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Packaging Industry News | May 2010 |
Issue 171 |
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NEWS INDEX
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 2009
Annual Review: A Year of Achievement
The Confederation
of Paper Industries has released its 2009 Annual Review.
The paper and board industries suffered further declines in both
consumption and production in 2009. However, there was some positive news
in that recovery rates continued to improve, and a recycling rate of 78.8%
was reached – the highest for any material.
Investment in new plant and machinery was also the highest for many years,
which bodes well for the future. However, as CPI President Bob McLellan
points out, improved communication with government and other stakeholders
is essential if we are to help create a level playing field for
manufacturing industries and one from which industry can prosper.
2009 marked the ten-year anniversary of CPI and, as well as taking a
detailed look back at the organisation’s activity through 2009, the Review
also provides a retrospective on the changes and developments that have
taken place in the paper industries over the organisation’s first ten
years of life. Issues covered include:
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a summary of the UK
recovered paper market, collection systems and associated legislation;
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climate change
agreements;
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the EU Emissions
Trading Scheme;
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energy supply and
security;
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carbon foot printing
and sustainability;
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health and safety;
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promotional activity.
The 2009 Annual
Review offers a wealth of market data and a full list of CPI Members. Key
Industry Facts, located at the back of the Review, provides statistics
relevant to all four Sectors of CPI’s Membership, including:
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UK paper and board
consumption;
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paper and board mills
and employees;
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paper and board
woodpulp usage;
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recovered paper
markets;
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production of
corrugated boxes.
CPI’s 2009 Annual
Review can be viewed online, at:
www.paper.org.uk
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Ilapak to open new European manufacturing centre in Lugano, Switzerland
Ilapak is to open a new European manufacturing and R&D centre in Lugano,
Switzerland.
The new 2,500 sq
metre facility will be dedicated to the design and manufacture of
rotary-jaw horizontal, form, fill and seal machines as well as
complete automated systems. It is located adjacent to Ilapak’s
existing factory which specialises in horizontal form, fill and seal
machines for extended shelf life of fresh products. The entire complex,
which also includes offices and R & D facilities, covers nearly 8,000 sq
metres, making it one of the largest packaging machine manufacturing
facilities in Europe.
Due to open in the summer of 2010, the new facility will allow Ilapak to
consolidate production of their HFFS (horizontal form, fill and seal)
range of Delta and Carrera flowrappers for all European Countries and
significantly improve efficiency. The rotary horizontal and extended shelf
life machine production facilities will remain separate and continue to be
staffed and managed by specialist application teams, allowing ILAPAK to
maintain their high levels of technical expertise in each product area.
ILAPAK’s state-of-the-art Product Centre will also be based at this new
facility; this will be the hub of Ilapak’s R&D programme for horizontal
machines where engineers will focus on developing new ideas, applications,
designs and technology. New machines and technology will then be rolled
out to Ilapak’s other manufacturing facilities in Europe, China and the
USA.
 The
new factory is a key part of Ilapak’s strategy to bring significant
benefits to its customers, as Ilapak president Luciano Sottile explains:
“The move to a larger, integrated manufacturing complex serving the whole
of Europe is part of Ilapak’s long-term business strategy. Although our
manufacturing strategy has worked successfully for many years, and in fact
in 2010 we are proudly celebrating the company’s 40th anniversary, we will
no longer be producing Swiss/Italian packaging technology to sell to all
the markets our subsidiaries operate in, as it no longer suits many of
today’s customers. Instead, we are looking ahead to meet the needs of a
more global marketplace by building dedicated manufacturing facilities on
each continent to meet the specific requirements of our customers.”
“This gives us specialist knowledge of the requirements for each
particular market and also provides faster lead times for customers when
ordering new equipment. For example, we recently opened a new factory in
Beijing (manufacturing horizontal machines) to serve the rapidly expanding
Far East market. We also have a manufacturing facility in Arkansas, which
serves our US clients and specialises in manufacturing complete packaging
lines. For many years, we have focused on providing a first class sales
and service facility local to our main markets and with the construction
of new local manufacturing centres, we are taking this a step further to
offer our customers the very highest standards in manufacturing, sales,
service and technical support.”
Website:
www.ilapak.com
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CATS-HAENSEL
supports Cadbury France in Krema makeover
 Europe’s
leading waxed and coated papers manufacturer Cats-Haensel has produced new
twist wrappers for a popular confectionery range which has been updated by
Cadbury France.
Wrappers for all 14 flavours of the Krema sweets have been redesigned and
Cats-Haensel has made bespoke, easy-to-remove twist wraps for them that
provide the best possible levels of efficiency during high-speed packing
processes.
Printed in six colours, the new Krema wrappers are designed to appeal to
young and old consumers and form part of the comprehensive range of flexo
and gravure twist solutions from Cats-Haensel, comprising ecological wax
and mineral wax coated papers as well as plain and metalised CPP, BOPP in
partial and full cover laminated finishes.
Cats-Haensel recently installed a state-of-the-art eight-colour flexo
printing press to increase its customer service capability and to respond
to growing demand for its products.
Cadbury France Purchaser Sophie Mayoussier said: “The creation of these
waxed papers for the Krema range was achieved with close cooperation
between Cadbury France and Cats-Haensel who guided and supported us in a
very dedicated and professional manner.
“The way this project was handled by one of our key suppliers for
individual wrapping papers is an example of how excellent co-development
and good understanding contribute to mutual success and great results, in
a highly competitive market.”
Cats-Haensel Managing Director Barry Marron said: “We have a long-standing
relationship with Cadbury France and we were delighted to be able to
support them in the production of these redesigned Krema twist wrappers.
“We are very proud of the high standard of our wax coated and wax
laminated products which, thanks to their excellent print quality and
easy-peel characteristics, play a key part in the appeal of popular
confectionery ranges like Krema.”
The 14 flavours of the soft and chewy Krema sweets are: lemon, orange,
cherry, raspberry, strawberry, apricot, apple, toffee, grenadine, iced
tea, peach, cola, liquorice-caramel and liquorice-mint.
Cats-Haensel, which has operations in Dresden, Germany, and Rotterdam, the
Netherlands, is the number one supplier of ecological and mineral wax
paper and waxed laminates in Europe, offering a range of packaging
products for the confectionery, bakery and food industries to the
European, American and Asian markets. To find out more, visit
www.clondalkin-group.com or email Lexrath@cats.nl.
Cats-Haensel is part of the Flexible Packaging Division of the Clondalkin
Group, an international producer of high value-added packaging products
and services, with over 40 production locations in 10 countries throughout
Europe and North America and annual sales in excess of €800 million.
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Sirane’s Sira Cook set for
take off
Europe’s premier packaging solutions company, Sirane Ltd, is
celebrating a rush of food packaging interest for its latest cook-in
packaging innovation, Sira Cook.
 Jeremy
Haydn Davies, Director of Sirane’s Food Packaging Division says that ‘we
gave Sira Cook an preliminary airing at Foodex in March, and even before
its formal launch we have already produced hundreds of thousands of units
– primarily for the seafood industry.’
This new product – a world first for chilled food - is likely to give
Sirane cause for investment in new lines of machinery to match the
expected demand. ‘Even by our own standards of innovation,’ says Haydn
Davies, ‘Sira Cook has grabbed the imagination of the retailing and food
sector for a number of reasons.’
Sira Cook is an elevated-temperature resistant film that cooks the product
inside – fish, vegetables or boneless meat together with marinades – in
its own juices. ‘The quality of the resulting food – suitable for
microwave or conventional oven – is exceptional,’ says Haydn Davies.
‘Trials in our own kitchens – and at home – have shown that we can sell
the merits of Sira Cook on superior cook-in performance alone.
However, this factor aside, the key driver for Sirane customers is the
quantum step forward in the Sira Cook pack cost-benefits; the exceptional
light weighting of the product and the simple consumer-friendliness of the
pack design. ‘Sira Cook is a clear and profitable alternative to the
existing metallised tray cook-in market,’ says Haydn Davies. ‘We estimate
a 400% lightweighting saving over the existing tray alternatives. Moreover
there are no secondary films to peel off before cooking and no
perforations to be made, and no odour issues. Thanks to our sealant
design, the pack is entirely self venting & its disposability after use is
much simpler than some alternatives.’
For these reasons – primarily the lightweighting – Sira Cook is also
likely to join its Sirane sister product Crisp It as a growing part of the
food service industry. ‘Airlines, trains and other food service stations
love the ease of handling, lightweighting and design of the product,’ says
Haydn Davies.
The Sira Cook product design also means that the product is not handled by
the consumer or the cook before consumption in any more. ‘I guess that
it’s no accident that Sira Cook’s first successes are in fish area - where
it is widely known that consumers do not like handling the product unless
they really have to.’
The transparency – and printability – of the film is also a necessary
factor to attract consumer sales. ‘Food shoppers increasingly desire to
see the quality of the food inside the pack – and our particular grade of
film makes this process all the more easier. In addition to a transparent
film cover we can also produce Sira Cook in black or silver backgrounds
for best presentation.’
Sira Cook is available in all shapes and sizes and in different colours
for chilled or frozen foods. The Sirane product is supplied in reels for
flow wrapping, pre-cut sheets, pouches or bags and is also available in
barrier versions for direct to oven fresh food MAP packaging
Website:
www.sirane.com
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Brooklyn Bottling Co. Offers Tropical FantasyTM Beverage Line in
Distinctive 24oz PET Container
Single-Serve Bottle From Amcor Delivers Portability, Resealability, and
Upscale Look for On-the-Go Applications
 Brooklyn
Bottling Co.’s Tropical FantasyTM line of teas and juices is now available
in 24oz single-serve PET bottles from Amcor Rigid Plastics, the world’s
leading producer of PET packaging. The switch from 16oz glass containers
to consumer-friendly PET affords the company numerous consumer benefits
including lighter weight, portability, and resealability, along with a
novel brand-specific shelf appeal. The company also offers the Tropical
Fantasy line in 16oz cans.
In particular, the PET bottle’s resealability is a critical advantage
because Brooklyn Bottling is looking to expand distribution to schools,
and promote usage at outdoor venues including sporting events and beaches,
according to Eric Miller, president of the third-generation, family-owned
company. "PET delivers an eye-catching bottle, a significantly better
carbon footprint, and avoids breakage issues," explains Miller.
Brooklyn Bottling has experienced strong sales growth in previous
conversions from glass to PET. The company’s tea product, formerly in a
16oz glass bottle, has achieved about 25% sales growth since converting to
PET without even securing any new distribution. Miller says hot-fill PET
has become a strong consumer preference and he looks forward to similar
increases in Tropical Fantasy sales as the conversion to PET occurs.
The custom bottle features an attractive, upscale design, including
distinctive 3-D diamond faceted shapes which encircle the neck. In
addition, the initials "TF" are embossed on the shoulder to instantly
identify the Tropical Fantasy brand. A high-gloss, metallized wrap label
is another eye-catching element that enhances consumer appeal.
The bottle’s finish is 38mm instead of 43mm – a feature that is reflective
of an industry trend focused squarely on sustainability issues such as
smaller package size, reduced material usage, and reduced manufacturing
costs.
Brooklyn Bottling has already started to roll out the new 24oz bottle in
the tri-state area of New York, New Jersey, and Connecticut with expanded
distribution in the mid-Atlantic region by the end of April. It will be
available in supermarkets, convenience stores, and supercenters.
Website:
www.brooklynbottling.com
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Wentus leads the
way in bioplastics expertise
Retailers and food producers searching for more
environmentally-sustainable plastic films are being encouraged to tap into
the expertise of one of Europe’s longest-established manufacturers of
bioplastics, Wentus.
 Wentus
has been developing biodegradable bags and films for the waste and food
markets for nearly 20 years and its commitment to technological
investment, product innovation and customer service has kept it at the
forefront of the fast-developing bioplastics sector during this time.
The Wentus product offer was recently highlighted at the MDD Expo in
France where bioplastics have become increasingly important after a
national framework to encourage the use of biodegradable waste bags to aid
recycling was agreed at the end of 2009.
Wentus’ Wenterra bioplastics range provides major international food
producers and retailers with products that are attractive to consumers and
more sustainable than conventional products as it is constructed from new
generation compostable materials certified to EN 13432 standard.
An intensive research and development programme supports Wentus’ product
innovation and recent breakthroughs have been achieved to further enhance
the barrier properties of the bioplastics and advance the range of
applications into the frozen foods, confectionery and non-food sectors.
R&D activity is supported by a strategic investment programme at Wentus –
a committed member of the European Bioplastics association – which means
its technological facilities include the latest extrusion and conversion
machinery.
 Wentus
Managing Director Wybren de Zwart said: “We have been working since 1992
in partnership with suppliers and customers to continually set new
standards in bioplastics. That remains a fundamental target for Wentus
today and is why our products will remain the best in the market place.
“The use of bioplastics will continue to grow significantly in the coming
years as more steps are taken like those in France to make products as
sustainable and eco-friendly as possible.
“With the massive amount of bioplastics experience and technical knowledge
built up at Wentus over the past two decades, we are best-placed in Europe
to provide sustainable packaging that offers great value and high quality
to our customers.”
Wentus, based in Germany, is part of the Flexible Packaging Division of
the Clondalkin Group. Wentus is an internationally recognised leader in
film and foil packaging manufacture and services the food, convenience
goods, hygiene, agricultural and horticultural markets.
Wentus has extensive blown and cast extrusion, printing and laminating
facilities and over 80 finishing lines capable of producing up to seven
layer films and printed laminates in up to eight colours and numerous
finishes. The extensive range of Wentus products includes biodegradable
films, complex blown films with special seal and peel characteristics,
cast polypropylene films with special transparency and luminance features,
cast polypropylene films developed for twist-wrap applications, composite
laminates for excellent visual and barrier properties and barrier films
for product protection and conservation.
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Chadwicks breathes new life into sleeves for R2 sports drink
Chadwicks has created a striking new shrink sleeve to give R2 Hypotonic
Recovery sports drink a fresh lease of life.
 Snowball
Holdings Ltd needed a shrink sleeve for the R2 Hypotonic Recovery drink, a
premium product that rehydrates twice as fast as water. It appointed
Chadwicks after being impressed by its professionalism, speed and
excellent turnaround capabilities.
The R2 Hypotonic Recovery bottles now benefit from quality, 50 micron PVC
shrink sleeves, reverse printed via UV Flexo and designed with visibility
windows.
Kursat Uysal, business development manager at Chadwicks, said: “We’re
really making our mark in shrink sleeves and Chadwicks is being recognised
by leading brands for its expertise, innovative approach and its efficient
way of working.
“This was a fantastic project for us to be able to demonstrate the level
of skill, focus and quality that we can provide to all our customers. Our
teams provide the highest levels of customer service, working hard to find
innovative, bespoke packaging solutions to suit specific products and
brands.
“Flexibility and fast turnaround is not only about how fast your equipment
can run but about the whole culture, people and focus within a business.
Having the right attitude and being prepared, trained and experienced is
key to achieving first time success.”
Nick Paterson-Jones, from Snowball Holdings Ltd, said: “R2 is a premium
product, and we wanted this to be reflected by the quality of the finished
sleeve. We are very impressed by the professional yet personal approach
that Chadwicks has showed us and were particularly pleased with the fast
turnaround on this job.”
R2 is a hypotonic non carbonated recovery drink which rehydrates in just
30 minutes. R2 has been developed and tested by sports scientists and its
rehydration qualities are scientifically formulated, tested and proven.
R2 is free from artificial ingredients, colouring or stimulants and is low
in sugar, which makes it suitable for diabetics who lead an active
lifestyle. R2 also contains powerful antioxidants that neutralise toxins,
plus glucose polymers to restore energy levels.
Chadwicks is part of the Flexible Packaging Division of the Clondalkin
Group which has more than 40 manufacturing sites located across Europe and
North America.
Website:
www.chadwicks-sleeves.com
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Britvic improves bottle drying efficiency, boosts throughput and saves on
energy with new dryer
On a poster in Britvic’s premises in Leeds it says, “Our vision in
Production is to become the World Leader in soft drink manufacture by
2012”. It will involve Britvic evaluating every stage of the production
process if this goal is to be achieved.
 One
step in attaining this goal is the recent installation of a new bottle
drying system that is helping to minimise downtimes to maximise production
output whilst also reducing energy consumption.
Previously, there were two identical drying units installed in series on
the 36,000 bottles/hr line in order to dry the bottles to ensure effective
label adhesion. As well as not fulfilling this requirement effectively,
the machines did not incorporate bottle guide rails so there was a
recurrent problem of bottles falling over causing line stoppages, lost
production and product waste. These ‘qualities’ resulted in moisture
build-up inside the bottle dryers and product deposits on the bottles. The
situation was made worse by the fact the units were not easy to clean.
These two units have now been replaced by a single ‘LNL’ unit from Air
Control Industries (ACI) of Axminster. This LNL features ACI’s unique
‘JetPlate’ plenum air delivery system. This plenum system enables air to
be delivered close to the bottles, whilst at the same time acting as guide
rails to promote bottle stability during travel through the LNL, thereby
helping to maximise throughput.
The LNL is a totally enclosed stainless steel unit with polycarbonate
inspection windows. The blower unit is mounted on top of the bottle dryer
enclosure to permit the use of adjustable mounting legs to facilitate
installation – even as a retrofit - and for easy all round cleaning.
This version of ACI’s LNL with JetPlates is also able to handle all the
different bottle sizes handled at the Leeds Britvic plant, from the 125 ml
size for mixers up to the 750 ml bottle for J2O, without requiring
adjustment.
With this installation, all these benefits are complemented by significant
energy savings. This is because one blower-powered unit is replacing two,
halving energy costs.
“The previous system was a nightmare,” said Mick Wigham, Engineering Team
Leader, Leeds. “Production hold-ups, ineffective drying, complicated
set-up and fiddly to clean design, all combined to undermine efficiency.
In contrast, the ACI bottle dryer enables us maximise throughput with no
issues relating to the bottle drying function and it’s also easy to switch
product runs.”
Website:
www.aircontrolindustries.com
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