Flexible Packaging May 2011

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 FLE X I B LE PA C K A GI N G

Table of Contents ®

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20 COVER FEATURE OFFICIAL GUIDE TO GLOBAL POUCH FORUM Global Pouch Forum: New Markets, New Technologies, New Opportunities The 2011 Global Pouch Forum is the major industry event celebrating the rise of the pouch for more than a decade. This is your insider resource to the Forum.

Cover Art product information listed front to back: Henkel Renuzit Crystal Elements Club Store/Dollar Store Pouch by Exopack, LLC, Fres-Co Systems USA and International Dispensing Corporation (IDC) Sunkist protein shots One-gallon Stand-up Pouch, Fresh N Tasty Produce Pouch by Robbie.

26 FEATURES 10 FPA UPDATE

46 INDUSTRY Q&A:

Flexible Packaging Association Update Bi-Annual Polyolefins Market Report Released…2011 Membership Directory…Pilot Programs Conducted to Examine Resource Recovery from Flexible Packaging Waste…and a New Member Announced.

EXTRUSION EQUIPMENT Developing Better Films with Extrusion Equipment David Nunes, president of Alpine American, Inc., offers the extrusion equipment industry 27 years of experience.

24 SPECIAL REPORT ON

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THE GLOBAL POUCH FORUM Global Pouch Forum Tentative Agenda This itinerary is the resource to turn to when planning your Global Pouch Forum travel and schedule plans.

26 PRINTING: NARROW WEB Sleeve Film Delivers High-impact Graphics Drink manufacturer and distributer San Benedetto invested in a new labeling system, which now cost-effectively allows the company to match the high impact of sleeves.

30 TECHNOLOGY:

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FITMENTS & CLOSURES Fitments to Bring Closure, Value to Flexible Packs From zippers to spouts, fitments and closures are a critical part of flexible packaging.

DEPARTMENTS 8 EDITOR’S FORUM 16 CONVERTER NEWS Plant Relocation and Machinery Purchase Announced… Innovative Package Design Partnership…The End Result…and Sustainability Initiatives for Zero Percent Waste-to-landfill. 32 INDUSTRY INSIGHT 36 SUPPLIER NEWS Two New Company Distrubition Agreements... Six-Color Press Installation Announced. 38 HOT PRODUCTS 41 CLASSIFIEDS

34 ROUNDTABLE ON BAG-/POUCH-MAKING (SPECIAL ADVERTISING SECTION)

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MAY 2011

45 CALENDAR OF EVENTS & AD INDEX

www.flexpackmag.com | FLEXIBLEPACKAGING

Better Together THE DOW CHEMICAL COMPANY & THE NORDMECCANICA GROUP WILL DEMONSTRATE

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Invitation Only Event Wednesday, May 11, 2011 Nordmeccanica’s Technical Center 250 H Executive Drive Edgewood, NY 11717 COME LEARN

How Dow’s: + MOR-FREE™ Solventless Laminating Adhesives + SARANEX™ Barrier Films + SEALUTION™ Peel Polymers work together for easy-open packaging and improved barrier lamination films. TO REQUEST AN INVITATION, CONTACT:

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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 FLE X I B LE PA C K A GI N G

Online Content ®

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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!

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www.flexpackmag.com | FLEXIBLEPACKAGING

Packaging. Processing. Powerful.

Every Possible Solution Across the Line Precisely integrated production has a powerful impact on your bottom line. PACK EXPO Las Vegas brings together the most innovative packaging and processing solutions just for you. Find all of the latest ideas and technologies to raise efficiency and safety to new levels—for great results. 1,600 exhibitors. 25,000 professionals. North America’s #1 industry event.

Register Today! www.packexpo.com

PACK EXPO Las Vegas 2011

P R O D U C E D B Y:

September 26-28, 2011 Las Vegas Convention Center Las Vegas, Nevada USA

CO-LOCATED WITH: C

Editor’s Forum

THE INDISPENSABL E TOOL F OR CONVERTERS & PRINTERS OF F LEXIBLE PACKAGING

®

ENSURE OPPORTUNITIES NOT OBSOLESCENCE any flexible packaging veterans say that one product propelled the flexible packaging industry to the forefront of packaging innovations: the CapriSun pouch. As a child of the 80s, I was the industry’s target marketing group. Thank goodness the flexible packaging industry is always improving, including making updates to the CapriSun pouch’s punch hole; I don’t think I could ever open the 1980s version of that hole-punch without spilling juice all over my forth grader desk. Improvements are vital in business – resting on your laurels only ensures you’ll become obsolete. Opportunities abound when improvements can be made. That’s why Flexible Packaging magazine has partnered with sister ePublication Packaging Strategies as host to an all-important industry event called the Global Pouch Forum (GPF). Involvement in events like the GPF is one key to growing and advancing as a business and an industry, in my humble opinion.

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Resting on your laurels only ensures you’ll become obsolete. The Global Pouch Forum calls on those involved in the bag/pouch niche to listen to and discuss case studies, best practices and future outlooks. PS Editor Joe Pryweller has penned our cover story, offering you a guide of what to expect at the Forum on page 20. Be sure to flip to page 24, too, for the GPF Tentative Agenda to reference while making your travel plans to sunny Fort Lauderdale, Florida, where the GPF will be held this year. The Printing section of this month’s issue, on page 26, includes how one drink manufacturer sought out a cost-effective shrink-sleeve option. Page 30 highlights different technologies offered in the Fitments & Closures segment of the industry, some of which are very innovative answers. Extrusion Equipment is discussed on page 46 as an encore presentation. The monthly Special Advertisers Section offers the Roundtable on Bag-/ Pouch-making, sharing executives’ opinions on what’s coming around the bend, the most efficient type of pouch, and what this sector might need in the future. And be sure to stop on pages 16 and 36 for our Converter News and Supplier News sections for the up-and-up of industry happenings. Understanding where you can make improvements and how is so important in business: This issue can help you do both. FP Sincerely, ERIN J. WOLFORD (847) 405-4042 [email protected]

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] EDITORIAL Editor-In-Chief Erin J. Wolford, [email protected] Executive Editor Rick Lingle, [email protected] Marketing Coordinator Elisabeth Cuneo, [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: Rob Liska at 800-223-2194 x.726 [email protected] Email contact: Shawn Kingston at 800-409-4443 x.828 [email protected] BNP MEDIA CORPORATE OFFICERS Publishing: Timothy A. Fausch 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 Conferences & Events: Emily Patten 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 4

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F LE X I B L E PAC K AG I N G A S S OCIATI ON | UPDATE

FPA RELEASES BI-ANNUAL POLYOLEFINS MARKET REPORT he cost and availability of raw materials remains an important issue for the flexible packaging industry. The recently published FPA/CMAI BiAnnual Polyolefins Market Report examines critical issues expected to drive the evolution of the industry. The Report is prepared exclusively for FPA members by Chemical Market Associates, Incorporated (CMAI) and is based on CMAI’s polyolefins market update presentation given during the 2011 FPA Annual Meeting in Naples, Florida. The Bi-Annual Polyolefins Market Report focuses on

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high, low and linear low density polyethylene. The Report provides an overview of the global economy, an outlook on the global energy supply, and how new capacity additions and changes in trade flow may impact the U.S. flexible packaging industry. Additional information about PET resin and film is also detailed within the Report. FPA members can view and download copies of the Report by visiting the Members Only section of the FPA Web site, www.flexpack.org. An update to the spring 2011 Bi-Annual Polyolefins Market Report will be published in fall 2011.

NOW AVAILABLE: 2011 FPA MEMBERSHIP DIRECTORY he Flexible Packaging Association’s 2011 Membership Directory provides a comprehensive listing of FPA members, in addition to FPA and related association information. The Directory is a benefit of FPA membership and is available in an easy-to-use electronic (PDF) format within the Members Only section of the FPA Web site, www.flexpack.org. Hard copies of the Directory are also available upon request. Distributed on an annual basis, the Directory is organized in alphabetical order by company name and includes a company and personnel index. The electronic version of the Directory offers contact information for FPA members, FPA official and alternate representatives, and additional company contacts. The Directory also includes a list of FPA trade press, academic and international members. The quick reference hard copy version of the Directory provides FPA members with the ability to readily locate information on FPA leadership, and converter, associate, international and trade press members. For more information about the 2011 FPA Membership Directory contact FPA at (410) 6940800 or fpa@flexpack.org.

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MARK YOUR CALENDARS! FPA meetings offer the great networking opportunities while providing insight into issues and trends affecting the flexible packaging industry. Be sure to mark your calendar for these upcoming FPA and industry events.

2011 FPA Fall Executive Conference October 5, 2011 Ritz-Carlton, a Four Seasons Hotel Chicago, IL

2012 FPA EHS Summit February 9-10, 2012 TradeWinds Island Grand Resort St. Petersburg Beach, FL

2012 FPA Annual Meeting February 22-24, 2012 Fairmont Scottsdale Princess Scottsdale, AZ

PACK EXPO International 2012 October 28-31, 2012 Chicago, IL

MAY 2011

FPA CONDUCTS PILOTS ON RESOURCE RECOVERY FROM FLEXIBLE PACKAGING WASTE he Flexible Packaging Association is conducting a series of pilot programs on behalf of its membership to examine new and emerging technologies for resource recovery from flexible packaging waste. The goal of the Resource Recovery from Flexible Packaging Waste Pilot Program is to identify companies that provide viable endof-life alternatives to landfill for flexible packaging waste, and to demonstrate the efficacy of technologies including microwave pyrolysis, gasification, thermal pyrolysis, and engineered solid fuel. While the vast majority of pre-consumer flexible packaging waste is reused by flexible packaging manufacturing facilities, FPA is utilizing pre-consumer waste as a proxy in the initial phases of the pilot program. Once the FPA pilots on pre-consumer flexible packaging waste are complete, FPA will develop a post-consumer waste pilot program. FPA’s first pilot was conducted by Climax Global Energy (CGE) in Fairfax, SC. During the trail, pre-consumer flexible

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packaging waste was successfully utilized as feedstock for CGE’s patented microwave pyrolysis process to generate a condensed wax end-product. The test clearly demonstrated that flexible packaging waste is a viable feedstock for CGE’s technology. Using a conventional refining technique, the condensed wax product can be used as a fuel to produce synthetic lubricants, commodity waxes, and diesel fuel. FPA is preparing to conduct another pilot with Agilyx Corporation to examine the efficiency of their gasification system. Agliyx is the first in the world to economically convert difficult-to-recycle waste plastics into crude oil through a patented system that is scalable, versatile, and environmentally beneficial. FPA is also conducting trials with Environ utilizing thermal pyrolysis, and Dongara, which produces engineered solid fuel to produce pelletized fuel. For more information on the FPA Resource Recovery from Flexible Packaging Waste Pilot Program, contact FPA at (410) 694-0800.

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

UMAX PACKAGING LIMITED JOINS FPA he Flexible Packaging Association is pleased to welcome Umax Packaging Limited to the association. As a FPA converter member, Umax provides its customers with a broad range of sophisticated flexible packing products produced to world class quality standards. Although supplying an array of markets, Umax is heavily focused on the Food and Confectionery markets, producing rotogravure printed and laminated multi-layer structures utilizing PET, BOPP, Paper, Foil, Metalized films, PE coextrusions, etc. Along with roll stock, Umax supplies pouches and bags of all configurations including zippered, stand-up, and handled. Umax’s FPA official representative is Ev Stephen, general manager; and the alternate

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representative is Atit Gandhi, executive director. For more information, visit Umax Packaging Limited at www.umaxpackaging.com.

MAY 2011

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FACILITY RELOCATION AND PURCHASE OF POUCHING MACHINE ANNOUNCED mpac, a global leader in the food, pet food, retail, security and medical packaging markets, announces the relocation of its Elk Grove Village, Ill., pouching facility in 2011. Ampac will be relocating its area pouching facility, currently located in Elk Grove Village, to a larger location approximately 10 miles west to Hanover Park, Ill. This new facility will allow for a more efficient layout of the plant, as well as provide additional space for growth of Ampac’s pouching business.

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Ampac plans to purchase the Totani Box Pouch making machine to add to its new plant location.

With the help of commercial real estate firm Cushman and Wakefield, brokers Si Pitstick, based out of the Cincinnati office, and Britt Casey from the Chicago office were very helpful in the selection process, lease negotiation and selection criteria for the new building. The site has experienced steady growth over the past five years, which included one expansion to the building. Because there is no room for future expansion, the facility will be moved to the new location. After the move, the plant footprint will increase by approximately 50,000 square feet at the new site. The new

location will be a state-of-the-art pouching facility specifically designed as a pouching-only operation. The move will take place during the second and third quarter of 2011 and is slated to be completed by October 1. It is expected that all current employees will transfer with the move with minimal disruption to the business. In addition to the move, the new Hanover Park facility will purchase a Totani BH-60DG-F (SG-6) Box Pouch making machine at this year’s interpack show in Dusseldorf. This purchase is the third pouch format Ampac has added within the past twelve months to its line of Totani pouch machines that run E-Z Zip, including plow bottom and inserted stand up pouch. The new machine provides Ampac with the first machine globally, that has two-up box pouch capability. Ampac can produce the E-Z Zip format in a two-up format while all other standard press-to-close zipper box pouch machines run a one-up format. Totani’s technology couples high-speed box pouch making and high-quality, high strength sealing to make the box pouch suitable for storage and transportation of both solids and liquids.FP Ampac (800) 527-2557; www.ampaconline.com Totani America, Inc. (920) 632-7319; www.totaniamerica.com

INNOVATIVE PACKAGE DESIGN ENSURES SHIPPING PROTECTION Custom-made candies shipped factory direct to consumers rely not only on their hard outer shell for protection, but also on an innovative packaging structure called the AirLiner, to ensure the candies melt in your mouth – and never in the mail. AirLiner, produced by Coldpack with barrier films by Danafilms, is an inflatable, insulating plastic liner that offers both the exceptional temperature control and protection from rough handling that delicate food items require. The key to the AirLiner’s success lies within A bag of personalized candies arriving safely on a consumer’s doorstep is due to the successful collaboration of dedicated suppliers, as well as ingenious package design.

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the multiple layers of film, which form air-filled baffles to insulate a shipment’s contents. “The finished film uses metalizing technology to provide a thin, reflective barrier, which refracts heat or cold back into the package and does not let it dissipate out,” says Steve Crimmin, sales manager at Danafilms. “At the same time, these films seal very well, which ensures the baffles inflate well and retain those cushioning and insulating properties throughout the product lifecycle.” Crimmin explains that creating a film that retains a metalized effect while achieving excellent sealability is, to some degree, a delicate balancing act — but not altogether impossible. FP Danafilms (508) 366-8884; www.danafilms.com Coldpack (866) 586-0800; www.coldpack.com

MAY 2011

the END RESULT

BANANAS GET A SECOND SKIN he bagging of fruit that does not necessary require a bag has reached another crescendo, with Del Monte’s announcement that it will widen its testing of bananas in a barrier plastic bag. Del Monte has told media outlets in England that it will sell individually wrapped bananas in a unique bag that keeps out oxygen and moisture and slows the ripening process. Dubbed “controlled ripening technology” by Del Monte, the packaging is designed to extend the shelf life of the fruit by six days. The company will begin selling the more expensive packaged bananas in convenience stores, gas stations and gyms, among other outlets. The company also is increasing trails of the bagged bananas in the United States. The first iteration of the barrierfilm bananas was launched in 2009 at 7-Eleven stores. While the move by Del Monte is not new – nor could be the technology – the trend of bagged fruit is also ripening. Competitor Chiquita Brands has its own plastic bag technology, with Landec Corp., which uses a breathable membrane that allows oxygen but not carbon dioxide to pass into the bag of fruit to enhance shelf life. Besides bananas, Chiquita has also started packing avocados in the bags.

Del Monte recently announced that it will widen its market testing of bananas in a barrier plastic bag.

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Converter News

SUSTAINABILITY INITIATIVES HELP COMPANY MOVE CLOSER TO ZERO PERCENT WASTE-TO-LANDFILL GOAL ealed Air announced that it has achieved another milestone in its SmartLife sustainability commitments by having 60 percent of its global manufacturing facilities attain “zero waste-to-landfill” for plastic raw material usage in 2010. “More than 95 percent of our plastic raw materials are used to produce saleable products. Much of our success in moving toward zero waste is the result of several programs we have implemented across our global manufacturing supply chain that improve yields and identify beneficial uses for our scrap material,” says Vince Herran, global recycling director for Sealed Air. According to Herran, these programs have resulted in Sealed Air being able to reuse in its own products, recycle into other useful products, or use for energy recovery a large

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majority of its plastic waste throughout all of its operations. In fact, an improvement of 72 percent has been realized, based on waste figures from 2002. “Our SmartLife approach focuses on understanding and improving the environmental profiles of our products and the products that our products protect. We look across the entire life cycle – from material use and energy consumption to CO2 emissions and waste generation,” says Ron Cotterman, executive director of sustainability for Sealed Air. “We recognize that this means starting with our own operations and setting goals to eliminate waste by reducing the amount we generate and finding practical uses for all that remains.” To achieve further progress on its zero waste-to-landfill initiative, Sealed Air is developing programs to find more applications for scrap including using recycled materials in construction, such as concrete blocks and roofing material, and railroad ties. FP Sealed Air (201) 791-7600; www.sealedair.com

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MAY 2011

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Cover Feature: Official Guide to Global Pouch Forum

NEW MARKETS, NEW TECHNOLOGIES, NEW OPPORTUNITIES

By Joseph Pryweller, ntributing Editor Contributing

he pouch market in packaging has been poised for a major U.S. breakthrough for much of this decade. Some would say that the market is still waiting. But others would be accurate in pointing out that time has come today, with many leading pouch innovations starting to reach across the waters from Europe and Asia and make their way into new applications in the United States. If nothing else, the 2011 Global Pouch Forum, the major industry event celebrating the rise of the pouch for more than a decade, has much to talk about this year. The event will be held June 7-9, 2011, at the Westin Beach Resort in Fort Lauderdale, Fla., and will continue

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an unprecedented run of critical information about the pouch, the new technologies and the business trends that are comingling to bring more success within the U.S. market.

A Growing Event The Forum’s recent popularity pays testimony to the growth in pouches in North America. This event is now in its 14th year, but continues to draw a large crowd. Last year, close to 300 attendees came to the Global Pouch Forum, one of the strongest attendance levels in the event’s history. With new applications for the pouch either now on the market or on the near-term horizon, this year’s event also is expected to draw a full house. Ever since the dawn of time (also known as the advent of a universally accepted drink pouch, when Capri-Sun was launched in the United States back in the early days of the Clinton Administration), pouches have been considered ready for major market penetration. But some factors have

delayed the pouch invasion in a major way. Among those has been the fact that existing equipment could not easily handle high volumes and compete with the production of rigid bottles and cans on high-speed packaging Ålling lines and in-line systems. Plus, while pouches offer consumers some market advantages due to their light weight and portability, they also mean a major equipment changeover at large end-user companies that had invested heavily in rigid-packaging equipment. But the pouch industry has not shown much quit over the years, and large market penetration now seems like an inevitable proposition in the short term. At the 2011 Global Pouch Forum, Dennis Calamusa, president of AlliedFlex Technologies in Sarasota, will offer his thoughts on how equipment and automated processing have improved to the point where the pouch is a more viable competitor to the bottle and can. Calamusa, a provocative speaker who is certain to challenge the audience at this event, will talk about how pouch

Neil Kozarsky, president/CEO of T.H.E.M. will moderate a panel discussion at the 2011 Global Pouch Forum on Global Pouch Technologies.

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MAY 2011

packaging and machinery have been married to affect the future growth of this format and the bigger-picture emergence of Æexible packaging as a substitute for rigid alternatives. As a keynote speaker, Calamusa plans to offer his thoughts on both the trends and technologies that are certain to drive the shift to the pouch. There has been recent market movement toward the pouch that is spurring more development. Within the past year, Seventh Generation and Ecologic Brands have partnered on a new laundry detergent bottle that features a compostable outer shell made of recycled cardboard and a pouch inside. Unilever has added an EZ Zip closure to a multipack condiment pouch.

Branding the Product The Forum plans to offer a brand owner panel involving companies that are moving to the pouch format. Another session will offer one of the most discussed new pouch launches on the market: Sunkist launched a onegallon standup pouch last fall containing 48 liquid “shots” of nutritional protein, with large retail outlets targeted in 2011. The large-format Sunkist pouches, produced on aseptic technology from Fres-Co Systems, also feature an innovative dispensing technology that

Dennis Calamusa will be a keynote speaker for the 2011 Global Pouch Forum, covering driving trends and technologies in pouches.

keeps the contents safe even without refrigeration. The closure system, from International Dispensing Corp. (IDC), and the pouch itself will be discussed during a special session at the conference, featuring representations from BioBev (the Sunkist licensee), FresCo, and IDC. The Forum will hone in on some of the key market and technology trends that should continue to help pouches gain notice on the retail shelves. Those include a special Market Landscape session featuring top packaging converters and consultants. That

session will include Rollprint president Dhuanne Dodrill discussing the shift in healthcare/pharmaceutical applications to the pouch; David Staker, president/ CEO of Plastic Packaging Technologies (PPT) on the pet food and pet treat market; Danny Beard, president of Packaging Specialists, talking about the recent emergence of pouches for liquid packaging; and Laurens Last, president of IPN Europe, discussing pouch growth in food and dispensing technologies. Plus, this year’s Forum will feature a round-robin discussion offering unique perspectives on varying aspects of new pouch formats and launches. That session will feature consumer-product insights on pouch launches from Lynn Dornblaser, director of the custom solutions group for Mintel International and my thoughts from Packaging Strategies on new technologies and market impact. And in a special, Årst-time session at this year’s Forum, a group of distinguished global companies will gather on a panel to share technologies that are yet to make its way to North America, but are already hitting hard overseas. The Global Pouch Technologies Panel Discussion is expected to include Steve Gosling, president of Cheer Pack North America and Joerg Schoenwald of Germany’s Schoenwald Consulting.

It is a new day for the pouch, as innovations and consumer recognition are leading brand owners to pursue the pouch as they also pursue profit growth for their brands.

MAY 2011

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Cover Feature: Official Guide to Global Pouch Forum

Neil Kozarsky of T.H.E.M. will moderate the discussion of the growth of Zip Box, another new global concept. In addition Sakaru Takahashi, president of Chokuko Plast Corp. will unveil another new technology, the Edge Stand skirted standup pouch, which offers new features to the old pouch format and allows it to stand up straighter on store shelves. That technology is expected to be introduced to North America soon.

Pouch Development Roots Much of the pouch development of the past several decades has started in Europe and Asia and includes the spouted pouch (sometimes in a Cheer Pack format) and micro-pouch technology. For the European front, frequent presenter Ampac will bring its general manager from Germany, Joachim Antz, to partner with director of innovation Sal Pellingra in a discussion of global pouch trends from other regions. A look at some of the emerging trends in pouch development – shared soon after the interpack show in May in Germany – will challenge the Global Pouch Forum audience. As is custom with the Global Pouch Forum, new package introductions are par for the course. Those will include a new dual-chamber pouch design that involves both DuPont and design Årm Kornick Lindsay. The exclusive presentation on the Genesis Duo-Pouch will shed light on the many issues with seal and standup failure and offer new advances in science and technology that can deliver a dual-chamber pouch for everything from functional food to pharma applications. New innovations also include new pouch Ålling and sealing technology advancements that will jump start the migration from canning and glass packaging. In another exclusive presentation, Jeffrey Crangle of Packaging Technologies and Inspection

(PTI) and partner Herman Waldner GbmH will share new technology in highspeed, premade pouch Ålling and sealing that can provide savings in material costs and transportation and could propel the pouch to new areas where high-volume production is required. In two special sessions, the focus will be on new trends. Mark Lazar of Wild Flavors will introduce a development process for beverage pouches concerned with portability and light weighting. And Jeff Fielkow of Tetra Pak will discuss the use of carton and aseptic package recycling and how that movement is both growing and could affect pouch growth. And, Jim Pease of Karlville Development Group will shed some light on alternative closure systems in Æexible packaging. The company has worked with Velcro, the world leader in hook and loop fasteners, and has created new hookto-hook closure systems for standup and three-side seal pouches. Pease will share how this exciting innovation, reÆecting the dynamic nature of the pouch market, can be applied to premade pouch making machinery or to form-Åll-seal equipment.

Progress in Processing Processing also has become an important feature, one that could help pouches and other Æexible packaging formats compete more effectively with rigid packaging in high-volume products. In a presentation on the

beneÅts of retort packaging and how manufacturers are communicating the value of retort for pouches and other formats, Christopher Nunes, CEO of Cornerstone Strategic Branding, will share some of these insights from a top branding company. Nunes also plans to reveal the 10 best practices and principles for creating effective packaging communication for retort and how it is helping pouches compete effectively against cans and glass jars. On the Æip side of the coin, Terry Baker, vice president of sales and marketing with Fres-Co Systems, will discuss how aseptic processing for pouches and Æexible packaging is rapidly becoming a key factor in highvolume applications and will be a major player in further market growth. There are a host of both new market developments, new processing developments, and new opportunities for pouches in North America, many of them just beginning to make their way across America as part of the dawning of new Æexible packaging. It is a new day for the pouch, as innovations and consumer recognition are leading brand owners to pursue the pouch as they also pursue proÅt growth for their brands. FP

Sal Pellingra, director of innovation for Ampac, spoke at last year's Global Pouch Forum and is on the agenda again in 2011.

About the Author Joseph Pryweller is editor/ conference director of Packaging Strategies.

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TO REGISTER... for the 2011 Global Pouch Forum, go to www.globalpouchforum.com.

MAY 2011

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Cover Feature: Official Guide to Global Pouch Forum

TENTATIVE AGENDA TUESDAY, JUNE 7 3:00 p.m. Registration Opens 6:00 p.m. – 7:00 p.m. Welcome Reception

WEDNESDAY, JUNE 8 7:00 a.m. Registration Opens 7:00 a.m. – 8:30 a.m. Continental Breakfast 8:30 a.m. – 9:30 a.m. Latest Trends & Technologies in Pouch Packaging and Machinery 9:30 a.m. – 10:00 a.m. Networking Break 10:00 a.m. – 12:15 p.m. • The Consolidation of Flexible Packaging: A Key Driver for the Future • Connecting With the Consumer: Branding and Communicating the Benefits of Retort Packaging • What Will Drive the Future: Brand Owner Panel 12:15 p.m. – 1:30 p.m. Lunch 1:30 p.m. – 3:15 p.m. • Pet Treat and Pet Food Market • Healthcare/Pharma Market • Liquid Packaging Market • Food/Dispensing Market • A Case Study in Success: The Sunkist Pouch 3:30 p.m. – 4:00 p.m. Networking Break 3:45 p.m. – 5:00 p.m. • Global Trends in Pouches: What’s Coming to North America from Other Regions? • Evolving and Emerging Flexible Pouch Technologies in Japan • Global Pouch Technologies Panel Discussion

THURSDAY, JUNE 9 7:00 a.m. Registration Opens 7:00 a.m. – 8:30 a.m. Continental Breakfast 8:30 a.m. – 10:00 a.m. Innovations and Technology Session I • The Innovations Edge: The Consumer, Financial and Packaging Implications of New Pouch Formats • Innovations in Dual Chamber Pouch Design and Reliability • High-Speed, Premade Pouch Filling and Sealing Technology Advancements to Replace the Traditional Steel Can 10:00 a.m. – 10:30 a.m. Networking Break 10:30 a.m. – 12:15 p.m. Innovations and Technology Session II • Beverage Development for Pouch Products and Global Beverage Trends in Pouches • Building Carton & Aseptic Package Recycling Access Nationwide • Latest Innovations in Aseptic Flexible Packaging • Hook-to-Hook as an Alternative Closure Technology for Pouches

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MAY 2011

Printing: Narrow Web

SLEEVE FILM DELIVERS HIGH-IMPACT GRAPHICS Batik Succoso finds sweet success in new label. an Benedetto is an Italian manufacturer and distributor of soft drinks, sports beverages, probiotics and bottled water, and the company knows the impact quality ingredients have on the end product. It does not compromise on what goes into each of its products and makes every effort to protect that quality. And it takes the same approach to projecting an image of that quality through its product labeling. San Benedetto was using a polypropylene-based roll-fed shrink label with a hot melt adhesive seam for its Batik Succoso juice brand. However, the company wanted to upgrade the look of the product to make it strongly reÆect a quality position more in line with the quality of the product itself. The polypropylene-based roll-fed shrink Ålm only allowed up to an 8 percent shrink ratio, which limited the amount of space the label could cover on the contoured bottle. Coupled with limited graphics characteristics of the Ålm, San Benedetto thought matching the high-impact shelf appeal of shrink sleeve labels was not attainable. “Roll-fed shrink Ålm allowed us to use a package with a contoured bottle and a label to match,” says Lorenzo Benvegnu, product manager with San Benedetto. “But the low shrink ratio meant we were limited to how high we could place our label on the Batik package. We literally could not go past the moderate shoulder. “There was a lot of space on the bottle we just couldn’t take advantage of, and we felt we were missing an opportunity. Still, we never gave up pursuing Ålm options that would costeffectively allow us to match the high impact of sleeves.”

S

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FLEXIBLEPACKAGING

Italian beverage manufacturer San Benedetto wanted an updated look to its shrink sleeve labels. “We never gave up pursuing film options that would cost-effectively allow us to match the high impact of sleeves,” says Lorenzo Benvegnu, product manager for San Benedetto.

Finding a Better Option At the beginning of 2009, San Benedetto’s patience was rewarded when it relaunched Batik Succoso with a new roll-fed sleeve Ålm label called polyphane Åt STS, which has a guaranteed shrink ratio of 50 percent.

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Polyphane Åt Ålm is a proprietary polyoleÅn that is machine direction oriented. This provides high tensile strength properties and excellent onpress stability. It also does not require refrigerated freight or air-conditioned storage because the Ålm has higher shrink initiation temperatures versus conventional sleeve label materials. Polyphane Åt was developed and is manufactured by Polysack Plastic Industries Ltd. “Many other shrink Ålms and sleeves were considered for this application, polyphane Åt STS was selected for its superior printing, labeling, welding and shrink performance,” says Hubert Mignolet, sales and marketing manager with Polysack. “Polyphane Åt Ålms are unique in that they perform more like shrink sleeves than traditional roll-fed shrink. We only had to adjust the graphics slightly to take advantage of the higher shrink ratio and enlarged display area.” The labels were Æexo printed in eight colors with solvent inks. With superior optics based on clarity of 98, haze of 3 and a gloss rating of 135, Polyphane Åt is an ideal medium for high-end graphics representation. “Polyphane Åt combines all the graphics beneÅts of shrink sleeves with the operating efÅciencies and cost-effectiveness of roll-fed sleeve labels,” says Laura Clark, marketing director for food and beverage, Avery Dennison. “With a shrink ratio of up to 50 percent, this solution allows San Benedetto to take full advantage of the entire Batik bottle, including the neck. The ability to apply the label top to bottom and around the full bottle delivers a signiÅcant advantage for improved shelf impact.”

MAY/ 2011

Leveraging Operational Efficiency Along with improved shelf appeal, San Benedetto sought an alternative seaming technology for its labels. While a label represents only a fraction of the total cost to package a product, its impact on the consumer is signiÅcant. Misplaced labels or split seams undercut the perception of quality. The company wanted to eliminate glue from the labeling process because it was an added consumable and reduced the operating efÅciency of the labeler. Glue seams also proved to be less robust and split when heated in the shrink tunnel, resulting in rework. San Benedetto opted to install a roll fed sleeve technology (RFST) labeler from Sacmi Labeling. The modular labeling machine allows the application of wraparound thermo-shrink plastic Ålm labels starting directly from the Ålm on the roll and uses laser-welding technology for seaming. The labeling operation is fully integrated with the bottling line and can handle line speeds up to 1,000 bottles per minute. “The laser seaming technology from Sacmi pairs well with the polyphane Åt material,” Benvegnu says. “It gives us a perfectly secure seam all along the full contour of the bottle for an extremely tight Åt without any gaps. I believe this was the Årst commercial launch of Sacmi’s RFST using a laser seam. The technology was new and untested. Polysack, the converters and San Benedetto worked together over a 6-month period, proving the technology, working through minor challenges to bring application to commercialization.” While San Benedetto realized a cost savings by eliminating glue as a consumable and the related extra work associated with added time for machine setups and downtime for cleaning, it has also been able to reduce its energy consumption. The previous roll-fed shrink Ålm required a hot air tunnel temperature of 600 degrees F to shrink just 8 percent. However, the new material of the roll-fed sleeve allows the company to use its existing steam generator at just 200 degrees F. FP MAY 2011

Limited label space and limited graphics characteristics of the film were the motivating factors for this manufacturer to look for other shrink sleeve options.

San Benedetto +39 041 585 9847; www.sanbenedetto.it Avery Dennison (440) 558-6000; www.averydennison.com Sacmi Labelling +39 045 634 7511; www.sacmilabelling.com Polysack Plastic Industries Ltd. +972 8 9989796; www.polyphane.com

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27

ADVERTORIAL

CONFECTIONERS STRIKE GOLD WITH NEW MIRRORINK PROCESS By Sarah Anderson Marketing Communications Specialist at Sonoco n the highly competitive candy industry, confectioners require products that not only appeal to taste buds, but also are packaged in a way that is just as tempting to the eye, resonating with shoppers’ senses and causing them to choose a product over the hundreds of others on the shelf. In 2010, the market saw over 2,500 product SKUs launched in the U.S. alone. Achieving distinctive shelf appeal while maintaining cost savings can be difÅcult for confectioners, especially when dealing with metallic decorations on packaging. The de-metallization and foil stamping processes involved in metallic Ånishes provide a distinctive look, but are time consuming and costly. Choosing to use cost effective metallic inks instead often resulted in a satin Ånish, which was not the “pop” on the shelves confectioners required. The goal then, was to develop a metallic ink technology for packaging applications that would attract customers’ attention and evoke an emotional reaction while providing cost savings, increased speed to market and environmental responsibility. To discover if there was a way to achieve a mirror metallic Ånish without de-metallization or foil stamping, Sonoco, a vertically-integrated global manufacturer of consumer and industrial packaging and provider of printed innovative high-barrier, high-performance Æexible packaging, partnered with Eckart, an innovative

I

global manufacturer of metallic pigment and effects. As part of its diverse packaging portfolio, Sonoco provides the confectionery industry, among others, with Æexible packaging made from thin-gauge, value-added rotogravure and Æexographic printed performance laminations, as well as rotogravure cylinder engraving. Eckart supplied Sonoco with a unique proprietary metallic ink technology, made using real metal Æakes that, when properly aligned, produce a mirror-like sheen. From there, Sonoco took the lead to further optimize and reÅne the metallic effect into the Mirrorink ™ Process, which would serve as

a sustainable decorating alternative to the de-metallization process. Scott Schultz, market development manager at Eckart, said, “Eckart is a leading specialty effects, pigment and metallic ink supplier, and the synergy with Sonoco, a leading innovative Æexible Ålm printer, along with their market intelligence, enabled us to take that next step and move our metallic effect technology into the converting process. This technology opens doors to applications that were typically off limits in the past.” Working internally with Trident, Sonoco’s global artwork brand

Sonoco worked with Eckart on the creation of packaging for a mock-up brand of candy, Dazzle Dots, to display the high quality look achievable with the Mirrorink Process.

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MAY 2011

ADVERTORIAL

management, Æexographic and rotogravure cylinder engraving business, Sonoco researchers optimized cylinder parameters to more efÅciently transfer ink out of cells and deliver the best look. Sonoco identiÅed the correct adhesive to prevent degradation of the pigment on the substrate, producing a mirror-like metallic appearance for the Årst time in a two-ply structure. Mirrorink Process inks come in both gold and silver, and the gold ink can be tinted to create varying hues. “I’ve been in the packaging business for 25 years and this is the Årst time I have seen this kind of a mirror Ånish off a printing process,” said Scott Huffer, senior research and development associate at Sonoco, who worked with Eckart to develop the Mirrorink Process. Sonoco was able to work with materials and performance properties

MAY 2011

to create a robust package that will hold together with enough strength to withstand drop testing, transportation, distribution and usage. The package is metal detectable, and the opening was optimized and tested for seal strength and the ability to maintain package integrity throughout distribution. With the new Mirrorink Process it is less expensive for confectioners to showcase the product through a clear window, as the printing process only registers metallized ink where necessary. By optimizing existing technology and utilizing in-line equipment, Sonoco and Eckart have found a sustainable, cost-saving and innovative process that requires no additional capital. As an alternative to de-metallization, the Mirrorink Process has less impact on the environment, consuming less

water and eliminating the waste stream of highly corrosive elements. Less energy is used because of its singlepass operation which eliminates the additional pass through printing and drying units, reducing customers’ footprints. By skipping the time consuming de-metallization process, Sonoco and Eckart have increased customers’ speed to market. Sonoco and Eckart are now providing clear value to large premium confections companies through the chain of supply and converting process, all the way to placing the brand on the shelves, while recognizing the importance of package decoration and sustainability. SpeciÅcally for the Æexible packaging Ålm laminations sector of the industry, this one-of-a-kind technology is liquid gold.

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29

Technology: Fitments & Closures

FITMENTS BRING CLOSURE, VALUE TO FLEXIBLE PACKS From zippers to spouts, fitments and closures are a critical part of flexible packaging. By Rick Lingle, Executive Editor requently ubiquitous, sometimes innovative and always essential, closures and Åtments are found in Æexible packaging in a myriad of sizes, formats and materials that match general market trends and are tailored to speciÅc applications. The growth of Åtments in Æexibles is tied to the overall growth of this market segment. “It appears that many brands are looking for ways to move from rigid containers to Æexible containers,” observes Sal Pellingra, Ampac’s director of innovation. “One of the issues involved is developing dispensing and reclose technologies that consumers are already comfortable with or that are intuitive to use.” Dave Johnson, strategic business development manager, food market, Aptargroup, believes that convenience is fundamental. “According to [research Årm] Mintel, 46 percent of consumers said that packaging convenience often plays a part in their purchasing decisions, and pouches that incorporate Åtments are delivering on this need,” he says. “Closures that provide resealability and cleanliness are just a couple of attributes that the consumer can expect when using a Æexible package with an integrated Åtment or closure.”

F

Closures can help to provide more convenience, functionality, shelf appeal and safe use, Johnson summarizes. Typical Åtments in the Æexible packaging market are either on the corner, top or face of a pouch, Pellingra explains. For corner and top Åtments, the most common is a 9-mm spout. For larger particulates or difÅcult-to-pour products, larger Åtments are required; these can be 60 mm or more. The larger the pouch, the greater the need for support. Larger closures also help to bring more structure to the package by providing better handling, adds Johnson. Issues with Åtment or cap designs are related to pourability, dosing, child resistance, easy opening, choking hazard, safety and tamper evidence. Fitments for retort applications—and their seals— must be capable of withstanding hightemperature retort conditions.

A popular Åtment found on Æexible packaging is that of zipper reclosures. Supplied in roll form, they can be applied by converters when producing premade bags or by packagers during form-Åll-seal operations. Zip-Pak’s Bob Hogan estimates that premade pouches account for about 40 percent or more of resealable packages. Slider reclosures comprise about 10 percent of premade pouches, he notes. In collaboration with Novamont, Zip-Pak has developed a cellulosebased, 100 percent compostable proÅle for resealable packaging. As to what’s next, Aptargroup’s Johnson cites designs that address portability, convenience and designs that provide more structure, safety and Æow/portion-control to the package, especially for child safety. “Also look for fun, interactive pouch/spout package designs,” he adds. FP

Ampac 513-671-1777; www.ampaconline.com Aptargroup 815-477-0424; www.aptargroup.com Novamont 011-39-321-699-611; www.novamont.com Zip-Pak 800-488-6973; www.zippak.com

Resealability such as for this energy gel is one of the value-added convenience features that fitments bring to flexible packaging.

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PHOTO COURTESY OF AMPAC.

MAY 2011

WILD NEW FITMENT SET FOR DEBUT

W

ild Flavors, Inc., Erlanger, Ky., and its associated company, Pouch & Pack Concepts, Inc., are introducing an innovative closure, the "Wing Cap,” debuting in the U.S. as part of the new Spouted Pouch System. WILD in Germany first introduced the Capri Sun straw pouch that developed into a global brand and is licensed in the United States by Kraft Foods. The Spouted Pouch concept was introduced into the European Capri Sun market in 2004. Wild Flavors sells flavors and ingredients for customers’ beverages and Pouch & Pack Concepts fills the beverages using its Wing Cap and three-layer foil laminate pouches on Pouch & Pack’s proprietary equipment. The 1 x 1.5 inch, injection-molded Wing Cap offers the following features: • It is large enough to not be considered a choking hazard for infants or toddlers.

The licensor of Capri Sun is introducing a first-of-its-kind fitment, the Wing Cap, for its U.S.-based beverages.

• It uses a minimum amount of plastic. • It has a hole in it so that if it were to get lodged in a person's throat, it would not cut off breathing. • It makes an attractive presentation because the lines of the cap visually continue with the lines of the pouch. • It can hang for display or in use. • It has good leverage for easy opening. • The tamper-evident ring, which remains with the spout, has passed use and abuse tests which means it doesn't easily come off and become a choking hazard. The first stateside filling line is expected to be operational in mid 2011. Pouch sizes range from 100 mL to 500 mL. FP Wild Flavors, Inc. 888-945-3352; www.wildflavors.com

ACCUPOUCHER Designed For Today’s Complex Pouches

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MAY 2011

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31

Industry Insights

SINGLE-USE PACKET EXPERTS DELIVER SPECIALTY OPTIONS By Michael Mackey, Contributing columnist onsumers increasingly want the freshest, most securely sealed packages of many products, from cosmetics to a whole range of home care items. To be certain, they turn to single use packettes, resulting from form-fill-seal packaging providers. These single-use pouched products provide a number of benefits for consumers. Single pouches offer the ability for the vendor to present fresh contents every time. Contrasted with products that are opened and re-opened, singles assure users that each wipe, gel, lotion, ointment or other item is completely uncontaminated and assuredly new each time.

C

Positive Offerings FDA- and EPA-established facilities offer another level of assurance for companies working with contract packagers. Securely sealed singles promise a long shelf life. It’s inherent in the process of sealing single use packs. Without having to engineer open and re-open packages, manufacturers can concentrate on best-protected products. Convenience is a big plus for many items. For example, single use sun screen packages make it easy for beach-goers and golfers to take along. Air travelers and vacationers also recognize the ease of transport. Compared to products in tubes, bottles, jars and even larger pouches, singles offer consumers the ability to take just what they need for the day or the trip. Single pouches also play a major role in product sampling. Compared to the cost and amount of packaging in a small bottle sample, sample packettes use far less plastic. A small pouchpack can contain ¼ oz. of product, the ideal amount for trials.

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With changeover-friendly production lines, service-oriented pouch packagers handle many of the smaller order sizes as well as many millions of units per order.

Adding to attractiveness of pouched products are the printed surfaces of pouches. From single color to multi-color, often beyond 4-color printing, makes these pouches attractive to consumers. Metallics, bright branded choices and high-tech visuals attract attention.

How It’s Accomplished Form, fill and sealed pouches come off of seamless, beginning-to-end production lines. Many production facilities have over a dozen production lines for speed to market of new products and samples. Quick production for trade shows, mailings and product roll-outs is critical to customer service when innovative, fast-moving developments occur. Results are most assured when customers know what they want up front. Pouch packagers can help with suggestions, but selection of raw materials is preferred, where customers have a good idea of what they need. Choices of pouch materials, laminates and layers for barriers and product protection are best done in advance. For example, certain ointments or other content may require barrier resistance that cannot breakdown. A robust choice of pouch substrates

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prevents all kinds of pending problems. It's often a matter of the right structure for the particular chemical content. With changeover-friendly production lines, service-oriented pouch packagers handle many of the smaller order sizes as well as many millions of units per order. Pouch size and other specifications determine line speeds, but today's production lines are typically high-speed and custom built. Single-use pouches tend to range in inches, from 2-inch by 2-inch to 9-inch by 12-inch. Some packs are dual-channeled containing, for example, a gel and a wipe. Today's singles pouchpacks have come a long way, tapping into the best technologies of the packaging arena. FP

About the Columnist: Michael Mackey is president of American FlexPack, a Green Bay, Wisc., producer of singleuse pouchpacks. Contact Michael at [email protected]. American FlexPack (866) 353-1971; www.AmericanFlexPack.com

MAY 2011

Roundtable: Special Advertising Section

ROUNDTABLE ON BAG-/POUCH-MAKING Ryan Breese, Ph.D.

Dharmisth Patel

Technical Director Eclipse Film Technologies

President Mamata Enterprises, Inc.

5 years with the company

7 years with the company

(877) 275-4800 www.eclispefilmtech.com

(630) 801 2320 www.mamatausa.com

Joe Vann

James Russell

Sales and Service Engineer Totani America, Inc. 2 years with the company

President Modern Manufacturing Services 2 years with the company

(920) 632-7319 www.totaniamerica.com/en

(585) 289-4261 www.modernmfg.net

By Erin J. Wolford, Editor-in-Chief

Q:

What new features or technologies are being introduced to this sector of the industry? Breese: Film orientation, primarily

machine direction orientation processing (MDO), has emerged over recent years as a method to improve Ålm performance while lowering overall packaging costs and minimizing the package’s environmental impact. MDO Ålms have higher stiffness and strength, better optics and barrier relative to conventional blown and cast Ålms. These enhancements allow converters to down gauge their current structure,

replace less desirable polymers (such as PVC, PET, etc., relative to polyoleÅns) and in some cases eliminate secondary processes, such as coating and laminations. Patel: Processors are shifting to

unsupported Ålm structures and replace laminates, which is creating new challenges for machinery manufacturers. Mamata had already identiÅed this shift long back and had designed its pouch machines and even bag machines to process such Ålms with ease. Vann: Machine improvements come as

a result of continual advancements in Ålm structures, which allow converting

companies to produce pouches made out of bio-based materials, co-extruded polyethylene, and even retorted Ålms on the same machine. Convertors are switching from 2mil to 4-6mil laminations on the same versatile machine, and it is important for the pouch machine to be designed to easily handle this change. Convertors are asking for many features to be done inline. Russell: With environmental impacts

and today’s struggling economy, the Ålm thicknesses are being reduced, leaving tension control and speed as major factors with modern pouch making equipment. We have been able to address these issues with innovative, lowered tension controls, along with higher speed servo drive systems to achieve a meaningful approach to solving these issues. I have known for some time that Åtting the products to the machine is key to productive success. Modern Manufacturing offers the Accupoucher, which is available in 14-, 24-, and 36-inch widths.

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MAY 2011

Q:

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

Breese: The traditional stand up pouch

still proves to be the industry standard and continues to make progress. Many variations of the standard gusseted pouch exist today. Some have additional gussets or unique geometries to enhance the performance and aesthetics of the

from the consumer. There needs to be a conscious effort to embrace these new packaging concepts for their ease of use as well as their environmental impact. I would like to see more consumer education on the beneÅts of Æexible packaging as consumers will drive the continuous innovation.

Patel: The pet food market is growing

very rapidly today. Whether it is side gusseted pouch from single web or multiple webs as in feed, or bottom gusseted stand-up pouches with recloseable zippers from single web, this is what converters are looking for. Processing of unsupported co-ex Ålms is becoming more popular. Russell: It is my opinion that the stand

up pouch is still one of the best product designs on today’s market. This is still a growth market after more than a decade of use, in the market place. Undoubtedly, this will continue to drive additional market share for Æexible packaging. With a heavy introduction of the quad-seal side-gusseted pouch recently, there has been some added presence on the store shelves. This is nothing more than a continuation of the innovative products in the market. Vann: In my opinion, the most common

and durable pouch style on the market is the stand up pouch. The stand up pouch is made from one web of material and typically has a plowed, bottom gusset. Features include: press-to-close zipper, slider zipper, tear notch, perforation or laser score, spouts, and holes for displaying or hanging. The stand up pouch is versatile in appearance and design. It is used for human or pet food applications and can be frozen, retorted, micro waved, boiled, etc. The stand up pouch is very recognizable in markets outside of the U.S. I have seen examples of paint being sold in the stand up pouch.

Mamata offers its Vegaplus pouch making machine, pictured here, in working widths of 24-, 32-, and 40-inches.

package. This type of pouch provides numerous performance and marketing beneÅts, including the incorporation of opening/reclosing features, spouts, eye catching design and brand recognition. The commercialization of new Ålms has helped Æexible packing enter many markets that were previously dominated by rigid packaging. The improvements in Ålm mechanical properties, such as those found in the previously mentioned machine direction oriented (MDO) Ålms, allows for the use of larger size pouches for many club store applications. Another example is where retort Æexible packages have made progress with replacing cans. The aesthetics of the Æexible package helps the brand owner market their product as a premium quality good..

Q:

What’s missing from this sector? What would you like to see improve?

Russell: I believe there is still a large arena

of untapped uses for Æexible packaging. The research has begun and inroads have been made, but we can still do more. A signiÅcant area of improvement comes

Patel: Awareness towards using

materials and Ålms that are ecologically sustainable needs to be improved. Breese: While Æexible packaging has

made great advancements in recent years, there are still many opportunities to replace rigid packaging. An improvement in product innovation to develop unique Æexible packaging structures can provide a competitive edge and better product recognition. Vann: Robotic Packing – It’s fairly

reasonable to assume that convertors want more output, given the same amount of resources. High speed machines can and do operate at one hundred Åfty cycles per minute or more. It is possible that robotic packing will become a new addition to pouch machines in the future. Data Collection on Pouch Machines – In my opinion, there has been a recent renewed desire for data collection on pouch machines. Pouch machines historically have lagged behind other machines (e.g. printing presses, laminators and extruders) in the ability to compile data and integrate into data management software systems. FP

Totani's Box Pouch Machine offers a solution for inserted side gusset pouches that are made from 2 webs of film, among other configurations.

MAY 2011

FLEXIBLEPACKAGING

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35

Supplier News

COMPANY AUTHORIZED TO DISTRIBUTE POUCH MAKING MACHINES odern Manufacturing Services, a leading U.S. manufacturer of high performance pouch making machinery and other auxiliary equipment, has appointed PPC Technologies & Solutions (PPCTS) as its exclusive agent and sales representative for its range of pouchmaking equipment. Modern Manufacturing Services’ offering of machinery includes the Accupoucher for stand-up, flat and three side-seal pouches, with or without zippers, side gussets, spouts/fitments, as well as static shielding bags and medical pouches, and offline stand alone equipment for folding, fitments, sealing and more. With decades of experience, Modern Manufacturing offers standard and tailored machine solutions with an attention to details, productivity and reliability, and offers as well, customized development machines for special applications.

M

Richard McDonald, president of PPCTS, notes, “We are pleased to add Modern Manufacturing to our select portfolio of manufacturers, which will allow PPCTS to offer USA-designed and manufactured solutions to our growing number of customers serving the pouch- and bagmaking markets. Modern Manufacturing, which has many years of experience and several installations in the U.S. and Canada, is a strong leader in pouch and bag making machinery, that can also develop in partnership, new customer driven solutions for this continuously evolving packaging field.” FP Modern Manufacturing Services (585) 289-4261; www.modernmfg.net PPC Technologies & Solutions (PPCTS) (262) 695-7536; www.ppcts.com

DUPONT PACKAGING GRAPHICS EXTENDS DISTRIBUTION AGREEMENT WITH PITMAN uPont Packaging Graphics and Pitman, an Agfa Company and supplier of prepress, industrial inkjet, pressroom and packaging printing products and systems, have signed a distribution agreement for the DuPont Cyrel portfolio of flexographic products in the United States. As a result of the agreement, DuPont and Pitman are extending their market reach and Pitman is combining sales and technical specialist resources to more effectively support Cyrel customers. “Pitman is a distribution powerhouse in printing and has been strengthened with the resources Agfa Graphics has added since the acquisition,” says Wendy Andrushko, North American sales director – DuPont Packaging Graphics. “Working

together, DuPont, Pitman and Agfa offer our Cyrel customers a win-win with superior products, service and support.” Pitman has been a U.S. distributor for Cyrel and Cyrel FAST products for over 35 years, and was acquired by Agfa Graphics in August 2010. “We are pleased to extend our relationship with DuPont and look forward to future success as we expand DuPont’s market reach and penetration,” says Peter Wilkens, president of Agfa Graphics. “We are known for our best-in-class packaging product portfolio. Our goal is to deliver complete integrated solutions that maximize productivity and therefore, profitability for customers who are always striving for workflow improvements.” FP

D

36

FLEXIBLEPACKAGING

Pitman remains to be a distributor of DuPont Packaging Graphics' flexographic printing systems, including Cyrel brand photopolymer plates and Cyrel FAST processing equipment, Cyrel round sleeves, mounting and finishing products.

| www.flexpackmag.com

DuPont Packaging Graphics (919) 248-5598; www.dupont.com Pitman/Agfa Graphics (201) 737-4646; www.agfa.com

MAY 2011

Supplier News

SUTTLE-STRAUS INSTALLS SIX-COLOR KOMORI PRESS WITH UV COATER AS PART OF $2.6 MILLION CAPITAL INVESTMENT omori America Corporation, a premier manufacturer of sheetfed and web offset printing presses, announced that Suttle-Straus has recently installed a six-color Komori Lithrone S40 (LS640) with UV as part of its $2.6 million capital improvement plan. Suttle-Straus is recognized as one of the Midwest’s premier providers of communications solutions, specializing in producing high-end corporate communications, direct mail and advertising materials. The impetus for the investment is to provide customers with cutting-edge end-to-end technologies and enhancements designed to increase efficiencies and deliver a new level of productivity. The advanced capabilities of the Komori press will offer SuttleStraus’ customers expanded print applications

K

including paper, board and plastic substrates as well as conventional UV and hybrid processes. “We are delighted with the speed and flexibility of our new press. We did a lot of research and evaluated all the major equipment vendors, but found Komori to be the best fit for us,” says John Berthelsen, president of Suttle-Straus. “Prior to installing the LS640, all of our equipment was from another manufacturer so it took a lot to put another company’s press on our floor. However, in our search for the right solution, Komori delivered all of the advanced features, speed and capabilities we were looking for to offer our customers an expansive range of quality products and services, with a quick turnaround, and at a competitive price.” FP Komori America Corporation (847) 806-9000; www.komori-america.us

HITACHI EXHIBITOR AT With over 35 years of experience, Hitachi continues to improve technology to meet the requirements of our customers globally. The RX Series industrial small character Ink Jet Printer is capable of marking/coding various product materials and offers consumer superiority print quality, reliability and total cost of ownership. Key applications include; expiration date codes, lot, batch, time stamp and pouch serialization. For a FREE evaluation, contact [email protected] and begin saving today.

HITACHI AMERICA, LTD. 5808-Q Long Creek Park Drive, Suite Q Charlotte, NC 28269 Tel: 704.494.3008 ext. 21 www.hitachi-america.us/inkjetprinters

MAY /2011

FLEXIBLEPACKAGING

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37

Hot Products Duplex Slitter/Rewinder Ideal for Metalized Films The Model SR7000 Duplex Slitter/Rewinder from REM is designed for thin gauge films, foils and packaging materials. Capable of running 84-inch wide webs at 1500 FPM, the SR7000 model can handle 48-inch diameter unwind rolls while producing 24-inch diameter slit rolls at rewind. Pull rolls are placed before and after the slitting zone to assure isolation of tension zones. Web tensions as low as ¼ PLI are achieved using driven unwind and independent rewind drives with load cell feed back of locked core and differential winding techniques. Programmed pneumatic lay-on rols include roll mounts on linear slides to facilitate set-up. Controls ator interface. PLC for machine logic with a touch screen for operator REM (920) 729-6666; www.rem-mfg.com (92

Grooved Rolls Remove Trapped Air

Sealant Films for High Performance

Precision mach machined idlers with custom groove patterns eliminate trapped tr air that causes web slipping. Machined surfa surface patterns ideal for eliminating trapped air include inc the spiral “V” groove, the herringbo herringbone groove, the diamond knurl and tthe micro groove. Grooves are available on all Webex rolle rollers, including aluminum, ste steel, stainless steel and rubbe rubber covered idlers. Groove Grooved idlers are available in variet a variety of sizes and finishes.

The DXSHC family of high performance barrier sealant films from NEX Performance Films is ideal for use in adhesive and extrusion laminations. The sealant films’ EVOH core provides the optimal barrier needed, replacing the need for PVDC coated PET. These customized sealants are available for specialty applications, including shredded cheese packaging. DXSHC films are a result of NEX Performance Films’ 20 years of experience in developing high performance barrier films; the company has already sold millions of pounds of this sealant film.

Webex We (9 (920) 729-6666; www.webexinc.com

NEX Performance Films (608) 868-5757; www.nex-films.com

Wood od Core Plugs C Customized Wood core e plugs are rreadily available from Badger Plug, om-ma wood plugs from particle board, including custom-made MDF and plywood. Sizes range from 1 ½ inches to 60 inches. A variety of center-hole diameters and configurations are available, including square and rectangular. Special plugs can also be provided in thickness up to 4 inches, with straight taper and shoulder taper combinations available. Badger Plug’s highly automated machinery assures exacting plug dimensions and tight tolerances. Badger Plug (920) 757-7300; www.badgerplug.com

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FLEXIBLEPACKAGING

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MAY 2011

Company Offers Bandolier-style Overwrapping Lauraville Packaging, LLC, manufacturer and contract packager of Smart-Pak pressure sensitive pouches and encapsulated labels, has introduced FrameSeal bandolier-style overwrapping. The overwrapping provides an economical non-pressure sensitive pouch sealed on four sides without a rear fin, as well as EasyNeck custom prepackaged neck hangers. Lauraville Packaging, LLC (315) 781-6364 ; www.lauraville.com

New Solvent Recycling Machinery

Large Air Adapter Chucks Offered Large air adapter chucks from NimCor are designed to handle the largest cores without investing in new core shafts. Single and dual chucks are readily available to fit 8-, 10- or 12-inch diameter cores. Special sizes of 16 or 20 inches are also common. Large air adapter chucks are ideal for fast clamping to bars, spindles or conventional shafts. A pneumatic bladder offers high-torque grip up to 37,500 inch pounds when inflated without wear or damage to cores. Bladder material is available in a variety of durometers based on the customer’s application. Dual chucks employ a shared air supply through a quick interconnect air hose. Clamping collars are available in both aluminum and steel. Chucks remove easily without damage to core ends.

Reduce new solvent purchases and dirty solvent disposal costs by 90 to 95 percent with ECOpure solvent recyclers. Ideal for solvent ink press wash and flexo plate solvent developers, this machine helps reduce dirty water disposal by 70 to 90 percent. PPCTS (262) 695-7536; www.ppcts.com/solventrecyclers

NimCor (888) 464-6267; www.nimcor.com

Pouch Making Machine Available The new Accupoucher pouch making machine is designed and manufactured in the USA by Modern Manufacturing. Available in 14-, 24and 36-inch widths with zipper capability for stand-up and flat pouches, the Accupoucher is customizable and designed for future plug & play additions, with quad seal side gusseted pouch capability available as an option. Modern Manufacturing (585) 289-4261; www.modernmfg.net.

MAY 2011

FLEXIBLEPACKAGING

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39

ONLY BRAND INNOVATORS CAN TAKE THE LEAP A DESIGN LEADERSHIP SUMMIT CPG decision-makers in peer-to-peer discussions on the business value of strategic design and the challenges and opportunities they face in their design journeys. Some of the brand leaders who have taken the LEAP

Visit www.leapdesignforward.com to hear what some of these brand leaders said about this unique conference October 5, 2011 W Chicago –City Center LEAP Design Forward co-locates with Packaging That Sells conference, October 6-7, 2011

Sponsor

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

Manufacturers Reps Wanted One of the Northeast’s largest Flexible Packaging Companies is looking for experienced brokers. Our capabilities include: • Up to 10 Color Process Printing • 80” Wide Web Printing • Laminating • Slitting • Converting & Pouch Making

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)

packaging specialists since 1898

Send Resume To:

[email protected]

Please direct your inquiries and resume to: [email protected]

RECRUITMENT

PET / BON / PLA FILM

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

WANTED TO BUY

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

ADVERTISE HERE Flexible Packaging Classifieds Call Diana Rotman: 847-405-4116 or email: [email protected]

MAY 2011

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

FLEXIBLEPACKAGING

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41

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

• 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 -----

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

SERVICES

LOOKING FOR A BAG/POUCH CONVERTER?

Since 1977, KLEER PAK has specialized in manufacturing of custom bags and pouches for the converting industry

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

[email protected] • www.kleerpak.com • 1-630-543-0208 320 S. La Londe Ave. Addison, IL 60101

AIB CERTIFIED EXCELLENCE THROUGH DILIGENCE

Advertise in the Flexible Packaging

Classified Network !! Call Diana Rotman at 847-405-4116 or [email protected]

42

FLEXIBLEPACKAGING

| www.flexpackmag.com

MAY 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

ROLLERS

Does the Inside of Your Heat Transfer Roll Look Like This?

Eliminate problems caused by uneven nip-pressure with Roller Nip Impression Paper. Uneven Nip Pressure Causes-Wrinkling; Uneven Winding; Poor Laminating and Poor Coating - Simple to Use - Takes Minutes Includes Instructions and White Paper for Solving ems ems Uneven Nip Problems

We take Visa 847-487-8877

If So, Your Rolls Will Be Running Slower to Achieve the Heating or Cooling Your Process Requires We can remove the shell and re-engineer and repair your roll to run as good as new. Depending on its age and engineering, we can make it run Better than New at a cost of 25-40% less than a new roll.

Before

After

Menges Roller is an all inclusive Rubber Covering and New Core Manufacturer

Toll Free: (888) 856-1753 / Fax: (847) 487-8897

www.mengesroller.com FILM

MATERIALS WANTED




Polyester Film 48 GA-1400 GA

Plain, Coated, Metalized, Slit, Sheet & Warehousing (877) 838-1702 www.plasticconnections.com

ADVERTISE HERE IN FLEXIBLE PACKAGING'S CLASSIFIEDS Contact Diana Rotman at 847-405-4116 or email: [email protected]

GRAPHICS

PLASTIC CORE PLUGS

SCREEN GRAPHICS

Screen-printed and Thermal Die Cut Decals, Bumper Stickers, Corrugated Signs 800-848-4462 www.inovarscreen.com

MAY 2011

FLEXIBLEPACKAGING

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43

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

OOPS...

Quality, Experience &Value 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.

SUPPLIES

Roll Printers, Have You Ever Left Out a New Wt. or Some Other Printed Image and Rendered Your Otherwise Perfect Print Job Worthless? We Will Add This For You in Register and Restore the Job to its Original Value. Cover-up and Reprint Also Possible.

Cincinnati Convertors, Inc.

Post-Print Dept. • 1730 Cleneay Ave. Cincinnati, OH 45212 • (513) 731-6600 www.cincinnaticonvertors.com

Contract Printing & Laminating 80” Wide Web Printing Capable of printing on: Polyester • Nylon • PE Non-Wovens • Paper • OPP • Full Laboratory • Excellent Process Control • Well documented Quality Assurance Program

Other Available Services: Converting • Pouch Making • Slitting Laminating • 10-Color Process Printing

Advertise in the Flexible Packaging Classified Network !!

Please Call or email: Michael Kauffman 800-556-6454 ext 417 [email protected]

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

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FLEXIBLEPACKAGING

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MAY 2011

Calendar of Events

May 12, 2011 to May 18, 2011 interpack 2011: Processes and Packaging Dusseldorf, Germany www.mdna.com

Jun 21, 2011 to Jun 24, 2011 Expo Pack México Mexico City, Mexico www.expopack.com.mx Sep 11, 2011 to Sep 14, 2011 Graph Expo 2011 Chicago, Ill. www.gasc.org

Jun 7, 2011 to Jun 9, 2011 Global Pouch Forum Fort Lauderdale, Fla. http://www.globalpouchforum.com/

Sep 20, 2011 to Sep 22, 2011 Sustainable Packaging Forum and Exhibition Dallas, Texas www.sustainablepackagingforum.com/

Jun 7, 2011 to Jun 9, 2011 EastPack New York, N.Y. http://www.eastpackshow.com

Ad Index COMPANY NAME

PAGE

WEB SITE

American Profol, Inc.

14

www.americanprofol.com

CMD Corporation

3

Danafilms, Inc. Dover Flexo Electronics Eckart American Corporation Eclipse Film Technologies

COMPANY NAME

PAGE

WEB SITE

Modern Manufacturing Services

31

www.modernmfg.net

www.cmd-corp.com

Pearl Technologies

25

www.pearltechinc.com

11

www.danafilms.com

Pillar Technologies

29

www.pillartech.com

2

www.dfe.com

PMMI

7

www.pmmi.org

PPC Techonologies & Solutions

23

www.ppcts.com

Tesa Tape

9

www.tesatape.com

28, 29 27

www.eckart.net www.eclipsefilmtech.com

12, 13

www.flexpack.org

The Dow Chemical Company

5

www.dow.com

17

www.hitachi.com

The Robinette Company

33

www.therobinetteco.com

Hosakawa Alpine America

19

www.halpine.com

Totani America, Inc.

18

www.totaniamerica.com

Macchi S.P.A.

47

www.macchi.it

Windmoeller & Hoelscher

48

www.whcorp.com

Mamata Machinery USA

15

www.mamatausa.com

Flexible Packaging Association Hitachi America Ltd.

Reader & Marketing Services LETTERS Erin J Wolford Mail: Flexible Packaging 155 Pfingsten Road Deerfield, IL 60015 E-mail: [email protected] 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 Mike Barr E-mail: [email protected] Call: (630) 801-4152 Randy Green E-mail: [email protected] Call: (248) 244-6498 CUSTOM PUBLISHING John Schrei E-mail: [email protected] Call: (248) 786-1637 SUBSCRIPTIONS P.O. Box 1080 Skokie, IL 60076 E-mail: [email protected] Call: (847) 763-9534

LIST RENTAL For postal information: Rob Liska E-mail: [email protected] Call: (800) 223-2194 ext. 726 For e-mail information: Shawn Kingston E-mail: [email protected] Call: (800) 409-4443 ext. 828 CLASSIFIED SALES Diana Rotman E-mail: [email protected] Call: (847) 405-4116

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]

MAY 2011

FLEXIBLEPACKAGING

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45

Industry Q&A: Extrusion Equipment

DEVELOPING BETTER FILMS WITH EXTRUSION EQUIPMENT David Nunes, president of Alpine American, Inc., offers the extrusion equipment industry 27 years of experience.

David Nunes Alpine American, Inc.

By Erin J. Wolford, Editor-in-chief

Q:

What kinds of changes are film extruders seeing?

A:

Margins are razor thin and there is no room for error, and pressure for quick deliveries remains high. Newly developed materials require ultimate Æexibility from Ålm extruders. End-users no longer tolerate any inefÅciencies in the blown Ålm process.

Q:

How has that altered the industry overall?

A:

Film producers need to operate at higher throughputs than ever before, with impeccable quality, zero tolerance for waste or downtime, and with maximum Æexibility. High cost barrier materials need to be processed with exacting distribution to allow for thinner layers.

Q:

What new development(s) have come about in the film extrusion arena? How have those changes impacted the extruding business?

A:

To meet and exceed the rigorous demands and expectations of the blown Ålm industry, all phases of the extrusion process need to be optimized. Multi layer Ålm dies are designed for quicker job changes, exacting layer distribution, higher outputs and better gauge. Cooling systems have been developed that drastically increase throughputs and improve bubble stability. Control systems aid in quick start up and improved resin control.

Q:

What innovations do you see coming down the pike?

A:

Improved internal bubble cooling (IBC) and gauging systems may eliminate the need for oscillating haul off nips. Materials will continually be developed to improve performance at thinner gauges. Quicker job changes will be required as resin and production time becomes more precious. All phases of the extrusion process will continue to be incrementally improved.

46

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Alpine American's Dave Nunes says, "Newly developed materials require ultimate flexibility from film extruders. End-users no longer tolerate any inefficiencies in the blown film process."

Q:

What kinds of developments/ changes is your company making to provide the best service to its customers?

A:

Alpine has always placed an extremely high level of emphasis on customer service and support to keep our customers’ lines running and proÅtable. Continuous advancement of our domestically designed control systems gives the operator the tools to produce the highest quality products at maximum efÅciency and uptime, with repeatable, easy and quick job changes. Open data acquisition capabilities allows for complete quality control. Additionally online troubleshooting capabilities for both process and equipment issues without having to waste time and money on travel further increases customers’ uptime and production. Alpine’s job is to increase our customers proÅtability and we continue to improve our service and support systems to do just that. FP Alpine American Inc. (508) 655-1123; www.halpine.com

MAY 2011

EXTRUSION

PR RIN INTI TING TI NG NG

CON ONVE VE V ERT RTIN IN NG

BEST IN CLASS: A TRADITION THAT RUNS IN OUR FAMILY.

Best in class. It‘s a claim we live up to by developing new ideas and exceptional technologies. Take our new OPTIMEX 3-layer blown film line as an example; its modern die technology and ease of operation put it ahead of the class in terms of output and film quality. Plus, the OPTIMEX gets top marks in economic efficiency. Excellent prerequisites for being best in class in packaging, carrier bags, laminations, as well as in shrink- and stretch-hoods. For more information, visit www.wuh-group.com.

PASSION FOR INNOVATION

FLEXIBLE PACKAGING EQUIPMENT THAT MEETS THE DEMANDS OF AMERICA'S TOUGHEST CUSTOMERS 23 NEW ENGLAND WAY | LINCOLN, RHODE ISLAND 02865 - 4252 | Phone: 800 - 854 - 8702 | [email protected] | www.whcorp.com