Automation in new pet food factoryKormotech, one of the largest animal food producers from Eastern Europe, is going to build a new factory for the super premium Optimeal and premium Club4Paws pet food brands in Lithuania. Lan’s contribution concerns the delivery of a pouch handling line with 3 loaders, 2 unloaders with integrated In-Line Dryers to handle pouches with wet cat and dog food. Steriflow supplies the sterilisation retorts. Delivery is planned for April 2020.
Lan works in multidisciplinary teams: mechanical, electrical and software designers work together with our technicians to achieve the best results. The new, state-of-the-art building in Tilburg where a large glass wall separates the office from the production hall, makes an enormous contribution to this.
We can handle innovative packaging – such as uncommon shapes. We have solutions to handle multipack with different flavors. We are market leader in pouch handling. Benefit from our extensive experience with more than 500+ projects worldwide. We integrate the latest techniques and trends (digitization, low energy and air consumption).
These firms are advised to develop alternate and sustainable packaging material.
E-commerce companies, which contribute to about 40% of India’s annual plastic consumption, have been asked to gradually phase out the practice of single-use plastic in packaging products being sold through their platforms, said TOI report quoting govt official.
Almost all the e-commerce firms, including Amazon and Flipkart, have been using plastic to package products. However, they are claiming to make efforts to shift towards eco-friendly packaging gradually.
Amazon said that it has brought down usage of single-use plastic to 7% and plans to stop using them in the next eight months completely.
Whereas Flipkart, which claims to have reduced single-use plastic usage by 25% till August, aims to achieve 100% plastic-free supply chain by March 2021.
Earlier this year, the Maharashtra Pollution Control Board (MPCB) had sent a show-cause notice to Amazon over the use of bubble wrap plastic packaging.
Meanwhile, industry observers pointed out the lack of complete guidelines and definition of single-use plastic by the govt.
Under the Plastic Waste Free-Swachhata Hi Seva Campaign, the DPIIT has been asking industries to recycle plastic waste. It has also invited CEOs and MDs of industrial estates under the DPIIT to ensure collection and transportation of collected plastic waste.
In India, close to 30,000 tonnes of plastic waste is generated every day. Of this, 10,000 tonnes of plastic waste does not get collected. The starting point of a mass movement to achieve the target by 2022.
Earlier, PM Narendra Modi, in his Independence Day speech, appealed to shun single-use plastic to protect the environment. All government offices in states and Union territories have been asked to not use plastic in any forms like, carry bags, thermocol disposable cutlery and plastic flags, flowers, water bottles and folders. The Environment Ministry has also asked national parks, zoos and wildlife sanctuaries across the country to become single-use plastic-free.
The govt plans to do away with single-use plastic by 2022.
The challenges of true recycling:
A crucial and often neglected step in the recycling process is sorting. Failure to sort the collected packaging into material streams that recyclers can use leads to down-cycling – that is, the production of recycled material no longer suitable for its original application. “If you want to avoid a ‘garbage in, garbage out’ scenario,” explained Immo Sander, Head of Packaging Development, Werner & Mertz Group, “the entire value chain must be aligned – from packaging producers through players in sorting and recycling to buyers of recycled material.” This is the aim of the Recyclate Initiative that Werner & Mertz launched in 2012.
In order to develop packaging that would yield high-end recycled material, Werner & Mertz and Mondi consulted multiple recycling experts: Der Grüne Punkt – Duales System Deutschland, EPEA Switzerland as well as Institut cyclos-HTP for later certification.
The packaging needed to be made of a polyethylene mono-material, which is a prerequisite for recycling. “Our collaboration with Werner & Mertz shows, in the best possible way, how challenges can become solutions,” said Jens Kösters, Manager Technical Services, Mondi Consumer Goods Packaging, “We worked our way through an ‘innovation funnel’— testing different materials until we arrived at a designed-for-recycling concept that convinced everyone at each point of the value chain. Furthermore, the concept offers clear benefits related to sealing strength and maximum filling volume.”
A giant leap: a pouch with detachable decorative panels:
A final touch was added to solve the issue of recycling printed plastic materials. The pouch has two layers. “We dress the pouch up in an eye-catching ‘outer garment’ that is printed with brand design on the front and consumer info on the back,” said Sander. “When the pouch is empty, we ‘undress’ it automatically by shredding and sorting the two components into separate recycling streams.”
The patented pouch is now 100-percent recyclable. The material is of course free of glue or adhesive. Spout and cap are also made of polyethylene – which means the recycled material will be equivalent in quality to the original material.
With our own air cushion machines, the AirWave and AirBoy series we have for each packaging and shipping challenge the appropriate solution. The reliable AirWave air cushion film is manufactured by us in Germany and is 100% recyclable. The reduction of the storage space for packaging material, very low shipping weight and a high production speed characterizes the air cushioning machines. Our PaperWave paper padding machines are the perfect complement for packaging sharp-edged goods. With FLOETER you get the right air cushion film in a variety of materials such as antistatic, biodegradable or special high pressure films suitable for air freight shipping. In addition, we offer complete air cushioning systems and integration solutions for the packing stations in your packing departments.
Meltblown nonwovens from the Reifenhäuser R & D Center are now only supplied to manufacturers of masks for medical facilities and care services in the German market. The search for industrial converters continues.
Troisdorf, April 06, 2020 | Reifenhäuser Reicofil has found customers in Germany for the nonwoven fabric currently produced in the R & D center and urgently needed for the production of face masks. The material is also supplied to public or charitable initiatives that manually produce face masks for medical practices, hospitals and care services.
London-headquartered SharpEnd has done extensive connected packaging work within the alcohol industry, mostly in the whisky sector – a feat not to be underestimated, given the proud heritage of such tipples. As Rob Hollands, MD of the SharpEnd told Packaging Scotland, ten years ago our televisions weren’t connectable, let alone whisky bottles!
“It will get to a point where it’s just the default – consumers are looking for that code to scan or point to tap to get additional information, then authenticate it, and for us (that’s) a lot of this work we’re doing now,” he explained.
Rob said it would be impossible for heritage brands to not be in the digital and social world today – regardless of who their target audience is – meaning that firms now realise that they have to engage with consumers through digital channels.
In 2017, the firm partnered with Irish whiskey firm Jameson. To celebrate St Patrick’s Day, consumers in Ireland were able to tap their phone on Jameson bottles to unlock access to exclusive giveaways, product information and quizzes.
Rob said that products being on shelves and in the hands of consumers will ‘always dwarf any other media opportunity’ that a brand will get. He continued, “I think sometimes that we underestimate the fact that actually just showing your consumers that you’re innovating and doing things differently, you’re adding value through creative technology. There’s a lot to be said for that.”
In the Jameson instance, an NFC chip was inserted into the bottle to ensure it was compatible with mobile phones. Given the increasing scrutiny over excessive packaging, such a method could possibly fall under that microscope.
Rob, however, said that work is carried out with technology providers to make sure additional items do not impact the product’s sustainability. He told of SharpEnd’s work with Unilever, in which a ‘sortscanner’ was developed. The barcodes of Unilever products could be scanned by consumers to receive advice on how best to recycle the product based on their geolocation.
“I definitely think there’s an opportunity for connective packaging and creativity and technology to help support sustainability,” he added.
The key point in digital packaging is that there has to be an incentive for the consumer. Rob told of discussions he has had with sceptical clients, who had a discerning view of digital packaging due to their own experiences.
“When we go in to talk to clients and they tell us that ‘three years ago we trialled a QR code on a pack and it was a total failure’, once you start to unpack that with them, a lot of their work would’ve been focused on getting the actual code on the pack and then all of a sudden they’re dropping someone into a corporate ‘.com’ website where no consumer in their right mind has ever been to before or would want to – that website is for stakeholders and they’ve totally forgotten to deliver the creative experience or value for the consumer.”
Rob told how the firm never acknowledges that there may or may not be a technical challenge, saying that they always overcome them eventually. Instead, they see the actual challenge and opportunity as a creative one.
“What is the reason someone would ever tap or scan the product? I think you start there and try and understand that reason. What’s the benefit to the brand and the consumer? Then you come up with a winning solution.”
Incentives vary in terms of what the product is. As online marketplaces grow, so does the prominence of counterfeit goods. A QR logo can act as a trusted system in consumers being able to verify the authenticity of an item – with the code leading them to a site which checks that the code hasn’t been duplicated and that it is official.
Save on packaging materials
The banderol delivers a number savings. The amount of packaging material required in relation to the size of product to be packed can be small. Especially so when compared to alternative packaging such as shrink wrap, bags, boxes and other complex packaging. Additionally, banding often renders the use of other additional packaging unnecessary. Such as metal clips, elastic bands or adhesive labels.
Interesting examples at Lufthansa and in retail
After extensive customer research Lufthansa has replaced in-flight blankets in plastic bags by those with a neat paper Bandall band. This is an important change in policy that is now being emulated by other airlines needing to reduce their use of plastic packaging. All industries, whether in furnishings, furniture, wood or fruit and vegetables, everyone is looking for ways to cut their use of plastics and packaging materials in general.
The finest banding materials
There is only one banding machine that can process a just 35 micron banding material and that is the Bandall - all models include Bandall’s unique band transport technology. Using finer banding materials reduces packaging volume and in turn packaging waste volumes. Additionally, rolls of banding material are smaller, taking up less space and creating savings in transport and storage.
Biodegradable banding materials
At Bandall we have a number of sustainable options in banding materials. Such as FSC certified Kraft paper and bio-based banding film,100% recyclable, compostable, biodegradable – all can be supplied with or without full colour printing. Banding means the need for adhesives and self-adhesive labels becomes superfluous thanks to the UCS (Ultra Clean Seal). An organic and compostable hot-melt seal is also available
Flexible printing during the banding process leads to reductions in waste
Printing flexible information onto bands prevents unnecessary wastage of packaging materials. For example, a small change in product details can mean that stocks of printed primary packaging is no longer usable. Printing flexible information onto a pre-printed band during the banding process avoids losses from wasting outdated stock.
Bandall’s unique Print & Band model with integrated printer can print unlimited data in any number of positions along the band. Over the entire length and width. So, for example, printing bar codes, dates, language changes and updates in nutritional values onto a smartly designed band.
Energy and cost saving banding equipment
In addition to savings in packaging materials, Bandall’s banding equipment is a sustainable option when compared to machinery for other types of packaging.
Minimal consumable parts and a long life
Bandall is the only banding equipment worldwide that operates pneumatically rather than mechanically. Its unique band transport system ensures consistency and accuracy in performance, reliability and continuity as well as fewer consumable parts than any alternative banding machines. Bandall has the lowest cost of ownership.
Energy saving packaging
Bandall equipment requires compressed air and electricity. One comparison is with shrink wrap solutions - the Bandall uses less electricity than needed for shrink wrap machinery.
Bandall and Corporate Social Responsibility
Setting and achieving sustainability goals is in Bandall’s DNA. In addition to focussing on sustainable banding solutions Bandall contributes to the environment within the company itself. Bandall’s headquarters in De Meern and factory in Heemskerk are equipped with LED lighting only. LED lighting saves 60% of electricity compared to normal fluorescent lighting. 265 solar panels have also been installed on the roof of the offices in De Meern, producing sufficient energy to supply all branches with power, including the electricity required to charge all of our electric and plug-in hybrid cars. We are striving towards running a completely energy neutral operation.
Drawing on unrivalled heritage in design, science and manufacturing, Amcor and Moda offer multiple innovative solutions in flexible packaging for food processors. “Specifically for protein applications, meat processors can experience increased throughput up to 40 bags per minute, while reducing labor costs by 50 percent or more with Flow-Tite® shrink rollstock and Moda equipment,” explained Don Schnabel, Sr. Marketing Director at Amcor.
Moda is a global leader in producing high performance modular packaging equipment that integrates the latest technology with hygienic design for vacuum packaging. High performance Moda packaging systems have been crafted to endure the challenges of demanding environments, increase productivity, and deliver energy, labor and total package cost savings. The rigorously tested line of Moda systems provides improved ergonomics, product-flow and food safety, too.
“As we continue to accelerate in solving packaging challenges, we are pleased to welcome Moda as our partner. Moda provides industry knowledge, machine expertise, and capabilities that will strengthen our ability to deliver valuable products and services to our customers,” Schnabel said.
See the Amcor packaging film and Moda equipment duo demonstrated live at the International Production and Processing Expo in Atlanta, Georgia, January 28-30, Amcor booth B6119, or contact Amcor Flexibles North America at NorthAmericaFlexibles@amcor.com to learn more.
Moda brings decades of protein industry experience and intelligent engineering to a meat and cheese industry that is ready for smart automation. With a factory and design head-quarters in New Zealand and service centers around the globe, Moda delivers high performance vacuum shrink packaging technology to the largest meat and cheese processors in North and South America, Canada, Europe, Asia, Australia and New Zealand.
Amcor is a global leader in developing and producing responsible packaging for food, beverage, pharmaceutical, medical, home- and personal-care, and other products. Amcor works with leading companies around the world to protect their products and the people who rely on them, differentiate brands, and improve value chains through a range of flexible and rigid packaging, specialty cartons, closures, and services. The company is focused on making packaging that is increasingly light-weighted, recyclable and reusable, and made using a rising amount of recycled content. Around 48,000 Amcor people generate US$13 billion in sales from operations that span about 250 locations in 40-plus countries.
The life cycle assessment of packaging types in Austria which was presented in April 2019 delivered some informative findings. Roland Fehringer’s independent consultancy company c7-consult took a close look at the environmental impacts of packaging types made of plastic, glass, metal and carton for various product groups. In the area of mineral water, for example, the life cycle assessment examined single-use and reusable bottles made of PET both with and without recycled materials and also single-use and reusable bottles made of glass. The data clearly illustrates that weight, the ratio of packaging weight to the contents, shipment distances and the proportion of recycled materials used have a bearing on the environmental impacts.
From theory to practice
In the product category of mineral water, the theoretical winner of the study was the reusable PET bottle made entirely of recycled materials. It was the winner in theory only, as this packaging solution did not actually exist within the Austrian market when the study was presented in April 2019. At the time, Christoph Hoffmann, Director Corporate Strategy, Sustainability & Circular Economy at ALPLA, made the following statement: ‘We will focus more on reusable systems in the future and will develop practicable solutions in close cooperation with our customers.’
On the one hand, the data for other European countries showed very similar results and lent weight to this project. But on the other hand, innovative solutions for plastic reusable bottles were in short supply due to a declining reusables quota in German-speaking countries. It was therefore evident that there was room for improvement here. And ALPLA wanted to harness this potential together with its innovative partner KHS. This company has more than 20 years of experience in the area of preform and bottle design for reusable PET solutions.
Exclusive partnership with many advantages
ALPLA had already successfully performed sampling for a new reusable solution made of PET at the beginning of this year, in other words eight months after the study was presented. An optimised reusable bottle was then developed in close cooperation with the global KHS Group. ALPLA produces the preforms, which are then stretched, blown and subsequently filled on the KHS production lines.
The lightweight among reusable packaging units
Collaboration with KHS ensures that the bottles are ideally adapted to the bottling and washing systems. This is a major advantage when it comes to production processes. The new bottle design also boasts neck and base optimisations that allow for a significant reduction in weight. The bottle weighs a mere 55 grams, and the ALPLA experts say further reductions can realistically be achieved. As a comparison, standard reusable plastic bottles weigh around 65 grams, while reusable glass bottles can even be as much as 550 grams – in other words, ten times the weight of their plastic counterpart.
The bottle is designed with a high circulation rate in mind, in spite of its minimal material usage. The material has to be adequately alkali-resistant in order to maintain the quality and the look of the bottle even after multiple washing cycles. The ALPLA experts additionally took the use of recycled materials into account from the outset when developing this packaging solution. Even when the bottle is withdrawn at the end of its life cycle, it can be recycled and the material can be turned into new PET bottles. Overall, this innovative 1-litre reusable PET bottle takes into account the three principles of the ‘reduce, reuse and recycle’ waste hierarchy.
This joint project with KHS demonstrates once again that there is nothing standing in the way of anyone who earnestly wishes to identify and realise sustainable solutions which are in the interests of the circular economy. The technological possibilities exist. Nevertheless, the packaging should always be adapted precisely to the product and to the market. We recommend you talk to our ALPLA experts to determine whether a reusable or a single-use solution is more suitable for your project.
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