Flexible Packaging October 2011

◆

WE CALIBRATE SUCCESS TO THE THOUSANDTH OF AN INCH.

We’ve earned the right to be precise. Four decades of research gives us an edge in the marketplace—and development never stops. From on-site evaluation and laboratory confirmation to maintaining state-of-the-art equipment, we take innovation seriously. And that’s how we engineer solutions with a speed-to-market flow that saves our customers time and money. Look to danafilms.com or call our film experts at 800.634.8289.

ISO 9001 Certified

®

EBECRYL 571 Resin A New Benchmark in Shrink Sleeve Performance & Productivity Introducing EBECRYL® 571, Cytec Industries’ newest resin system for UV/EB curable flexographic shrink sleeve printing ink and coating applications. EBECRYL® 571 has excellent pigment wetting, is suitable for process colors and is compatible with metallic and white pigments. Find out more about how EBECRYL® 571 can reduce cost and time while increasing the overall performance of your narrow web energy curable printing by contacting us at the e-mail address and phone numbers listed below.

Email: [email protected] l Worldwide Contact information: www.cytec.com Contact Us Today : US Toll Free: 800-652-6013 l Tel: 973-357-3193 l Belgium: +32 2 560 4511 Trademark Notice: The ® indicates a Registered Trademark in the United States and the ™ or * indicates a Trademark in the United States. The mark may also be registered, the subject of an application for registration or a trademark in other countries. © 2011 Cytec Industries Inc. All Rights Reserved.

T H E IN D I S P E N S A B LE TOOL FOR C O N V ER T ER S & P R I NT ER S O F FLE X I B LE PA C K A GI N G

Table of Contents ®

O CTO B E R

2 0 11

| VOLU M E 1 3 , N U M B E R 8

20 COVER FEATURE PROFILING A BAG-/ POUCH-MAKER Crisp images, well-made pouch lines and excellent customer service has morphed Diamond Flexibles into a pouching success.

28 FEATURES

DEPARTMENTS

12 FPA UPDATE

8 EDITOR’S FORUM

Flexible Packaging Association Update 2011 Fall Executive Conference a Success… Internship and Scholarship Programs Announced… Operating Ratios Reported…2011 State of the Industry Report.

16 CONVERTER NEWS New Coex Line Launched…Solvent Recycler Installed… Recession Recovery News…MSU Packaging Alumni Association Announcement…and more.

28 PRINTING: SHRINK SLEEVES Streamlining Shrink Sleeve Production The global $3 billion shrink sleeve market is growing at about 7 percent a year, yet shrink sleeve production remains one of the biggest challenges in packaging for both designers and converters.

30 TECHNOLOGY: INKS Challenges and Changes in Flexible Packaging The flexible packaging industry is seeing many changes taking place: squeezed margins, environmental concern, and the demand to produce clean process inks.

38 INDUSTRY INSIGHTS Efficiency – The Key to Today’s Converting & Packaging Committing to continuous improvement is the key to today’s industry needs, and Susan Stansbury explains how. 39 SUPPLIER NEWS Celebrating 100 Years…Expansion Projects Announced…Creative Center Opens…and more. 42 HOT PRODUCTS 45 CLASSIFIEDS

30

32 ROUNDTABLE ON SLITTING/REWINDING (SPECIAL ADVERTISING SECTION)

49 CALENDAR OF EVENTS/ AD INDEX

50 INDUSTRY Q&A: BAG-/POUCH-MAKING Adding Technology to Bag-/Pouch-Making Scott Fuller is CMD Corporation’s intermittentmotion product line manager and has shared his expertise with CMD for the past 4 years.

32 4

FLEXIBLEPACKAGING

| www.flexpackmag.com

OCTOBER

2011

“THESE BLADES HELP US ACHIEVE OUR SUSTAINABILITY COMMITMENT.” “Since switching to SWEDCUT, our print defects and overall waste have declined. Also, because they last longer, we have fewer blades to dispose of.” Production Manager / Wide Web Flexible Packaging Manufacturer Northeast, USA

* SWEDCUT doctor blades are manufactured under strict ISO 9001 control and ISO 14001 environmental standards. FLXON IS THE EXCLUSIVE DISTRIBUTOR IN CANADA – USA – MEXICO FOR

Printing Doctor Blades

Committed to Sustainability

+1.704.844.2434 www.flxon.com

T H E IN D I S P E N S A B LE TOOL FOR C O N V ER T ER S & P R I NT ER S O F FLE X I B LE PA C K A GI N G

Online Content ®

O CTO B E R

2 0 11

| VOLU M E 1 3 , N U M B E R 8

WWW.FLEXPACKMAG.COM FAST ACCESS TO WEB-ONLY FEATURES SUCH AS:

JOB SEARCH epackagingjobs.com, the premier online job search site for packaging professionals. “Unwrap your potential!”

TIMELINE OF INNOVATIONS in Flexible Packaging from the past 10 years.

NEW! FLEXPACKREPORT NEWSLETTER delivers the latest research and business data needed by flexible packaging converters. Includes links to sources of current resin prices. Sign up for your FREE subscription today.

BREAKING NEWS about film manufacturers and converters—get your competitive intelligence here!

CONNECT WITH FLEXIBLE PACKAGING NOW: FACEBOOK AND TWITTER

6

FLEXIBLEPACKAGING

| www.flexpackmag.com

OCTOBER

2011

Editor’s Forum

THE INDISPENSABLE TOOL FOR CONVERTERS & PRINTERS OF FLEXIBLE PACKAGING

®

WHAT DOES YOUR COMPANY’S ROADMAP LOOK LIKE? Results. hey are what all of us are after when it comes to business. You want to put in some effort, and see the fruits of your labor. But sometimes, without a strategy in place, the results might not be what one anticipates. This could be a blessing in disguise. What is your sequence for results? For some companies, the road to successful results is carefully mapped out with meticulous planning prior to the initial action. But from what I observe, more often than not, companies will travel that road to results with a “we’ll figure it out once we get there” plan in place. This month’s cover story is a question-and-answer interview with one company that drove down that bag- and pouch-making road without much mapped out first. The cover story highlights Profiling a Bag-/Pouch-Maker, and demonstrates how sometimes taking chances and figuring things out as you go along is the roadmap to results.

T

Maybe it is all about the destination, and not the journey. The Printing section of this month’s issue, on page 28, explains how Streamlining Shrink Sleeve Production can create a better outcome when it comes to a clean, correct shrink sleeve. Page 30 discusses the Inks industry and how different industry changes are affecting the demand of inks. The Industry Q&A on Bag-/Pouch-Making discusses the addition of technology to bags and pouches to make them that much more attractive, which can be found on page 50. The monthly Special Advertisers Section offers the Roundtable on Slitting/Rewinding, which can be found on page 32. This Roundtable offers insight on this sector from three companies involved in it, including new features for this sector, as well as problems solved by this industry mainstay. As always, be sure to stop on pages 16 and 39 for our Converter News and Supplier News sections for the up-and-up of industry happenings. We have a large Hot Products section this month, page 42, which highlights new and exciting products on the market. Converting Influence’s director Susan Stansbury penned a column, on page 38, about how Efficiency is the key to converting and packaging. So for those seeking results, maybe it’s not as the saying goes. Maybe it is all about the destination, and not the journey. At least that’s how it works out for some companies. What does your company’s roadmap look like? FP Sincerely, ERIN J. WOLFORD (847) 740-2338 [email protected]

8

FLEXIBLEPACKAGING

| www.flexpackmag.com

Packaging Group Publisher Mike Barr, [email protected] Publisher Randy Green, [email protected] National Sales Manager Steve Liput, [email protected] Inside Sales Kristina Lorio, [email protected] BNP Custom Media Group Christopher Wilson, [email protected] EDITORIAL Editor-In-Chief Erin J. Wolford, [email protected] Associate Editor Elisabeth Cuneo, [email protected] Marketing Coordinator Cedric Brown, [email protected] Art Director Frank J. Mayeran Advertising/Production Manager Courtney Warnimont EDITORIAL BOARD George Thibeault, Constantia Hueck Foils LLC Michael Impastato, Flint Ink. Fredy Steng, Berry Plastics Marla Donahue, Flexible Packaging Association FPA OFFICERS Chairman John Baumann, Ampac Packaging LLC Immediate Past Chairperson James E. Love, III, Printpack Inc. Executive Vice-Chairman (chairman-elect) William Burke, Nordenia USA Treasurer Michael Impastato, Flint Group President (non-voting member) Marla Donahue, Flexible Packaging Association Executive Committee Members At Large Hans Deamer, Windmoeller & Hoelscher Corp.; Jim Mize, Sealed Air Corp.; Ken Swanson, Berry Plastics Corp.; Rob Tiede, Sonoco Flexible Packaging AUDIENCE DEVELOPMENT Corporate Audience Development Director Rita M. Foumia Audience Development Manager Kourtney Bell Multimedia Specialist Katie Jabour Audience Audit Coordinator Carolyn M. Alexander For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected] List Rental Postal contact: Kevin Collopy at 800-223-2194 x.684 [email protected] Email contact: Michael Costantino at 800-223-2194 x.748 [email protected] BNP MEDIA CORPORATE OFFICERS Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Clear Seas Research: Beth A. Surowiec FOR VOLUME REPRINTS: Reprints Sales Representative Jill DeVries Phone: (248) 244-1726 • Fax: (248) 244-3934 E-mail: [email protected] CONTACT FLEXIBLE PACKAGING Phone: (847) 405-4000 • Fax: (847) 405-4100 Mail: 155 Pfingsten Road, Suite 205, Deerfield, IL 60015 Internet: www.flexpackmag.com Circulation: (248) 244-6421

BNP MEDIA HELPS PEOPLE SUCCEED IN BUSINESS WITH SUPERIOR INFORMATION. VOLUME 13, NUMBER 8

OCTOBER 2011

THE NEW STANDARD IN FLEXO STACK

CI

INLINE

GEARLESS SERVO OR GEARED FAST ON-PRESS PLATE/ANILOX SLEEVE CHANGES SERVO OR MANUAL PLATE/ANILOX POSITIONING 1-10 COLORS • 2-150” WIDE DOWNSTREAM OR COMPLETE LINES

CONTACT RETROFLEX

phone: (920) 532-4850 • fax: (920) 532-4854 [email protected] • www.retroflex.com

F L E X I B L E PACK AG I N G A S S OCIATI ON | UPDATE

FPA HOLDS SUCCESSFUL 2011 FALL EXECUTIVE CONFERENCE he Flexible Packaging Association’s 2011 Fall Executive Conference, recently held in Chicago, IL, provided great networking opportunities for flexible packaging leaders and peers, and focused on key issues and topics important to the flexible packaging industry including Opportunities for the U.S. Flexible Packaging Industry; M&A Activity in the Packaging Industry; U.S. Fiscal Challengesy; Food Safety; the Global Economy; and, the Cost and Availability of Flexible Packaging Materials. Presentations from the 2011 FPA Fall Executive Conference are available in the Members Only section of the FPA Web site (www.flexpack.org). This issue of the FPA Update provides a recap of those presentations.

T

FPA Update Bill Burke, president and COO of Nordenia U.S.A., and chairman of the FPA Board of Directors, opened the 2011 FPA Fall Executive Conference with a review of recent FPA activities and accomplishments. Bill also discussed the results of the FPA Flexible Packaging Waste Resource Recovery Pilot Program.

Bill Burke

Jeff Bornstein, vice president; and, Bruce Deckman, president Jeff Bornstein Bruce Deckman of SAI Industrial LLC, presented the results of the FPA Opportunity Assessment for U.S. Flexible Packaging Industry study. FPA commissioned SAI to conduct this research, which explored top trends, opportunities, and barriers to flexible packaging growth. The study also examined issues and opportunities for conversion from other packaging formats to flexible packaging.

Packaging Industry: M&A Perspectives Richard Weil, director, Investment Banking; and Louis Mitchell, managing director, Investment Banking for Mesirow Financial discussed recent merger and acquisition activities in the packaging industry, and their impact on flexible packaging businesses. Combined, Richard and Louis have more the FLEXIBLEPACKAGING

Richard Weil

Louis Mitchell

Addressing our Nation's Fiscal Challenges: What it Means for Manufacturers Dorothy Coleman, vice president of Tax and Domestic Policy at the National Association of Manufacturers (NAM) discussed current U.S. economic and financial challenges and their impact on the Dorothy Coleman manufacturing industry. At NAM, Dorothy is a spokesperson for tax policy issues and provides NAM members with important tax-specific information, and represents NAM’s position to Congress.

Applicability of Food Safety Modernization Act on Packaging Manufacturers

Opportunity Assessment for the U.S. Flexible Packaging Industry

12

25 years of M&A experience, and have advised on more than 70 mergers and acquisitions in a variety of industries, including manufacturing, packaging, plastics, and flexible packaging.

| www.flexpackmag.com

Joseph Levitt, partner, Hogan Lovells discussed the applicability of the recently enacted Food Safety Modernization act (FSMA) to makers of food packaging materials. During his address, Joseph Joseph Levitt examined several key issues including Act compliance, regulation implementation, and material adulteration.

Flexible Packaging Materials Update Nick Vafiadis, business director of Polyolefins & PVC at CMAI provided an update the cost and availability of flexible packaging materials. Nick’s presentation focused on polyolefin resins - the highest volume raw material for the flexible packaging industry – Nick Vafiadis including polyethylene (high, low, and linear low density), and polypropylene. Nick also discussed key issues that are expected to drive the evolution of the industry in the near future. OCTOBER

2011

2011 FPA FLEXIBLE PACKAGING INDUSTRY INTERNSHIP & SCHOLARSHIP PROGRAM FPA Honors Flexible Packaging Industry Intern with Scholarship his summer, FPA converter member American Packaging Corporation participated in the Flexible Packaging Association’s 2011 Flexible Packaging Industry Summer Internship & Academic Scholarship Program and sponsored packaging school student Michael Rutalis, in a summer internship with the company. For his successful completion of the internship, FPA and American Packaging Corporation jointly awarded Michael a FPA Flexible Packaging Industry Academic Scholarship valued at $3,000. A packaging science student at Rochester Institute of Technology, Michael interned at American Packaging Corporation’s headquarters in Rochester, NY. During his internship, Michael worked in the QA department and assisted in the testing of materials to ensure they were defect-free. He also worked as a technician where he was responsible for the testing of the offline samples. “Working with the people at American Packaging Corporation was by far the best part of his internship. They were extremely helpful and supportive, and challenged me to expand my knowledge of the flexible packaging industry. This internship has provided me with a strong foundation in the flexible packaging industry,” commented Michael. The FPA Flexible Packaging Summer Internship & Academic Scholarship Program provides packaging and printing schools students with career enriching

T

internships that expose them to the diverse industry of flexible packaging. Since 2005, through the Program, FPA has awarded $75,000 in flexible packaging academic scholarships to students successfully completing internships with FPA converter members. For more information about the 2011 FPA Flexible Packaging Summer Internship & Academic Scholarship Program, and FPA’s Student Leadership Program, visit www.flexpack.org or contact FPA at (410) 694-0800. FP

American Packaging Corporation summer intern Michael Rutalis is flanked by Steve Rickey, technical director, American Packaging Corporation (left) and Mark Christensen, quality assurance supervisor, American Packaging Corporation (right).

2010 OPERATING RATIOS REPORT he 2010 Operating Ratios Report, produced by the Flexible Packaging Association, provides an annual review of operating expenses for flexible packaging converters. Data within the Report is provided to assist flexible packaging converters benchmark their overall performance, as well as, key operating factors and expense components, with that of composite information for other flexible packaging converters. The Report is a benefit of FPA membership and is available only to FPA converter members that participated in the 2010 Operating Ratios Report Survey. FPA is pleased to report that 46% of FPA converter members participated in the survey. The Report also provides a view of the flexible

T

OCTOBER

2011

packaging industry with additional perspective on both total employees, and factory versus non-factory employees; data regarding profitability, materials, and key operating statistics (for survey participants); and, information on key expense components as a percentage of net sales (2006-2010). For more information about the 2010 Operating Ratios Report, and additional FPA benchmarking reports including the State of the Flexible Packaging Industry Report, the Industry Earnings Report, the Pulse of the Industry Report, and the Industry Compensation Report, contact Bob Zaborowski, Director, Business and Economic Research at [email protected] or (410) 694-0800. FP

FLEXIBLEPACKAGING

| www.flexpackmag.com

13

F L E X I B L E PACK AG I N G A S S OCIATI ON | UPDATE

2011 FPA STATE OF THE INDUSTRY REPORT Industry Structure and Consolidation, Imports and Exports 9 in 2008. The 2011 State of the Flexible Packaging Industry Report includes a complete list of flexible packaging company mergers and acquisitions in 2010.

U.S. FLEXIBLE PACKAGING INDUSTRY Structure by Revenue % Total Industry Revenue ($25.5 Billion)

he 2011 State of the Flexible Packaging Industry Report, produced by the Flexible Packaging Association, provides an overview of performance and profitability of the U.S. flexible packaging industry. Several aspects of the industry are examined within the Report including sales and utilization levels, profit trends, capital spending, M&A activity, U.S. imports and exports, and industry growth. This issue of the FPA Update focuses on the Industry Structure and Consolidation, and Imports and Exports sections of the Report. The 2011 FPA State of the Flexible Packaging Industry Report is a benefit of membership and is available in the Members Only section of the FPA Web site, www. flexpack.org. The Report is also available to FPA nonmembers for $3,500. For more information, contact Bob Zaborowski, Director, Business & Economic Research at (410) 694-0800.

T

100

100%

80 77% 68%

60 58% 48%

40 38%

20 0

Top 5

Top 10

Top 20

Top 50

Top 100

Top 407

Source: Flexible Packaging Association

Industry Structure and Consolidation Today, there are approximately 407 flexible packaging converters/manufacturers. Of those, the top 10 flexible packaging converters account for nearly half of flexible packaging industry revenue; and, the top 5 account for 38% of industry revenue. In 2010, the U.S. flexible packaging industry experienced an increase in M&A activity with 16 domestic transactions completed, versus 7 in 2009, and

Imports and Exports According to the Report, U.S. flexible packaging exports increased by 15 percent to 1.5 million in 2010. Eighty-eight percent of domestic FPA converter members were involved in export activities. Over the past 10 years, flexible packaging exports have accounted for a consistent share of domestic production (measured in dollars) in the range of 4 to 6 percent each year. FP

TOP 5 COUNTRIES RECEIVING FLEXIBLE PACKAGING U.S. EXPORTS % breakdown by segment 700 Canada

Mexico

United Kingdom

Japan

Germany

Exports in $ Millions

600 500 400 300 200 100 0 2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

Source: Census Bureau, Foreign Trade Division Calculations by the Flexible Packaging Association

14

FLEXIBLEPACKAGING

| www.flexpackmag.com

OCTOBER

2011

Converter News

NEX PERFORMANCE FILMS LAUNCHES

NEW COEX LINE AT MILTON, WIS., PLANT EX Performance Films announced that it has completed the installation and startup of a new Windmoeller & Hoelscher (W&H) three-layer Varex coextruded blown film line at its Milton, Wis., plant. The new line adds an additional 5.5 million pounds to NEX Films’ coex capacity. It also uses W&H’s state-ofthe-art die design, gauge control, blending and winding technologies. By investing in the new line, NEX Films can expand its high-performance blown film capabilities, and further demonstrate its commitment to the market and its customers. “This new line will allow us to continue to provide our customers with the service and quality they’ve come to expect from NEX,” says Kathy Bolhous, NEX Films’ CEO. “We’ve seen considerable growth in our business and we’re committed to investing in the equipment needed to support this growth.” FP

N

NEX Performance Films (800) 248-5168; www.nex-films.com

POLYPAK AMERICA CONTINUES ITS DRIVE TOWARD ZERO CARBON EMISSION WITH SOLVENT RECYCLER n a continued commitment to its target of zero carbon emissions, PolyPak America recently installed an ECOpure SR60V solvent recycler from PPCTS, for the recycling of its dirty flexo press wash solvent, used for the cleaning of the printing decks and inking systems of its solvent-based flexo presses. By recycling its spent dirty solvent with the ECOpure solvent recycler, PolyPak America is reducing its purchases of new press wash solvent by approximately 95 percent, with a corresponding reduction of waste disposal, positively impacting the environment and the company’s sustainability efforts, with an ROI of less than 1 year. The state-of-the-art ECOpure solvent recycler features one of the safest electronically controlled distillation processes that separate contaminants from the used solvent. The result is clean, distilled, original solvent ready for reuse. The ECOpure solvent

I

16

FLEXIBLEPACKAGING

| www.flexpackmag.com

recycler distillation process for flexo solvents is conducted under vacuum to increase efficiency with a recovery rate of 95 percent or higher. FP PolyPak America (800) 826-4000; www.polypak.com PPC Technologies & Solutions LLC (PPCTS) (262) 695-7536; www.ppcts.com

OCTOBER

2011

PE FILM EXTRUSION RECOVERS FROM RECESSION eading plastics industry consultant, AMI, has just published the ninth edition of its Guide to the Polyethylene Film Extrusion Industry in Europe. As can be expected with recession hitting Europe in 2008, the PE film extrusion industry took a downturn. Between 2007 and 2009, PE film production fell by 1 million tons. About half of this lost volume was recovered during 2010 and the industry continues to make steady progress in 2011. With a volume demand in excess of 7.5 million tons for 2010, PE film extrusion still represents one of the largest plastics processing sectors, accounting for 19 percent of polymer consumption in Europe during 2010. Inevitably, the recession has had an impact on the number of companies operating in Europe. As the industry moves out of recession AMI forecasts that production will move in line with underlying GDP growth for Europe. An annual average growth of around 2-3 percent per year would result in an industry processing over 8.7 million tons by 2015. FP

L

AMI 44(0)117 924 9442; www.amiplastics.com

CHEER PACK NORTH AMERICA EXPANDS

C

heer Pack North America (CPNA) has expanded its manufacturing presence in the New England region by moving into a 30,000 square-foot facility in Plymouth, Mass. The facility in the Plymouth Industrial Park features office and manufacturing space. CPNA has expansion plans to convert films and manufacture pouches, as well as injection molding, in the very near future. Cheer Pack North America’s business and staff are growing rapidly and further expansion in New England and the West Coast are already underway. FP

Cheer Pack North America (508) 927-7800; www.cheerpack.com

Innovative, cost-saving converting machinery optimized for flexible packaging More efficiency, less downtime, less waste Catbridge can help you become more efficient and competitive. We build durable, innovative slitter rewinders that provide immediate cost savings and quality gains. Our unique technology and smart designs significantly increase run time while improving roll quality and minimizing waste. We’ve optimized our machinery for flexible packaging and tailor our equipment to your exact needs. To learn more, visit www.catbridge.com or call us at 973-808-0029.

Standard or custom — we build solutions: slitter rewinders • knife systems • unwinds • perforators • coaters & laminators Catbridge Machinery • 222 New Road, Parsippany, NJ 07054 USA • Tel 973 808-0029 • www.catbridge.com

OCTOBER

2011

FLEXIBLEPACKAGING

| www.flexpackmag.com

17

Converter News

EXOPACK INVESTS $13 MILLION INTO PET FOOD & SPECIALTY PRODUCTS OPERATIONS xopack is in the process of completing a yearlong, $13 million investment in new manufacturing equipment and technologies for their Spartanburg, S.C., and Tomah, Wisc., manufacturing facilities. This investment

E

will afford Exopack the capability to expand its current product offering with new materials and package styles. The key addition to the Spartanburg facility is its new Starlinger woven poly propylene converting cell. This equipment will allow Exopack to manufacture and distribute domestically manufactured rave WPP, woven poly propylene sewn and slider zipper bags for use in a variety of end-use markets such as pet food, lawn & garden, seed and other agricultural products. FP

It's A Real Jungle Out There.

Exopack (877) 447-3539; www.exopack.com

MSU PACKAGING ALUMNI ASSOCIATION APPOINTS VANLOOCKE TO ITS BOARD OF DIRECTORS xopack is pleased to announce the appointment of Cory VanLoocke, Corporate Innovation Manager, to the Michigan State University Packaging Alumni Association (MSUPAA) Board of Director’s during June of 2011. The MSUPAA is a constituent association of the Michigan State University Alumni Association designed to provide an advisory service to the School of Packaging, the University, and Packaging alumni. FP

E There's a better way to protect your roll products from a world of danger. Guard your precious rolls from all the bumps, bites and bruises that can come from careless handling and uncontrolled environments. Badger Plug roll protection solutions are the best defense in the whole wild world.

Nobody protects your rolls better!

Ser vi ce e xc ell

ence

sin ce 1 93 1

  swww.badgerplug.com

Call us for all your roll protection needs, large or small. 18

FLEXIBLEPACKAGING

| www.flexpackmag.com

Exopack (877) 447-3539; www.exopack.com Michigan State University Packaging Alumni Association (MSUPAA (877) MSU-ALUM; www.msupaa.org

Taking Barrier Films to the Generation

Alpine's X-Die Barrier Film Line

David A. Frecka, CEO

“When we decided to step up to barrier films, our choice was obvious: The Alpine X-Die line”

Superior Film Technology - Most Flexibility - Best Service and Support

Cover Feature: Profiling a Bag-/Pouch-Maker

O M A I D A

. . . S I ND

By Erin J. Wolford, Ed Editor-in-Chief dito or-iin-C Chiief or Diamond Flexibles, creating a pouch is more than just converting. It’s a learned skill. Flexible Packaging interviewed Scott Hansen, director of sales and marketing for Diamond Flexibles, to learn about how the company came about its bag-/pouch-making capabilities.

F

What makes your company unique in its offerings?

FP:

Hansen: “Diamond Flexible Packaging is a toll converter of printed

and laminated films from a variety of customers. While some of our capabilities are the same as other converters, we do have capabilities that are unique to us. Diamond has been in business for over 85 years having gotten its start manufacturing and supplying cellophane bags, then BOPP and polyethylene bags to the Midwest regional market. “In 2004, we decided that pre-made pouching was a market that we needed to enter as it is the future of flexible packaging. We purchased a stand-up pouch converting machine, along with a Pactiv Slide Rite slider attachment to be the first converter in the market to successfully add Pactiv’s hooded slider technology to premade stand-up pouches. Talk about putting the cart before the horse! Not only did we have learn how to make stand-up pouches, we had to learn the slider application as well. “Over the following couple of years, we ended up becoming experts at converting slider pouches and added a The Pactiv hooded slider is being converted on a KHS Bartelt pouch converter.

20

FLEXIBLEPACKAGING

| www.flexpackmag.com

significant amount of capacity. During that time, we acquired two additional pouch machines and two additional Pactiv slider attachments. These included both exposed slider technology that utilizes clips for better slider end retention and an additional hooded slider attachment. We were working with two companies that had customers who were growing their presence at club stores and wanted slider pouches for those product lines. “Based on this information, we acquired that additional slider attachment so that we would be able to meet our customers’ demand and this was intended to run on our new Mamata Vega 610. As a result of having three Pactiv slider attachments, we have become very adept at running slider pouches of various configurations. As a result of our experience, we have manufactured numerous slider pouch configurations – hooded for both top and bottom fill, exposed utilizing the ergonomic slider, exposed with clips, extra wide exposed slider pouches (i.e. 30+ inch-width), and pouches with handles.”

OCTOBER 2011

Within the last 12-18 months, what packaging innovations or upgrades are you most proud of and why?

FP:

Hansen: “We recently added a new pouch converting machine that we are especially pleased with regarding its capabilities. This is the Mamata Vega 820. Why are we so excited about the capabilities of this particular machine? It will convert recloseable side gusset quad seal pouches with registered side gussets. This allows us to enter the pet food market as the flexible packaging configuration for these companies is of the side gusset quad seal format. With pet food companies using the side gussets as a company advertising billboard, it is very important to them that the gussets be registered so they can consistently display

their message to the consumer. The most appealing aspect about our format of side gusset quad seal pouches is that the gussets are terminated below the zipper, which allows the consumer to open the package through only two webs, just like a regular stand-up pouch. This makes for a much more consumer-friendly package versus having recloseable feature that runs through the gusset. Those that are familiar with this style of pouch manufacturing will note that it requires two webs – one for the front and back panel and one for the side gussets. And our capabilities range from small format side gusset pouches to medium/large format to cover the 15 to 20 pound pet food packages. Our Mamata 820 is also slider ready as it has been proven out on our plant floor. “The Mamata 820 capabilities do not stop there though. We can also convert side

gusset pouches using a single web. This pouch style does not have a reclose feature as this machine does not have the ability to insert the press to close zipper transverse to the machine direction. Since the gussets are formed and plowed in machine direction, we have the ability to run this style of pouch using a single web. That is especially important for the printer/laminator who is looking to provide a more cost effective solution versus having to run two separate print jobs for the pouch.” What is your specialty? What is the company’s bread and butter?

FP:

Hansen: “I would have to say that our specialty, besides slider capability, is service. We really try to accommodate our customers’ requirements with quick

The Man Behind the Machines

FP:

What kind of converting industry problems has your company solved with your machines?

Patel: “Mamata Universal Machines has addressed the need for quick and easy changeovers, from side seal to bottom seal to twin seal bag styles. Converters can shift from side seal to bottom seal to twin seal within 10 minutes on the same machine. This has eliminated the need for separate side seal and bottom seal machines for a converter. “Converting zipper poly bags at high speeds have always been a challenge for converters. Mamata’s Wicketers can convert zipper poly bags at speeds up to 250 CPM, whereas Mamata Flat Bed Machines can convert zipper poly bags at speeds up to 200 CPM. This changes cost conversion equations for such bags and gives more value for the money. “Processing bags with wide pouch style seals had always been a challenge for converters. Mamata offers its Flat Bed Machines and Wicketers with this capability to produce bags with wider pouch seals at speeds up to 200 CPM. This allows converters to address needs of leak proof bags or hermetic seal bags. “Processing unsupported coex films to make pouches was a big challenge for converting industry. Mamata has addressed this issue very efficiently with its Pouch Machines. Mamata is one of the unique companies that offers this capability on it’s Pouch Machine to make 3 side seal pouches, zipper pouches, stand-up pouches from single web or multiple webs, side gusseted pouches from single web or multiple webs. “What you can expect to see from us within the next year is a Flat Bottom Pouch Capability on Mamata Pouch machines.”

OCTOBER 2011

Dharmisth Patel President Mamata Enterprises, Inc. 7 years with the company Mamata Enterprises, Inc. (630) 801-2320; www.mamatausa.com

The Vega 610 Pouch Machine by Mamata Enterprises, Inc. is one that Diamond Flexibles uses at its Deerfield, Illinois plant.

FLEXIBLEPACKAGING

| www.flexpackmag.com

21

Cover Feature: Profiling a Bag-/Pouch-Maker The Mamata Vega 610 (foreground) converts press to close pouches at competitive speeds.

turns and short lead time. I believe that the industry standard is to not even schedule an order to the production floor until the roll stock has arrived. Well, for a company that is trying to differentiate itself from some very worthy competitors, we need to do something different. Competitive price is a given and so is quality in today’s market, so we have to depend on our service levels to set us apart. It is our goal to have a machine ready within a few

days (or even immediately) from when the shipment of film arrives at our dock. “Another area that is a specialty for us is the conversion of unsupported monolayer polyethylene films into stand-up pouches. That is a special capability of the Mamata brand of pouch conversion machines in that they have numerous servo controlled tension areas that allow us to make pouches from monolayer films without stretching the structure. The Mamata also

Leaders Totani has become the world leader in pouch making machinery by producing the most cost efficient machines in the industry.

has the ability to double cut and we have successfully run e-beam coated PE with a double cut. We have also run successful trials of monolayer structures in a single web side gusset configuration. “Even though we are very excited about these capabilities, our bread and butter business is the basic standup pouch. Go look at the retailers’ shelves and you can see the tremendous growth pouching that has occurred in the packaged food industry. And as older technologies are replaced by new, flexible packaging will gain a stronger foothold here in the U.S. market. Look at the growth overseas of unique ways to package your product in a pouch – shapes, liquids, spouts, stick packs, retort. We want to be well positioned to participate in the growth that this industry is experiencing as technologies and ideas hit the U.S. market.”

Leaders aren’t born, they’re made. And they are made just like anything else, through hard work. VINCE LOMBARDI

Our machines are the: Highest Quality Longest Running Lowest Maintenance

The World Leader in Pouch Making Machinery TOTANIAMERICA.COM 920-632-7319

22

FLEXIBLEPACKAGING

| www.flexpackmag.com

OCTOBER 2011

WHETHER IT’S DOG FOOD, MIXED NUTS OR BEES,

KNOW THAT IT’S CLOSED. ABLE F AS

R

NE

NE

W

LOS

TE

C RE

Easy-aligning hooks engage without precise lineup. New VELCRO® brand PRESS-LOK™ is a self-engaging hook-to-hook fastener ideal for packaging applications. PRESS-LOK™ integrates readily into existing pouching equipment, and is heat sealable to most polyethylene films. It’s the simple alternative to “zipper” and “slider” fasteners.

Call 800.225.0180 or email [email protected] VELCRO and other marks are owned by Velcro Industries B.V. © 2011

Cover Feature: Profiling a Bag-/Pouch-Maker What can we expect to see from your company within the next year?

FP:

Hansen: “We have some exciting things planned for the coming year and some I can share with you here. An issue that is very important to every employee at Diamond is being food safe

and producing a high quality product for our customers. As we focus on continuous improvement, we will be striving to improve our score with AIB certification each year. We have been audited by third parties that include our customers, as well as AIB, and have performed well in the past few years, but the goal is to improve with every

White Clear & CMYK PRINT VARNISH EMBOSS CREASE CONTOUR CUT All with one device.

Roland VersaUV from Anderson & Vreeland

As the world’s first UV inkjet printer/cutters, Roland’s DPI award-winning VersaUV LEC has revolutionized the packaging, prototype and short-run label industries. For the first time, professionals can print CMYK plus White and Clear inks for varnishing and embossing effects on virtually any substrate and then crease, contour cut or perf-cut their designs, all on one device through one seamless workflow.

nce erence! erieD p x E the if f 866.282.7697 fx 800.223.6869 www.AndVre.com [email protected]

24

FLEXIBLEPACKAGING

| www.flexpackmag.com

audit. We decided that the best path for success was to implement ISO 9000 policies and procedures. This pursuit will best position our manufacturing environment to ensure a consistent and quality product for our customers. Producing a high quality product is essential to our success and every employee, from machine operators to top management, is focused on producing pouches with the lowest defect rate possible. Our continuous improvement efforts through our quality assurance team target zero defects as our ultimate goal. These efforts will ensure that we become a better supplier to our customers. We are very excited to announce that we have hired a new quality control manager to lead this charge. “As far as manufacturing capability, our plan is to add the ability to provide a folded over and glued bottom to our side gusset pouch line. I have found that numerous pet food companies like that look for their packages as it provides an additional billboard on which they can advertise to the consumer. In addition to the glued bottom, I have also had a number of requests for adding fitments such as spouts to our pouches. We have looked at this capability off and on for the past couple of years, but just have not had enough demand to justify the capital expenditure. Based on what I am seeing in the market, we will be looking very closely at adding that capability in 2012. “And, we are always looking to acquire additional pouch capacity with another stand-up machine. We are working on a couple of fairly sizeable projects that will utilize a large portion of our open capacity, so if those come to fruition, then additional capacity will need to be acquired. As for the other projects we are working on for the coming year, you will just have to wait and see. 2012 should be a fun year for the Diamond team.” FP Diamond Flexible Packaging (847) 418-3000; www.diamondpack.com Mamata Enterprises, Inc. (630) 801-2320; www.mamatausa.com Pactiv Corporation (888) 828-2850; www.pactiv.com

OCTOBER 2011

Advanced Technologies in solvent recycling/reclaim/reuse & water waste treatment

SOLVENT RECYCLERS FOR FLEXO PLATE DEVELOPERS & PRESS WASH SOLVENTS Safe in-house solvent recycling typically reduces your solvent purchases by 95% and disposal costs by 90%. Available in different sizes and installations from 8 to 600 gallons per day or more, to meet your specific needs. Reduce your environmental impact, increase sustainability and profitability. Typical ROI: 4 to 12 months. Specifically designed systems for flexo press wash solvents and photopolymer developers. Dan Doherty Executive VP / Principal Prairie State Group

Richard McDonald President PPCTS / ECO

SR180V—Solvent Recycler Prairie State Group Franklin Park, IL

Solvent Recyclers Distillation Columns Water and Solvent Separators Water Evaporators Thermal Evaporators Water Flocculation Systems

Contact PPC Technologies & Solutions LLC for more information Ph: (262) 695-7536 ● [email protected] ● www.ppcts.com/solventrecyclers.htm

ECKART is the world’s leading manufacturer of effect pigments for the graphic arts industry. Our complete product range provides innovative solutions for applications in coatings, paints, printing inks, plastics and cosmetics. Innovation, research & our continuous process of product development ensure ECKART‘s leadership position. ECKART – take the brilliant way.

INK not Foil

ECKART Metallic Inks for Gravure & Flexography & Screen Printing are the alternatives to foil and metalized substrates! MIRRORGOLD – the outstanding gold effect from a bronze based printing ink, in particular for reverse applications. ULTRASTAR – ultra brilliant mirror effect from one component press-ready silver for surface or reverse onto film, paper or carton.

  PLATINSTAR – mirror-like effect inks with an excellent price-performance ratio. They are especially developed for reverse printing on transparent film.   ROTOSTAR – radiant effects for markets, where it is important to find a compromise between ”good enough“ brilliance and a more economic price.

INK not Foil ECKART offers drop on demand Digital Metallic Inks JETFLUID – add metallic effects to your digital prints and create a real eye catcher with JETFLUID. Solvent and UV curable inks are available for many leading piezo technologies.

INK not Foil ECKART offers fascinating metallic effects for offset printing METALSTAR – are ECKART‘s offset standard inks for all kinds of typical offset applications. METALSTAR 06 7500 PANTONE® PREMIUM Silver – is a new metallic color standard. ECKART‘s PANTONE® PREMIUM Silver combined with PANTONE Goe™ bases results in a new PANTONE book – The Premium Metallics PLUS Series.  TOPSTAR – is an attractive offset metallic ink range using colors combined with PVD aluminum dispersions. This range offers a whole spectrum of brilliant metallic colors.

For further information please contact ECKART GmbH · Guentersthal 4 · 91235 Hartenstein · Germany Tel +49 9152 77-0 · Fax +49 9152 77-7008 · [email protected] ECKART America Corporation · 830 East Erie Street · Painesville, Ohio 44077 · USA Tel: +1440 954-7600 · Fax: +1440 354-6224 · Toll-free: 800-556-1111 · E-Mail: [email protected]

PANTONE® and other Pantone trademarks are the property of Pantone LLC. Pantone Trademarks and Copyrights used with the permission of Pantone LLC under License Agreement with ECKART. All rights reserved.

The ECKART effect – added value for brilliant results. PLATINSTAR® Silver, a new solvent-based silver metallic ink for gravure & flexo printing that provides mirror-like effects at greatly reduced costs. This brand new technology gives designs that special touch and makes them real eye-catchers, guaranteeing the most emotional reactions. PLATINSTAR® Silver is especially designed to expand the possibilities of brilliant metallics in applications that were previously off limits. ECKART is the world’s leading manufacturer of metallic pigments for the graphic arts industry. Innovation, research and the constant further development of our products ensure that we remain so! ECKART – take the brilliant way. For further information, please contact: ECKART America Corporation · 830 East Erie Street · Painesville, Ohio 44077 USA Tel: 440-954-7600 · Fax: 440-354-6224 · [email protected] · www.eckart.net

Printing: Shrink Sleeves

STREAMLINING SHRINK SLEEVE PRODUCTION he global $3 billion shrink sleeve market is growing at about 7 percent a year, yet shrink sleeve production remains one of the biggest challenges in packaging for both designers and converters. Historically, it’s a difficult, cumbersome process – creating the correct amount of distortion for shrink sleeves is complex, labor-intensive, and typically requires a significant amount of trial and error to get the design right. The process also demands long lead times, and if the distortion isn’t correct, it costs the packager big, in time and money. With customers requiring headspinning turnaround times, and profit margins incredibly tight, packagers are looking for a way to resolve the shrink sleeve conundrum. The search for a solution to this all-too-common problem brought Total Quality Labels, a high quality producer of labels and packaging products, to EskoArtwork’s Studio Toolkit for Shrink Sleeves, a recipient of a Printing Industries of America 2011 InterTech Technology Award.

T

Located in Dallas, Total Quality Labels supplies premium heat shrinkable film products – full body sleeves, multi-pack bands and neckbands – for a wide variety of markets, including beverage, food, heath and beauty, pharmaceutical, household products, automotive and petroleum. Its capabilities include flexographic printing in up to 10 colors, four-color process, custom die-cuts, as well as metallic, overprint, UV, and water-based inks. The company also provides laminate and UV coating. Meeting or exceeding customer’s quality expectations is an ongoing mission, prompting Total Quality Label to develop and seek out unique solutions to common package and labeling needs.

Improving the Process “We are constantly looking for ways to improve the production process – to streamline operations, boost quality and hold costs down,” says Greg Swindle, production manager, Total Quality Labels. “Last year we installed Studio Toolkit for Shrink Sleeves from EskoArtwork. Our immediate goal was to streamline the shrink sleeve process, trying to eliminate some of the steps and get products out the door faster.” The biggest challenge with shrink sleeves, notes Swindle, occurs during prepress, “when you’re trying to assess just how much distortion you’ll need, where Using Studio Toolkit, preparing art for shrink sleeves isn’t any more time consuming than preparing art for any other job.

28

FLEXIBLEPACKAGING

| www.flexpackmag.com

Total Quality Labels created a shrink sleeve design for a honey bottle, which had a lot of detail. The label had to line up correctly, including the bear's eyes, nose, mouth, arms, feet, which was actually correctly made the first time around using the new software.

you’ll need the most and the least, to make sure that the graphics are positioned correctly and in the right alignment on the package or bottle,” he explains. “Before we had Studio Toolkit for Shrink Sleeves, we would take a sample of the material and create a grid on film, shrink wrap it on to the product, and then measure the distortion of the sleeve off the grid,” says Swindle. “Sometimes we got it right, and sometimes we didn’t.” When the distortion didn’t work, the prepress department would have to rebuild the art and start the project over from scratch. Test runs consisted of burning plates, going to press, and seeing how close the department came to getting the right distortion so the graphics would look good. It was a time-consuming and costly process; it wasn’t unusual for the company to conduct two to three test runs to get it right. Each test run cost the company $300$400 for plates, plus an hour of press time. “Each time we were wrong, it would cost us between $500-$600,” says Swindle.

OCTOBER 2011

Art is Eased Using Studio Toolkit, preparing art for shrink sleeves isn’t any more time consuming than preparing art for any other job. “Shrink sleeve jobs now take us two to three hours, instead of 20-24 hours,” says Swindle. Studio Toolkit is able to work with asymmetrical shapes and multipacks, on a wide variety of substrates, taking into consideration the specific shrinking properties of each. A key feature of Studio Toolkit is its 3D viewer, which shows a virtual 3D image, or a mock-up, of how the shrink sleeve will look on the bottle or package. “We can see exactly how graphics are positioned on the label ahead of time, before we make a plate,” says Swindle “We can manipulate the art to make sure it looks good, and then show it to the customer.” Customers are also thrilled with the feature, as they can also see a 3D mockup of what the label will look like prior to printing. It hastens the design approval process and gets products out the door faster and for less cost. A recent project emphasizes how critical Studio Toolkit for Shrink Sleeves has become to Total Quality Label’s production process. “We worked on a honey bear that had a lot of detail, like nose, eyes, feet, legs, and everything had to line up over the bottle, so it was a pretty complex deal,” says Swindle. “Using Toolkit, we actually nailed it the first time through. We ran it through the software and looked at the viewer, tweaked it in a couple of spots, but none of the art moved more than 1/16 of an inch, and when we rendered it again, it lined up very nicely. If we had to do it with a grid and using math, it would have required at least 3 or 4 trial run-throughs,” he says. Studio Toolkit for Shrink Sleeves accomplished everything Total Quality Labels hoped it would and more. “The entire shrink sleeve process has been streamlined,” says Swindle. “It’s helped us immensely in the production process. We Total Quality Labels (888) 242-6807; www.tqlinc.com

typically only have only one go-around now. We’re not making plates and going to press to see if the predistortion is correct. We might have to make changes in the artwork and work on the design after the customer has previewed it, but we don’t have to remake plates. Also, our designers are not spending all that

time on math, which, of course, is not what they should be doing, anyway. We don’t have to make grids to figure out the distortion. It’s point and click.” For Total Quality Label, what was once a tedious, frustrating part of the production workflow has become just another part of the packaging process. FP

SEARCHING FOR FULL AUTOMATION FROM AN ERP OR MIS SOLUTION?

Packaging companies running EFI Radius achieve 9% or

GREATER PROFITABILITY at

TWICE THE RATE of other packaging companies. With EFI Radius, packaging companies achieve outstanding results – regularly outperforming their peers running other solutions. The EFI Radius ERP solution offers packaging companies the comprehensive capabilities of a world class ERP system, while fitting the unique business processes of packaging operations producing labels, flexible packaging, folding cartons and extruded materials. The solution’s comprehensive capabilities are able to address the needs of packaging companies with complex operating environments such as multi-site, multi-currency, multi-language and multi-product production processes.

Learn more at www.efi.com/profit6 or call us at 1-800-875-7117.

©2011 EFI. All rights reserved.

EskoArtwork (937) 454-1721; www.esko.com

OCTOBER 2011

FLEXIBLEPACKAGING

| www.flexpackmag.com

29

Technology: Inks

CHANGES AND CHALLENGES IN FLEXIBLE PACKAGING By Wayne Wasielewski, Contributing writer he flexible packaging industry is seeing many changes taking place. All packaging print markets, especially the commodity markets, are seeing margins being squeezed harder than ever before due to the rising costs. The plastic bag industry is seeing plastic bans in some areas of the country with additional taxes on these items being discussed, and reduced demand as consumers are bringing their own bags to the supermarket. While this is not news

T

30

FLEXIBLEPACKAGING

to most, those who participate in these markets are having their challenges. The positive side to the packaging industry is that growth opportunities still exist for those who want to lead new areas of the market. One of the growth areas is in high strength clean printing process inks. The highest end printers now use push screens to 175 and beyond, and is especially the case for lamination structures. Why go where few have gone before, especially since high strength inks cost

| www.flexpackmag.com

considerably more? Does it make sense to use valuable resources to develop products that actually cost more in a market place that demands lowering pricing? The answer is a big yes. Most of the leaders in the industry realize that when you purchase inks, the important thing is not the price coming in the door. The real cost of an ink is your running uptime, or cost per impression, and the overall throughput you get from your equipment. Additional

OCTOBER 2011

benefits are clean images and color reproduction that cannot be achieved with commodity products. It is true that formulating inks to run clean and achieve acceptable print densities is not an easy task, and technical problems certainly exist and present themselves more than most like to admit. However, if the converter does the work up front, monitoring press characterizations, fingerprinting and controlling the other variables, quality can be achieved that most will only dream about. When done correctly, flexo is a strong rival to roto-gravure, and this can be proven by looking at the award-winning prints from this year’s conventions. The industry’s packaging engineers are committing valuable resources to develop new and innovative products,

Ink is only one vital component of the flexible packaging supply chain.

all of which demand exceptional print quality. Co-suppliers in the industry are also doing their part. Ink is only one vital part of the supply chain.

About the Author Wayne Wasielewski has worked for Toyo Ink America, LLC in its regional technical sales department for 3 years. Wasielewski has 33 years of experience in the packaging industry.

Clean Your Cast Rolls And Central Impression Drum Automatically

Examples of changes are around us: Presses are running faster and able to maintain better registration. Plates are made with finer screens with new dot structures. Plate cushions are made from various materials responding quicker with more predictability. Aniloxes are made finer, and doctor blades are made from materials offering better wiping under different conditions. Dryer technologies are changing; roller and cleaning equipment are improving; color and separations have new technologies. Tape suppliers are making improvements. Practically everywhere you look, major progress has been made in recent years. As a lifetime packaging participant, the industry has seen many changes. In past years, old ideas seemed to just recycle again and again. That is no longer the scenario of our industry. FP Toyo Ink America, LLC (630) 930-5100; www.toyoink.com

 

Modern Manufacturing Services ZERO CLEARANCE PUNCHING SYSTEMS

• Reduce defects • Reduce downtime • Reduce injuries • Reduce solvent usage Central Impression Drum Cleaner

Cast Roll Cleaner

• Wipe rolls and drums during production without diminishing product quality

Models available for water based or solvent inks.

♦ Clean cut outs every time ♦ Works with almost all converting films including straight PE ♦ No aligning each head is designed for the punch shape required, simply mount to your existing machine and run ♦ Low cost of ownership ♦ Optional mounting carriages available ♦ Most standard sizes in stock and ready to ship

Ask for our full Punching systems catalog Modern Technology Designed For Today's Complex Processes

Cleaning Up Your Bottom Line www.rgegan.com Phone: (585) 671-0465 Email: [email protected] OCTOBER 2011

Modern ManufacturingS e r v i c e s . L L C 298 Canandaigua Rd, Rte 21 Palmyra NY 14522 Phone 585-289-4261 Fax 585-289-7909

FLEXIBLEPACKAGING

| www.flexpackmag.com

31

Roundtable: Special Advertising Section

ROUNDTABLE ON SLITTING/REWINDING Michael Pappas pas

Ray Ivaska

Barrie Homewood

President

Production Manager

Sales & Marketing Director

Catbridge Machinery inery

Channeled Resources Group 25 years with the company

Titan/Atlas

10 years in that position osition

8 years with the company/ 6 years in current position

By Erin J. Wolford, Editor-in-Chief

Q:

What new features or technologies are being introduced to this sector of the industry?

Homewood: With today’s high speed printing and laminating technologies, the slitter/rewinder has had to evolve to cope with a much higher production volumes. Since slitting and rewinding is a start/stop process, this has led to more innovation in reducing set-up times. These technologies include core loading and positioning devices, automatic adjustment to knife positioning, automatic tail cut-off and stick-down, turret rewind systems and job memory to quickly re-set all machine parameters. Converters needing to produce shorter rewind lengths and therefore smaller rewind reel diameters are taking advantage of the latest turret rewinding machines, which ensure that the cycle time between rewind sets is as short as possible and always maintained.

What kinds of problems has this segment solved in recent years?

through the use of differential winding. Set-up times can be considerably reduced using more automation and production speeds have increased to match the productivity coming from the printing and laminating processes. The slitter/rewinder is becoming more intelligent with connections to the internet enabling productivity tracking or high-speed fault diagnostics. Productivity tracking can be monitored from any PC with reports generated automatically. Remote fault diagnostics are now highspeed and secure enabling machine faults to be diagnosed quickly and effectively. Alarms can be set and even text messages sent from the machine, alerting engineers immediately of any malfunction.

Homewood: Today’s modern slitter/

Pappas: Recent slitter/rewinder

rewinders have generally overcome any issues with tension control

advances have resulted in much more efficient production. Slitters now offer more precise tension

conventional winders by 200-300 percent or more in some applications. Turret winders equipped with features that allow more fully automatic function, especially in the area of cut-off and transfer, have become the standard for medium to large run flexible packaging work. Additionally, auto knife placement has become increasingly popular to help minimize downtime and is especially valuable for short and medium run jobs where there are many knife setups per shift.

Q:

Pappas: New turret rewinder

technologies for flexible packaging applications provide substantial time savings without sacrificing quality. By targeting areas of the slitter/rewinder process causing the most downtime, these technologies help turrets out produce Turret rewinders integrate technologies that substantially improve productivity.

32

FLEXIBLEPACKAGING

| www.flexpackmag.com

control for a wider variety of substrates on the same machine, fully automated and dependable cut-off and transfer, improved core placement technologies, faster machine speeds, and a wider variety of rapid roll discharge options, demanded when machines produce more rolls per hour.




8FµSF
UBMLJOH
TBWJOHT

Ivaska: The last couple of years have

been very challenging for the industry. Many companies are forced to run with smaller inventories in order to free up cash. This puts more pressure on converters to shorten lead times through improved efficiencies which include shorter set up and faster run times. Shorter run time puts a premium

Quality, consistency and efficiency in a pressroom translates into lower production costs. And no company is more committed to helping you achieve these goals with unprecedented results than Harper. So much so, we devote an entire division to the cause. Call 800-438-3111 to get started and receive a copy of our “Seven Element Flexo” free. To learn more, call 
or Toll Free at  Or visit our website. Americas U Europe U Asia

GRAPHICSOLUTIONS DIVISION HA R PE R I M A GE . C OM ©2011

Channeled Resources offers solutions for slitting/ rewinding and can help their customers with converting issues.

on slitters that can reach maximum speed with the right tensions in the least amount of time. The industry is also moving towards the conversion of larger diameter rolls resulting in longer run times as an alternative to reducing set up time. Finding the right equipment with all these attributes is the key to turning a profit. In our business, we’ve seen an evolution from crush slitting to shear slitting and now razor slitting although our preference is for shear slitting. Another area experiencing growth is custom converting for research and development. This part of the business can be a high risk, high reward. Just by the nature of this business, converters do not have a lot of material to work with. This requires getting the product slit correct the first time with the right tension. There is no second chance, since OCTOBER 2011

FLEXIBLEPACKAGING

| www.flexpackmag.com

33

Bobst Group - with its tradenames FISCHER & KRECKE, GENERAL, ROTOMEC and KOCHSIEK - is the world’s leading supplier of equipment and process solutions for the printing, laminating, metalizing and converting of flexible materials. These include all types of plastic film, flexible packaging materials, labels, wallcovering, giftwrap, transfer paper and more.

Rotogravure otogravure Rotomec otomec and Kochsiek’s innovative, technologically chnologically advanced gravure solutions provide ovide the most comprehensive range of gravure printing nting capabilities in the market. ROTOMEC has established an unparalleled reputation in gravure printing technology, setting the standard for state-of-the-art, ultra productive and user-friendly gravure printing lines. The high efficiency features and waste reduction performance of Rotomec gravure printing lines are enhanced by the integration of the Rotomec Electronic Shaft (ES) with REGISTRON register control system, which reduces time and material waste to unprecedented levels. With its specialized gravure equipment, KOCHSIEK serves the markets of decorative printing and liquid packaging. Rotomec and Kochsiek’s cutting edge technology and innovation meet customers' requirements for high speed/high volume production, multi-purpose gravure printing, short runs and quick changeovers, efficiency, cost effective operation and highly customized solutions. Our wide range of options include solutions for very short runs with minimum waste, to high-speed and high-volume on medium and long printing runs. Our machines also offer solutions for printing on a full range of materials including decorative, security and liquid labels, and webs from 31 to 65 inches. Flexographic With their varied repeat lengths and their medium to super wide printing widths, FISCHER & KRECKE CI flexo presses meet the requirements of the most demanding package printing applications.

well-equipped Beyond the well-equippe standard configuration, all models can be fitted with a multitude of additional technical options to adapt specific production requirements – all the press to specific for your competitive advantage. F&K’s award winning smartGPS™ registration and impression presetting system minimizes changeover time and material waste (yield) by allowing setup to be performed offline at the plate mounting stage. Print settings are finalized before the job enters the press allowing it to immediately accelerate to production speed, with perfect impression and registration, once the sleeves are inserted. Our flexographic presses are suited to all applications, printing onto any absorbent or non-absorbent substrate, including very thin extensible films and aluminum and provide high quality printing, short changeover times, minimum waste and low manpower requirements. F&K solutions include the Flexpress 16-Series, a flexible platform for small to large runs, a broad range of substrates and special applications; the high volume 36-Series and the wide web Flexpress 96-Series for preprinted linerboard production with widths up to 110 inches and repeats up to 81 inches. Service and Technology All Bobst Group products are supported by the industry’s leading technical, service and support staff. Regionally based local technicians as well as product and process experts are always available to help you maximize your productivity and efficiency, and get the most out of your Bobst equipment.

Does it matter that we offer.. multiple laminating solutions? Or simply that our CL has the ideal solution for you? Select the system that best matches your job mix — now and in the future.

The CL 850 Laminator from Rotomec.

Having the perfect metering and coating system for your specific needs and those of your customers is what sets Rotomec apart. Each of our coating trolleys is ergonomically optimized and features fast job changeovers without tools. Our simple interchangeability of systems also insures that as your needs may change, so too will your laminator.

The Options of the CL Series Rotogravure Coating

The accuracy of gravure printing along with an interchangeable pressure system and blade provide true precision and functionality.

Bobst Group North America, Inc.

SemiFlexo / Flexo Coating

Solventless Coating

Semiflexo is regarded as the most versatile system available, while Flexo is proven as the highest quality application for coating solvent-based adhesives.

146 Harrison Avenue, Roseland, NJ 07068 -1294

Our solventless design allows for a consistently repeatable process with low waste and minimal downtime.

Tel: 888-226-8800

Roundtable: Special Advertising Section

Raising the bar

in most cases only enough material is supplied to do the job at hand. One error can result in the manufacturer going back and producing more material which can be very costly and could very well be passed on to the converter.

Q:

With so many options in the slitting/ rewinding segment, in your opinion, what is the most versatile style currently on the market?

Homewood: Historically, many converters used ‘center surface’

in slitter rewinder technology

slitting and rewinding technologies and there are many applications when this technology is the most suitable. However, a majority of converters have now moved to ‘center’ winding formats, as these provide the most flexibility and enable the shortest set-up times.

Titan slitter rewinder technology is taking another leap forward by providing unsurpassed levels of modularity, slitting productivity and rewind reel quality. The countdown has started to the next generation of Titan DT (Dual Turret) rewinding technology. Be amongst the first to witness this latest technology at ICE Europe 2011. Or find out more by pre-registering your interest at: www.atlasconverting.com And you could be the lucky winner of an Apple iPad2!

Converting Equipment Ltd., Bedford MK42 7XT, UK • Atlas T: +44 1234 852553 E: [email protected] Converting North America, Inc., Charlotte, NC 28273 • Atlas T: +1 704 587 2450 E: [email protected]

www.atlasconverting.com

This dual turret rewinding is running on a Titan slitter.

Pappas: Versatility is defined by the variety and length of jobs

a given company must run through their slitting department; it does not necessarily mean the same thing for all. For example, small companies that run a wide variety of materials may define versatility in terms of the ability to use different types of slitting such as shear, razor, or even score slitting in some cases. A variety of slitting features offers more versatility to them than automated knife placement or fully automated cut-off and transfer. Companies running more long run jobs would define versatility more in terms of automation to eliminate downtime between sets and exceptional tension control for higher speeds. Versatility needs, then, vary depending on a company's job mix. Turret rewinders can offer more automation, though they're not the best choice for all applications. FP Atlas Converting Equipment Ltd. +44 1234 852553; www.atlasconverting.com Channeled Resources Group (800) 633-6272; www.channeledresources.com Catbridge Machinery, LLC (973) 808-0029; www.catbridge.com

Rewind to the Future 36

OCTOBER 2011

MAMATA POUCH MAKING SYSTEMS $YDLODEOHLQßß ßZRUNLQJZLGWKV

'HVLJQHGWRPHHWWRGD\·VGHPDQGVRI flexibility & sustainability System features include :

 4 web print registration control without drop in outputs  Double cut capability with adjustable cutting gap (3 mm-30 mm)  Servo driven Independent seal time control for each sealing station.  3URFHVVLQJFDSDELOLW\RI8QVXSSRUWHG&R([ILOPV%DUULHUVWUXFWXUH6WUDLJKW3(  Processing widths from 24" to 40"

Process capabilities include :

Pouches using Multiple printed webs (upto 4 independent webs) 3RXFKHVZLWK)XOO%OHHGSULQWIURP/DPLQDWHV8QVXSSRUWHG&R([ILOPV X 4XDGVHDOVLGHJXVVHWHG5HFORVDEOH]LSSHU3RXFKHVIRU3HW)RRG)HUWLOL]HUHWF X 3RXFKHVZLWKSUHVVWRFORVH6OLGHU=LSSHUV$SOL[ŠUHFORVDEOHV\WHPZLWK self-mating micro-hooks. X Side gusseted Pouches from Single web with One edge / quad / Centre fin / overLap seal. X 6WDQGXS3RXFKHVIURP6LQJOHZHERU,QVHUW%RWWRPV X

X

No matter what your pouch making needs are, we have the right machine for you !

USA Office :

INDIA Office & Works :

2275, Cornell Ave., Montgomery, IL - 60538. USA. Phone : +1 630 801 2320 )D[  Email : [email protected]

5/1/1A, Phase-1, G.I.D.C., Vatva, Ahmedabad - 382 445, India. 3KRQH‡)D[ E-mail : [email protected]

www.mamatausa.com

www.mamata.com

09/2011 marg

Talk to us today and experience the difference!

Industry Insights

EFFICIENCY–THE KEY TO TODAY’S CONVERTING & PACKAGING

By Susan Stansbury, Contributing Writer onverting and packaging companies have long been proficient at benchmarking and measurement. Going back to serious advances through quality process programming, and on to statistical process control, lean, six sigma and similar efforts – it still pays to revisit these useful ways of committing to continuous improvement. Unfortunately, there is still too much “flavor-of-the-month” programming, switching from one approach to another as fast as key management changes within companies. It’s almost unheard of to have a program that lasts beyond a couple years. Too often, a program or system change is a complete turnover,

C

rather than layering in new useful tools. What is lost is true cultural change when employees have a hard time keeping up with the current favored buzzwords and associated latest techniques. Also lost are some great, solid approaches that should come along with new methods. “As companies are bought and sold, change names and corporate direction, there are also some valuable losses in basic knowledge of how this equipment and associated packaging really works,” says Patrick DeLorey, an industry veteran and now a solutions consultant. “You first have to understand the equipment parameters you’re dealing with before you can move on to make it more efficient.” DeLorey points out three important basic factors to achieving efficiency by understanding: 1) Clear product/equipment capabilities; 2) Technical knowledge of the equipment; and 3) Commitment to training operators and technical support personnel. There is no dismissing the great knowledge of industry veterans who take current equipment and move it to the next level of efficiency or add to its range of capabilities. Gary Forehand, a principal at American Custom Converting exemplifies this world of expertise that’s built on bedrock, but always adding to the knowledge base. “We have taken so many pieces of converting equipment and improved productivity, expanded the range of substrates run and surprised our customers with suggestions for improvement with economy,” he says. “At the same time, many of our customers can get real-time production results on their own computers as we run their orders.” “You first have to understand the equipment parameters you’re dealing with before you can move on to make it more efficient,” says industry consultant Patrick DeLorey. Photo courtesy of Multi-Conveyor

38

FLEXIBLEPACKAGING

| www.flexpackmag.com

Today’s Issues Solutions to measuring quality, advancing factory efficiency and improving cost-to-manufacture abound. However, determining all the things you want to do in automation, knowing what you really need and want to achieve—is the great challenge, says DeLorey. Considerations of raw materials, packaging options and other system input are part of the decision process.

Committing to continuous improvement is the key to today's industry needs. Photo courtesy of Multi-Conveyor

Attention to detail and common sense efforts yield significant results too. Whether a company adopts the latest continuous flow or lean flow techniques, has seamless operations, or subscribes to similar efficiency and automation programs—the companies who have met their goals for efficiency improvement adapt the chosen principles to their particular situation. They enlist employees in flow analysis and seek employee input for many of the best ideas. FP

About the Columnist: Susan Stansbury is executive director of Converting Influence and Converters Expo. [email protected] Converting Influence LLC (920) 265-6407; www.ConvertingInfluence.com

OCTOBER 2011

Supplier News

100 YEARS OF REIFENHÄUSER n 1911, locksmith Anton Reifenhäuser founded a small forge in Troisdorf and laid the cornerstone of a company that ranks among the worldwide leading technology companies in the plastics machinery industry today: Reifenhäuser. This year, the wholly family-owned enterprise celebrates its 100-year history true to the motto “Preserving our values. Shaping the future. Reifenhäuser turns 100.” Today, the company is a worldwide active group with six subsidiaries, eight branch offices and over 50 agencies worldwide. The product portfolio includes machines and complete extrusion lines for the production of films, nonwovens, tapes and monofilaments, in addition to a 24hour service. More than 80 percent of these machines and lines are delivered overseas. FP

I

Reifenhäuser +49 (0)2241 23510-0; www.reifenhauser-group.com

APPLETON AUTOMATION SIMPLIFIES CORE CUTTING AND SAVES MONEY ppleton Mfg. Division, the leader in core cutting and handling equipment, is the exclusive provider of Appleton Automation. This advanced automation system can be added to any Appleton Core Cutter, and offers increased control and productivity while reducing capital and labor costs. Appleton Automation also increases output by streamlining core cutting operations and procedures with increased flexibility and control. Appleton Automation offers a one-touch control over core cutting systems, reduces the amount of resources by minimizing trim and butt waste, and cuts operational costs through process automation. Programmable models feature Allen-Bradley brand controls from Rockwell Automation, providing industry-leading customization and feature selection. FP

A

Appleton (800) 531-2002; www.appletonmfg.com

ANDERSON & VREELAND ACQUIRES FLEXOLUTION IN EXPANSION MOVE nderson & Vreeland (A&V) announces the acquisition of Flexolution, a leading distributor of flexographic printing materials serving Quebec, New Brunswick, Nova Scotia, and Prince Edward Island. The acquisition is part of Anderson & Vreeland’s strategic growth initiative to provide expanded service and support to North American customers. Flexolution, founded in 1989 by Pierre Noël, has a sales/ warehouse and a long and successful history in servicing the flexographic and packaging markets. “Pierre’s success with the Flexolution team allows us to better serve the Canadian market in one bold move,” says Thomas Gavin, CEO of Anderson & Vreeland, Inc. “Pierre’s intense drive and commitment to provide better service and performance is in perfect sync with Anderson & Vreeland’s core values,” adds Gavin. Pierre Noël notes, “A&V’s state-of-the-art product line and well-recognized technical support are tremendous strengths that will better serve our customers. Combining the strengths of our two organizations will create a synergy to achieve long-term growth and truly benefit all of our customers.” Noël will continue to direct all sales activities for the new company, now identified as Anderson & Vreeland Canada, ULC, throughout Eastern Canada. Anderson & Vreeland’s expansion into further solidifies the company’s commitment to the North American market. Future plans call for establishing a sales/warehouse in the

A

OCTOBER 2011

Thomas Gavin, CEO of Anderson & Vreeland, and Pierre Noël, founder of Flexolution, shake hands over the new acquisition.

area to better serve customers and then expanding into western provinces. The company has nine distribution sites throughout the United States and three distribution sites in Mexico. FP Anderson & Vreeland (866) 282-7697; www.andersonvreeland.com Flexolution (888) 832-1600; www.flexolution.ca/English.htm

FLEXIBLEPACKAGING

| www.flexpackmag.com

39

Supplier News

ROLAND EXPANDS U.S. CREATIVE CENTER GALLERY he Roland DGA Creative Center, located at the company’s headquarters in Irvine, Calif., has recently updated a gallery of innovative applications, which includes hundreds of exhibits celebrating the imagination of Roland professionals from around the world.The center brings together the work of Roland customers focused on a wide range of creative disciplines, including screen printers, sign makers, label makers, fabric decorators, interior designers, product designers, fine artists, package designers, engravers, jewelry makers, vehicle graphics designers, movie and television set designers and others.

T

The Roland DGA Creative Center has recently updated a gallery of innovative applications. The Creative Center is divided into five themed sections and includes more than 100 exhibit items.

UFLEX U.S. PROJECT GOES FULL STEAM AHEAD he India-based Uflex Group, one of the world’s leading producers of flexible packaging materials, has made considerable progress on its new Greenfield Packaging Films project in the USA since the signing of the MOU in April 2011 with the state of Kentucky, where the facility will be located. The total project outlay will be approximately $180 million, half of which will be spent on the first phase: Setting up a state-of-the-art biaxially oriented polyester (BOPET) film line and a plasma enhanced high-barrier metallizer. At 8.7 meters width and running at 500 meters/ minute, the line will be one of the world’s largest film plants and will be bigger than any other film line presently operating in the USA. It is due for start-up before the end of 2012. The project is being set up under the aegis of Flex Films (USA) Inc., a new company set up by Uflex. Land for the project has already been allotted and the company has finalized its choice of engineering consultants. The ground breaking and commencement of civil construction at the site is slated for October 2011. FP

T

Uflex 91-120-4012345; www.uflexltd.com

GLUNZ & JENSEN STRENGTHENS ITS POSITION lunz & Jensen, the world’s leading pre-press manufacturer has acquired the Danish technology company KH-Microflex to strengthen the fast growing flexo-plate division. The deal was signed by Keld Thorsen, CEO and Per Birk-Sørensen, CFO at Glunz & Jensen together with the shareholders of KH-Microflex, Søren Jørgensen, Knud Hansen and Jesper Banke, making Glunz & Jensen a 67 percent shareholder of KH-Microflex. The remaining shares of 33 percent are still owned by the previous shareholders. The acquisition of KH-Microflex is part of a major growth strategy in order to expand Glunz & Jensen business areas within packaging. The aim is to utilize the competencies within product development, supply chain and distribution. With this being the second acquisition, after taking over Degraf S.p.A in March 2011, Glunz & Jensen now holds a total global market share of 50 percent within the flexo prepress technology. FP

G Recent additions to the Creative Center include “Roland at the Movies” and “Roland at Work” exhibits. All together, the U.S. gallery is divided into five themed sections and includes more than 100 exhibit items. The centerpiece, a 20-foot replica of the 1895 Otto Lilienthal flying machine, hangs from the ceiling and features full-scale fabric wings printed on a Roland AdvancedJET grand-format inkjet printer. The gallery is part of an international network of Roland Creative Centers, with additional venues in Japan, Belgium, Italy, Germany and Australia. An online tour of the Creative Center gallery is available via webcam at www.rolanddga.com/gallery/ creativeCenter. FP Roland DGA Corp. (800) 542-2307; www.rolanddga.com

40

FLEXIBLEPACKAGING

| www.flexpackmag.com

Glunz & Jensen +45 5768 8181; www.glunz-jensen.com

OCTOBER 2011

[email protected] s www.uteco.com [email protected] s www.uteco.com

H I G H

S P E E D

F L E X O

P R I N T I N G

Leading edge innovation in flexographic printing

!(0 2!.'%

©

s0RINTCONlGURATIONSORCOLOR s-AXIMUMPRINTSPEEDFPM s0RINTINGWIDTHSvTOvMM s0RINTREPEATRANGEvTOvMM

s(IGHPRODUCTIVITYMACHINE s2EDUCEDJOBCHANGEOVERTIMES s)NNOVATIVEANDDYNAMICMACHINEDESIGN s#ONSISTENTRETURNONINVESTMENT

sP2P® : dynamic adjustment system controls printing pressures sPCT® : Press Control during Transition sPTC ® : Predictable Torque Control sSprintWash® : new automatic washup system sFlexoSmartPackHP® : Uteco engineering platform for improved performance and GENETIC INNOVATION profitability in flexographic printing sShopWare® Production Management, Control & Monitoring: easy machine-operator 54%#/./24(!-%2)#! interface to manage productivity 4/7.0/).4$2)6%s35)4% ® +%..%3!7 '!s0(  s&!8   sLogiPack : automatic handling [email protected]swww.uteco.com of reels and cores

19fp6m0

And a new innovation is coming...

5 4 % # / # / . 6 % 2 4 ) . ' 3 0 ! s )      # / , / ' . / , ! ! ) # / , , )  6 2 s 0 (                s & ! 8              

Hot Products

Flexco Debuts the Novitool Ply 130 Flex Flexc introduces the Novitool Ply 130 Ply Separator, a tool designed to easily Flexco split a variety of thermoplastic belts. The easy-to-operate Ply 130 features robust construction, as well as consistent results for both finger-over-finger and stepped const splice preparation in only one pass. With the Ply 130, only two adjustments need to be made before the job starts – setting the blade position where the fabric layers need to be separated and setting the depth minimum or maximum. The rrobust construction of the Ply 130 features a rigid, solid housing. Users can separate as little as 0.14inches (0.35 milimeters), drive rollers are captured on sepa both ends for stability and the Ply 130 can either be moved to a specific location mounted to a workbench. One of the biggest advantages of the Ply 130 is or mo that it can split the plies as deep as 5.1inches (130 milimeters) in only one pass. Flexco www.flexco.com (800) 323-3444; 3

Reclosable Fastener from VELCRO VELCRO brand PRESS-LOK is a new and exciting reclosable fastener from the Velcro Companies. Featuring an innovative hook-to-hook closure system, PRESS-LOK is easy aligning and does not require precise line-up, secure with great burst strength, and simple to open and close making it extremely consumer friendly. VELCRO brand PRESS-LOK is heat sealable to most PE flexible films and its transparent design integrates seamlessly into a variety of products. VELCRO. (800) 225-0180; www.velcro.com

Ne Technology from EDI Promises Increase New in Shelf Life for Foods in Barrier Packaging A patent-pending technique developed by Extrusion Dies Industries, LLC (EDI) adds a new dimension of oxygen and moisture control LL to food packaging. The “active microlayer” technology combines the concepts of active packaging and microlayer extrusion, yielding film and sheet in which layer multiplication is applied not yie only to the barrier polymer but also to active components such on as oxygen absorbers or desiccants. Previous research by EDI has demonstrated that by dividing and recombining the barrier ha layer to create many micro-barrier layers, it is possible to increase lay significantly the shelf life of retort and hot-fill containers, stand-up sig pouches, and vacuum skin packaging. Now researchers at EDI’s po Technology Center in Chippewa Falls have gone a step further by Te incorporating active components in layers outside the barrier core, inc then subjecting those components to layer multiplication as well. the Extrusion Dies Industries (715) 726-1201; www.extrusiondies.com

42

FLEXIBLEPACKAGING

| www.flexpackmag.com

OCTOBER

2011

Custom Fabricated Endboards Precision-cut custom endboards are combined with sleeve plugs to secure e and protect medium to large rolls during shipping and storage. Endboards are made with high-density particleboard, plywood or hardboard up to two inches thick with any variety of holes, slots, notches and other precision cuts necessary to meet a range of roll shipping and storage needs. Both standard and custom sleeve plugs are available. Endboards can be configured to suspend one or multiple rolls. Suspended d rolls can be easily stacked and unitized by using Badger Plug’s H-channels s and U-clips. Recycled endboards, sleeve plugs, H-channels and U-clips are e also available at reduced pricing. Badger Plug (920) 757-7300; www.badgerplug.com

Durable Nip Rolls are Custom Engineered Nip rolls from PFE Rolls, Inc. are designed for a variety of converting applications including thermal bonding, compacting and squeezing webs, creating composite webs, web pulling or braking, and web calendering. These same precision rolls are routinely engineered for temperature controlled nip applications. A variety of surface finishes and coverings are readily available, including chrome plating, plasma coatings and rubber coverings. Every nip roll is custom engineered for exacting performance, from low-tension applications to those with extreme nip loads. PFE Rolls, Inc. (978) 544-7803; www.pferolls.com

Nip Stations for Laminating and Calendering AccuNip nip stations from PFE Rolls, Inc. can be custom configured for a wide range of uses in the converting industry, including laminating and calendering. Available in welded steel, cast-iron, or lightweight aluminum frames, AccuNip stations are designed for nip pressures up to 25,000 pounds. These versatile stations can be configured vertically or horizontally and customized with doctor blades, dual-roll gear drives, heating or cooling rolls, and adjustable nip pressures es and gaps. AccuNip stations are used in many unique applications and are custom m engineered to meet the most demanding nip machinery applications. PFE Rolls (978) 544-7803; www.pferolls.com

Safe-Slab Core Recycler™ Žƒ†‡ ”‡‡‘ŽŽŽƒ„„‹‰ƒ†‘”‡‡…›…Ž‹‰

—‹…Ž›ƒ†•ƒˆ‡Ž›”‡‘˜‡Ž‡ˆ–‘˜‡”‘” †ƒƒ‰‡†”‘ŽŽƒ–‡”‹ƒŽ•‘…‘”‡•…ƒ„‡ ”‡—•‡†ƒ†•…”ƒ’ƒ–‡”‹ƒŽ”‡…›…Ž‡†Ǥ visit ǣ www.appletonmfg.com call ǣ 1-800-531-2002

A Product By:

search ǣ“Appleton Safe-Slab”

OCTOBER 2011

FLEXIBLEPACKAGING

| www.flexpackmag.com

43

Hot Products DuPont Packaging Graphics to Market Compressible Adapters Powered by Inometa DuPont Packaging Graphics (DuPont) has announced a global agreement to market a series of print adapters and adapters for CDI imaging manufactured by Inometa, The adapters are specially designed to optimize the performance of both Cyrel round Thin sleeves and Cyrel FAST round Thin sleeves, and provide excellent register accuracy, low dot gain and outstanding print quality from run to run. Made of precision fiberglass, they are engineered to be sturdy and smooth running with minimal run-out. The adapters have a rubber stop and bayonet locking system for superior handling and long life, and are available in all standard sizes. DuPont Packaging Graphics (302) 774-1000; www.dupont.com

Inometa 49 (5221) 777-0; www.inometa.de

INX Digital Debuts LD Series Inks INX Digital introduces its new TRIANGLE LD (low durability) series of high performance inks. The solvent-based ink series includes STX for HP Scitex XL1200, XL1500 and Grandjet printers, and VUV for printers using Spectra, Hitachi Koki, Xaar 126 and Seiko 572 with 14pl print head technology. Both inks are designed to be outdoor durable for one year. TRIANGLE STX and VUV inks are available in the Asia-Pacific (except in Australia and New Zealand), Africa, Eastern Europe, Latin America and Middle East markets. INX Digital International Co. (510) 895-8001; www.INXdigital.com

LCR Load Cell/ Roll Assembly Provides Accurate Tension Control Nip rolls from PFE Rolls, Inc. are designed for a variety of converting applications including thermal bonding, compacting and squeezing webs, creating composite webs, web pulling or braking, and web calendering. These same precision rolls are routinely engineered for temperature controlled nip applications. A variety of surface finishes and coverings are readily available, including chrome plating, plasma coatings and rubber coverings. Every nip roll is custom engineered for exacting performance, from low-tension applications to those with extreme nip loads. PFE Rolls, Inc. (978) 544-7803; www.pferolls.com

Color Resolutions International Introduces New Bond-Rite for Lamination Applications The Montalvo Corporation, international specialists in industrial web control systems, offers its LCR load cell/roll assembly, an accurate way to measure web tension and improve productivity. The system can be manufactured to a customer’s exact specifications with a variety of load ranges, mounting options, roll materials, and finishes. Using Montalvo’s new ES load cells, for dead shaft/idler, live shaft, or live roller, the LCR system is sensitive to the slightest changes in tension which makes a customer’s application as productive and profitable as possible. It provides precise, accurate, and consistent tension measurement and is ideal for low start-up inertia. It is available with extra low drag, maintenance-free bearings and can be dynamically balanced for speeds up to 1500 fpm. Color Resolutions International (800) 346-8570; www.colorresolutions.com

44

FLEXIBLEPACKAGING

| www.flexpackmag.com

OCTOBER

2011

To place your classified ad in Flexible Packaging call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] CAREER OPPORTUNITY

SALES POSITIONS AVAILABLE ✔ Modern Manufacturing Services is looking for experienced sales representation, for domestic and international territories. ✔ Prospecting and developing new accounts will be top priority. ✔ Candidates should have direct experience with pouch, bag making equipment and accessories. ✔ Existing customers in some territories, many untapped potential new customers. ✔ Fast paced growing company with great product growth opportunity. ✔ Independent representatives and direct hire options available.

Please e-mail or fax resume/ inquiries to: [email protected] | Fax: 585-289-7909

LOOKING FOR MANUFACTURER DIRECT REPS/ BROKERS

An expanding company based in the Northeast, with multi-location facilities, is looking to establish relationships with manufacturers’ representatives, brokers and direct representatives (expense & commission) in all regions. Our focus is in developing markets for our Barrier, Thermoforming and other value added products. Our Capabilities include: • 3,5,7 Layer Co-Extruded Film • Printing (8 Color) • Lamination (Solventless, Water, Solvent) • Pouching (Stand-up, Zipper, Center, 3 Side) Please direct your inquiries and resume to: [email protected]

flexpackmag.com

EQUIPMENT FOR SALE

HELP WANTED

3508 Ervin Price Road • Gilbert, SC 29054 USA • Office: (803) 892-6937 Fax: (803) 892-0568 Cell: (803) 413-2477 E-mail: [email protected] | [email protected] Visit our Website: www.intermach.com for a complete listing of machinery & services.

International Machinery, LLC

Executive Secretary needed for a world class flexible packaging company in Brooklyn, NY. Must have experience in the flexible package industry and have excellent written and verbal skills in English and Spanish. Also, must be proficient in Microsoft Word and Excel. Competitve salary and benefits. Interested candidates are invited to email their resume to [email protected]

EQUIPMENT FOR SALE

Specializing in: Including:

Web fed printing and converting machinery. New and used Flexo, Rotogravure, Coating, Laminating, Slitting, Extrusion. and Miscellaneous lines. Services include: New and used machinery appraisals and plant liquidations, rigging and transportation plants and process consulting projects.

“Building relationships since 1987”

Advertise in the Flexible Packaging Classified Network !! Call Diana Rotman at 847-405-4116 or [email protected] PLASTIC CORE PLUGS

OCTOBER

2011

FLEXIBLEPACKAGING

| www.flexpackmag.com

45

To place your classified ad in Flexible Packaging call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] SUPPLIES

Impex International Group LP Importer/Exporter/Converter/Distributor of all types of Industrial, Packaging and Specialty Films.

✷ ✷ ✷ “Excellent Customer Service, Prompt Deliveries & Competitive Pricing”✷ ✷ ✷ POLYESTER FILMS Corona / Chemical treated Industrial Grades Packaging / Metallizing Thermal Lamination / Matte Graphics / Antistatic Coated Wire and Cable Wrap PVDC Coated Milky and Opaque White Hot Stamping / Roll Leaf Metallized / Pigmented Sealable / Ovenable

BOPP FILMS Coextruded Plain / Tape Pearlized / White Anti Fog Metallizing / Metallized PVDC Coated / Acrylic Print Lamination/ Matte Labels / Decals Holographic Thermal Lamination Synthetic Paper/Teslin

BIAX NYLON FILMS Clear Metallized PVDC Coated CAST NYLON FILMS Thermoforming Non Forming HOLOGRAPHIC FILMS Polyester / BOPP Patterns METALLIZED LACQUERED FILMS Polyester / Polypropylene

PAPERS PP Based Synthetic Direct / Transfer Metalized Holographic Metalized Wet Strength (Beer Labels) CPP FILMS Metallized Lamination Retort Twist Soft Blister Textile grade

Aluminum Foil Gauge: from 0.00022” to 0.157” Dingsheng Aluminum USA Office: Raymond Xu Tel: 804-690-3483 Email: [email protected] www.dingshenggroup.com

• Thickness range: 20-1400 gauge (5 - 350 micron) • Width range: 3/8 inch - 88 inches Converting Capabilities: Custom Slitting, Custom Sheeting, Label Printing & Packaging/Board Laminations. Warehouses: Bedford Park, IL; Atlanta, GA; Simpsonville, SC; Trenton, NJ; Milbury, MA; Houston, TX

CORPORATE OFFICE: 2801 W. SAM HOUSTON PKWY, N., SUITE 100, HOUSTON, TX 77043 USA PH: (281) 416-4449 • FAX: (281) 416-4989 • EMAIL: [email protected] • WEB SITE: WWW.IMPEXFILMS.COM ----- SEEKING NATIONWIDE

AND

WORLDWIDE SALES REPS -----

SERVICES

SPECIALIZING IN : • Manufacturing of Custom Bags/ Pouches for the Packaging Industry. • Converting your FILM into high-quality Custom Bags / Pouches.

[email protected] www.kleerpak.com 630-543-0208 ext. 102

Advertise in the Flexible Packaging Classified Network !!

AIB CERTIFIED | EXCELLENCE THROUGH DILIGENCE

Call Diana Rotman 847-405-4116 or [email protected]

RECRUITMENT

PET / BON / PLA FILM

Converter’s Converter Since 1977

320 S. La Londe Ave. Addison, IL 60101

320 Remington Blvd., Bolingbrook, IL 60440 Phone: 630-226-9800 / Fax: 630-226-9400 Toll Free: 1-888-PET-FILM Website: www.PetFilm.com

46

FLEXIBLEPACKAGING

| www.flexpackmag.com

OCTOBER

2011

To place your classified ad in Flexible Packaging call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] SUPPLIES

WANTED TO BUY

WE BUY LAMINATE SCRAP • FOIL SCRAP • FILM SCRAP • PAPER SCRAP

We Also Buy Surplus Rolls CONNECTICUT METAL INDUSTRIES (203) 736-0790 • [email protected] • www.foilfoil.com

ROLLERS

Why do the top OEMS use Menges Roller Company?

Lotar LLC Tel: 920/465-6678 Fax: 920/465-7262 [email protected] www.lotarenterprises.com 1221 Bellevue St., Green Bay, WI 54302

ADVERTISE HERE

· · ·

we listen we sell what the customer wants we make it happen

Flexible Packaging Classifieds Call Diana Rotman: 847-405-4116 or email: [email protected] Me Menges en Roller is an all inclusive rubber covering and new core manufacturer co

Toll Free: (888) 856-1753

www.mengesroller.com PLASTIC RECYCLING

We purchase Laminated/Printed PET, or BoPP trim/slab, as well as almost all other primary plastics!!

Equipment to sell? Services to provide? Positions to fill? Advertise in Flexible Packaging's Classified Network

P Please visit our website www.parcusa.com or call w AAlex at 815.372.3500 ext 129

OCTOBER

2011

Contact Diana Rotman at 847-405-4116 or [email protected]

FLEXIBLEPACKAGING

| www.flexpackmag.com

47

To place your classified ad in Flexible Packaging call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] SERVICES

Roll-Fed SOLUTIONS ••• Don J. Kemps LLC ••• Exclusive Agent in the U.S. and Canada for M.A.L.I. Hole Punching Apparatus "MALI is the world leader for punching holes in poly, paper or foil"

Quality, Experience &Value

N5949 Cordy Road Cell: 920-850-3546 Hilbert, WI 54129 Fax: 920-439-1253 Email: [email protected]

ALL ROLLED INTO ONE! At Contract Converting, we’re focused on anticipating your needs to professionally deliver quality converting solutions at a moment’s notice. Custom slitting. Roll finishing. Distribution and packaging. We have the experience, products and capabilities to handle your most complex challenges. (On time. Anytime.) Papers, film, foil, laminates, tissue, non-wovens, plain or printed...let Contract Converting’s experienced professionals provide solutions to your specialized converting needs. Boost your bottom line with services and solutions designed exclusively for you. Visit www.ContractConverting.com or call us toll-free at 800-734-0990.

E-3 Epoxy CORONA TREATER ROLL COATING ★★ ★★ ★ GUARANTEED ★ ★★ ★★ ★ ★ Call us or send your rolls to:

SOLO SYSTEMS, INC. 4001 Industrial Street Rowlett,TX 75088

800/259-5570 • fax: 972/475-5128

EQUIPMENT TO SELL? POSITIONS TO FILL?

FILM

Polyester Film 48 GA-1400 GA

Advertise in the

Plain, Coated, Colors! Slit, Sheet & Die Cut 877-838-1702


www.plasticconnections.com

MATERIALS WANTED

CLASSIFIED NETWORK Call Diana Rotman 847-405-4116 | [email protected]

48

FLEXIBLEPACKAGING

| www.flexpackmag.com

OCTOBER

2011

Calendar of Events

Oct 18, 2011 to Oct 19, 2011 Packaging Expo Trenton, New Jersey www.hughesent.com

Nov 9, 2011 to Nov 11, 2011 Holo-pack/Holo-print 2011 Las Vegas, Nevada www.holopack-holoprint.com/

Nov 2, 2011 to Nov 3, 2011 MinnPack Minneapolis, Minnesota www.MinnPackShow.com

Nov 21, 2011 to Nov 23, 2011 Flexible Packaging Middle East 2011 Dubai, United Arab Emirates www2.amiplastics.com

Nov 7, 2011 to Nov 9, 2011 Packaging Outlook Summit 2011 Atlanta, Georgia www.packagingoutlook.com/

Mar 18, 2012 to Mar 21, 2012 FTA's Flexo: Brand of Choice San Antonio, Texas www.flexography.org

Ad Index COMPANY NAME

PAGE

WEB SITE

COMPANY NAME

PAGE

Harper Corporation of America

33

Hosakawa Alpine America

19

www.halpine.com

Mamata Machinery USA

37

www.mamatausa.com

Modern Manufacturing Services

31

www.modernmfg.net

NEX Performance Films

BC

Anderson & Vreeland

24

www.AndVre.com

Appleton Mfg.

43

www.appletonmfg.com

Atlas Converting Equipment

36

www.atlasconverting.com

18

www.badgerplug.com

Badger Plug Bobst Group North America

34-35

www.bobst.com

Catbridge Machinery

17

www.catbridge.com

Channeled Resources Group

33

www.channeledresources.com

CMD Corporation

7

www.cmd-corp.com

Cytec Specialty Chemicals

3

www.cytec.com

Danafilms, Inc.

2

www.danafilms.com

Eckart American Corporation

26-27

www.eckart.net

EFI Radius

29

www.efi.com

Flexible Packaging Association

15

www.flexpack.org

Flxon

5

www.flxon.com

Pearl Technologies

SINGLE COPY SALES BACK ISSUES Ann Kalb E-mail: [email protected] Call: (248) 244-6499 VOLUME REPRINTS Deb Soltesz E-mail: [email protected] Call: (248) 786-1596

PRINT & INTERNET ADVERTISING Randy Green E-mail: [email protected] Call: (248) 244-6498 Steve Liput E-mail: [email protected] Call: (847) 405-4112 CUSTOM PUBLISHING Chris Wilson E-mail: [email protected] Call: (248) 244-8264 SUBSCRIPTIONS P.O. Box 1080 Skokie, IL 60076 E-mail: [email protected] Call: (847) 763-9534

LIST RENTAL For postal information: Kevin Collopy E-mail: [email protected] Call: (800) 223-2194 ext. 684 For e-mail information: Michael Costantino E-mail: [email protected] Call: (800) 223-2194 x748 CLASSIFIED SALES Diana Rotman E-mail: [email protected] Call: (847) 405-4116

www.harperimage.com

www.nex-films.com

10-11

www.pearltechinc.com

PPC Technologies & Solutions

25

www.ppcts.com

Retroflex, Inc.

9

www.retroflex.com

R.G. Egan

31

www.rgegan.com

Siegwerk USA Co.

30

www.siegwerk.com

Totani America, Inc.

22

www.totaniamerica.com

Uteco North America

41

www.uteco.com

Velcro USA, Inc.

23

www.velcro.com

Windmoeller & Hoelscher

51

www.whcorp.com

Reader & Marketing Services LETTERS Erin J Wolford Mail: Flexible Packaging 155 Pfingsten Road Deerfield, IL 60015 E-mail: [email protected]

WEB SITE

T H E I N D I S P E N S A B L E T O O L F O R C O N V E R T E R S & P R I N T E R S O F F L E X I B L E PA C K A G I N G

®

BNP Media 155 Pfingsten Road, Suite 205 Deerfield, Illinois 60015 (847) 405-4000 Fax: (847) 405-4100

Also publishers of: Beverage Industry, BrandPackaging, Candy Industry, Dairy Foods, Food & Beverage Packaging, Food Engineering, Food Master, Industria Alimenticia, The National Provisioner, Nutrasolution, Prepared Foods, Private Label Buyer, Refrigerated & Frozen Foods Retailer and Snack Food & Wholesale Bakery.

FLEXIBLE PACKAGING (ISSN 1535-0797) is published 10 times annually, Jan/Feb, Mar, Apr, May, Jun/Jul, Aug, Sept, Oct, Nov, and Dec, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (Int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: FLEXIBLE PACKAGING, P.O. Box 1080, Skokie, IL 60076. Change of address: Send old address label along with new address to FLEXIBLE PACKAGING, P.O. Box 1080, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O.Box 25542, London, ON, N6C 6B2. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected]

OCTOBER 2011

FLEXIBLEPACKAGING

| www.flexpackmag.com

49

Industry Q&A: Bag-/Pouch-Making

ADDING TECHNOLOGY TO BAG-/POUCH-MAKING Scott Fuller CMD Corporation

Scott Fuller is CMD Corporation’s intermittent-motion product line manager and has shared his expertise with CMD for the past 4 years. By Erin J. Wolford, Editor-in-chief

Q:

What new features or technologies are being introduced to this sector of the industry?

A:

Pouch and bag designs will continually evolve to meet the changing demands of consumers for convenience and quality. But converters have told us what is most important to them: Technology that will put more money to the bottom line. In today’s marketplace, where margins are thin and competition is fierce, converters are looking for technology that gives them the power to reliably control their process, which will improve process efficiency and product quality. By applying the discipline of process driven innovation, CMD introduced Intelligent Sealing Technology to the medical packaging market. This propriety technology combines mechanical and electronic controls innovation to carefully maintain and document the three critical sealing parameters of time, temperature and pressure. CMD's process driven This new technology has adinnovation, Intelligent dressed the need of the medical Sealing Technnology, uses packaging converter by maintaining mechanical and electronic controls innovation process consistency and building to maintain and document confidence in product quality and in- critical sealing parameters. tegrity through data acquisition and product/process traceability. We now offer this same level of control and confidence to stand-up-pouch converters. It is very exciting to see how enthused customers are when they see this technology for the first time. Their reaction is: “Finally, someone listened to me!!”

Q:

What kinds of trends are happening now, and what are customers requesting less or more of? Is there a formerly hot trend that is cooling off now?

A:

Sustainable packaging formats are hot now; pouches that do more with less are efficient to ship, fill, store and display. Even in basic bag converting, overlapped bags-ona-roll are overtaking folded bags as a dispensing option because they are more efficient to produce, ship and store.

50

FLEXIBLEPACKAGING

| www.flexpackmag.com

While it’s important to remain innovative in package design, converters are also looking for sustainable converting processes. Monitoring and maintaining the critical sealing functions of time, temperature and pressure enhances process efficiency and reduces scrap, downtime and overall converting costs. This is the heart of sustainability.

Q:

With so many options in the bag-/ pouch-making segment, in your opinion, what is the most durable style currently on the market?

A:

While niche packaging styles find their place in short-term product differentiation efforts, or run their course in test marketing, the store shelves are mostly populated by the traditional bottom-gusseted and side-gusseted stand-up pouch formats. There’s a reason for this: the stand-up pouch offers superior functionality, economy and brand identity. It’s a ‘bang-for-the-buck’ thing.

Q:

What kinds of problems has this segment solved in recent years?

A:

Having spent 25 years as a converter myself, I think the greatest advancements and ‘problem-solving’ have come from the geniuses developing film structures. Through the advancement of film technology, a large variety of products have migrated to the SUP format. Think about the environmental impact our industry has had. By transitioning many consumer products from traditional rigid formats into pouches and bags, our industry has reduced the overall carbon-footprint left by consumer packaging significantly. FP CMD Corporation (920) 730-6888; www.cmd-corp.com

OCTOBER

2011

r Co

p.

s ic s w t as d o Pl war f Sh e in 1 A st o h ns 201 Be u S TA & F old G

D L D O AR GW A

Sweeter...

Nothing could be

... than our customers’ success at the Flexographic Technical Association’s Excellence in Flexography Awards. In the wide-web category, 20 of the 25 winners were printed on W&H flexo presses - including the Gold Award & Best of Show. Sunshine Plastics of Montebello, CA printed this stand-out wrapper on a W&H 10-color press and has garnered 7 awards in the past year. Congratulations to Sunshine Plastics and all the FTA winners.

PASSION FOR INNOVATION

WINDMOELLER & HOELSCHER CORPORATION

FLEXIBLE PACKAGING EQUIPMENT THAT MEETS THE DEMANDS OF AMERICA’S TOUGHEST CUSTOMERS 23 NEW ENGLAND WAY | LINCOLN, RHODE ISLAND 02865-8702 | Phone: 800-854-8702 | [email protected] | www.whcorp.com