unique packpaper 02|14 upp · 2018-08-06 · Shutterstock Inc. pogonici/michal812/Dejan Ristovski/Anna RubaK/ Julia Ivantsova/Mjak/ Subbotina Anna Creation, concept, and artwork:

THE WORLD PREMIERE for cup packaging

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uppthe magazine for professionals

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When we at Greiner Packaging speak of innovation, we mean progress on several levels. Our latest packaging innovation sets new standards in terms of product protection, sustainability, POS differentiation, and convenience. We call it inert barrier technology. The world premiere for cup packaging clearly reduces gas permeability and allows for optimal flavour sealing. This new innovation forms a functional barrier – a technology that prevents retort shock.

The inert barrier technology is suitable for various plastics. It is invisible and has no impact on the transparency of the packaging. Compared to other plastic packaging with barriers, it scores points through its excellent recycling properties.

Tobias Strasser

ManagerGreiner Packaging Switzerland

EditorialDear Readers,

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You can learn more about the innovating solution of the inert barrier technology on pages 6 to 11 of this magazine. This issue of unique packpaper also provides you with answers to interesting questions, such as “Why is Greiner Packaging International opening a site in the US at this particular time?” Or “What are the advantages of labeling and marking with lasers?”

Happy reading!

YoursTobias StrasserManagerGreiner Packaging Switzerland

Greiner Packaging goes to USA 03

Plant power – sustainably packaged 04

New camera system optimizes the IML process 05

World premiere: cup packaging with ibt. inert barrier technology 06–11

Optimized waste toner containers 12

Company Information 05

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Greiner Packaginggoes to USASite in Pittston, Pennsylvania, Initial operation

in the 4th Quarter

For Greiner Packaging International, there are many good reasons for an entry into the US market. The demand for high quality food is growing in this market. This change in consumption habits also means an increasing need for premium dairy packaging. At the same time, sustainable packaging concepts are very much in trend. Some customers of Greiner Packaging International have already made the step toward the US and can now take advantage of continuing the proven partnership at the new site.

Big Market PotentialGreiner Packaging International offers excellent packaging solutions for the current demands of the US dairy industry. The K3® technology, in particular, provides a suitable response to the main challenges. The numerous possibilities for communication (decoration of the cardboard wrap on the interior and exterior) make it ideal for the highly developed US marketing system. Its sustainability advantages – renewable raw materials, less plastic content, improved carbon footprint – are very much in touch with the times. In summary: The K3® technology opens up large market opportunities in the US for Greiner Packaging International as well as for its customers.

Attractive regionThe Pennsylvania region is a great attraction to the packaging industry. About half of the country’s population lives in the northeast

and midwest of the United States. Many milk-processing plants are based here. A 10,000 square meter area is available for the first development stage.

Ideally positioned:

Near the New York metropolis Near highway connections Good flight connections to Europe

In the region – for the region:

Top quality workplaces Skilled employees from the region Excellent working conditions Long-term future prospects In-house training for personal advancement

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COMPANY INFORMATION

Owner, editor, publisher, and editorial office: Greiner Packaging GmbHGreiner Straße 70, 4550 Kremsmünster, Austriawww.greiner-gpi.comCourt of Reg.: Landesgericht Steyr, Chamber of Commerce Reg. No.: 176892k

Responsible for content: Kenneth BoldogPhotos: Greiner Packaging, Wolfgang Stadler, Clemens Pürstinger, Nik Fleischmann, Drinkmaster, Rosenbauer, Shutterstock Inc. pogonici/michal812/Dejan Ristovski/Anna RubaK/Julia Ivantsova/Mjak/ Subbotina AnnaCreation, concept, and artwork: Das Kommunikationshaus Bad Aussee, Austria, www.kommhaus.com Printer: Samson Druck GmbH Subject to alterations, errors, and misprints.

Greiner Packaging and Alpro have been successfully collaborating since 2008. The roots of this collaboration lie in two core aspects of K3® packaging solutions: premium quality and sustainability. Both packaging characteristics are perfect for the product. Soya-based yogurt alternatives from Alpro are just the right response to current consumer needs. On the one hand, they are an important part of healthy eating, and on the other hand, they promote sustainable management of the environment.

Packagingfacts

Capacity: 250 mL Material

Cup: PP Decoration: printed

cardboard wrap Technology

Cup: K3®, cup thermoformed

Cool-to-the-touch inK3® TechnologyConvenient cups for hot instant beverages

Hot drinks need well-insulated packaging solutions that provide protection from heat. This requirement becomes particularly important in „instant“ products such as coffee, tea, or soups. The British vendor Drinkmaster previously used injection-molded cups in this sector. Greiner Packaging Switzerland worked closely with them to develop a K3® cup packaging that combines many advantages.

More cost-efficient, more flexibleThe new packaging solution is lighter and therefore more cost-efficient. The cardboard wrap beautifully displays the famous name brands, such as Nescafé, Douwe Egberts, PG tips and Batchelors, that work with Drinkmaster. Ridges on the thermoformed cup help to improve insulation. The contents therefore stay hot while the outer surface stays “cool-to-the-touch”. The technically sophisticated inner-sealed chamber for the instant powder is unique in the industry and was developed for the filling machine in close cooperation with the engineering company. The sealing of the lid during the filling process was particularly challenging.However, its clever design allows for a greater gram throw of ingredients in the cup, resulting in a better tasting drink.

Packagingfacts

Capacity: 500 mL Material

Cup: PP Lid: R-PET

Decoration: printed cardboard wrap

Technology: K3®, cup thermoformed Lid: thermoforming

Plant power – sustainably packagedSoya-based yogurt alternatives

in K3® cups

Market leader in EuropeAlpro is a European market leader for soya-based yogurts and is part of the American WhiteWave Foods Company. Alpro’s mission statement places plant power in the forefront: “We create delicious, naturally healthy plant-based foods for the maximum well-being of all mankind and with the utmost respect for our planet”. The company has grown significantly in the last 30 years and today employs more than 800 people.

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New Camera System Optimizes the IML ProcessBetter quality with increased flexibilityIn-Mold Labeling (IML for short) is a decoration option where a plastic label can be integrated with the packaging in a non-detachable form. The feeding process of the labels into the injection molding is monitored by a camera system. This must accomplish a series of inspection tasks (see info box). Working closely with camera and injection molding equipment manufacturers, Greiner Packaging was able to develop a camera system that sets new standards.

Two instead of five camerasWhere five cameras were previously necessary for monitoring the IML process, the new system manages with only two. The five-camera variation was originally developed for mass-produced articles. Converting to other products is time-

Inspection tasks of both cameras

Side camera:Label available/not available, label mismatch, overlapping error, distance to feed edge at bottom/shoulder area, bar code

Transmitted light camera:Back-injection, if a cup is recognized as bad by one of the two cameras, it is rejected immediately after the camera inspection.

consuming. With the new camera system of Greiner Packaging, the process can be done in a much simpler and time-saving way. This increases flexibility – a benefit for special niche products. Furthermore, the range of tolerance for recognizing errors and rejects decreased significantly, thereby making it possible to improve the quality to a very high level.

From a single source!Comprehensive Packaging Expertise for Zott Dairy Delight

Packaging facts

Contents: 330g Material: PP Decoration: printed

cardboard wrap Technology: K3, cup

thermoformed

Quality gourmet dairy from a single source! This is what Zott, the gourmet dairy from Mertingen, Bavaria, stands for. A wide variety of packaging and decorating solutions from a single source. This is what customers of Greiner Packaging can expect. Zott was convinced that Greiner‘s comprehensive packaging expertise, paired with an integrated approach that characterizes both companies, was the way to go. Greiner Packaging has therefore been supplying the company for many years with attractively decorated thermoformed cups where enjoyment is already discernible in the design, such as for example, the Jogobella cups. Thanks to the unique product quality, Zott Jogobella has set the standard for premium fruit yogurt in many East European

countries and has established a leading position there.

Third generation family enterpriseZott Dairy Delight (established in 1926) is an independent family enterprise, now in its third generation. The vision of the company manifests itself in the harmonization of entrepreneurial success with ecological and social aspects, and in maintaining the values for generations to come. With estimated consolidated sales of 894 million EUR, dairy processing of 951 million kg, and 2,120 employees in 2013, Zott is one of the leading dairies in Europe. The yogurt, dessert, and cheese specialties of the company are available in more than 75 countries.

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What do these really mean?

BarrierA functional barrier made of plastic is a barrier composed of one or more layers of any type of material. It ensures that the food contact material, in its finished state, is compliant with the requirements of the Plastics Regulation (EU) No. 10/2011 and with Item 3 of Commission Regulation (EC) No. 1935/2004.

MigrationAccording to the EU definition, „migration is the quantity of plastic material that can transfer to foodstuff that comes into contact with it, and which poses a risk to human health and can result in an unacceptable change in the composition of this foodstuff.“ Or simply put – molecules can transfer from the packaging to the foodstuff or vice-versa. This can have various effects, ranging from loss of quality to changes in flavor, or even to contamination.

PermeationPermeation goes even „one step further“ than migration. Derived from the Latin term “permeare”, permeation describes the process in which a material penetrates or gets through to a solid body. This occurs when an external substance permeates through the packaging and into the foodstuff, or vice-versa.

The term “chemically inert” applies to substances that do not react with potential reaction partners (e.g., water, air, and other substances) under the usage conditions they are intended for. „Stable and non-reactive under given conditions“ is the official definition of the term used by the International Union of Pure and Applied Chemistry. The silicon oxide-based (SiOx-based) inert barrier technology from Greiner Packaging ensures the best product protection.

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Silicon Plasma

Greiner Packaging gives its customers a competitive edge through the world‘s first use of an inert barrier for plastic cups. The original technology has already proven its worth a million times over in other types of packaging (e.g., bottles or packaging made of flexible films). Now, Greiner Packaging is transferring it to the cup packaging industry. The inert barrier technology makes use of the outstanding properties of silicon oxide. A wafer-thin layer

of this material – about 500 times thinner than a strand of human hair – is applied to the cup interior in a vacuum chamber using a plasma deposition process, which binds the sealed inner layer with the plastic in the form of a so-called „covalent bond“.

A wealth of outstanding propertiesThe layer applied through inert barrier technology

A wafer-thin layer of silicon oxide extends the shelf life of foodstuff, bringing it to a whole new level.

The World Premiere inert barrier technology

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is flexible and can also be sterilized or pasteurized. This allows it to be used even in cups made of highly transparent materials. Because the silicon oxide layer is very thin, there is no weight added to the cup – a critical factor for logistics and CO2 emission. The layer also has no impact whatsoever on disposal or recycling. Cups that are coated with the inert barrier technology can be milled without any problem. The ground material is reused in

the production of new plastic cups. Coated packaging is declared as a mono-material.

New dimensions for barriersThe inert barrier technology brings multiple benefits for barriers and migration. It forms an additional functional barrier that greatly reduces the oxygen and water vapor permeability of plastic cups. This increases the oxygen

The World Premiere inert barrier technology

The cup is fed into a chamber. A vacuum is generated in the chamber. Then gas containing silicon and oxygen are introduced into the chamber

and plasma is generated using the electrode. This results in the coating on the cups.

gas containing silicon + oxygen

vacuum chamberelektrode

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barriers compared to uncoated packaging by a factor of 20 in PP and by a factor of 30 in PS. Packaging with inert barrier technology also provides perfect flavor sealing, almost entirely retaining the aroma and taste of the contents. The silicon oxide coating is completely immune to temperature and humidity, rendering these factors irrelevant. Retort shock is prevented.

Factors that affect barrier effectiveness (functional barrier) in plastics

Type of fill material Type of plastic Plastic thickness Storage time Storage temperature Solubility of migrating material in the plastic Molecular weight of the migrating material

Effective product protection

inert barrier technology protects the fill material from a wide variety of effects – thanks to these exceptional features: excellent oxygen barrier water vapor barrier odor protection (odor and taste) color protection temperature- and humidity-resistant appropriate for pasteurization and sterilization

10-2 m 10-3 m 10-4 m 10-5 m 10-6 m 10-7 m 10-8 m 1 milimeter 1 micron

pencil line

1-2 mm

bacterium 1 micron

To illustrate the thickness

of the layer: wafer-thin,

thinner than a strand of hair

hair

60 micron

10

”Inert barrier technology is a packaging innovation. It utilizes a coating that significantly enhances the protective function of packaging, thereby extending food shelf life.“

Greiner Packaging2014

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produces this cover via the process of thick-gauge thermoforming. The surface obtains its unique gloss through a PMMA layer.

Optimized Waste Toner BoxSavings through close cooperation

Tech-Facts

Technology: Injection molding Assembling: Dismantling – Cleaning – Assembly Special feature:

Poka-yoke in recycling

Tech facts

Material: ABS/PMMA (high-gloss) in the form of semi-finished products

Technology: thick-gauge thermoforming, milling Surface treatment: PMMA layer

High-gloss surfacein thermoforming technologyVisually attractive paneling for freshwater module

Visual appearance is no longer a “poor relation” in the housing technology sector. On the contrary, it is becoming increasingly important for boilers, buffer storage tanks, solar equipment, etc., to look good. Modern housing technology scores points with its esthetic appearance. ETA, the leading Austrian company for heating boilers, demonstrates this with its new fresh water module, enhanced with high-gloss surface cover for the control unit. Greiner Assistec

Greiner Assistec has presented numerous optimization suggestions for the production and recycling process of waste toner boxes to his customer, a globally operating enterprise for business process and document management. These suggestions have fallen on fertile soil as their implementation brings improvements to several sectors: Production costs are reduced thanks to the use of a new raw material (HIPS). A new packaging variation facilitates the transport of a larger quantity per palette. Embossing the labeling in relief instead of using common labels and design changes have led to a simplified and more efficient automated recycling process. And the yield in the product recycling can be increased. It‘s a win for all parties involved: Greiner Assistec gains a constructive customer partnership, the customer enjoys sizeable savings, and the end consumer gets a better product.

Proven PartnershipThe globally operating enterprise and Greiner Assistec have joined forces in a

long-term collaboration. The flow of data and goods of both business partners were tightly integrated to produce toner and waste toner boxes, resulting in significant logistic advantages. Greiner Assistec and its customer currently work together according to the logistic principle of “SCI – Supplier-controlled Inventory”. Under this supply concept, the supplier assumes the responsibility for inventory management and forward supply planning of its products at the customer’s. The customer benefits from optimized stock levels at minimal inventory level.

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Tech factsStove control knobs

Material: PBT Technology: Injection molding, lasering

Tech factsElectronic

Material: Raw components made of white ABS, provided

Technology: Lacquering, tampon printing, lasering

The laser is ultra-flexible at decorating plastic parts. It can be used in many areas of application, one of which is the labeling and marking of parts. Depending on the setting of the laser parameters and on the material, engravings or colorizations on the surface can be created. Markings without tactile recesses on the surface are also possible. The laser label is abrasion-, heat-, and acid-resistant.

An exciting combination: Lacquering and laseringAt its St. Gallen site, Greiner Assistec uses a combination of lasering and lacquering for Philips, manufacturer of electronic devices for body care. Structural components are manufactured and processed in two versions – “high end” and “mid-end”. A lacquer layer is applied to the “high end” parts, followed by the laser engraving of a battery symbol. This is then followed by the application of a second and third lacquer layer. When in use, the battery symbol becomes visible as soon as the battery is drained. It appears through the second and third lacquer layer.

Mora MoraviaThe Czech company Mora Moravia is part of the Gorenje Group and manufactures household appliances. At its Brezová site, Greiner Assistec received the order from Mora Moravia to produce 16 different stove control knob models. The control knobs are produced in injection molding and are then marked with a laser. Compared to tampon printing, in which the markings are made with an elastic inkpad, the laser method boasts clear advantages: it is placed with

the utmost precision and the highest quality. It has proven very resistant to handling and wear and tear. This durability is what makes it particularly highly appreciated by the end customer.

Extremely versatile: Labeling and Marking with LasersDecoration technologies delight customers

High-performance

laser marking station

Greiner Assistec uses a state-

of-the art laser station for

labeling and marking.

At more than 400 characters

per second, it ensures

maximum productivity and very

short lead times.

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Thirst Quenching on the Road with Push-PullA new closure system – practical and simple

Swift thirst quenching on the road – for sports, driving, or at work: More and more people are feeling this commonplace need at a time when mobility has become part of everyday life. A push-pull nipple closure developed by Greiner Packaging, working in collaboration with the leading toy manufacturer LEGO, has now made drinking on-the-go much easier. The new cap may

be opened and closed with the mouth. It is therefore possible to drink from the bottle using only one hand.

Suitable for all Kavodrink bottlesPush-pull closures are manufactured in Austria and conform to common “food contact regulations”. They are robust, dishwasher-safe, and fit all three Kavodrink bottles (500, 750, and 1,000 mL). Greiner Packaging produces this bottle family using Tritan™ Copolyester, keeping it completely free of BPA (Bisphenol A). This food-safe and flavor-retaining raw material boasts outstanding properties. It offers design flexibility and is clear, impact-resistant, dishwasher-proof, and resistant to heat and chemicals.

Packagingfacts

Material: PP Technology: Injection

molding

Tech facts

Material: ABS/HT (high temperature resistant) in the form of semi-finished products (plates)

Technology: thick-gauged thermoforming, milling

A change of procedure improves the surfacePositive thermoforming proves itself

in the production of outer paneling parts for vehiclesThe production of outer cover for fire fighting trucks made by the leading Austrian manufacturer, Rosenbauer, has been shifted to positive thermoforming by Greiner Assistec. Before the change the parts were produced by thermoforming in the negative forming direction in which the plastic material is forced into the female mold. In the changed process of positive thermoforming the plastic is drawn over a male-mold. The change achieves better surface properties. It also helps achieve optimally distributed wall thickness. Together, Rosenbauer and Greiner Assistec have thus improved the quality of the products.

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IKEA Offers Comfort in the BathProduction of three-part bathroom sets

IKEA has been offering a new three-part bathroom set since April 2014. It consists of a soap dispenser in a bottle shape, a soap dish, and a toothbrush cup. All three parts are made of PET, are transparent turquois in color, and have shiny surfaces. Its lightweight and user-friendly design is perfectly suited to daily use. Moreover, all three articles are shatter-proof – a big advantage in bathrooms, most of which are fitted out with hard tile floors.

A single production sourceA major strength of the Greiner Packaging Group proved to be important to the production of the bathroom set: its wide technology portfolio. The soap dispenser is manufactured using the injection stretch blow molding process and the two other

Tech facts

Material: PET Technology:

Injection molding, Injection stretch blow molding

Customer proximity – in every respectLenhart Kosmetik benefits from nearby GPI Location in Rastatt

Lenhart Cosmetics is among the biggest German private label producers. An annual production volume of about 30,000 tons, 120 employees, and more than four decades of experience in the cosmetic industry distinguish the company, which exports its products to over 40 countries. For consumers, the body care products of Lenhart Kosmetik are, in the most literal sense, close enough to touch every day.

Soap dispenser made of PETGreiner Packaging produces PET soap dispensers for Lenhart Kosmetik. In this business relationship, customer proximity is likewise the key. It had already begun

with the design, which started at Greiner Packaging, and was further developed and implemented together with the customer. With sustainability in mind, the suitable production equipment was moved from Wartberg an der Krems (Upper Austria) to Rastatt in Germany, thereby shortening the transport distance and consequently protecting the environment.

Tech facts

Contents: 500 mL Material: PET Technology: Injection stretch blow molding

parts in injection molding. The customer therefore obtains a comprehensive solution from a single production source.

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