for the filling of small amounts of drugs.
Th e operation includes disposable systems and a Restricted Access Barrier System (RABS) that greatly reduces the risk of contamination. Th e system fills the vials, inserts rubber stoppers and applies aluminum caps.
Vetter Managing Director Th omas Otto says, “In our Chicago facility, we focus on early-stage products from preclinical through phase II, after which we will scale up and transfer them to our commercial manufacturing facilities for phase III filling and market production. To help ensure a seamless transition to commercial manufacture, we’re replicating commercial processes at our early-stage (Chicago) site.”
Th e Chicago facility is an expansion of Vetter Development Service. Vetter, headquartered in Ravensburg, Germany, is an independent international specialist and contract developer and manufacturer of aseptically prefilled syringe systems, cartridges and vials. It has more than 25 years of experience producing high-quality aseptically prefilled injection systems.
Th e new automated production line at VDS Chicago is used to fill lyophilized or liquid products (up to 10,000 units/batch). It features an integrated monitoring system for the filling and closing process. Th e line can run glass containers ranging from 0.1mL to 23mL capacity.
Th e Restricted Access Barrier System (RABS), which is supplied by Bosch, is a rigid wall enclosure equipped with HEPA filtered unidirectional air to yield an ISO 5 classified space. All air handling equipment is built into the system and glove ports, sleeves and gloves are secured to the walls. Operators at Vetter are excluded from the RABS during normal operations. Any operator activities are performed
through the glove ports. Th e RABS at Vetter´s Chicago site is housed in a Class 10,000 area and is itself rated as a Class 100 cleanroom. Vials for the operation are
sterilized in an autoclave and are then conveyed onto a turntable inside the
RABS. Th e vials leave the turntable in a single file on a conveyor and travel to a pickup point. A handling unit picks up two vials at a time and swings over and places them on load cells.
Th e load cells weigh each empty vial, after which fill nozzles descend and fill the product until it reaches the set weight of product in the vial, at which point the filling stops. Th e precision weighing system can be programmed for diff erent filling volumes and products, allowing for 100 percent in-process control of the amounts filled.
Disposable partsProduct is pumped from a tank
into the vials by a peristaltic or a rolling-diaphragm pump. Th ese
types of pumps and the associated disposable product contact components are used to eliminate the need for cleaning validation and the long lead times for dedicated product contact components. After every product run, every piece of equipment that contacts the product is disposed of in order to ensure there is no contamination of the next product to be run. Peristaltic and rolling-diaphragm pumps are available with PreVAS single-use sets from Bosch and so readily fit this requirement.
Th e PreVAS family of aseptic single-use dosing systems is a completely pre-assembled,
and pre-sterilized dosing system that is supplied with supporting validation documentation.
Th is allows risk free scale up of filling operations in a single-use format. PreVAS eliminates the need for complicated cleaning procedures and validation protocols, and the entire system is quickly installed and operational in a fraction of the time that previous systems required.
Rubber stoppers are fed from a vibratory bowl and travel down a conveyor to a point where a handling unit picks up two stoppers and places them on tops of two vials, which are still in the fill zone. Rods then descend and push the stoppers tightly into place. If the filler is running lyophilized products (see below), the rods only partially seat the special lyo stoppers.
Th e vial handling unit then picks up the vials and places them at another station, where a cap is applied. Like the stoppers, caps are delivered down a chute from a vibratory bowl to a point where another handling unit picks up two caps and places them on top of the stoppers on two bottles.
Th e caps have aluminum skirts attached to them and the vials are next transferred to another station where they are spun against rotating horizontal
Precision vial filling
The line can run glass containers ranging from 0.1mL
to 23mL capacity.
The MHI 2020B vial fi ller from Bosch Packaging Technology—the fi rst of its kind specifi cally developed for aseptic clinical manufacturing—allows for highly automated vial fi lling and closing, particularly for the fi lling of small amounts of drugs.
Vials for the operation are sterilized in an autoclave and are then conveyed onto a turntable inside the Restricted Access Barrier System (RABS). The vials leave the turntable in a single fi le on a conveyor and travel to the fi lling pickup point.
31 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
Th is operation is repeated until all 10 trays are inserted, after which the unit is closed and vacuum is applied to the chamber.
It typically takes about one to four days (depending on formulation and fill volume) to complete the lyophilization, which yields a solid layer of product in each vial called a lyo cake.
Th e vials containing the lyo cake
are placed back on the infeed turntable and enter the line. Th e vials bypass the filling and stopper insertion steps, and the operation resumes at the point where rods descend to push the stoppers into the vials.
Otto says, “Vetter is the first company to use the new Bosch system, designed specifically for clinical-stage, high-value pharmaceuticals. Th e Bosch filler
uses all disposable drug-contact components, which eliminates the need for cleaning validation and thus saves valuable time and costs.”
Otto continues, “It is a compact machine with minimum tubing lengths for increased API [active pharmaceutical ingredient] yield, which is especially important for the high value products Vetter
wheels that come in against them and crimp the skirts tightly against the vials.
Th e vials discharge in parallel lanes and discharge onto a right angle take-away conveyor.
LyophilizationSome products require lyophiliza-
tion, which is another term for freeze drying. Freeze-drying is a method of choice to remove the liquid reactant to support stability. Freeze-dried products will typically have a longer shelf-life than liquid compounds.
Freeze-drying works by freezing the compound and then reducing the surrounding pressure to allow the frozen water in the material to sublimate directly from the solid phase to the gas phase. It is typically used to dry heat-sensitive products, because no heat is applied to the product being dried.
At Vetter, vials are diverted out of the filling line after the lyo stoppers
have been partially inserted. To evacuate water vapor, lyo stoppers have channels in their sides through which the water vapor can discharge. In addition, the stoppers are not pushed completely into the vials.
Th e vials are pushed onto an enclosed platform mounted on the side of the RABS. When it is filled, the operator pulls the accumulated vials onto a tray, which he inserts into the lyophilizer. Th e unit at Vetter, which was supplied by Hof Sonderanlagenbau GmbH, can accommodate 10 trays on five levels.
After two trays have been inserted side-by-side on the first level, the unit automatically raises them so two more trays can be inserted on the next level.
Two vials at a time are placed on load cells that weigh each empty vial. Fill nozzles then descend and fi ll the product until it reaches the set weight of product in each vial, at which point fi lling stops.
Continued on page 32
The Evolutionof the best-selling printerapplicator in the industryOur Specialists at ID Technology raised the bar with the industry-leading Model 250 label printer applicator. Now, they’re raisingit again. Introducing the new, evolved Model 252.
We took a deeper look into the needs of our customers and developed the Centerline-Modularity™ approach. This newdesign philosophy removes as many adjustment points as possible,coupled with hot-swap modules for quick-fault diagnosis and repair. The benefit? Greater uptime and lower running cost.
To learn more about the new Model 252 label printer applicatoror the Centerline-Modularity™ process, call an ID Technology Specialist at 1-888-438-3242 or visit www.IDTechnology.com
32 APRIL 2012 PACKAGING DIGEST www.packagingdigest.com
manufacturers for its customers. One liter of API could easily be valued at over $1 million and be the result of several years of eff ort by a biopharmaceutical development team. And the machine includes a 100 percent check-weight system. Th at’s important, because if the amount of drug in a vial is inaccurate, that may aff ect the outcome of a clinical study, especially in small, early-stage trials.”
Extensive automationVetter’s production line has
elevated clinical manufacturing and development to a new level. Th e MHI 2020B allows for self-monitoring and self-controlled filling. Th e extensive degree of automation enables a high level of safety of the filled drug substances. Th e line also has automatic processes for transportation and in-process controls as well as filling and closing.
Vials are filled with high precision and are closed in conditions that meet the highest possible cleanroom classification standards. Th is increases the protection for both the drug substances and for the participants in the clinical tests, an important contribution towards the successful completion of the early drug development phases. Rapid and fl exible use of various disposable systems permits Vetter to eff iciently adjust the manufacturing process to
the requirements of the respective drug substance.
Clinical development of new drugs is a key challenge for the international pharmaceutical and biotech industry. Ever-increasing competition and the pressure for innovation—combined with high development costs, government regulations of quality and safety—all require new solutions.
Th erefore, eff iciency combined with high international standards and
Vial handling units pick up two vials at a time and transfer them to the various stations in the machine.
Rubber stoppers are applied to the vials while they are still at the fi lling station, after which the vial handling unit transfers them two-at-a-time to the next station where a cap is applied.
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33 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
optimal time-to-market is critical. Often, candidate drug substances are produced in complex laboratory processes and are only available in limited quantities. In addition, many drug substances are complex compounds that are extremely sensitive to environmental infl uences.
Vetter´s vial-manufacturing line in Chicago provides a solution to the economic and technical requirements of clinical development. Th e facility can run small-scale fillings for testing during preclinical to phase II stages with greater eff iciency and safety.
Th e modular use of disposable filling system kits allows for faster and safer preparations for each fill and also reduces complexity and costs during the preparatory period. Small-scale fillings for development studies (compatibility, informal stability tests) can be realized on the line. Using tubes and pumping systems that are particularly gentle on the product, as well as automation of the product from start to end, enables Vetter to obtain especially high process yield.
Fewer sample removals, avoiding destructive in-process control (IPC) testing and reduced loss in the tubing, all assist in a considerable reduction in the loss of active drug substance.
Th e production line meets high international standards, contributing to higher yields of available amount of drug substance candidates and saving
valuable time and money. In addition to the automated
vial line, the 24,000-sq-ft Chicago facility includes a second cleanroom for semi-automatic filling of a variety of drug-delivery systems, as well as chemical analysis lab, microbiology lab, material preparation and compounding functions, visual inspection, cGMP storage area and administrative off ices.
Overall, the site allows the company to off er a range of services revolving around the clinical development of parenteral drugs, supporting customers from preclinical development to phase II.
For phase III and commercial manufacturing, the Chicago facility provides seamless product transfer to Vetter’s large-scale manufacturing facilities in Europe.
Vials containing products that require lyophilization are diverted out of the RABS after the lyo stoppers have been partially inserted and are placed in the lyophilizer. When lyophilization is completed, the vials are transferred back into the fi lling machine, and the operation resumes at the point where the stoppers are pushed completely into the vials.
Bosch Packaging Technology Inc.,
763-424-4700. www.boschpackaging.com
Hof Sonderanlagenbau GmbH,
+49 6462-6080. www.hof-sonderanlagen.de
0 More information is available:
34 APRIL 2012 PACKAGING DIGEST www.packagingdigest.comp
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AAs pharma companies increase the number of products on their fi lling lines, quick changeover and careful monitoring become critical. Pharmaceutical companies are handling more products on single production lines these days, resulting in incredible demands on fi lling and packaging lines. For some companies, smaller batches are the norm, challenging line operators to execute changeovers quickly and suffi ciently. Machinery providers are keeping up, thankfully, off ering a range of solutions.
“We are seeing requests to handle more products on one fi lling line, in smaller batches,” explains Uwe Kellermann, vp of pharmaceutical applications, Optima Machinery Corp. “Pharmaceutical companies and contract manufacturing organizations are handling more products these days.”
Similarly, Walter Langosch, director, sales and marketing, ESS Technologies Inc., has been fi elding requests to build fi lling and handling machinery that can support multiple products. Such high turnover requires expeditious changeovers.
Disposable societyOne of the biggest headaches in changing over
from one product to another is cleaning. Not only does it take time and eff ort, but you have got to follow a validated process, so there can be no corner-cutting.
Unless you move toward disposable components. “Th ere is a defi nite trend toward use of disposable pumps and tubing to eliminate the cleaning validations required. Coupled with CIP and SIP, disposables can cut turnaround time by 50
percent,” says Kellermann.Disposable nozzles, product bags and tubing
are used with peristaltic fi lling technology, whose latest-generation systems can compete better with positive-displacement pump fi lling, Langosch says. “Peristaltic pumps are suited for disposables because the only components that touch the product are the nozzles and tubing. Changing the product ‘bag-in-box,’ the tubing and nozzle takes only minutes. Th ere is no risk of cross contamination,” he says. But the tubing itself must be suitable for the product, while remaining malleable enough for the system to work properly, he adds.
At its fi rst U.S. facility, contract manufacturer Vetter is using the new MHI 2020 B automated vial fi ller from Bosch Packaging Technology. Located at the Illinois Science + Technology Park in suburban Chicago, the 24,000-sq-ft site features
three cleanrooms for aseptic fi lling and visual inspection (see in-depth article “Precision vial fi lling” on p. 30).
Minimizing contaminationDesigned to handle clinical-stage, high-value
biopharmaceuticals, Vetter’s new automated vial fi ller can run up to 10,000 liquid or 6,000 lyophilized vials per batch. Employing a Restricted Access Barrier System (RABS), the system relies on automated fi lling and capping to mitigate risk of contamination by minimizing human intervention. It can run a range of fi ll volumes, from 0.1 to 23 ml, providing fl exibility.
“Vetter’s intention is to utilize only disposable liquid path technology for various reasons: reduce potential of contamination, eliminate cleaning process of product path and of cleaning validation, and ability to get to fi lling customers as quickly as possible,” says David Cousins, director of sales, pharma liquid, Bosch Packaging Technology Inc., pharmaceutical operations.
“Th is is the fi rst MHI 2020 B fi ller capable of precise dosing (either through rolling-diaphragm or peristaltic pump dosing), stoppering and capping,” he adds. “Vials move through the various stations via robotic handling, eliminating the potential for glass-to-glass contact during the fi lling operations.”
Vetter’s managing mirector Peter Soelkner explained in a statement: “Our Chicago facility provides customers with a top-of-the-line clinical manufacturing site located in the heart of the United States. Because Vetter consistently strives to stay at the forefront of innovation, securing Bosch’s new fully automated vial fi ller was a natural for us.”
Multiple fi lling technologiesNot every product is suitable for peristaltic
pump fi lling, and users simply may want other options. Kellermann says that Optima fi llers can be developed with options for more than one technology, such as rotary-piston pumps, time-pressure fi ll systems and peristaltic pumps.
“We have modifi ed our systems to off er interchangeability,” he explains. “Users can take the whole fi lling system out in one hour and change from peristaltic to time pressure, for instance.”
Filling a nichePharma companies are facing GROWING DEMANDS FOR QUICK
CHANGEOVERS of their fi lling and packaging lines as the number of products being run on the lines increase dramatically.
Daphne Allen, Editor, Pharmaceutical and Medical Packaging News
Pharma Tech Industries is using a Ropak Stik Pak 10-up machine to form, crimp, fi ll and seal stick packs.
Filamatic’s Monobloc Fill/Finish Packaging system can accommodate different container sizes and shapes. A chuck-style capping system handles containers ranging in size from 10 to 1,000mL. The fi llers are digitally controlled with menu-driven programs that electronically adjust operating parameters.
35 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
Making the change within a RABS isn’t as easy, however, he explains.
Optima has also made the fi lling station accessible from the back of the machine and added a transport and lift system for easy access. A roll-up module is also available to allow users to switch to peristaltic technology if needed, Kellermann explains.
ESS Technologies can also off er two fi lling or product delivery systems on one machine. “We can also add a servo-driven auger fi ller or even a tablet fi ller, if requested,” Langosch says. When asked whether customers have sought equipment that can regularly switch from liquids to powders to tablets, he says “no, but theoretically it is possible.”
ESS employs 100 percent net-weigh fi lling on its starwheel-based system. “As the container enters the starwheel, it travels over a cell to capture the tare, then moves through the fi lling station, then indexes to another weighing station to capture the fi ll weight,” explains Langosch. “We designed the process to be extremely accurate and have added a feedback loop to allow pump adjustment on the fl y.”
Speed limitationsBecause of the intermittent motion,
there are speed limitations, and smaller volumes typically mean faster speeds. But the number of weigh cells can be doubled to increase throughput.
Accuracy, however, can be a time saver. “You can greatly reduce the rework or scrap by addressing issues inline before containers leave the machine, and that’s where our feedback loop comes in,” Langosch adds.
Optima begins its monitoring with net-weigh fi lling, switches to in-process control and then back to net weighing. Such sequencing enables Optima to minimize product waste during priming, which can be a concern for high-value biologicals, says Kellermann.
Optima systems also monitor seal force/torque, as well as stopper pressure and crimping in-process.
ESS uses product and component detection systems throughout fi lling and assembly, Langosch reports. “We can verify that the pump has triggered and cycled, and we can then detect streams and placement of stoppers, caps and overcaps.”
ESS recently developed servo torque technology for the fi nal torque at a second station. “It allows customers to customize the fi nal
torque needed, and our in-process monitoring allows us to track the torque of every cap,” he adds.
Time mattersLangosch reports that changeover
time convinced one customer to opt for ESS equipment. “One customer picked our HMI-controlled system with 10-minute changeover over a system with a 20-minute changeover.
Th e HMI controls all servo-driven functions, which include nozzle diving, fi lling, capping and torquing.”
Ten minutes may not sound like a much of deal maker, unless you hear Langosch’s explanation: “If one shift has three changeovers, you save 30 minutes per shift. If you only run one-shift per day, 250 days per year, you save enough time to run 15 extra days of production.”
Bosch Packaging Technology Inc., 763-424-4700. www.boschpharma-us.com
ESS Technologies Inc., 540-961-5716. www.esstechnologies.com
Filamatic, 866-258-1914. www.filamatic.com
Optima Machinery Corp.,
920-339-2222. www.optima-usa.com
Ropak, 256-350-4241. www.ropak.com
0 More information is available:
IIn Africa, drug counterfeiting is a huge concern. According to the World Health Organization, up to 30 percent of all drugs taken by patients in the developing world aren’t authentic. Th is illegal activity drains approximately $75 billion from the pockets of legitimate pharmaceutical companies. More importantly, fake drugs threaten the lives of the patients who believe the medications they’re taking are real; in 2008, more than 80 Nigerian children died after taking counterfeit cold medication that contained antifreeze.
Mobile Product Authentication (MPA) technology from Sproxil is designed to combat the problem. Th e technology allows consumers to verify a product’s authentication at the time of
purchase or use, using unique identifi ers or codes on each package. Response to the technology has been signifi cant; in January, the protection service received its millionth request for drug authenticity verifi cation.
According to Alden Zecha, Sproxil CFO and chief strategist, the product succeeds by off ering a unique and necessary service to pharmaceuticals in the region.
“Th is is the fi rst solution that addresses the consumer-level verifi cation that is really necessary in emerging markets,” he says.
In the U.S., pharmacists are likely to fi ll a prescription bottle for patients at the time of purchase, but in countries like Nigeria and Kenya, most pharmaceuticals are sold pre-
With Mobile Product Authentication, the patient sends the unique on-pack identifi er code via text, web or phone todetermine authenticity.
The MPA system responds to the patient’s request for verifi cation with a text message either verifying it is real and safe, or alerting that there could be a problem.
Continued on page 38
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Mobile technology ensures drug authenticityIn Africa, drug counterfeiting is a prevalent—and life-threatening—problem. Technology puts THE POWER TO VERIFY PACKAGE AUTHENTICITY directly into the hands of patients.
Jenni Spinner, Senior Editor
packaged. For the consumer to be confi dent that the drug is real, Zecha states, authentication needs to be put in his or her hands; retailers, clerks or distribution warehouses could be a source of tampering.
Dr. Paul Orhii, director general of Nigeria’s National Agency for Food and Drug Administration and Control, says, “Th is technology puts the power of detection of counterfeits in the hands of millions of Nigerian consumers, thereby enlisting them in the war against counterfeiting.”
How it works Sproxil works with drug manufacturers and
their packaging partners on mass serialization. Th e product gets unique identifi ers on each package; this can be performed at the factory in the manufacturing line, or in a controlled environment post-manufacturing but prior to distribution in the supply chain. Having the manufacturer handle the process in the factory or a secure location before distribution ensures the package isn’t messed with by an unethical distributor looking to make a quick buck.
Next, the products move through the standard retail distribution chain; because the technology is on the pack and verifi ed by consumers, no change in distribution practices or behaviors is necessary.
At the time of purchase, the consumer does three things:
• Th ey expose or reveal the coating on the package. While Zecha relates that nearly all clients to date have used tamper-evident protection over the code on the pack via a scratch-off code, the unique code also can be overt.
• Th e consumer sends the code to Sproxil’s system via text message, phone call to the company’s call center or via the web; because in Africa there’s a relatively low market penetration of data- and web-capable smartphones, text is the prevalent method of messaging.
• Th e Sproxil system processes the code to verify if the product is safe and authentic.
Depending on what Sproxil fi nds out about the product when decoding, the message back to the consumer can be diff erent. If the product is authentic and safe, the user gets a code back telling them it’s real and okay to use. Because literacy rates are low in the markets served by
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Sproxil, the message is usually simple—the word “OK” and then information about the product (name, dosage and other formulary info). If the manufacturer chooses, the basic information can be supplemented with targeted messages specifi c to the drug—if it’s a diabetes treatment, for example, the user could be advised to watch his sugar intake. A phone number is provided for additional follow-up.
Th e product also could be determined to be authentic, but the code might have been used. Th e most common reason is user or phone error: the user might accidentally have sent the code twice, or transposed numbers when typing. In this case, the consumer receives a message advising them as such, and encourages him to try again. Or, the drug could be found to be authentic, but the package has passed its expiration date; in that case, the user receives a message indicating its use-by date has passed.
Putting it in placeAccording to Zacha, the MPA
technology requires only minor
modifi cations to a manufacturing operation.
“We can make it so simple that the manufacturer doesn’t have to change anything at their factory if they don’t want to,” he says. “Th ere is no requirement to purchase or lease equipment, and no capital
equipment required. Th e ability for a pharmaceutical company to put it in play can be made simple.” He adds that the system on the manufacturing end requires no specialized software; if the user chooses, they can opt for a system that uses a web interface. However, if a manufacturer wants
to implement a high-end MPA system, they can opt for high-speed automated production, printing and label application equipment. Th e user has a high degree of fl exibility in choosing equipment to use with the Sproxil technology.
BIOFEM Pharmaceuticals is a large pharmaceutical distribution fi rm in Nigeria, importing and distributing more than 20 name-brand and generic drugs. Its off erings include Glucophage, a popular diabetes drug manufactured by Merck Sante s.a.s. in France. In 2009, BIOFEM discovered its products were plagued by counterfeiting. Crooks were leveraging the company’s brand name and reputation to sell false products, and sales of the company’s legitimate products had fallen 75 percent over the previous year. After implementing the Sproxil system, the company saw dramatic results after just three months. Sales of Glucophage bounced back more than 10 percent and, according to a BIOFEM representative, the company received a return of 10 times what it invested in MPA.
Additionally, according to
In addition to on-pack messages, in-store displays and other signage communicates the packaging technology and its benefi ts.
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BIOFEM CEO Femi Soremekum, patients have come to rely on the technology: “No one will buy it now without the Sproxil label,” he says.
Standing outWhile other technologies exist to
verify product authenticity, Zecha says, Sproxil’s MPA technology is diff erent because unlike RFID, bar codes and other methodologies, it doesn’t take the power to verify out of consumers’ hands, or require specialized equipment.
“Sproxil stands out because it is a consumer-friendly solution,” he says.
Further, the codes and labels containing them cannot be copied to defeat the system, unlike holograms.
In addition to providing consumers with peace of mind, Sproxil can be used to track down thieves and bring them to justice. One customer suspected they had had a batch of drugs stolen from them but could not determine exactly where in the supply chain the loss had occurred. Zecha says Sproxil representatives worked with the company to determine the product had in fact been stolen, and they set up a custom message for the product. When patients entered their code, they received additional messaging asking them to contact the call center.
“We didn’t want to scare them; when they called, we just said, ‘We just want to reassure you the product is genuine, but we have some market questions—do you mind if we ask?’ We asked where they’d purchased the product, so we took that list of locations where the stolen goods had been purchased. Th e manufacturer sent investigators and asked retailers where they’d purchased the products.”
By partnering with Sproxil, the manufacturer narrowed the point of theft to a single source—a legitimate wholesaler that unfortunately had “gone rogue,” and arrests were made.
Sproxil’s technology is designed to be easily adjustable, so that changes can be made in response to changing patient behavior or customer needs. For example, in recent months the company has made adjustment for wording messages in markets where literacy is an issue. Other adjustments leave greater room for patient error, and addition of a web portal where customers can review. Th is feature lets
pharmaceutical companies monitor data beyond product authentifi cation, such as how their products are being tested, checked and sold, how much time it takes the product to get from the factory to customers, and (through Google Maps) how far a product physically travels to get to users. After fi nding out consumers were contacting the call center with medical questions (such as dosing,
interaction with other drugs and a host of doctor-specifi c queries), the company added the capability to pass a call onto the company or a physician.
The MPA code can be protected with a scratch-off coating or left uncovered.
Sproxil, 209-877-7694. www.sproxil.com
0 More information is available:
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40 APRIL 2012 PACKAGING DIGEST www.packagingdigest.com
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Jenni Spinner, Senior Editor
Ever had to wrap a gift in a box? It’s a challenge fi nding a corrugated box that fi ts (or almost fi ts), cramming wadded paper or other extra material to keep the present safe, and making sure the item is secure before you send it to the recipient. Now, multiple that one item by hundreds—or thousands—and you’ll get an idea of why large-format printing and packaging fi rm Meisel, made the switch to on-demand packaging.
Th e idea behind the Packsize technology is enabling packaging operations to make boxes
that are tailor-made to hold the product at hand, when and where they’re needed. Th e concept cuts inventory costs, frees up warehouse space and (because less supplementary packing is needed to keep the product from rattling around a too-big carton) cuts down materials expenses.
Opportunity knocksMeisel, based in Carrolton, TX, is a full-service
company that specializes in large-format printing and packaging for retail products for a diverse roster of high-profi le clients. Its customers range from outdoorsoutfi tter REI, to shoe giants like Nike and Puma, to multinational fast-food companies such as
KFC and McDonald’s. Th e items that the company is called on to produce packaging for is as varied as the list of its clients.
According to Meisel evp Hoddy Peck, keeping stock-size boxes to fulfi ll clients’ needs was problematic. Th e inventory took up valuable fl oor space that could have been used to bring in other work, ordering boxes for a job required lead time, gobbled up shipping costs and (because boxes usually didn’t fi t exactly right) also required investment in fi lling material. Peck was, like many other packaging professionals, frustrated by the waste in time and material caused by box-making business as usual.
“For many years, people have been packaging products the same way,” says Brandon Brooks, vp of marketing for Packsize. “Th ey’ll make a widget, then they buy preset sizes of boxes, which they’ll store. Th en, once the widget is made, they’ll shove it into the box. Th e system is ineffi cient—it’s hard to predict how many boxes you’ll need, when you’ll need them, etc. It’s a supply chain nightmare.”
Sascha Tietje, cost reduction and packaging executive at Packsize, approached Peck at a packaging association event. Peck saw an opportunity to make a diff erence at his operation, and to meet goals relating to process improvement and sustainability.
Machine produces made-to-order boxesUsing on-demand packaging equipment, this large-format printer with high-profi le clients SAVES TIME, MONEY AND FLOOR SPACE by producing boxes tailor-made to accommodate products as they’re needed.
Distribution manager Daniel Spencer programs the box dimensions required for a project with the EM-725 touch screen.
Continued on page 42
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“A lot of the attributes of the equipment and how the workfl ow is tied to the technology fi t in with what we were trying to do,” Peck says. “Th e concept of custom-made boxes that are right-sized appealed to us.” He adds that because the company is certifi ed as a Sustainable
Green Printing operation, the idea of avoiding the material waste associated with using added material to pad items in boxes, or to discard unused boxes when they become obsolete, investing in the Packsize system made sense. His interest increased when a colleague at a Specialty
Graphic Imaging Assn. meeting raved about the Packsize product. He traveled to a facility to see the machinery in action, and decided to give it a try in his own operation.
The technologyTh e Packsize system consists of an automated
packaging machine using Windows-based operating software to create boxes according to custom dimensions. Corrugated board (supplied by Corrugated Supplies Co.) feeds into the machine to construct boxes in widths ranging from 10.63 to 94.49 in., in a range of thicknesses, with no limit on box length. Th e system is able to perform a range of complex functions, including longitudinal/transverse cutting, creasing, perforation, and creation of handles and holes. Meisel uses the multi-faceted EM-725 model, with the Auto Gluer II automated gluing module attached; the EM-6, geared toward large-box production, also is available.
While the block of fanfolded corrugated takes up some square footage, the tradeoff is noteworthy compared to when Meisel relied on an inventory of stock boxes.
“It opened up a lot of rack space,” he says, adding that the warehouse space previously taken up by inventoried corrugated boxes now is used to store replacement parts for equipment around the plant.
The automated packaging machine produces boxes within feet of where a packaging operation needs them.
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43 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
Further, the Packsize system eliminates problems associated with ordering a large number of stock boxes in a particular size for a client, only to fi nd them gathering dust and eventually tossed on the recycling pile when the client no longer needs them.
“Obsolescence is no longer a problem,” says Tietje. “Waste is brought down to nearly zero, because you don’t make a box unless you need it.”
Making a differenceAnother benefi t of the system is that Meisel
can provide its clients with tailored product. One of the earlier jobs Meisel handled with its new Packsize system is a project for shoe retailer Johnston & Murphy. Set to deliver to 200 diff erent stores, the job normally would have called for Meisel staff to order boxes with dimensions close to their needs, then wait for them to arrive. Th e Packsize system enabled them to enter the precise dimensions, produce a single box to determine if the size was appropriate, make necessary adjustments, then produce containers that fi t the project perfectly.
While the machine has only been in place since the second week of November 2011, Peck says the company’s accounting staff already has an impact.
“Return on investment analysis says we’re saving approximately 25 percent of our costs,” Peck says. “In December, when we looked at packaging costs as a bulk item on our profi t-and-loss statement, the numbers seem to be signifi cantly improved. Th e Packsize system gives us tangible savings in our packaging costs. It’s so much more than just a better box.”
It takes approximately eight seconds from the time the start button is pressed, to the time the machine processes the corrugated board to create the box.
Corrugated Supplies Co., 708-458-5525.www.csclive.com
Meisel, 800-527-5186. www.meisel.com
Packsize, 801-944-4814. www.packsize.com
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A new weatherproof pusher tray lets Burpee display its seeds in outdoor garden centers, keeping its COLORFUL PACKETS IN EASY VIEW of potential customers.
Edited by Lisa McTigue Pierce, Editor
Burpee—one of the country’s biggest garden-seed companies—has multiple accounts with garden centers operated by such customers as Lowes and Home Depot, where its fl oor-standing retail display was being used only indoors at the stores.
“A customer asked if we could provide an outdoor fl oor-standing retail display for our seed envelopes to go outside in the Garden Center,” says Burpee’s Mike Wooters, purchasing manager for retail components and general merchandising. “Th is meant developing a waterproof pusher tray that would retrofi t into the outer display panel already in use.”
Seed packets are poly-coated for water resistance but the entire display wasn’t designed for wet environments. Th e outer panel holds trays of
seed packets, which are four to six pockets across. Previously, the seed packets had been pushed—or advanced—forward by an injection-molded, metal coil-spring “pusher” or “anvil” so that there is always a packet front-and-center as customers take product from the tray. Although the outer panel was waterproof, the pusher tray with its metal coil-spring never needed to be until Burpee received the request. And, since metal will rust when exposed to outdoor elements such as precipitation and water hoses, any new design would have to be inherently weather-proof or metal-free.
But Wooters also wanted the new waterproof pusher tray to address another concern of an outdoor display: Keeping the lightweight package secure. Th e previous injection-molded pusher left a 1/4- to 1/2-in. space in the pocket-front. In the Garden Center area, the last one or two
seed packets could be blown out by wind, lost to customer view, possibly aff ecting sales. “We wanted a pusher-tray design that would hold our 1-oz envelopes in tight and keep seed packets from blowing away in the wind,” Wooters says.
So in spring 2010, Burpee searched for a thermoformer who could design a retrofi tted waterproof pusher-display tray and found Package Development Co. “We visited our customers to get a directive and then talked to a few diff erent thermoforming companies,” Wooter says. “Package Development had the best fi t and design. Th eir prototype was original, so we partnered with them.”
Design breaks new ground“We call it a ‘Retail Articulating Pusher
Display,’” says Package Development president Charles (Skip) Schwester. “We have an active R&D
Pushing the envelope
A new weatherproof seed display withstands the wet and, at times, windy environment of outdoor garden centers.
44 APRIL 2012 PACKAGING DIGEST www.packagingdigest.comre
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45 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
department, which had already developed a pusher (or anvil) design that we thought could work for Burpee’s application. It took two or three more versions before we had a working pusher tray. But with our fi rst concept, we were suffi ciently on-track to solve the problem so that Burpee supported and encouraged us to continue.”
Prior to this, Burpee and Package Development had never worked together. But the collaboration proved fruitful. “Burpee was the inspiration for the Retail Articulating Pusher Display,” says Schwester. “Th ey had valuable input. Both companies share the patent that’s now pending, and there are many new patent-pending design modifi cations in the works.”
Th e ingenuity of the pusher-tray design stems from its being die-cut and vacuum-formed from one contiguous piece of Pentaform recycled polyethylene terephthalate (rPET) rigid fi lm supplied by Klöckner Pentaplast. “RPET is reusable,” says Klöckner Pentaplast’s business manager for thermoforming fi lms, Peter Gianniny. “And it can be streamed back into the recycling loop under the right waste-management conditions.”
Wooters applauds the choice. “Th e clarity, functionality and quality of the Retail Articulating Pusher Display is working fi ne. No complaints,” Wooters says. “Clarity is important because our seed packets are printed in bright four-colors—meant to grab retail customers. Th ey need a good view. It helps in forming purchasing decisions. And the clarity of Klöckner Pentaplast’s fi lm is high quality.”
Solving a perennial challengeA fl oor-standing retail display that leans back and
pushes product forward is not new. But the typical injection-molded design has always been expensive because it is comprised of three separate parts, including a metal coil-spring. Not only is tooling expensive, injection molding is time-consuming to manufacture and therefore low volume. (On the other hand…Burpee still uses the original injection-molded design for indoor retail display panels due to
its durability.)Part of the challenge
was keeping the same panel structure and having it work with the redesigned tray that accommodates various display iterations. Th e display panels can be up to 5-ft tall, and may contain from four to 12 vertical rows of trays. Much also depends on the type of seed. For example, pumpkin seeds might fi ll out the bottom of a packet to a quarter-of-an-inch, while celery seeds are practically fl at, necessitating varying tray depths. And width-wise, trays need to be four-, fi ve- or six-pockets wide. “Package Development’s design allows us to tailor the Retail Articulating Pusher Display to each account. In fact, we have added more sizes
for the 2012 gardening season,” Wooters says.
An upstanding designWith brilliant simplicity and a little physics—
what Schwester describes as “almost an epiphany”—Package Development formed a design that solves both of Burpee’s concerns by die-cutting a “T” at the head of each long pusher-arm. Th ere are four or six pusher-arms on an extension off the main Continued on page 46
An all-plastic tray design uses a sliding arch behind the packets to push them forward.
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tray. Th e “T” slots into a cut-away groove centered in the middle of each pocket. Schwester says, “It takes a fast 15 seconds to hinge and snap-lock the pusher-arm extension to the main-tray backside and u-bend the four or six pusher-arms in place, slotting the ‘T.’ It’s practically simultaneous.”
On both sides of the “T” slot are thermoformed fl utes to prevent bottom sagging or bowing when loaded. Th ese fl utes also help maintain spacing of the necessary 5-in. clearance between trays. Th e die-cut front tray wall (double-sided) is further strengthened
with fl utes at its highest points (5 in.). Th ese fl utes act as stiff ening ribs that help prevent defl ection. Th e wall in front of each pocket is only 3-in. high for easy reach-in access, accommodating standard seed-packet dimensions: 4-1/2-in. high x 3-1/4-in. wide.
Wooters says, “It is a fi ne line for the front wall to be high enough to hold packets in place while also making them able to be pulled out. Th at’s also the reason there are 5-in. of head-space between pusher trays.”
Th e pusher-arm itself supports the seed packets vertically with the help of four fl utes near the “T,”
providing a fl at surface with which to advance them. Advancement takes place because the plastic pusher-arm is pulled back when the pocket is fi lled, but wants to push forward. Th e “T” slides up as product is depleted. In eff ect, the bottom of the pusher-arm acts as a coil that creates energy, performing like a spring.
Displays assembled manuallyBurpee manually assembles each Retail
Articulating Pusher Display at its Pennsylvania facility, scoring a right-angle bend in the pusher-arm to further help vertically support seed packets, which are themselves hand-fi lled into pockets.
Th e pre-loaded Retail Articulating Pusher Display went into usage at outdoor garden centers in February 2011, the start of gardening season. In the end, Package Development also re-engineered the plastic corrugated outer display using the same footprint. Th ey used a process of concurrent engineering on the patented pusher display and outer display to assure both would work well in concert. For example, thumb recesses thermoformed into either side of the tray for easy placement inside the display are then secured with folding side-fl aps that are keyed into the display.
Burpee buys the outer plastic corrugated displays from a paper corrugated supplier who brokers the panel through a plastic vendor.
Quality savings“Th e simplicity of the design relies on the quality
46 APRIL 2012 PACKAGING DIGEST www.packagingdigest.com
The one-piece trays are thermoformed from a clear sheet of recycled PET.
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47 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
of Pentaform rigid plastic fi lm we specifi ed from Klöckner Pentaplast,” Schwester says. “We chose them as our supplier because we know from experience that their gauge tolerance will hold. Klöckner Pentaplast quality allows us to use a thinner gauge—which reduces material costs. Even at 30-thousands-of-an-inch, the formability of their fi lm is more forgiving and its cut-ability reliable.”
Not only does the innovative one-piece Retail Articulating Pusher Display save on production costs—materials, tooling, time, labor—it reduces shipping costs as well.
Unlike injection-molded product pusher displays that ship fully assembled and are limited to a small number per shipper carton, Package Development’s design allows for each display to nest together like drinking cups. Depending on the size and design, hundreds of displays can be packed per shipper. According to Schwester, this saves hundreds if not thousands of dollars in shipping cartons, freight and warehousing—with the much welcome benefi t of reducing transportation greenhouse gases.
No rain on this paradeAs for wet conditions found
at an outdoor garden center, a vent allows water to run down the back of the Retail Articulating Pusher Display and exit out the fl at
bottom. Th e pusher-arms actually lean back in a cradle, which acts as a drain. “Package Development’s design exceeded our expectations by leaps and bounds,” Wooters says. “We thought of this project as a new adventure, and they had the capabilities and qualities to make a more effi cient fl oor display.”
Package Development continues to strengthen and adapt its Retail Articulating Pusher Display for
Burpee, as well as for heavier potential applications such as candy bars, pharmaceuticals, cold remedies, liquid powders, fragrances or cosmetics. As the company builds its own specialty equipment and custom machinery, there is no stopping its push to get the Retail Articulating Pusher Display into mass merchandising.
“Just think,” Schwester says, “a pre-loaded pusher-display panel could save retail stores hours of labor
in stocking and restocking. And it could help manufacturers keep their products in full view of customers at all times.”
Klöckner Pentaplast, 540-832-3600.www.kpfilms.com
Package Development Co. Inc.,
973-983-8500. www.pkgdev.com
0 More information is available:
The existing stand-up display rack easily accommodates the new tray design.
Great ideas become great products. Great products deserve great packaging.
xpedx is packaging expertise®DESIGN | ENGINEERING | MATERIALS | EQUIPMENT | WORKFLOW | LOGISTICS
xpedx.comxpedx, a business of International Paper © 2012E-mail us at [email protected]
48 APRIL 2012 PACKAGING DIGEST www.packagingdigest.comp
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FFor decades, producers of PET blow-molded containers have been shipping bulky bottles and jars that contained nothing more than air, in many cases over long distances. Until these containers are fi lled with product, they take up valuable space on cargo pallets and in transport vehicles—not to mention warehouse shelves. Th is is particularly true with wide-mouth, bulk containers that are used to package a range of products ranging from snacks to candies and novelty items.
Today, however, a far more effi cient two-step manufacturing process is eliminating the need to transport and store empty PET containers prior to fi lling. In the two-step process, the fi rst step begins with the production of “uninfl ated” plastic bottles, called pre-forms, which can be nested like paper cups in space-saving stacks for transport and storage. During the second step, the pre-forms are infl ated to full size using stretch blow molding equipment that can be purchased or leased for on-
site production, or outsourced to a local vendor.By breaking the process into two steps, with the
second step performed locally, manufacturers can enjoy savings in transportation and inventory costs, along with increased production fl exibility to create PET containers essentially on-demand.
Transport capacity increasesTh e potential savings become much clearer when
you learn that instead of shipping 5,000 to 10,000 full-size containers in a shipment, a manufacturer could ship 100,000 pre-forms—10 to 20 times as much—at a similar cost. Of course, that improved effi ciency also means a substantial savings of energy.
Th e lead time for transit from distances such as Asia are also considerably longer than those required for domestic shipments, possibly six weeks or more. Th at can translate to big dollars. Outsourcing PET pre-forms overseas can tie up hundreds of thousands of dollars in inventory
fl oating on the ocean while in transit.Th e other major benefi t of a two-step PET
molding process is the extensive fl exibility that it provides for managing inventory.
Th e lower cost of shipping makes it aff ordable to inventory a larger supply locally. Also, since the PET preforms are stored in a more compact manner, you don’t require the warehouse space that you would with full-size, blow-molded containers.
Rez-Tech, for example, off ers economical equipment to manufacture pre-forms, as well as step-two equipment to complete the bottles. Th e company’s step-two equipment is not quite as fast as more expensive high-volume equipment, but that can be virtually irrelevant if packagers allow a little more lead time.
Certain shapes such as handles are not possible using a preform, and there may be a small trade-off in the visual quality of the fi nal product. However, for most wide-mouth applications, the fi nal result is comparable to most conventional extrusion molding techniques.
For the second step of the PET container manufacturing process, customers have the option of purchasing or leasing stretch blow molding equipment. If a company does not want to purchase equipment, they can farm it out to a local supplier to do the work.
This article was prepared by Jack Podnar, president of Rez-Tech Corp., a Kent, OH, manufacturer of wide-mouth PET and vinyl plastic containers. For more information, call 800-673-5277 or visit www.rez-tech.com.
PET molding takes two steps forward
A worker shows pre-forms being fed into a stretch blow molder, along with the fi nal wide-mouth PET bottle.
By DIVIDING THE BOTTLE MANUFACTURING process into two steps instead of one, manufacturers can experience signifi cant savings in shipping and inventory costs.
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50 APRIL 2012 PACKAGING DIGEST www.packagingdigest.comfo
od
packag
ing
IJack Mans, Plant Operations Editor
Induction sealers have solved problems with leaking jars that have plagued SaltWorks, a producer of gourmet salts in boutique jars, at its plant in Woodinville, WA. SaltWorks began 10 years ago as a hobby for Mark Zoske, who created a web site committed to educating food enthusiasts about the unique qualities and diff erences of gourmet salts. What started as a hobby rapidly grew into what is now a company supplying more than 150 varieties of gourmet salts from around the world.
Zoske says, “I’ve devoted my life to researching, importing and packaging the best salts possible and it takes a tremendous amount of eff ort.”
Himalayan, Kosher, Fleur de Sel, smoked, black truffl e, course, fi ne, organic—have you ever looked the grocery store shelf overwhelmed by the selection of salts? SaltWorks has not only mastered the fi ne art of artesian salt, but it has also mastered fl avoring it with a secret fusion process; and discovered how an induction sealer provides an air tight seal for product freshness.
SaltWorks’ products make up 70 percent of the artisan salt market share, and today it is the world’s largest supplier of smoked salts. In late 2011, it moved to a renovated 100,000 sq-ft warehouse and factory.
SaltWorks has expanded its product line to include smoked salts, Fusion fl avored salts and even bath salt, all created without chemicals or artifi cial fl avoring. Its Fusion collection starts with an all-natural sea salt base, and then, with a secret process, infuses the salt crystals with other completely natural fl avors, ranging from spicy jalapeno to bold espresso brava. Zoske says, “Our No. 1 rule is that all of our products are 100 percent natural.”
Sourcing salts from the Himalayas to Hawaii, SaltWorks works closely with farmers, educating them on how to package the raw minerals to ensure they arrive safely at its factory in Woodinville, WA.
When the salt reaches SaltWorks’ factory, it goes through a thorough, waterless cleaning process. Th e minerals are “cleaned” with an optical sorter that uses a high-powered camera to detect and remove contaminants with jets of air. Th is process sorts and disposes of matter that does not meet a
prequalifi ed size, shape or color. Every grain of salt is run through this process twice, making it 99.999 percent pure salt mineral.
Just how precise is the sorter? SaltWorks put it to test it by adding grains of sand to a batch of salt. It effi ciently removed every last grain of sand.
Packaged to perfectionSaltWorks not only imports and cleans the salt;
it also packages and labels the product. Its packaged product sizes range from 1 oz to 2,200 lb. SaltWorks has fi ve packaging lines, two of which have Enercon Industries Corp. induction cap sealers.
In 2008, Zoske consigned an Enercon Industries Corp. handheld system that held him over until his new high-speed Enercon Super Seal induction sealer arrived. He liked the handheld system so much that he purchased it as well. In 2011, he installed a new packaging line and added another Super Seal cap sealer to meet the demand for his expanding business.
Zoske says, “I knew immediately, when I saw the Enercon induction sealer at a tradeshow, that it was what I wanted. We liked the quality of Enercon’s construction and the ease of adjustment for our diff erent sizes of jars and caps.”
SaltWorks induction seals PET jars ranging from 4 to 32 oz at speeds from 20 to 60 jars/min. Th ey are outfi tted with 63mm fl ip-top shaker caps from Weatherchem Corp.
Zoske says, “Prior to induction sealing, we used pressure-sensitive liners. Due to the nature of salt, if just one grain got on the jar’s rim, the pressure-sensitive liner failed. We also started adding oxygen scavengers and desiccants to our packaged product. We decided it would all be a waste if we did not have an air-tight seal.”
By incorporating an induction seal, SaltWorks now has insurance against inconsistent seals. Its customers benefi t from increased product freshness and tamper evidence.
Enercon’s induction sealer is designed to be easy to use. Th e induction sealer is comprised of two main components: the power supply and the sealing head. Th e sealing head produces an electromagnetic current, heating the induction foil liner fi tted inside the capped jar which in turn melts the polymer coating on the inner seal. Th e heat, combined with the pressure of the cap, causes the inner seal to bond to the lip of the container, resulting in a tight
Sealed for success Induction sealers at SaltWorks PREVENT LEAKING JARS caused by grains of salt getting in the seals of boutique jars. A sealer is part of a new packaging line installed in November 2011.
Induction sealer applies air-tight seal to tops of jars, thus ensuring product freshness and tamper evidence.
SaltWorks enjoys 70
percent of the artisan
salt market.
51 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
induction seal. Zoske says, “It’s the only packaging machine I’ve
ever bought that I’ve been able to plug in and let it go. Due to the nature of the salt, we work in a very corrosive environment, and it’s never been down a day.
“We are very satisfi ed with our Enercon sealers. Th ey were easy to set up and install. We had a couple of questions during installation that they answered over the phone. I think Enercon is a great company. Th ey really care about their equipment and their customers.”
Packaging lineSaltWorks installed its new packaging line in
November 2011 to run PET jars ranging from 4 to 32 oz at speeds from 20 to 60 jars/min. Jars are stacked in square rows on pallets, and an operator sweeps several hundred jars at a time onto the large infeed table of a jar unscrambler from Inline Filling Systems Inc. that feeds a 72-in. turntable. A pallet lifter raises the pallet so that each row of jars is at the proper height to be pushed onto the infeed table.
Jars are conveyed to a Model PMB-402-S twin-head linear scale/fi ller from Weigh Right Automatic Scale Co. Th e intermittent-motion PMB net weigher uses vibratory scales that can deliver 2g to 15 lbs of product into containers. Th e fi ll nozzles descend into the jars to fi ll the product, and then rise when the fi lling is complete.
Th e unit at SaltWorks fi lls two jars at a time using the “bulk and dribble” method of weighing,
in which most of the desired weight discharges quickly into the weigh bucket (bulk speed) and the remainder discharges slowly (dribble speed) to provide an accurate weight.
Th e machine features menu driven, touch-screen controls from AutomationDirect that allow operators to select the product to be run directly from the screen, as well as off ering help menus and easy-to-read graphics.
Salt is delivered to the weigher/fi ller in large bags, which are lifted into fi lling position by an overhead hoist system from Harrington Hoists Inc. Saltworks loads the amount of salt to be fi lled each shift into 500-lb or 2,200-lb super sacks, which the hoist lifts over the fi lling machine to gravity feed into the hopper. Zoske says, “We do this for two reasons. First, our salt is very fragile. By using gravity and vibratory feeding we create the least amount of fi nes.
“Th e second reason is sanitation. By using disposable super sacks, we have a clean and sanitary bulk hopper for every run. We fi ll more than 150 diff erent types of salt. Th ere are very few contact points that need to be cleaned during change over. We can switch from one type of salt to another in a matter of minutes.” Th e company has eight separate super sack hoist systems throughout the factory.
Capping successTh e fi lled jars are conveyed to an 8-quill in-line
capper from Pack West Machinery Inc. Th e fl ip-
Salt is delivered to the weigher/fi ller in 500 or 2,200 lb super sacks, which are lifted into fi lling position by an overhead hoist system. A twin-head linear scale/fi ller handles two jars at a time. Continued on page 52
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52 APRIL 2012 PACKAGING DIGEST www.packagingdigest.com
top caps for the jars are loaded into a fl oor hopper and a vertical elevator lifts the caps. Horizontal rails are sized and slanted so that caps with the open side facing inward fall back into the feed hopper. Only caps with the open side facing outward are raised all of the way to the top. A sensor on the elevator detects caps without liners and caps with open fl ip tops and rejects them.
At the top of the elevator, the caps discharge down through vertical orienting and spacing wheels onto a track that carries them down to the application point in the capper. Jars entering the capper pick a cap from the discharge “shoe” at the bottom of the cap track and pass four pairs of horizontal rotating rubber wheels that tighten the caps to the set torque.
In a motion that mimics the way a person applies a cap to a jar, the fi rst set of wheels rotates backwards in order to seat the cap in the threads on the jar. Th e second set of wheels tightens the cap most of the way, and the third set of wheels fi nishes the tightening. Th e fourth set of wheels is a fail-safe in case the cap has not been completely tightened.
A sensor at the outlet of the capper checks that the caps have been applied properly, after which the jars are conveyed through the Enercon Super Seal induction cap sealer and then travel through a PowerDry Spyder blow-off cleaning and drying manifold from ITW Paxton Products. Th e system incorporates four fl exible plastic ducts that can be adjusted to direct the air to the exact points on the jars to accomplish the optimum drying.
Top and wraparound labelingFrom the dryer, the jars are transported to a
model A107 stainless steel wraparound labeler from Colamark Asia Ltd. that applies pressure-sensitive labels. It was custom modifi ed for Saltworks to also apply pressure-sensitive top labels. Labels are supplied by Labels West Inc.
Zoske says, “We originally purchased an American-made top and wraparound labeler. It never worked correctly and we sent it back. We found Colamark through the internet. We visited their factory and were really impressed. Th ey have great quality and superior technology. Th is was the fi rst Colamark labeler installed in the U.S., and as far as I know, it is still the only one.”
Th e labeler applies the top label and then the wraparound label in two separate operations. Th e jars have a small indent on their base, which is used to orient them during the labeling operation so that the top and wraparound labels and the fl ip top are all in the same exact orientation.
Th e jars enter the labeler and are spun until a sensor detects the indent, at which point they are gripped by a unique three-point system that holds them securely. Zoske says, “Th is is one of secrets to their labeling excellence. It forces the labels to go on straight and correctly oriented.”
Top labels, which are applied fi rst, are stripped from a roll mounted over the machine and are applied to the tops of the jar. Th e procedure is repeated in the wraparound section. Th e labeler is equipped with Sanyo Denki servo drives and Mitsubishi Electric Automation Inc. controls and touch-panel HMI that provides user friendly operation that includes menu-driven memory,
A vertical elevator lifts the fl ip-top caps to the top of the capper, from which they travel down a cap track to the application point in the capper. Jars entering the capper pick a cap from the discharge “shoe” and pass four pairs of horizontal rotating rubber wheels that tighten the caps to the set torque.
Stainless steel labeler applies pressure-sensitive top and wraparound labels. The manufacturer integrated an ink-jet printer and a fi nal rotary accumulation table into the system.
Four plastic ducts can be adjusted to direct the air to the exact points on the jars to accomplish the optimum drying.
53 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
intelligent label quantity management, error messages and help messages for operators.
Th e labeled jars travel past a model 9020 ink-jet printer from Markem-Imaje USA that applies a production date and lot code and then continue to a rotary accumulation table from Colamark. Th e labeler, printer and accumulation table were supplied as a system by Colamark.
Finished jars are manually packed into cases.
SaltWorks sealed for successZoske says, “Our mission is to off er the most
comprehensive selection of premium specialty salts, with an emphasis on superior quality, exceptional value and outstanding customer service. Th is packaging line supports that mission.” SaltWorks has taken the earth’s highest quality salts and blended them with the right combination of packaging equipment, resulting in a SaltWorks’ recipe for success.
AutomationDirect,
800-633-0405. www.automationdirect.com
Colamark Asia Limited,
+852 2634 8011. www.colamark.hk
Enercon Industries Corp.,
262-255-6070. www.enerconind.com
Harrington Hoists, Inc.
800-233-3010. www.harringtonhoists.com
Inline Filling Systems Inc.,
941-486-8800. www.fillers.com
ITW Paxton Products,
800-441-7475. www.paxtonproducts.com
Labels West Inc.,
800-540-3009. www.labelswest.com
Markem-Imaje USA,
866-263-4644. www.markem-imaje.US
Mitsubishi Electric Automation Inc.,
847-478-2100. www.meau.com
Pack West Machinery Inc. 626-814-4766. www.packwest.com
Sanyo Denki America Inc.,
310-783-5400. www.sanyo-denki.com
Weatherchem Corp.,
800-680-3412. www.weatherchem.com
Weigh Right Automatic Scale Co.,
800-571-0249. www.weighright.com
New packaging line runs PET jars ranging from 4 to 32 oz at speeds from 20 to 60 jars/min.
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TTrade Associates Group Ltd., (TAG), Woodridge, IL, was receiving an increasing number of complaints from its customers regarding the expanded polystyrene (EPS) loose fi ll it was using to protect its shipments.
TAG is a well-known designer and manufacturer of houseware and giftware products that are sold through retail channels. For many years, the company had used EPS to protect its more than 3,000 SKUs while in transit.
“Although EPS performs well as a packaging material, it also has several negatives,” explains David Abraham, director of distribution operations, TAG. “For example, shipments are subjected to vibration. EPS doesn’t block and brace the load, so products have a tendency to shift during transport. Th is is especially the case with heavier items, such
as glassware, which tend to migrate to the edge of the case. Th at’s when they become most susceptible to damage.”
Additionally, the company had been receiving consumer complaints—particularly from smaller retailers who did not like the mess the EPS made when the products were removed from the shipping cases.
“Th ey would often fi nd themselves having to sweep up the particles that had fallen onto the fl oor. Empty shipping cases still fi lled with EPS also took up a signifi cant amount of space in their storage area which is typically small to begin with. On top of that, they frequently had to incur additional fees to dispose of it,” Abraham says.
In addition to the mess and disposal issues at the retail level, TAG also had similar clean-up
issues to contend with at its own facility. Using traditional overhead bins and blow-in delivery systems with a “scissors” opening to drop the loose fi ll into the cases, EPS particles would frequently end up on the plant fl oor, machinery and work surfaces.
“Between the customer complaints and our own experience, we knew it was time to make a change. We started to review alternatives in 2010. Our goal was to satisfy our customers by fi nding a more environmentally-responsible option which would eliminate the mess and make disposal easier for them. Th e new system also needed to protect our products while being cost-eff ective,” Abraham notes.
In addition to those attributes, the solution needed to be fl exible. TAG has both a standard product off ering as well as seasonal. Products vary widely in size, weight and material.
“Our packers deal with everything from tall outdoor patio torches to small glass objects. It was important that whatever system we switched to could protect our entire product line regardless of the item’s shape or size,” Abraham says.
With many fulfi llment operations already having shifted to infl atable packaging, TAG felt that was also the direction they wanted to head in. Th e company then embarked on an extensive evaluation process to determine which equipment and fi lm combination would meet all of its performance and cost parameters.
Evaluating fi ll alternatives“Early in 2011, we evaluated machines from
several manufacturers. We actually did test runs using our packers and products. We hold our packers to both quality and time standards. So, we wanted to make sure that the system we converted to did not negatively impact our productivity,” Abraham says.
Pregis Corp. worked with TAG to review its packaging requirements. A detailed evaluation of the products, packing process, current costs and effi ciency (such as speed, shipment weight, cost, protection and ease-of-use) was conducted.
“After the evaluation was complete, we found that the Pregis system was the most fl exible and that its sales and engineering team provided the best ideas for our situation,” Abraham notes.
TAG selected Pregis’ AirSpeed HC (hybrid cushioning) Versa system combined with the company’s high-performance, low-density polyethylene (LDPE) air pillow fi lm.
Hybrid cushioning diff ers from traditional void-fi ll pillows because it features multiple air chambers in a horizontal and vertical pattern vs one large cell.
Flat, perforated rollstock is mounted onto the AirSpeed Versa unit, which creates the rows of small air-fi lled pockets as the air is transferred between the individual chambers. Th e new, compact design positions the roll externally, making it easier for packers to changeover.
Pregis’ Versa represents the state-of-the-art in hybrid cushioning. It can handle multiple roll widths (up to 32-in.). It has a reduced profi le, which enables the unit to be placed in locations where space is a premium.
Th e AirSpeed HC Versa is also the fi rst hybrid
Air pillows offer soft landing for TAGHousewares and giftwares company reduces damage, eliminates mess, improves environmental profi le by switching to HYBRID CUSHIONING system.
TAG packing station with Pregis’ AirSpeed HC Versa produces hybrid cushioning for on-demand protection. Rolls are removed from unit and placed overhead for easy packer access.
54 APRIL 2012 PACKAGING DIGEST www.packagingdigest.comsh
ipp
ing
55 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
cushioning unit to produce pads in three diff erent widths: 24-in. wide cushions from 32-in. rolls, as well as 18- and 12-in. wide sizes. It can also produce three diff erent cell heights: small (3/4 in.), medium (1 in.) and large (1-1/4 in.). Typical perforation preset is every 6- and 12-in.
TAG is using the unit in conjunction with
Pregis’ high-performance, recyclable LDPE air pillow fi lm that is made with 30 percent less resin than competitive hybrid infl atable cushioning alternatives.
“Not only have we been able to engineer a space-saving unit, but we have also added to its capabilities while still retaining industry-leading 75
feet per min speeds. Th e speed and small size are important for tight work spaces and high volume operations,” explains Scott Peterson, business development manager, packaging systems, Pregis.
It was determined that the 24-in. pads with medium height bubble would best address TAG’s
Left: Packer pulls cushioning off the overhead roll and lines the case. Right: Hybrid cushioning fl aps are folded over top of contents to create an additional layer of protection before case sealing.
Continued on page 56
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56 APRIL 2012 PACKAGING DIGEST www.packagingdigest.com
requirements. A roll winder was added to each unit to create bundles that could be easily transported to the pack stations, and mounted on a custom dispenser for operator use.
TAG’s packing protocol mandated protection on all six sides of the case. So, the solution was to lay two pads across the top fl aps of the shipper
in a cross pattern, place the houseware items on top and allow the pads to sink into the bottom, enveloping the contents on all sides. Each case is a master shipper. Multiple products, some already in small shipping cartons, are co-mingled in the pack.)
“We also like that the hybrid cushioning
material is fl exible. Th at gives our packers the ability to also wrap it around individual products if they think added protection is warranted,” Abrahams points out.
In mid 2011, TAG installed nine AirSpeed HC Versa units to handle 18 pack stations. (Th e company maxes out at 25 pack stations at the height of its seasonal packaging.) Th e HC Versa also off ers a simple-to-use operator panel which makes it easy for new or seasonal employees to use.
“Providing an eff ective shipping solution for our customers is important. We have received a signifi cant amount of positive feedback from our customers since we converted to Pregis’ Versa system. Additionaly, we have been able to eliminate multiple protective packaging problems,” Abraham says.
In addition to positive customer feedback, TAG’s employees say that the systems are easy-to-use and the need for constant clean up has been eliminated.
“Since the Versa units have been installed we haven’t experienced any problems. Pregis’ maintenance on the machines has been stellar, as well as the follow-up training. We are pleased that we now have a leading-edge operation with an improved environmental profi le,” concludes Abraham.
Pregis Corp., 877-692-6163. www.pregis.com
0 More information is available:
In addition to top and bottom protection, the cushioning is also used as void-fi ll.
Find the Latest Innovations and Solutions to Accelerate Your Packaging Projects
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www.packagingdigest.com PACKAGING DIGEST APRIL 2012 57
industry insightsTh e food industry is beginning to recognize that food safety is a shared responsibility and there is a strong need for an end-to-end supply chain approach to food safety right down to the packaging of food products.
Over the past few years there has been a great push in the retail and foodservice industries toward certifi cation of suppliers against Global Food Safety Initiative (GFSI)-benchmarked schemes. Soon, food packaging producers will be able to earn certifi cation to one of three
packaging schemes up for benchmarking against the Global Food Safety Initiative. Th ese include BRC Global Standard for Packaging and Packaging Materials, Food Safety System Certifi cation 22000/PAS223 and Safe Quality Food (SQF).
Th e GFSI is a business-driven initiative for the continuous improvement of food safety management systems to ensure confi dence in the delivery of safe food to consumers worldwide. GFSI allows collaboration between some of the world’s leading food safety experts from retailer, manufacturer and foodservice companies, service providers associated with the food supply chain, international organizations, academia and government.
Th e initiative was launched in 2000 following a number of food safety crises when consumer confi dence was at an all-time low.
GFSI is managed by Th e Consumer Goods Forum, an independent global network for consumer goods retailers and manufacturers worldwide. It serves nearly 400 member companies in more than 150 countries.
Th is article will help you understand why certifi cation is important and how you can start to prepare your packaging facility for compliance.
Why is certifi cation important?Contaminated food can have potentially fatal
eff ects on consumers’ health. According the Centers for Disease Control (CDC), food-borne illnesses cause about 300,000 hospitalizations and 5,000 deaths every year in the U.S. alone. .
Food recalls are also really, really expensive. In the U.S., the economy hemorrhages about
$7 billion every year due to these outbreaks, according to a recent article in the Washington Times.
Th e costs of a food recall—which include removing contaminated food from store shelves, lawsuits and sometimes revamping the facility that is believed to have produced the contaminated product—really add up. Not to mention the loss of sales caused by a bruised reputation and lowered consumer trust. Everyone in the supply chain tends to share the burden—
retailers and manufacturers alike.If the food industry is going to avoid these
costly food safety incidents, they will need to hold each other to higher schemes. Certifi cation to GFSI-recognized schemes enables food companies at every link in the supply chain to achieve best practices and standards that are recognized globally.
Certifi cation allows a facility to demonstrate to their customers further down the supply chain they are committed to food safety,
including packaging.
Why should I earn certifi cation?
Retailers and foodservice companies need to be sure the packaging they are sourcing is not going to contribute risks to food safety and quality. Certifi cation to Global Food Safety Initiative-benchmarked schemes enables packagers to demonstrate to their supply chain partners—and ultimately major retailers—that they are a strong partner
in food safety and have quality systems in place that ensure packaging products will not have an adverse eff ect on the safety and quality of the food products you package.
How can I get started?An online assessment tool to help facilities
understand their readiness for compliance against GFSI-recognized schemes is available at http://bit.ly/xn0rEG.
NSF Intl. also developed a white paper specifi cally for packagers to help educate them about the BRC/IOP Global Standard for Packaging and Packaging Materials. You can download this white paper at http://bit.ly/yeun2X.
Author Robert Prevendar has 20 years of experience in public health and food safety. He serves as
director of supply chain food safety at NSF Intl., a leading provider of certifi cation for Global Food
Safety Initiative schemes. For more information, visit www.nsf.org.
Packagers must prepare to complywith global schemes for food safety
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JUNE 19-21, 2012Jacob K. Javits Convention Center, NYC
HBA Global is celebrating 20 years!To mark this very special year, HBA will provide a variety of new onsite
activities, pavilions and tools to assist you and your needs in an ever changing
competitive marketplace, which include:
20Celebrating years of Creativity, Innovation & Beyond
• NEW online appointment making feature for exhibitors and attendees!
• Enhanced New Product Showcase in prime location on HBA Global’s show floor.
• New SPLASH! Pavilion showcasing the best in emerging brands.
• Innovation Pavilions, showcasing suppliers, education, networking opportunities all in one area!
• Design Hot Spots — a new area for inspiration, innovating materials to further develop creativity and ideas.
For more information and updates visit us online at
www.hbaexpo.com
Celebrate with us and register for your complimentary Exhibits Hall Pass at www.hbaexpo.com/register with priority code: PPTD
59 www.packagingdigest.com PACKAGING DIGEST APRIL 2012o
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Sign up for Packaging Digest’s Daily Packaging News e-newsletter to receive news as it happens. Keep up to date with our quick-scan headlines—the best source for what’s happening in packaging,
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Go to www.packagingdigest.com/Daily
Talk back!Here’s what readers of packagingdigest.com are saying:
The household products company has added to its line of concentrated cleaners, which are
designed to be poured into refi llable bottles.
www.packagingdigest.com/SCJohnsonRefi lls
“I’m all about cause marketing, but this takes it to a new level. Very insightful and ingenious packaging. Here’s to hoping it helps direct many people to the registry!”Kayla, blog writer for Container & Packaging Supply, on
“Bandage package takes on blood cancer”
“What is extended producer responsibility supposed to fi x? It is an idea in search of a problem! With two-thirds of all municipal solid waste in the U.S. not packaging, when all the (unsustain-able) recycling and take-back propaganda has run its course, the country’s municipalities still have all that solid waste in need of disposal.”Tom Dunn, packaging developer, on “EPR laws continue
to spread”
Cheap, intelligent item-level RFID tags now possibleEuropean researchers have made the fi rst reader-talks-
fi rst low-temperature thin-fi lm transistor (TFT) RFID circuit. This
technology will allow the creation of RFID tags that are cheap enough and
have enough performance to be used as intelligent item-level tags on the
packaging of retail consumer goods.
www.packagingdigest.com/CheapRFIDtags
QR code on Budweiser packs lets consumers ‘Track Your Bud’
Budweiser, the iconic global beer brand, has introduced “Track Your Bud,” a digital campaign integrated with packaging that will allow consumers to trace the origins of the beer they hold in their hands to one of Budweiser’s 12 U.S. breweries.www.packagingdigest.com/BudweiserQRcode
Packaging among factors driving upprivate-brand pricesConsumers traditionally have turned to store brands to save money on their grocery bills. Store brands soon might not be so cheap, though. Those goods could begin increasing in price to compensate for the costs of packaging and product improvements.
www.packagingdigest.com/PLprices
Cardinal Health debuts space-saving packaging for surgical glovesCardinal Health’s new half-fold glove
dispenser boxes are at least 30 percent
smaller and use at least 15 percent less
paperboard than competitive products
sold in tall packaging confi gurations.
Individual pouches within the half-fold dispenser boxes are said to be at least
48 percent smaller than competitive products.
www.packagingdigest.com/HalfFoldGloveBox
Recycling of non-bottle rigid plastics soars 72 percent in single year
Nearly 820 million pounds of post-consumer rigid
plastics were collected for recycling nationwide in
2010, an increase of 72 percent from 2009 and
154 percent since 2007, according to a new report
from the American Chemistry Council.
www.packagingdigest.com/
NonBottlePlasticRecycling
SC Johnson expands its line of concentrated cleaner refills
Ask the ExpertsNeed a little help? We’ve got experts standing by to answer
your questions about Labels, Automation and Sustainability.
http://packagingdigest.canon-experts.com/
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SustainabilityinManufacturing.com
February 14–16, 2012Anaheim Convention Center
Anaheim, California
May 22–24, 2012Pennsylvania Convention Center
Philadelphia, Pennsylvania
March 14–15, 2012Fort Worth Convention Center
Fort Worth, Texas
June 19–21, 2012McCormick Place North
Chicago, Illinois
May 2–3, 2012Charlotte Convention Center
Charlotte, North Carolina
November 14–15, 2012Palais des Congrès de Montréal
Montréal, Québec, Canada
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Reduce your carbon footprint
Head off the regulation blues
Reduce your energy costs
Meet supply chain requirements
Give your product, your customer and your company something to be proud of.
www.packagingdigest.com PACKAGING DIGEST APRIL 2012 61
info showcaseLiterature and other multimedia, product announcements and websites for packaging machinery, materials,
containers, supplies, and services. Contact supplier directly or respond online for information.
For more information, contact Steve Everly at 610/705-8705, [email protected]
Machinery & Materials
marketplacePACKAGING DIGEST 11444 W. Olympic Blvd, Los Angeles, CA 90064 • Fax: (310) 362-8808Attn: Steve Everly at 610/705-8705Email: [email protected]
YUPO Gives You a Sustainable Edge in Packaging. Why choose YUPO Synthetic Paper over other label substrates?
Waste Reduction – No Label Liner to Discard 100% Recyclable Bottle Label Starts & Finishes Green – 100% tree-free Cost-Saving Benefits – Compared to other methods Diverse Packaging PossibilitiesBlow and Injection Molding Clear and Opaque Grades
The Choice For PreformsOaklee preforms provide a secure tamper-evident band for hard to seal and small production run con-tainers. Simply place the preform over the closure and container edges then apply heat to gain a snug, secure fitting seal. No investment in package sealing machinery or technical expertise. With an inventory of over 200 preform molds, in a wide array of sizes and shapes, we can accommodate your packing needs using clear, custom colors or custom printed film.Oaklee International Inc.
Domino’s A320i. A revolution in ink jet coding innovation.The A320i is the first ink jet printer in the industry to eliminate the service routine, while guaranteeing predictable start-up, reduced costs and less waste. See firsthand how the A320i performs, and discover ink jet innovation designed to maximize your productiv-ity.Domino Amjet Inc.1290 Lakeside Dr Gurnee, IL 60031
Up Your “Wow Factor” with Vibrant Printed Shrink!Convert your multi-packs and bundled items from paperboard trays, labels or sleeves to 100% printed polyolefin shrink film—Bemis Clysar makes it easy! You’ll wow consumers with colorful 360° brand graphics, premium-quality film and great cleanup. Plus, you’ll dramatically reduce material usage to boost sustainability and cost savings. Bemis Clysar888-4-Clysar or [email protected]
Numatics G3 Fieldbus Valve ManifoldThe G3 is the next-generation electronic platform that allows easy access to I/O connections. It’s simple to assemble, install, commission, and maintain. The G3 is the only pneumatic valve manifold that contains a graphical display used for configuration, commission-ing, and diagnostics. The platform’s electronic modules can be used for centralized or distributed architecture.Numatics Incorporated46280 Dylan Drive, Novi, Michigan, 48377-4906 USA
www.numatics.com
APRIL 2012 PACKAGING DIGEST www.packagingdigest.com62
newsmakers
PACKAGING DIGEST® (ISSN 0030-9117) is published monthly, with a special issue in summer, by UBM Canon, 11444 W. Olympic Blvd., Los Angeles, CA 90064-1549; 310-445-4200; FAX 310-445-4299. Periodicals postage paid at Los Angeles, California, and at additional mailing offices. SUBSCRIPTIONS—Free to qualifi ed subscribers as defi ned on the subscription card. Rates for non-qualifi ed subscriptions, including all issues: 1 yr. $150, 2 yrs. $250, 3 yrs. $300. Except for special issues where price changes are indicated, single copies are available for $10 USA and $15 foreign. For telephone inquiries regarding subscriptions, call 763-746-2792. CHANGE OF ADDRESS—Notices should be sent promptly to P.O. Box 47461, Plymouth, MN 55447. Please provide old mailing labels as well as new address. Allow two months for change. EDITORIAL CONTRIBUTIONS—Unsolicited manuscripts should be submitted via e-mail to [email protected]. Copy will receive every reasonable care; however, the publishers assume no responsibility for safety of artwork, photographs, or manuscripts. NOTICE—Every precaution is taken to ensure accuracy of content; however, the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein. POSTMASTER—Send address changes to PACKAGING DIGEST, P.O. Box 47461, Plymouth, MN 55447. Canada Post: Publications Mail Agreement 40612608. Return undeliverable Canadian addresses to: BlueChip International, P.O. Box 25542, London, ON N6C 6B2. Printed in U.S.A. Copyright 2012 by UBM Canon. All rights reserved. Reproduction in whole or part without written permission is prohibited.
ad indexSteve EverlyBrand [email protected], DC, DE, FL, HI, MD, NC, PA, SC, WV, Canada (eastern), Europe
Russell Thibeault781-255-2053 Fax: [email protected], AR, CT, IA, LA, MA, ME, MS, NH, NJ, NY, RI, TN, VA, VT, Canada (East)
Steve Slakis630-990-7429 Fax: [email protected], GA, ID, IL, MN, MO, MT, ND, NE, NV, OR, SD, TX, UT, WA, WI, Canada (West)
Tom Corcoran215-275-6420 Fax [email protected], CO, IN, KS, KY, MI, NM, OH, OK, UT, WY
INTERNATIONAL REPRESENTATIVES:Europe/Middle East | Lisa [email protected] | Sylvia [email protected]
Japan | Masayuki [email protected]
Taiwan | Robert [email protected]
Mary WilliamsMarketing Services Manager630-990-2371 Fax: [email protected]
REPRINTSFoster Printing [email protected]
Sales and Marketing Offices
sales staffAdalet ......................................................................................32
Advanced Antivibration
Components (AAC) .......................................................53
Asco Numatics GmbH ................................................37
AutomationDirect .............................................................3
AXON.........................................................................................42
Berlin Packaging ...........................................................63
Bosch Packaging Technology Inc. ....................5
Bosch Rexroth Corporation ..................................23
Burrow Industries Inc. .............................................61
Busch LLC. ..............................................................................6
Cardinal Packaging .....................................................64
Columbia Machine .......................................................33
Dairy Farmers of America .....................................25
Domino Amjet Inc. ........................................................18
Enercon Industries Corp.........................................55
Fowler .....................................................................................45
Fres-Co Systems USA ................................................43
Groninger ..............................................................................55
Hammer .................................................................................16
HBA Global Expo ............................................................58
Highdream ...........................................................................11
Hitachi ........................................................................................2
ID Technology ...................................................................31
Institute of Packaging Professionals ..........49
Kliklok-Woodman Packaging Solutions ......14
Klockner ................................................................................51
Leibinger ..................................................................................7
Matrix ......................................................................................38
MRI Flexible .......................................................................29
NAFM ........................................................................................19
Overnight Labels Inc. ....................................................6
Paktech ..................................................................................39
Patlite ......................................................................................35
Posimat ..................................................................................21
Primera Technology .......................................................9
Sato ...........................................................................................17
Schneider .............................................................................53
Sharp Packaging ...........................................................12
Simplimatic ........................................................................13
Squid Ink ..............................................................................41
Videojet ..................................................................................15
Xpect Solutions ...............................................................13
xpedx .......................................................................................47
Yupo Corporation America ....................................22
MOVERS & SHAKERSAdept Technology
appoints Robert
Malley as vp of
global operations.
B & H Labeling
Systems appoints
Rodrigo Melo as
assistant global
fi eld service
manager.
Ball Corp.
promotes Robert
Miles to svp, North American sales.
Intelligrated hires Tom Sullivan as
national sales
manager for
fulfi llment
solutions team.
Key Technology
promotes Steve
Pellegrino to vp
of sales.
TricorBraun
names Charles
Pfi ster as CFO.
Emerson
Bearing launches
new packaging
division and
promotes Lee Holt
to head it.
The Plastics
Industry Trade
Assn. appoints
Jacqueline Dalzell
as director,
industry affairs.
O-I names
Georgette Verdin as vp of global talent
management and organizational
development and Sergio Galindo as
president of
its Asia Pacifi c
region.
PolyOne Corp.
promotes Robert
Patterson to COO
and hires Richard
Diemer, Jr. as svp
and CFO.
Eriez hires
Craig Lorei,
Christopher
Ramsdell and
Jayne Corey as
technical sales
representatives.
Hoover Group Inc.
hires Paul Lewis as
president and COO.
Aaguard Group
LLC hires Jim
Guttridge as key
account and area
sales manager.
Beumer Group names Christian
Matzen as sales manager for
packaging systems.
Nordenia Slavnika, the Russian
subsidiary of Nordenia Int. AG, hires
Oleg Obertinyuk as its general director.
Dymax Corp. appoints Jon Galaska as
territory sales manager.
GROWING & GOINGIntelligrated relocates its Dallas-based
regional operation to Coppell, TX.
BUYING & ALLYINGTriangle partners with Southeastern
Packaging Equipment Sales LLC.
Sato America Inc. acquires Achernar
of Argentina.
Amcor acquires Aperio Group, an Asia
Pacifi c producer of fl exible packaging,
for $238 million and India-based
Uniglobe for $19.8 million.
Optima Group (Germany) acquires
Doyen Medipharm.
Ardagh Group acquires the Boxal
group of companies from Exal Corp.
for approximately €85 million.
NatureWorks and BioAmber
form AmberWorks joint venture
to commercialize new bio-based
polymers.
Mocon Inc. acquires PBI-Dansensor
A/S (Dansensor) of Ringsted,
Denmark.
H.B. Fuller acquires ForboGroup’s
global industrial adhesives business.
International Paper completes
Temple-Inland acquisition with total
transaction value of about $4.5
billion.
Mauser Group acquires Varicon
Solutions in North America.
Robert MilesBall Corp.
Robert MalleyAdept Technology
Steve PellegrinoKey Technology
Tom SullivanIntelligrated
Rodrigo MeloB & H Labeling Systems
Page numberPage number
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