Packagingdigest201109 DL

www.packagingdigest.
com
Packaging with
a Latin flavor
Leg up on
packaging
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2
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PACK EXPO
LAS VEGAS
Attractive pouch offers
recipe for success 30
Eager packagers head to the show seeking
the latest innovations. INSIDER GUIDE
34
Robots get a grip
on efficiency 48
PD1109 001 1 8/31/11 3:46:04 PM
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PD1109 002 2 8/31/11 3:46:30 PM
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PD1109 003 3 8/31/11 3:46:42 PM
contents
www.packagingdigest.com
features
SEPTEMBER 2011 volume 48 no. 9
43
new technology
66
48
Supplement
R
a
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y

L
y
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u
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30 COVER STORY Cook-in bag gives lamb a leg to stand on in competition for space inside retailers meat cases.
34 LATIN FLAVOR Goya Foods keeps growing with packaging that simplies preparation of popular ethnic foods.
38 COOPERATIVE DESIGN Sharing intelligence on packagings planned use can improve development.
43 SUPPLY SIDE Vendors of packaging containers build design and creative services into their value proposition.
52 MAKING CONNECTIONS 3M revives sales of electrical connectors with updated packaging.
INSIDER GUIDE Supplement included with this issue oers ultimate preview of PACK EXPO Las Vegas.
48 GET A GRIP Bird seed shipper gains productivity with robotic palletizing system.
56 STRONG ARM Flexible robot handily stacks pool chemical pails in a range of sizes.
60 CHECK, PLEASE Brewerys checkweigher ensures consumers receive promised amount in every can.
64 PLASMA TREATMENT Eco-conscious carton maker switches from solvent- to water-based adhesive.
66 BASIC BREWING Maker of craft beer returns to basics with remake of bottles and packaging lines.
72 SMOOTH OPERATOR Inkjet coder helps maintain high uptime for microbrewerys operations.
PD1109 004 4 8/31/11 3:48:57 PM
P R O D U C T I D E NT I F I C A T I O N S O L U T I O NS F R O M I D T E C H NO L O G Y
2051 Franklin Drive s&t. Worth, TX 76106 s 888.438.3242 s www.idtechnology.com
2011 ID Technology.
The Specialist To Call On For
Your Product Identification Challenges
When it comes to Product Identification, you can count on the specialists at
ID Technology to have all the answers.
With the only nationwide
manufacturing, sales and
service network in the industry.
IDT brings years of experience, the latest technology and a complete range of
labeling, coding and marking products to solve your Product Identification
challenges. So whether you need print and apply, high-resolution inkjet or laser
coding, or thermal transfer marking, IDT has the right solution for your needs.
Make sure to ask about the complete line of IDT consumables and how using them
can qualify you for our limited lifetime warranty on all IDT parts and services just
one more reason to call the specialists at ID Technology.
And best of all, every ID Technology product is backed by our nationwide network
of PMMI certified service technicians. To talk with the specialist nearest you,
call 888-438-3242, or visit www.idtechnology.com today.
laser coders
thermal transfer
overprinters
high resolution and
drop on demand printers
inkjet coders
label printers
and label applicators
See us at Pack Expo Las Vegas, Booth C1419
PD1109 005 5 8/31/11 3:49:16 PM
staff
departments
8 PACKAGING CONCEPTS
14 COMMENT Population, consumption collide
16 NEW EQUIPMENT
22 NEW MATERIALS
28 GO GREEN Support for EPR
29 SPC SUSTAINABILITY Migrating oils
81 PACKADEMICS Incredible Journey
82 ON PACKAGINGDIGEST.COM
83 INFO SHOWCASE
84 MARKETPLACE
86 NEWSMAKERS
86 AD INDEX
Editorial: 1200 Jorie Blvd., Suite 230, Oak Brook, IL 60523
630-990-2364 Fax 630-990-8894 e-mail: john.kalkowski@ubm.com
Corporate Headquarters 11444 W. Olympic Blvd, Los Angeles, CA 90064
310-445-4200 Fax 310-445-4299 www.ubmcanon.com
Editorial
Editorial Director John Kalkowski
630-990-2364 john.kalkowski@ubm.com
Editor Lisa McTigue Pierce
630-990-7384 lisa.pierce@ubm.com
Senior Editor Linda Casey,
630-990-7385 linda.casey@ubm.com
Plant Operations Editor Jack Mans
630-990-4208 jack.mans@ubm.com
Associate Art Director Jennifer Field
Art/Production
Lead Art Director Marco Aguilera
Associate Art Directors Tim Burns, Laura Pappada
Production Director Jeff Tade,
Production Manager Martin Schneggenburger
Senior Production Artists Jeff Polman, Derric Treece
Production Artist William Baughman
Production Coordinator Adrienne Davis
Director of Circulation Sandra Martin
Circulation Manager Carlota Valle-Martinez
Sales/Marketing
Associate Publisher Steve Everly
Sales Steve Slakis
Sales Russell Thibeault
Marketing Manager Mary Williams
Sr. Group Publisher
Patricia Spinner
973-808-1250
patricia.spinner@ubm.com
Executive Officers
Chief Executive Officer Paul Miller
Chief Financial Officer Fred Gysi
Vice-President/Executive Director, Stephen Corrick
Sr. Vice President, Events Division Kevin OKeefe
Vice President, Operations Roger Burg
Vice President, E-Media Jason Brown
www.exlink.com
Our new generation of stainless steel conveyors are robust, modular
and clean. Delivering high throughput, exibility and gentle product
handling that will boost your production efciency.
And with over 700 employees worldwide and operations in more
than 60 countries, youre never far away from a FlexLink ofce. Contact
us today at info.us@exlink.com or give us a call at +610-973-8200.
Strong yet fully exible
See us at Pack Expo Las Vegas, Booth S5703
PD1109 006 6 8/31/11 3:49:22 PM
Once again, H.B. Fuller has transformed
hot melt performance with our new
Advantra Encore
packaging adhesive
platform. With performance surpassing
metallocene-based technology (which
we invented), the custom designed
Advantra Encore platform changes
the rules of hot melt performance and
supplyfor the long run.

Q
Better bonding

Q
Higher mileage

Q
Broader service temperature
range

Q
Globally available
Revolutionize your case & carton
sealing with one new adhesive
Advantra Encore hot melt.
Better than the Best
hbfuller.com/advantra-encore
Copyright 2011 H.B. Fuller Company
Catch Our Wave of Innovation
at PACK EXPO, Booth S-5004
PD1109 007 7 8/31/11 3:49:37 PM
SEPTEMBER 2011 PACKAGING DIGEST www.packagingdigest.com 8
packaging
concepts
www.
mintel.com/gnpd
New Product of the Month
L
aunch pad
12,000
10,000
8,000
6,000
4,000
2,000
0
New Products Launched Globally
Source: Mintel Global New Products Database (GNPD)
11
Jun
11
May
10
Jul
11
Jul
10
Aug
10
Sep
10
Nov
10
Oct
10
Dec
11
Jan
11
Feb
11
Mar Apr
11
Food
Beauty & Personal Care
Beverage
Household
Healthcare
Healthcare
Beverage
Household
Food
Source: Mintel Global New Products Database (GNPD)
New Products Launched in the U.S.

11
Jun
10
Jul
11
Jul
10
Aug
10
Sep
10
Nov
10
Oct
10
Dec
11
Jan
11
Feb Mar
11
May
11
Apr
11
2,000
1,800
1,600
1,400
1,200
1,000
800
600
400
200
0
Food
Beauty &
Personal Care
Beverage
Household
Healthcare
Food
Healthcare
Beverage
Household
Market Source, a fresh produce repacker and
distributor headquartered in Milwaukee, WI, has
launched a new 4-pack of limes, called Beer Lime, the
ultimate combination of convenience, taste and long-
lasting quality.
According to the company, the Beer Lime 4-pack
is better than bulk and bagged limes because of the
packaging design that bundles convenience with
extended shelf life.
Each package of Beer Lime contains four perfectly
sized, premium quality limes, which remain frm, plump
and juicy long after their bulk and bagged counterparts
have begun to show age. The secret to lime longevity
is the virgin APET packaging material combined with
the respiration rate within the carton to create an
optimum atmosphere for storing limes.
Our initial goal was simpleto bring consistently
sized, frm, green and juicy limes to the eating and
drinking world, says Sam Maglio, president of Market
Source. We never set out to create a package that
made limes last longer; we just thought the [plastic]
box had a lot of consumer appeal. After creating the
package and having some samples sitting around
our office, we realized we had created the perfect
atmosphere for dramatically extending the average
shelf life of limes for up to four weeks.
The transparent cartons are offset-printed using the
four process colors: cyan, magenta, yellow and black.
The graphics used allowed for visibility of the limes.
The graphics draw you to it, says John Berger, general
manager at Market Source.
Market Source began production of Beer Lime in
June and is distributing to select retailers across the
U.S. Beer Lime is packed and shipped from a new
plant in McAllen, TX.
New in Canada from Upper Canada Soap &
Candle Makers is Naturally Upper Canada
Signature Collection Golden Maple Sugar
Bubble Bath available in a decorative 240-mL
glass bottle molded in the shape of a maple leaf;
and featuring an elasticated hanger portion.
The closure is a simple screw-on, injection-molded PP cap
covered with a security seal shrink band. Apart from using
glass, there is a new attachment method for the hanging plastic
label. The highly elasticated hanger portion is shaped to ft the
neck and sealed onto the tag.
Mintel notes how the use of glass
and the maple leaf style design goes
a long way in denoting luxury, as does
the products food-inspired formulation:
It is made with maple sugar extract,
Shea butter and cocoa butter, and is
said to offer ultimate relaxation and skin
nourishment. The packaged product
further highlights the ongoing crossover
between food and beauty markets,
and how consumers can be
drawn to beauty products
which incorporate familiar
and indulgent food
ingredients.
Beer Lime 4-pack extends shelf life, appeal
Maple Sugar Bubble Bath
PD1109 008 8 8/31/11 3:51:02 PM
The CX1200 Color Label Press delivers short- to medium-run,
full-color digital label printing at a breakthrough price. Utilizing
one of the fastest and highest-resolution color laser engines avail-
able, CX1200 delivers the quality, speed and exibility of digital
presses costing many times more. Add Primeras new FX1200
Digital Finishing System to laminate, die-cut, slit and rewind.
Call us today at 1-800-797-2772 (USA and Canada) or +1-763-475-6676 for more information.
Ask about our special limited-time bundle pricing when you purchase both machines together.
New! Digital Label Press and Finishing System
Ideal for 10 to 10,000 labels at a time.
New! LX900 Color Label Printer
Ideal for short runs of 1 to 1000 labels.
Label Applicators LX400 Color Label Printer
Label Supplies
New Product Videos
NEW! Color RFID Printer
Powered by Intermec
The LX900 Color Label Printer is Primeras newest, fastest

and most economical to operate color inkjet label printer.
Features include print speeds of up to 4.5" per second, in-
dividual ink cartridges and up to 8.5" media width. Youll
save time and money on every label you print!
Call Primera at 1-800-797-2772
www.primeralabel.com.
LX400 is Primeras most affordable desk-
top label printer. It has a convenient
single-cartridge ink system and up to
4.25" maximum print width. With LX400
youll be able to print highly professional
full-color labels for all of your short-run
products, helping you to sell more!
Primeras AP-Series Label Applicators are the perfect
semi-automatic labeling solution for cylindrical con-
tainers as well as many tapered containers, including
bottles, cans, jars and tubes. See how fast and easy it
is at www.primeralabel.com/videos.
Primera offers ink cartridges and a large
selection of stock label sizes in various
shapes. Need a quote on a custom label
size? Just complete our custom label form
on www.primerastore.com.
Want to see any of our digital color label
printers, digital presses or label applica-
tors in action? Just go to
www.primeralabel.com/videos.
Need full-color printing with built-in RFID
encoding? Check out Primeras new
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www.primeralabel.com/RFID.
Great Products Deserve the Best Labels.
Primera has everything you need to produce gorgeous, full-color labels for your products.
2011 Primera Technology, Inc. Primera is a registered trademark of Primera Technology, Inc. All other trademarks are the property of their respective companies.
See Primeras Full Line of Label Printers and Presses at Pack Expo Booth #5660
Primera Technology, Inc.
Two Carlson Parkway North
Plymouth, MN 55447 U.S.A.
Ph: +1 763 475 6676
www.primeralabel.com
sales@primera.com
Primera Asia Pacic
Rm 1206-7, 12F New Victory House
93-103 Wing Lok Street
Central, Hong Kong
Ph: +61 3 8586 3030
www.primera-ap.com
sales@primera-ap.com
Primera Europe
Mainzer Strasse 131
65187 Wiesbaden/Germany
Ph: +49 (0)611 - 92777-0
www.primeralabel.eu
sales@primera.eu
Primera Latin America
Avenida Marques de Sao Vicente 446 CJ 205
Sao Paulo, SP 01139-000 Brazil
Ph: +55 11 26 26 80 17
www.primera.la
sales@primera.la
PD1109 009 9 8/31/11 3:51:27 PM
packaging
concepts
Colorful cans quickly
chill infused waters
New Age Beverage introduces Just Pure Water in
24-oz cans to markets in Denver, CO, and Phoenix,
AZ. The 24-oz can offers consumers a quick-chilling,
lightweight package for the unsweetened, zero-calorie
purifed water infused with the natural essences of
three favors: lemon-lime, orange or berry.
Packaging our Just Pure Water in aluminum cans
was the natural solution for our company, says Scott
LeBon, president and CEO of New Age Beverage.
Selecting the purest of natural ingredients for Just
Pure Water and then offering it in recyclable aluminum
cans combine the best that Mother Nature can offer
in a package that is environmentally friendly and
convenient. We are proud to have Sprouts as our frst
natural market chain to be selling Just Pure Water in
Colorado and Arizona.
The 24-oz cans are supplied by Broomfeld,
CO-based Ball Corp. (www.ballamericas.com),
which notes that aluminum cans are the most recycled
beverage package type in North America, and Balls
cans contain an average of 68 percent post-consumer
content and are 100 percent recyclable.
Barrier-coated PET bottle brings big
growth for single-serve wines
Sutter Home Family
Vineyards attributes its
leadership position in the
single-serve, 187-mL wine
category on name brand
recognition, high-quality and
affordably priced varietal wines,
and innovation, including
innovation in the packaging
arena. The vintner began
using barrier PET bottles,
supplied by Amcor Rigid
Plastics (www.amcor.com)
as a glass replacement in
2005 and has switched its
entire 187-mL production to
the plastic containers. The
bottles preserve the look of the
original glass container and
run on the winerys existing
glass flling line.
The sales results have been impressive. Sutter
Home currently is the wine industrys leading producer
of single-serve, 187-ml wines with a 38 percent market
share. While the 187-mL wine segment has grown 8.4
percent per year, Sutter Home has enjoyed explosive
sales with a 7.3 percent annual growth rate. The
company projects total sales of 2.2 million cases in
2011, according to Wendy Nyberg, senior director of
marketing at Sutter Home.
We have been innovators and taken an ownership
stake in the 187-ml category, Nyberg remarks. Weve
stayed focused on the category and effectively used
our brand image, while also offering new varietals
and moving to alternative PET packaging that
delivers consumer convenience and sustainability
benefts. Consumers have embraced PET because
of its great look and feel and
convenience.
The aluminum screw-cap
bottles portability provides
entre into venues that do
not allow glass because of
the potential for breakage.
In addition, consumers are
impressed with the glass-like
appearance and the high
quality of the packaging.
A barrier coating
technology developed by
Germanys KHS Plasmax
GmbH (www.khsplasmax.
com) affords the 187-mL PET
container the same shelf life
as glass. The Silicon Oxide
(SiOx) barrier coating is a
glass-like material that seals
the container from the inside
to protect the contents from oxidation. This ultra thin
less than 100nmmaterial is transparent and resists
cracking, abrasion and delamination. Moreover, it doesnt
degrade over time nor limit the storage time for empty
bottles. Plasmax is an FDA-compliant enhanced passive
barrier for oxygen-sensitive products. The barrier coating
also is easily removed during the recycling process and
does not contaminate the recycling system.
This sustainability beneft is in addition to those
delivered by the PET bottles themselves. Nyberg says
that these key sustainability benefts are in keeping
with Sutter Homes commitment to environmentally
responsible practices in all aspects of its wine making
operations. PET containers are one-sixth the weight
of glass bottles, unbreakable, less wasteful and
recyclable, she adds.
See us at Pack Expo Las Vegas,
Booth C4216
PD1109 010 10 8/31/11 3:51:54 PM
Global Distributor Network
For local distributor contact:
Leibinger
East Troy, Wisconsin
www.leibinger-group.com
262.642.4030
Wo r l d Cl ass I n k j et
n o w w i t h
I n t eg r at ed Vi si o n I n sp ect i o n
I n t r o d u ci n g :
Simple Integration
and
Operation
PD1109 011 11 9/6/11 1:50:14 PM
packaging
concepts
Welcome Home Brands asks retailers: Bag or box for bakeware?
The Welcome Home Brands line of oven-safe Paper
Bakeware offers two packaging options to give grocery
retailers more merchandising choices throughout the
store. Available in gift bags or boxes, both packages
showcase the beauty and simplicity of the product,
while offering consumers clear and concise wording to
describe the convenience of this whole new way to bake.
Consumers have never before seen this line of
high-quality paper bakeware in which you can bake,
store, serve and give. Our packaging is designed
to communicate our convenience advantage and
show how oven-safe Paper Bakeware replaces metal
bakeware with style, says Sam Sheppard, co-founder
and co-CEO of Welcome Home Brands.
The gift bag packaging alludes to the gift-giving
nature of home baked goods, especially when
presented in Welcome Home Brands decorative paper
bakeware molds. The bakeware pans are nestled in a
paperboard sleeve that illustrates the bakeware in use,
then wrapped in a clear plastic bag fastened at the top
with a twist tie. A hang tag adds the fnal touch,
giving the packaging a gift-able feel.
The clear plastic box packaging also
showcases the paper bakewares decorative
style. The sturdy boxes protect the product
while offering retailers the option of stacking on
the shelf, counter or on an end cap. An easy-
to-read paperboard sleeve illustrates the paper
bakeware in use.
Eye-catching and informative, both
packaging options are great choices for
merchandising Welcome Home Brands Paper
Bakeware throughout the store, whether they
are displayed in the bakeware section or cross-
merchandised with baking ingredients.
We offer both plastic bag and clear box
packaging options to our retailers, and were fnding
both of the packaging styles are doing equally well,
Sheppard says. Also, as an added convenience, our
paper bakeware can be customized to meet the needs
of our retailers, and it is available in multiple languages.
Welcome Home Brands offers a variety of styles
and sizes for every day or seasonal baking, including
paper and plastic baking cups and dessert cups, round
and rectangular cake pans, and muffin and specialty
shapes including futed and heart-shaped molds.
The paper bakeware is available for immediate
shipment.
Welcome Home Brands oven-safe paper
and plastic bakeware is available nationwide for
commercial use and will also be in more than 2,000
retail stores in the U.S. this fall.
Money saving bagging solutions
Rennco vertical packaging equipment provides a reliable, versatile, cost-effective alternative for your
bagging operations. Whether you have a single item, multiple items, large or small items, Rennco offers a
packaging solution for your application. Hand load systems are available along with fully custom designed
and automated systems.
For all your bagging needs go to www.Rennco.com or call 1-800-409-5225 for more information.
Ask Rennco to provide a solution to reduce labor and save material costs by utilizing centerfolded roll
stock on a Rennco packager instead of pre-made bags. See us at Pack Expo
booth #C-1616
PD1109 012 12 8/31/11 3:52:15 PM
Innovate With Conf idence
An innovative package requires a team of exper ts who know how
to get innovation done from concept to commercialization. Thats
why you get more than just packaging from Printpack. Our exper ts
help brands create innovative packaging that not only works, but works
better throughout your value chain. The worlds most trusted brands
work with Printpack to innovate with confidence, and you can too.
www. pri ntpack. com
Graphics/Pre-Press Rigids Flexibles Labels Medical
NORTH AMERICA | LATIN AMERICA | EUROPE | ASIA
See us at Pack Expo
Booth C-1508
PD1109 013 13 8/31/11 3:52:27 PM
John Kalkowski, Editorial Director
comment
A
Americans neednt look far to realize that we are consuming the
worlds resources faster than Nature can replenish them. Jared
Diamond, author of the fascinating book, Guns, Germs and
Steel, says that the rate of resource consumption and waste
production in North America, Western Europe, Japan and
Australia is about 32 times higher than it is in the developing
world. Te populations of those countries add up to about 14
percent of the worlds population, yet they (or should I say we?)
account for 60 percent of private consumption spending.
People in developing countries also aspire to a higher
consumption lifestyle. Just imagine what would happen if
residents of these developing countries ever catch up.
Te Earth currently is home to nearly 6.5 billion humans,
and its estimated the population will grow to 9 billion
before 2050. Te Sierra Club writes that rapid population
growth, coupled with high levels of consumption, are
stressing our limited natural resources, which also is
creating a number of social and political tensions around
the world.
Australian environmentalist Paul Gilding says that
because we are using resources far faster than they can be
sustainably replenished, we are eating into the future. He
writes that the Global Footprint Network, an alliance of
scientists, calculates that current global growth is consuming
the equivalent of 1.5 Earths. Tats the amount of land and
water we need to produce the resources we consume and
absorb our waste using current technology. If everyone in
the world consumed at the same rate we do in the U.S., the New
Economics Foundation estimates it would take 5.3 Earths to be
sustainable.
China is the worlds fastest growing economy, with 1.3 billion
people, yet their per capita consumption rate is about 11 times
below that of the U.S. If China catches up with the U.S. on a
per capita basis, it would roughly double world consumption,
Diamond estimates.
So, why should any of this matter to those of us in the
packaging industry of the worlds richest country? After all, the
day when the resources we need for packaging are depleted wont
happen in our own lifetime. But it will happen at some point.
It is said that a business that is not growing is dying. To most
U.S. businesspeople, that usually means breakneck growth in
manufacturing, sales, consumption and waste.
As Diamond writes: Just as it is certain that within most of
our lifetimes well be consuming less than we do now, it is also
certain that per capita consumption rates in many developing
countries will one day be more nearly equal to ours.
We have to nd a way to grow our businesses in a sustainable
manner. In many areas, we have the capability to do so. Its a
matter of social, political and individual will. In other words, its
up to you and me.
When population, consumption collide
PD1109 014 14 9/1/11 4:41:19 PM
PD1109 015 15 9/6/11 1:52:42 PM
Vision system The Vision Hawk machine vision system is a fully-
integrated smart camera, built for high performance in rugged
production environments. With a complete vision toolset that
includes powerful decode tools for reading bar codes
and text codes (OCR), the vision system enables
manufacturers to meet their traceability requirements
and automate inspection tasks such as cap alignment,
label positioning and fll-level verifcation. Liquid lens
autofocus technology reduces downtime by eliminating
the need to manually adjust the systems camera
during line changeovers. The system also features fully
integrated lens, lighting, industrial IP65/67 housing and
Ethernet connectivity. It performs inspections such as cap
alignment and fll-level verifcation.
Microscan, 425-226-5700.
www.microscan.com
equipment new products
Vibratory feeder The new HS-8
electromagnetic vibratory feeder with quick stop and
high conveying speed capabilities is designed for
improved efficiency in packaging, weighing, batching
and bagging operations. The vibratory feeder
features E-Z Tune technology,
which enables customers
who build their own trays
to signifcantly reduce
the time spent tuning
feeders. The feeder
features a low profle
design for easy installation in
areas where space is limited: The
machines unique wedge-shaped body allows
feeder arrangement in small diameter weigh scale
systems while the machines narrow width makes it
well suited for in-line scales, the company states.
Eriez, 814-835-6000.
www.eriez.com
Vertical sealing system The VCBS
is a USDA-approved Vertical Sealing System
with a synchronized lower support conveyor. This
continuous band sealer will seal products in stand-up
pouches and bags made of PE. Models are available
with a stainless steel frame, bag top trimmer and
vacuum scrap removal.
All Packaging Machinery, 800-637-8808.
www.allpackagingmachinery.com
Report logger The Report Logger monitors
the transportation and storage of temperature-
sensitive products. It is small enough to be placed
inside containers, packages or transportation
vehicles where temperature-
sensitive products are
shipped or stored. Used
with any Windows PC, this
logger requires no software
and, when plugged into a
USB port, creates a one-page report of the recorded
temperatures. It is compact, low cost and is reusable
since it has a user-replaceable battery.
Dickson Data, 800-757-3747.
www.dicksondata.com
Dont let your packaging down.
The worlds leading food companies rely on
Kliklok-Woodman for packaging machinery
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machine designs, application experience and
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kliklokwoodman.com | 770-981-5200
see the innovation - september 26-28 | pack expo 2011, las vegas - booth c-1400
PD1109 016 16 8/31/11 3:54:36 PM
www.packagingdigest.com PACKAGING DIGEST SEPTEMBER 2011 17
Integrated scale The companys EZ Weigh
Integrated Scale Option uses load cell technology
to combine pallet load weighing and stretch
wrapping into a one-step process. The machines
design separates the weigh system from the stretch
wrappers frame, ensuring only objects placed on
the wrappers turntable get weighed. Designed for
the companys Q-300, Q-300XT,
Q-400 and Q-400XT stretch
wrappers, the new option is
compatible with both 65- and
72-in. diameter turntables. Stretch
wrappers equipped with the
integrated scale maintain the
Q-Series classic low profle and
ship calibrated and ready for
immediate use.
Lantech, 800-866-0322.
www.lantech.com
Printer The new AutoPilot hi-resolution inkjet
printing system is designed for printing high-
resolution characters and other product information
directly on porous or non-porous products. The
printer uses proven Xaar piezo technology to print
up to 0.7-in. of high-resolution characters, text,
scannable bar codes and logos at 180-dpi. The 12.1-
in. full color touchscreen controller features ATM-
simple, easy to follow user prompts to program, save
and print messages. Programming and editing can
be done right at the production line, or at a remote
PC and uploaded to the AutoPilot via USB.
Squid Ink, 800-877-5658
www.squidink.com
Wrapper The new Starpac 600 HL wrapping
machine closes packages with hermetic sealing,
allowing for maximum protection of products
in single-wrap, die-fold packages. Chocolate
manufacturers can now differentiate their
products with the premium look of die-fold
packages while guaranteeing quality and safety,
the company says. The wrapper wraps small- to
medium-sized chocolates with an output of up to
600 pieces/min.
Bosch Packaging Technology, 763-424-4700.
www.boschpackaging.com
Magnet assemblies The company offers
18 types of magnet assemblies, a simple solution
for no-wear magnetic holding of an object. Types
of magnets include fat gripper, rod gripper, button,
and U-Magnets, in steel, stainless steel and brass.
Assemblies are also available in an array of sizes,
threads and fnishes, and are designed to provide a
variety of levels of pulling forces and accommodate
different mounting requirements.
J.W. Winco Inc., 800-877-8351.
www.jwwinco.com
Printer Vivo! Touch digital color label printer
includes a new web server, a new enterprise
printer driver for NiceLabel software, and the
new TouchPeel in-line label rewinder and Matrix
TouchPrint in-line label rewinder and removal
system. The TouchPeel is a combination label
rewinder and matrix removal system that
intelligently interfaces with the label printer. The
printer also features the ability to monitor the color
label printer from a standard web browser.
QuickLabel Systems, 877-757-7978.
www.quicklabel.com
PD1109 017 17 8/31/11 3:54:47 PM
18 SEPTEMBER 2011 PACKAGING DIGEST www.packagingdigest.com
new productsequipment
Robotic palletizer The EC-171 robotic
palletizer operates at speeds up to 20 cycles per
minute and implements a standard collision detection
feature. It maintains the smallest rotation radius and
excellent energy efficiency, the company claims.
The unit allows work in tight space constrictions.
The standard touchscreen allows quick program
changing and real-time tracking and comparing.
American-Newlong, Inc., 317-787-9421.
www.american-newlong.com
Vision inspection The company releases
a new version of In-Sight Explorer 4.5, expanding
the capabilities of In-Sight vision systems. The vision
inspection system now features an all-in-one edge
and surface inspection tool, an all-in-one bead width
and position tool, and a robust ID tool that reads
multiple codes at one time, allowing the systems
cameras to read bar codes and provide inspections
simultaneously. The new Flexible Flaw Detection
(FFD) edge and surface inspection tool works for
both color and grayscale applications and is used
to inspect for boundary defects, such as conformity
of shape, and surface defects, such as stains and
scratches. FFD also gives users the fexibility to
select accuracy versus speed requirements and the
ability to ignore defects during system run time.
Cognex Corp., 508/650-3000.
www.cognex.com
Inkjet printer The companys inkjet printers use sealed nozzle
technology, Windows interface and robust hydraulic components. The
printers feature no scheduled cleaning, easy operation and print job
setup, and simple annual maintenance with no fush requirements.
Cable TV series Profles with Terry Bradshaw will feature the
printers this fall as a manufacturer of equipment that improves
production line efficiency.
Leibinger Group, 262-642-4030.
www.leibinger-group.com
Shrink tunnels The Sleeve Seal line of
shrink tunnels features an array of options that
make setup fast and precise. Tunnels are available
in a range of sizes to accommodate the sleeve
labeler ranges. Every model in the tunnel product
line features external instrumentation and controls,
and individually positioned nozzle arrays or air
knives can be moved in all directions to place the
shrink wherever its needed. The arrays feature
location indicators to enable repeatable and
precise setup.
Sleeve Seal, 501-492-3893.
www.sleeveseal.com
Cartoner The Model 74A707 vertical
cartoner automatically loads bottles and vials at
speeds of 80 to 100 cartons/min. The product
is positioned vertically to eliminate leakage and
to ensure product integrity. The machine erects,
loads and closes the cartons for an operator-free
production line. The cartoner includes an infeed
conveyor, which can be mated with a rotary table
or other accumulating device to feed in the bottles.
A range of sizes and styles of cartons can be
accommodated, including glue, tuck and ffth-panel
display.
Bivans Corp., 323-225-4248.
www.bivans.com
Exceptional expertise, craftsmanship, and service,
with every facet of our manufacturing process
housed under one roof!
Made in the USA
labeling systems
Made in the USA
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Fax: 330-332-2144 | E-mail: CTMsales@ctmint.com
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360A WR
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PD1109 018 18 8/31/11 3:55:24 PM
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PD1109 019 19 8/31/11 3:55:50 PM
Case packer The Brenton Pro
Series Mach-2 case packer is an all-
servo-driven, side-load case packer
using indexing motion to load up to
25 cases/min. Cases accommodated
include RSC, HSC, tray, wraparound,
knock-down and harness for cartons,
bottles, cans and tubs. A continuous
welded frame is standard for a long
service life while the lightweight
aluminum guard package is seamless,
built into the frame of the machine for
a smaller footprint, which eliminates
gaps that can pose sanitary issues
with extrusion. The walk-in design
allows easy access into the machine
for cleaning and maintenance and
eliminates the need to lean over a
frame to work inside the machine.
Brenton, 800-535-2730.
www.brentonengineering.com
Robot Designed for high-density
installations, the MPP3 robot is
suitable for high-speed packaging,
kitting and assembly applications.
Featuring the best space utilization
in its class, it offers the largest
workspace with the smallest
footprint, the company states. The
robot features a payload capacity
up to 3-kg, and is controlled by the
compact FS100 controller with open
software architecture. This high-speed,
delta-style robot complements the
companys line of robotic automation
for food and consumer products.
Motoman Robotics, 937-847-6200.
www.motoman.com
Induction cap sealer The Super Seal Touch induction cap sealer
with the all-in-one universal sealing head is specifcally engineered to help
packagers achieve a perfect seal. Its design simplifes setup to ensure
operators correctly position the sealing head across the entire range of cap
sizes to be sealed. The system is ideal for sealing a range of cap sizes from
24- to 120-mm. The system offers increased sealing speeds, a re-engineered
cap inspection system, an intuitively-designed touchscreen interface,
simplifed setup and operation, and a host of capabilities for internal
monitoring and remote network communications.
Enercon Industries, 262-255-6070. www.enerconind.com
Continued on page 77
PD1109 020 20 8/31/11 3:55:54 PM
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Domlno. Do more. www.oomlno-na.com
1.800.486.7414
PD1109 021 21 8/31/11 3:56:08 PM
new productsmaterials
Barrier induction seal ALKOfex O2-sorb
is a one-piece sealing insert that enables food and
beverage packagers to add a peelable induction seal
to untreated glass or plastic containers made of PE,
PP, PET or PVC. The tamper-evident sealing insert
also has an oxygen-absorbing layer and features
product protection through the absorption of oxygen
that is located in the headspace after the sealing
process, or oxygen that migrates into the container
over time.
Meyer Seals, +49 5181-8018-0.
www.meyer-seals.com
In-mold-labeled tubes Production-
ready, in-mold-labeled (IML) tubes for personal care
and beauty products feature enhanced graphics
for outstanding shelf presence. The package is
the result of a partnership between cosmetics
packaging supplier Topline Products and Viva
Healthcare, an injection-molded tube specialist.
The process combines the decorating and molding
of polypropylene tubes into one simple procedure,
eliminating any post-mold printing or labeling
operations and costs. It embeds photographic-quality
artwork into the wall of the tube, with total surface
decoration even into the crimp area, for true-to-life,
eye-catching graphics that are durable and resistant
to fading or scuffing. From a sustainable standpoint,
the IML tubes have a recycling code of #5 and use
less resin than traditional tubes, the company says.
Topline Products, 973-785-1600.
www.topline-usa.com
Aseptic carton caps The company offers aseptic cartons featuring
caps made with PE that has been developed by Braskem, Brazils largest
petrochemical company, and is made out of sugar cane derivatives, which are
polymerized in plastics for cap production. These eco-friendly caps were used for
Nestle Brazils launch of two popular milk brands.
Tetra Pak, 847-955-6000.
www.tetrapak.com
Beverage closure DoubleSeal SuperShorty caps feature
DoubleSeal technology, a 2-in-1 outer-plus-inner seal in a single
piece, linerless closure. Instead of down-pressure during the sealing
process, DoubleSeal closures provide lateral, opposing-force
pressure from both the outside and inside, effectively supporting
instead of distorting the neck. The closure is able to keep a tight
closure seal to keep CO2 locked in, so that beverages dont go fat.
Made with HDPE rather than PP, the caps also offer cost, supply
and environmental advantages as well, the company states.
Bericap, 909-390-5518. www.bericap.com
300 Newsome Drive Yorktown, VA 23692
Phone: (757) 898-1530 Fax: (757) 898-1580
VERTICAL CONVEYING SOLUTIONS
Need to reduce operating expense
and minimize the cost of ownership?
Ryson can help. Our Spiral Conveyors
need less oor space than conventional
conveyors and are faster and more
reliable than any elevator or lift.
Quality and service come rst at
Ryson. We are the number one spiral
manufacturer in the USA. For application
assistance or more information, give us a
call or visit www.ryson.com.
Save Space
and Increase
Throughput
Visit us in Booth 5215 at PACK EXPO
PD1109 022 22 8/31/11 4:15:28 PM
PLA compounds New Terraloy BP-39070
series enhanced-PLA compounds for extrusion and
thermoforming have a bio-based content level of around
90 percent and are biodegradable, making them an
effective alternative to petrochemical-based resins in
applications where sustainability and compostability are
critical considerations. They meet FDA requirement for
food-contact applications.
Teknor Apex Co., 401-725-8000.
www.teknorapex.com
Copolyester flms The companys flm
product line now includes the MD-EK10R00 high-
performance rigid copolyester flms for medical-
device packaging applications. This flm solution
flls an unmet need in the industry for increased
toughness and temperature performance for
demanding medical f/f/s and tray applications.
Suitable for packaging heavy medical equipment
and frozen medical products, the flms are available
worldwide and have a high glass-transition
temperature, which allows for heat resistance that
slows aging and speeds validation and sterilization.
With these flms, quicker accelerated-aging protocols
are possible, as faster and more reliable shelf-life
qualifcation can reduce time, labor and speed-to-
market delays, the company states.
Klckner Pentaplast, 540-832-3600.
www.kpflms.com
Easy-open vacuum closure New 40-mm Ideal
Closure is designed for use with hot-fll and retort applications
such as soup, nutritional beverages, coffee and tea. A hybrid
of a plastisol-lined metal disk and a plastic band, the closure is
compatible with plastic or glass containers. The metal disk forms an
airtight seal against the container to guard against oxygen ingress
while the consumer-friendly plastic band is easy to grip, enhancing
the opening experience, the company states. The closures
two-stage opening mechanism separates the force required
to overcome the friction between the closure threads and the
container from that required to release the vacuum in the package,
further easing opening for consumers. The design of the closure
also creates multiple opportunities for brand owners to differentiate
their products on the shelf. Logos, messaging and nutritional
value can be printed on the metal disc and different favors can be
communicated with distinctively colored plastic bands.
Crown Closures Americas, 215-698-5100.
www.crowncork.com
www.millikenchemical.com
Copyright 2011 Milliken & Company. All rights reserved.
Millad is a registered trademark of Milliken & Company.
Milliken and NX are trademarks of Milliken & Company.
Milliken
Millad
NX
8000
the clear advantage
Increase Your Productivity and
Energy Savings for Clear Polypropylene
Millad NX 8000 raises the bar for claried
polypropylene, providing a clear, cost-effective
solution for injection molded housewares,
storage containers and packaging applications.

In addition to superior clarity and visual appeal,
Millad NX 8000 can enable increased
productivity and reduced energy consumption.
PD1109 023 23 8/31/11 4:15:37 PM
Hygenic pallet The versatile 40 x 48 in. StackR pallet allows
customers to use it in both stacking and lightweight racking
applications. The pallet is 100 percent recyclable
and has been made to stand up to a variety of
temperatures and harsh environments that materials
may meet when passing through the logistics chain in
the food and agricultural industry. The pallet is structural
foam molded and was developed to be a smooth and
non-porous product to avoid absorbing moisture or odors. The
products all-plastic construction ensures dimensional consistency
and repeatable performance in automated systems or high-rise racking.
Orbis Corp., 888-307-2185.
www.orbiscorporation.com
Easy-peel coatings New SoftpeelCoat
peel coatings allow for a smooth opening that
requires low opening force and no additional tools.
The coatings ensure tight seal of the packaging
during storage, distribution and display. The easy-
opening solutions are used for peel coating against
peel coating applications such as paper- and plastic-
based bags for food items or surgical equipment,
and for peel coating against tray or cup applications
such as snacks and dairy products.
Mondi Group, +44 1932 826 300.
www.mondigroup.com
Extrusion-coated lid The companys
extrusion-coated lid is made of paper and plastic
that can be separated from each other as a part
of the normal recycling process. The lid is durable,
easy to print on and can be cut into different sizes
or shapes. It is also easy for consumers to peel
off the lid without tearing it and to dispose of it
together with other paper waste. The fber-based
lid has strength and puncture-resistance, features
that are important in dairy product segments.
An advantage of the extrusion-coated lid is its
excellent printability, as it is capable of carrying
demanding graphics produced by modern printing processes, the company states.
Walki Group, +358 205 36 3111.
www.walki.com
See us at Pack Expo Las Vegas
Sept. 26th - 28th, Booth C-1411
Heat shrink applicators that
Fit your business.
Go to www.AxonSleeves.com or call
1-800-598-8601 for more information.
Whether you need shrink sleeve or tamper evident band
applicators that are flexible and economical or fast and
customizable, Axon has a system that meets your needs.
All systems are backed by ProCustomer service hubs on
the East and West Coasts with leasing programs available
to make it easy to get started today.
More efficient. More precise. More versatile. More reliable.
Axon.
PD1109 024 24 8/31/11 4:15:45 PM
(800) 835-9344
www.eastey.com
A leader in the packaging world,
Eastey Enterprises has been making
the industrys favorite shrink packaging
equipment for over 25 years. Our
products are MADE IN THE USA so
expect features like all-welded frames
made of 1/4 cold-rolled steel, casted
seal heads equipped with double
locking bolts, and proven quality and
reliability to keep your packaging line
up and running day after day.
Contact Eastey today and discover
your rst and last choice in shrink
packaging equipment.
See us at PACK EXPO Booth C-532, Sept. 26-28, Las Vegas Convention Center
SCAN THIS FOR DEMO VIDEO
EM16TTK SEALER and TUNNEL on common frame
EP2028TK PNEUMATIC L-SEALER
EM1622TK ECONO SEALER ET1608 ECONO SHRINK TUNNEL
PD1109 025 25 8/31/11 4:16:04 PM
Steam valve The pressure-sensitive Flexis Steam valve can be applied
to most fexible food packaging, lidding flms or molded containers for the
purpose of steaming or cooking convenience food in a microwave or oven.
The valves hermetic seal initially protects the contents of the product
and becomes self venting during the cooking process, the company says.
Developed in partnership with Avery Dennison, the technology also regulates
a gradual temperature balance throughout the cooking process to maintain
food quality.
LPF Flexible Packaging, +31 594 695 656.
www.lpffp.nl
Etch-on label Name It
labeling solution allows customers to
personalize any beverage container
with their own mark without using a
writing instrument. The label features a
thin layer of paraffin wax sandwiched
between two layers of plastic to create
a writing window. A consumer simply
puts pressure on the label with their
fngernail to write a custom message.
By peeling back the top layer of the
labels plastic, the label can also be
erased, a task that can be performed
multiple times. The label offers a value-
added feature to products with minimal
increase in production costs, the
company claims.
R Solutions, 440-735-9280.
www.rsolutions.us
Two-compartment
container The Smiler two-
compartment PET container lets brand
owners market a single serving of two
compatible products, such as a drink
and a snack (milk and cookies perhaps),
within one portable package. The
proprietary Smiler technology enables
bottles/containers to be injection blow
molded into different shapes and sizes,
including those suitable for vending
machine dispensing. The larger, top
compartment holds the liquid, while the
bottom holds the snack item. Additionally,
both can be used for dry products
and/or non-food items. The bottom
compartment is created by drawing
the base upwards which forms a small
cavity into which a heat-sealed portion
cup can be inserted and held by friction.
Plastic Technologies Inc.,
419-867-5400.
www.plastictechnologies.com
PD1109 026 26 8/31/11 4:16:13 PM
At rst we set out to change your footprint,
Now, we just want it gone.
Eco-One the organic additive that enhances
biodegradation of plastic products in biologically
active landlls.
Superior Technology
Superior Service
Superior Value

EcoLogic owns, manufactures and markets Eco-One brand of additives. Independent ASTM D5511 tests,
representing biologically active landlls (not available in all areas), have shown 5-15% biodegradation within 30 days.
Proud members of National Recycling Coalition, Flexible Packaging Association
and Project Network Members of EPAs Methane-to-Markets Program.
www.ecologic-llc.com
630.869.0490
PD1109 027 27 8/31/11 4:16:31 PM
Go green
EPR laws are in place, higher levels of containers
are recovered.
Te report is based on original research and scores
companies on key performance areas in packaging.
Grades were based on information submitted by
companies who responded to the survey. Tose
who did not respond were scored based on publicly
available information.
Several leading beverage companies continue
to make steady incremental progress on source
reduction but have not demonstrated strong
commitments to using recycled contenta
signicant driver in reducing the environmental
impact of packaging, says Amy Galland, As You
Sows research director and author of the study.
Brewing companies were notably absent from
the survey participants. For instance, Anheuser-
Busch did not participate, but that company
received the second highest score in the 2008
edition of this report.
Key ndings
Several survey respondents said that in
developing a recycling program, they are most
likely to support programs that set recycling fees
paid by producers or importers that are included
in the price of the product and administered by
industry.
Te Coca-Cola Co., historically opposed to
container deposit systems, indicated it is now
neutral on a deposit system administered by an
independent third party, an apparent softening of
its position.
Other ndings include:
PepsiCo continues to have the highest use of
recycled PET, 10 percent across all product lines,
with a commitment to increase this percentage.
Coca-Cola was unable to meet a commitment to
use 10 percent rPET across product lines in 2010.
New Belgium Brewing Co. uses 50 percent
recycled glass in its 22-oz bottles.
Nestl Waters uses 50 percent rPET in its re-
source brand bottles, but lacks a company-wide
commitment for reprocessed PET or rPET.
Several major U.S. beverage brands would
support laws making producers nancially
responsible for collection and recycling of post-
consumer beverage packaging, according to a new
report assessing corporate progress on recycling
released by As You Sow, a shareholder advocacy
group that promotes environmental and social
corporate responsibility.
Te new report, Waste & Opportunity:
U.S. Beverage Container Recycling Scorecard
and Report, is As You Sows third review of the
beverage industry since 2006. Nestl Waters North
America received the highest ranking, followed
closely by PepsiCo, Te Coca-Cola Co. and Red
Bull. All four received a letter grade of B-.
Te report discusses new eorts by several
companies to promote Extended Producer
Responsibility (EPR) mandates to reverse lagging
U.S. bottle and can recycling rates.
Te major development since our last survey
has been the willingness of leading beverage
companies to consider new legislative mandates
requiring them to take responsibility for their post-
consumer packaging,
says Conrad MacKerron,
senior director of As You
Sows corporate social
responsibility program.
Many beverage and
consumer packaged
goods companies pay
fees in other countries to
nance recovery of their
packaging. Its signicant
that companies are nally
acknowledging the need
to take responsibility in
the U.S. as well.
Of the 224 billion
beverage containers sold
annually in the U.S.,
only 29 percent by weight are recycled; the rest are
landlled or incinerated, resulting in a waste of
natural resources. In Europe and Canada, where
Report shows leading bottlers SUPPORT CONTAINER RECYCLING mandates.
Beverage brands open
to EPR, study finds
t
e
n
t
a
n
/
i
S
t
o
c
k
p
h
o
t
o
.
c
o
m
PD1109 028 28 8/31/11 4:21:02 PM
sustainability
F
Eric DesRoberts is a project associate for GreenBlues
Sustainable Packaging Coalition (www.sustainablepackaging.org).
For additional information, email spcinfo@greenblue.org.
Findings from a series of recent O cial Food Control Authority Laboratory
reports coming out of Switzerland have raised concerns over mineral oil migra-
tion occurring in packaging made with recycled content. Te reports focused on
technical grade oils that are largely linked to inks used in newspapers entering the
recycling stream. Tis research builds on previous studies suggesting that techni-
cal grade mineral oils pose health concerns and are found to accummulate in the
liver, lymph nodes and heart valves when ingested. Tere are additional concerns
about aromatic mineral oils being carcinogenic, though their toxicology data
remains uncertain.
Mineral oils, which are by-products of crude oil renement, have a number of
packaging applications including inks, adhesives, plasticizers and protective coatings.
Tey may also be found in some recycled bers used in paperboard packaging.
Te Swiss reports documented instances where mineral oils leached from
packaging materials made of recycled content, specically grades containing
newsprint, into food. As one example of how mineral oils can contaminate recycled
bers, mineral oils are present in petroleum-based inks as the vehicle that carries
the pigments. Te inks are applied to a surface such as newsprint, where the oils
absorb, attach to pigments or attach to bers. Te newspaper is then purchased,
read and discarded into the recycling stream. Some mineral oils will be removed in
the recycling process. However, most of the oils absorbed into the bers are likely
to remain present in the reclaimed bers. Te recycled ber may then be used in
paperboard, a common material for food packaging, where migration can occur.
As advocates for increasing recycling rates and using recycled content, how do we
address this issue?
First, there is still uncertainty about direct and indirect contamination
sources. Direct contamination is common in baking, when mineral oils are used
for applications like conditioning pans, knives and cutting boards. Agricultural
practices also have direct applications for removing grain dust or fruit and vegetable
coatings. Regulations are in place to ensure that these applications meet food-grade
specications, but this cannot be ruled out as a potential contamination source.
Indirect contamination occurs through mechanisms like
migration. At this time, a knee-jerk reaction to limit
applications or look to alternatives could do more harm
than good. Te uncertainties around contaminant
sources and health impacts should, however, be grounds
for further research.
As far as immediate actions to mitigate mineral
oil exposure, current steps to reduce exposure include
using functional bags or barriers made of PP, PET or
aluminum layers. Additionally, some manufacturers are
reducing the amount of recycled content they are using or
shifting toward higher-grade recycled ber. Petroleum-based ink
alternatives are also being considered, though all of these options could add costs that
cut into prot margins.
On a broader level, this brings up the issue of transparency. Tere is an underlying
need for greater transparency about the use of chemicals throughout all stages of
production. Tis is not something specic to mineral oils or packaging, but it is
applicable across all industry sectors and supply chains.
Tere is a need for better communication of product inputs and the impacts of
these intended applications. Such information could lead to proactive solutions in
the future and avoid recalls while reducing a companys exposure to risk and supply
chains. Policy development should also be included in this discussion. Europe
appears to be at the forefront of regulation and policy development while the rest of
us continue to play catch up. Furthermore, universal policies could help to mitigate
frustration and confusion among industry members and help ensure product safety.
Mineral oil migration creates
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PD1109 029 29 8/31/11 4:21:56 PM
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Lisa McTigue Pierce, Editor
Forget meek. Superior Farms has gotten aggressive
in recent years promoting lamb as an easy-prep,
succulent meat worthy of gracing any table on any
night of the weekand equally deserving of more
space in retailers meat displays. According to the
2010 National Meat Case Study, lambs share of
linear feet in the self-service case was just 3 percent.
Turns out theres good reason for this, though.
Superior Farms conducted consumer research that
revealed many people dont buy lamb because
they think its di cult to prepare, a perception the
company is determined to dispel.
We conducted focus groups, which gave us a lot
of insight as to why shoppers are hesitant to pick
up lamb. About a third of shoppers have never even
tried it, says Gary Pfeier, vp of sales for Superior
Farms. So our avor experts and packaging experts
came together to give shoppers what they needa
fool-proof way to cook lamb.
In 2010, the company launched its
Mediterranean Grill line of pre-seasoned, pre-
marinated lamb products in case-ready skin-
packed trays designed to draw in new customers
(see our article at www.packagingdigest.com/
MediterraneanGrill).
Following up on that success this spring,
Superior Farms created standout stand-up pouches
of Superior Leg of Lamb pre-
seasoned boneless roasts vacuum-
sealed in cook-in bags. Te April 1
launch was timed to hit stores prior
to Easter, a lamb-friendly occasion,
along with in-store demonstrations
at many retail locations the week
before the holiday.
Priced at around $8 to $9 lb (about the same
as a regular boneless leg of lamb), these lamb legs
weigh approximately 5 lbs and are seasoned with
a classic lamb avor prolerosemary, garlic, salt
and pepperthat has mass appeal.
Each roast has a pop-up timer that indicates
when the internal temperature reaches 145-deg
F. Angela Gentry, Superior Farms director of
marketing, says, People can either cook to their
desired doneness or simply look to the pop-up
timer to know when the meal is ready.
Hitting the easy button
Lamb as a meal option is getting some outside
helpMarinated meats are becoming more
popular ,and lamb is increasing in visibility with
the help of television networks and magazines,
explains Gentrybut the package still does most of
the heavy lifting at point of purchase.
Tats why Superior Farms chose a high-gloss
outer bottom-gusseted bag and artfully decorated
it with appealing graphics, nutritional information
and easy-to-follow cooking instructions.
We felt it would be confusing to have any
instructions printed on the cook-in bag or on labels
that people would have to remove, Gentry says. A
second, outer bag with graphics seemed like a good
option that consumers would understandthere
are similar packages for turkey, too.
Created by graphic designer Amy Bishop of
Sacramento, CA (see her portfolio at https://
picasaweb.google.com/amyshareebishop), the
package showcases a photo of a cooked leg of lamb
that Gentry says is appetizing to help people
understand what the nished product will look
like. Also, prominently placed on the front, a
starburst touts the packages main attributes: Easy!
Cook in the bag with pop-up timer. A notch and
TEAR HERE instructions with a dotted line give
consumers a start on opening the pouch easily, too.
Produced by Packall Packaging Inc., the
pre-made pouch is a structure of 48-ga biaxially
oriented polyester laminated to white coextruded
polyethylene (PE). Te 3-mil PE layer is the
companys proprietary lm blend made on a 7-layer
extrusion line. Packall Packaging president Henry
Ciszewski declined to identify the resin supplier.
Total pouch thickness is 3.5 mil. Te corona-
treated polyester is reverse-printed on a Fischer
& Krecke 10-color gearless exographic press, of
which Superior Farms is using nine colors.
Superior Farms new leg of lamb pre-seasoned roast uses
HIGH-IMPACT PACKAGING to show consumers how simple the
meat is to prepare. An inner cook-in bag then delivers on
the fool-proof claim.
Lamb made easy
Roasts in cook-in bags are manually loaded into the
rotary vacuum sealer infeed.
An inspector visually checks bags for quality and seal
integrity.
PD1109 030 30 8/31/11 4:33:28 PM
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PD1109 031 31 9/2/11 1:24:45 PM
Now were cookin
If the outer pouch sells consumers on the product
for the rst time, it could be the inner cook-in bag
that gets them coming back time after time. Supplied
by Sealed Air, Cryovac Food Packaging, the Oven
Ease bag conveniently goes from refrigerator directly
to conventional ovens. Cooking in a bag keeps
the lamb leg juicy and tender because it retains its
moisture and marinates while it cooks, delivering the
promised foolproof results.
Superior Farms receives clear, pre-made 2.5-
mil bags in a 9x19-in. size. But Oven Ease is also
available in 2 mil for lighter products and 3 mil for
more abusive applications or bone-in meats; as well
as in widths from 8 to 16 in. A rollstock version of
Oven Ease is currently in the works, too.
Te multilayer nylon bag withstands
temperatures of 375-deg F for up to four hours, as
well as 10-deg F for meats to be frozen. Designed
with a sealant layer, Oven Ease can be sealed on
standard vacuum-packing equipmentso food
companies can oer value-added products like
marinated lamb without capital cost. And the
material provides a shelf life of 28-plus days.
Introduced in 2009, Oven Ease has quickly
gained attention for its advanced cook-in packaging
technology, even winning a Silver Award for
technical innovation from the Flexible Packaging
Associations 2011 Flexible Packaging Achievement
awards. Shawn Harris, marketing director for
Sealed Airs Cryovac fresh red meat products,
explains the innovation is in the barrier that Oven
Ease provides. Even though Superior Farms is using
an outer pouch to boost shelf appeal and provide
instructions, products packed in Oven Ease could
be sold without an outer pack.
Whats changed to allow a high-barrier cook-in bag
now? Advances in resins, says Don Smith, marketing
director for Sealed Airs Cryovac Oven Ease products
(he, too, declines to mention the resin supplier),
combined with the companys coextrusion process.
Aside from good barrier, the vacuum bag also
provides a level of food safety for Superior Farms
customers. Because the meat goes right from the outer
pouch into the oven, consumers dont need to touch
the uncooked product, which prevents potential cross-
contamination during at-home food prep. Superior
Farms does recommend that consumers cut a small slit
(about 1/8-in.) in the bag prior to cooking, though.
Smith says this is just a safeguard, to take pressure o
the seals as the bag inates during cooking; although
they have not had an issue with seals letting go.
In fact, the Oven Ease bag keeps meats
contained and hot in the package hours after being
removed from the oven, according to Cryovac. Tis
impressive holding time is a key selling feature for
foodservice operations.
Time matters in the consumers kitchen, too, but
in a slightly dierent way these days. Convenience
cooking is more than four minutes and a ding
in a microwave, Harris says. People want to be
engaged in what theyre doing. Tis allows the
person whos preparing the meal to feel that theyre
more engaged in the meal preparation.
Smith adds, Yet one of the great beauties of this
is (that) Oven Ease is going to allow a consumer to
come in at ve oclock, preheat the oven, put this
in the oven for an hour or whatever and go about
whatever else they have to do. Its unattended cook.
No clean up. No preparation.
Teres a nancial aspect, too, that appeals to todays
budget-conscious consumers. People dont really want
to experiment with a (high) retail ring and mess it
up, Harris says. People, especially younger people
Millennialswant to try dierent avors and dierent
cuts and they just arent experienced enough to do it on
their own. Tis enables them to do that.
Vacuum-sealed roasts are manually inserted into
pouches.
Theres a packaging app
I nnovat i on Day!
Br ai nst or mi ng
Vi r t ual Conc ept s
Rapi d
Pr ot ot ypi ng
Di gi t al Pr e-Pr ess
Best i n Cl ass
Met al Li t hogr aphy
Hi ghl y Dec or at i ve
Met al Cont ai ner s
Ver sat i l e Pl ast i c
Cont ai ner s
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Dec or at i ng
St ock St r uc t ur es,
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Spi c e Cont ai ner s
Cof f ee, Tea
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Sust ai nabi l i t y
Si ngl e Sour c e
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PD1109 032 32 9/2/11 1:24:51 PM
33 www.packagingdigest.com PACKAGING DIGEST SEPTEMBER 2011
Seasoned operations
Although the packaging material was relatively
new, the equipment to put a packaging line
together already existed. Superior Farms had all the
systems it needed for this project in house at both
its Dixon, CA, and Denver, CO, facilities.
Here are details of the Dixon operation, which
is a mix of manual, semi-automated and automated
processes:
Te process starts with vacuum tumbling to add
brine and seasoning to the legs of lamb. Product
is then transferred in totes to a station where two
workers manually apply netting by feeding the meat
through a stainless steel loading horn and cutting
o the netting with a knife. Te netting holds the
muscle groups together in a roast shape and helps
keep portions from getting dried out during cooking.
A pop-up timer from Volk Enterprises is manually
inserted, and the product moves to the next station.
Here, a worker manually loads a Cryovac Cook
Ease bag onto another horn, while another person
feeds the netted leg into the bag. Filled but open
bags are conveyed to the infeed of the rotary Cryovac
8600 vacuum sealing system, where a worker
positions the product so the top of the bag lays across
the bottom side of the impulse heat seal bar. Te
vacuum chamber closes down on the bag, removes all
the air from the bag and then applies heat to seal the
top of it, thus preserving the vacuum status. Speed
on this line is about 20 to 25 rpm but the system can
be run at about 35 cycles per min.
As sealed bags exit the vacuum chamber, they
are rinsed in a water bath to clean o any escaped
seasonings or marinade and then pass under an air
blower for drying as they are conveyed to the next
packing station.
Sealed bags are visually inspected by an operator
for quality, making sure the seal is intact and that no
marinade is on the outside of the bags. Te use or
freeze by date is added with a manual pricing gun to
at outer pouches as theyre queued up for lling.
Roasts are inserted into the outer retail pouch
by hand and placed in a semi-automatic Cryovac
BW 25 bag sealer so the package is sealed just
above the tear-open notch on the side of the
pouch. Te 25-in. bar is wide enough to seal two
pouches at once, with a seal time of 0.5 sec at 72
amps and 32 volts.
A worker manually packs the nished product
into erected cases in counts of four. Corrugated
cases are automatically sealed on an Akebono
strapping machine and then manually palletized.
To accommodate retailer slotting requirements,
Superior Farms builds pallets ve layers high, with
10 cases per layer for a total of 50 cases per pallet.
Te short edges of the cases face to the outside in
this conguration: three cases face out on Side 1;
two face out on Side 2; three face out on Side 3;
and two face out on Side 4.
Superior Farms has done dry rubbed legs of lamb
before, but Gentry says this was the rst product that
it is tumbling and also packing in a cook-in bag.
Tis packaging really wowed our customers,
Gentry says. With lamb prices high this spring,
buyers were timid to try something new. But we
had a few pilot programs that showed good results
that we are going to take with us when we re-pitch
the product for the winter holiday season. Well
also be oering both a 5 lb and a 2.5 lb leg in the
fall and winter to give people the option for either
bigger family gatherings or more intimate dinners.
Fischer & Krecke, Bobst Group, 973-226-8000.
www.fischer-krecke.com
Packall Packaging Inc., 800-965-3314.
www.packall.com
Sealed Air Corp., Cryovac Food Packaging,
800-391-5645. www.cryovac.com
Volk Enterprises, 770-663-5400.
www.volkenterprises.com
0 More information is available:
Outer pouches are sealed, two up, on a semi-automatic
bag sealer.
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PD1109 033 33 9/2/11 1:25:09 PM
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For 75 years, Goya Foods has served its core
Hispanic customers a continuing feast of foods
steeped in ethnic avors that convey a taste of
home. Its Latin cuisine has found a place-setting
on tables of non-Hispanics, too, enticed by
alluring photos of authentic ingredients and robust
seasonings shown on many of its packages.
Today, the company is the largest Hispanic-
owned food company in the U.S. and the
established leader of Latin Fusion foods and
beverages with more than 1,600 products on its
menu. Its avor palette draws on time-honored
recipes from a range of areas: the Caribbean,
Mexico, Spain, and Central and South America.
Goya has expanded over the decades and
now operates 15 plants throughout the U.S.,
the Caribbean and Europe (including Spain
birthplace of company founders Don Prudencio
Unanue and his wife, Carolina). Still privately
owned and managed by the Unanue family, Goya
now combines the best of old and new worlds;
traditional dishes with modern conveniences. One
example is the companys easy-to-prepare seasoned
rice kitswhich combine rice, seasonings and
vegetables in a single pouchfor stove-top or
microwave cooking.
Te kits are one of many dry products
produced at the companys Secaucus, NJ, facility.
Te 99,000-sq-ft plant packages all the companys
rice and our, and most of the beans, sold
worldwide. Handling more than 140 SKUs, this
location processes about 20,000 cases/day during
peak production.
Of 12 packaging lines, six
package beans in bags, three put
our in pouches and three ll
rice in pouches that are then placed into cartons.
During an early June visit, Packaging Digest
toured much of the plant, but for this article, well
concentrate on representative Bean Line No. 1,
Rice Line No. 1 and the combined automated
palletizing/unitizing operations.
Lines stay current
Goya continues to upgrade the plants
established packaging setups for better e ciency
and improved food safety processes. For example,
one of the bean lines was down the day of the visit
so system electronics could be updated.
Additional recent improvements include
automated palletizing; x-ray inspection for
metallized pouches of rice; and new Allen-Bradley
control panels from Rockwell Automation
throughout the plant with bilingual (English/
Spanish) capability. Language selection is as easy as
touching a ag icon on the HMI displays.
Some operational gains are related to material
rather than equipment. On the bean lines, a
switch to PP instead of PE lm makes a better
looking package on shelf and seals easier on
existing equipment. Company vp Joe Perez says,
PP also allows us to increase packing speeds by
about 12 percent.
Ingredients arrive in super sacks, a.k.a. exible
bulk containers. All products go through cleaning
and screening to remove any foreign materials.
From there, beans (for example) are vacuum
Goya Foods has made a series of improvements at its Secaucus, NJ, plant with DUAL GOALS
OF ADDING EFFICIENCY AND SAFETY to the packaging lines of its popular ethnic foods.
Old-world taste;
new-world convenience
Seasoned rice, for microwave or stove-top
cooking, is packed in a metallized pouch
that then goes into a paperboard carton.
Packages are bilingual.
d i
Dehydrated vegetables, rice and spices are lled into
metallized pouches.
PD1109 034 34 8/31/11 4:25:53 PM
conveyed into a hopper, which feeds
elevating buckets that deliver the
product to packaging lines on the
other side of the wall.
For Bean Line No. 1, beans are
fed to one of two Hayssen Ultima
ST vertical form/ll/seal machines.
Each system operates at about 70
bags/min on the 1-lb bag size to
hit the 140 bags/min target output.
For product safety and quality
control, a Safeline metal detector is
positioned between the weigh cup
and the vf/f/s.
Filled and sealed packages
from each bagger drop onto a belt
conveyor, which merges the two lines
into single le simply by adjusting
the speeds of the side-by-side
conveyors and releasing one bag at
a time. A single stream of bags then
passes under the printhead of a Linx
4900 inkjet printer (distributed by
Diagraph Corp.) where a production
code is added.
On their way to case packing, bags
enter a vibration table where sensors
check for dropped beans, which
means a bag has broken open. If so,
the bag is ejected so it doesnt get
case-packed. Dropped beans are fed
back into the hopper.
At this point, the line makes a 90-
deg turn so bags can be collated and
packed into cases. Cases are erected
and bottom sealed with p-s tape on a
system from Wexxar.
Cases hold 24 bags, four rows
of six. Within the Blueprint
Automation gravity case packer, a
vibrator helps settle the bags and
shuttles back and forth to create the
pack pattern as bags drop into the top
of the case.
Cases are top-sealed with p-s
tape by a Little David unit from
Loveshaw, receive alpha numerics
and a bar code from a Domino inkjet
coder and then ascend to an elevated
conveyor to reach the palletizing
station, which is about 250 feet away.
Rice cartons are automatically collated and side-loaded into cases.
Bags of beans are conveyed from dual
vf/f/s machines and single-led prior to
receiving an inkjet production code.
PD1109 035 35 8/31/11 4:26:22 PM
palletizers, moves lled pallets to the
Lantech Q300XT stretch wrapper
and then loads them onto trucks.
Goya tries to schedule production
with minimal changeovers, running
the same product and, if possible,
the same package size a full day or
more. It has devised a simple system
to communicate with the control
system at the palletizer station. As
cases leave the main packaging area,
Goya adds a strip of reective tape
to the last case of the run. When
seen by a downstream photoelectric
sensor, it triggers the line control
system for a SKU changeover at the
palletizers. At the end of the day, this
same system prompts a shutdown of
the line.
Rice kit packaging
One of Goyas most popular
products is the convenient-to-prepare
seasoned rice line, with 14 varieties
to choose from. Rice, seasonings and
dehydrated vegetables (when part
of the recipe) are packed together
in one bottom-gusseted pouch. Te
metallized structure provides enough
moisture barrier to deliver a three-year
shelf life.
On Rice Line No. 1, a KHS
Klckner-Bartelt CN110 horizontal
form/ll/seal machine uses a
volumetric ller for the free-owing
rice, an auger for the less-movable
spice and a slide gate for the
vegetables (the actual lling order
is veggies, rice, seasonings). As
pouches reach the end of the f/f/s
system, a picker uses vaccum cups
to transfer the vertical pouches to a
horizontal position on a conveyor,
creating a 90-deg right turn in the
line. At this point, pouches are
automatically checkweighed on a
Mettler Toledo unit. For quality
control, Goya also periodically
veries weights o ine.
From there, pouches make
another right turn for a short
distance before turning left into
the cartoning operation. Tis hitch
Tree top-level Von Gal
palletizers handle the production
of all 12 lines, with each palletizer
dedicated to four packaging
lines. Te conveyor system from
Simplimatic Automation was
designed so cases could be diverted
to a dierent palletizer if necessary
with a simple push of a button.
Tat action raises or lowers a section
of a conveyor so cases drop down
to a dierent exit conveyor, feeding
cases to an alternate palletizer (a
gate holds cases until the section
is in place and cases are ready to
move again). Tis gives the plant
exibility in downstream operations
to keep production moving, but the
stacked conveyor layout also saves
space in the crowded plant.
One operator handles the ow of
cases from all 12 lines into the three
Newer, better-looking PP bags also allow
Goya to boost lling speed by about 12
percent.
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PD1109 036 36 8/31/11 4:26:37 PM
in the line orients the pouches for
carton insertion and creates room on
both sides to operate and service the
cartoning equipment.
Pouches are staged in pockets
prior to carton insertion. Here a
Klckner-Bartelt pouch flattening
system uses a rotary pad to tamp
down the pouch so it loads easier
into the carton. The gusset on the
bottom of the pouch helps with
carton loading, too, by presenting
a wide, flat surface for the pusher
bar on the Schneider Packaging
Equipment Co. horizontal
cartoner.
After hot-melt sealing, cartons
turn right 90-deg to pass through a
Safeline x-ray system, which checks
the metallized pouches for foreign
contaminants. An air reject system
removes any suspect packages. Te
x-ray system is tested once an hour
to make sure its working (workers
simply put a contaminated box
through and verify that it has been
rejected).
Cartons are collated and packed
into regular slotted cases (RSC) on
a Schneider case erector/packer/
sealer before continuing on to their
designated palletizer.
On track for quality
Staying on top of quality
procedures, Goya is ramping up to
comply with new rules in the Food
Safety Modernization Act. QC
supervisor Carolina Rivera says they
are ready to track packaging materials.
Teyll use the same procedures already
in place for tracking raw products,
but this new safety requirement will
double their paperwork.
BluePrint Automation, 804-520-5400.
www.blueprintautomation.com
Diagraph Corp. (Linx), 636-300-2000.
www.diagraph.com
Domino North America,
847-244-2501
www.domino-printing.com
HayssenSandiacre, A Barry-Wehmiller
Co., 864-486-4000.
www.hayssen.com
KHS USA (Klckner-Bartelt),
941-359-4000.
www.khs.com
Lantech, 800-866-0322.
www.lantech.com
Loveshaw, 800-572-3434.
www.loveshaw.com
Mettler Toledo, 800-836-0836.
http://us.mt.com
Rockwell Automation, 414-382-2000.
www.rockwellautomation.com
Safeline, 813-889-9500.
http://us.mt.com
Schneider Packaging Equipment Co.,
315-676-3035.
www.schneiderequip.com
Simplimatic Automation,
800-294-2003.
www.simplimatic.com
Wexxar Packaging Inc.,
604-930-9300.
www.wexxar.com
Von Gal, 800-542-6570.
www.vongal.com
Cases holding 24 bags of beans are p-s
sealed before continuing on to palletizing.
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be exhibiting at the show.
PD1109 037 37 8/31/11 4:26:59 PM
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Gary Chiappetta, Contributing Writer
In todays crowded markets, dierentiation is
increasingly important to get noticed. When a
retail product has a proprietary formulation (such
as Coke) or patented design feature like Swifter,
its easier to capture market share, and in some
cases, create a whole new category. Tis form
of intellectual property not only gives brands
a market edge, it creates a barrier for me-too
products and, in some cases, with a design or
utility patent or trademark.
But there are plenty of everyday retail products
on the market without patentsubiquitous
products that have become commodities, such
as toilet paper, dish soap or even snack foods.
However, manufacturers have been reluctant to
invest marketing dollars in everyday items that are
considered value-driven commodity products (unless
of course the products are well-known brands).
For smaller manufacturers margins are thin
and volume drives their market. Tere are ways to
dierentiate here and raise the reservation price
point (what consumers are willing to pay) and
increase margins. But to accomplish this goal,
brand marketers and designers must learn to
partner with engineering and manufacturing at
earlier stages of concept development.
Tere needs to be more action and less talk
about working together. If you want to make
big things happen, there needs to be big change.
Te change may have to begin with a paradigm
shift in thinking, by designers, about the value of
capturing creative thinking from the production
and manufacturing teams.
Recently, I participated in a large creative
ideation session that included engineers and
production sta. Some of the most interesting idea
builds came from the non-creative participants.
Not because their ideas were better or they had
better insights. Teir ideas were valued before the
session even started (by just inviting them) and
their ideas brought new perspective that didnt
exist in prior developments. When a new product
development process moves beyond aimless design
and leverages cross functional collaboration, its
magic, and everyone wins.
From ideation to manufacturing
Marketing, design and manufacturing working
in parallel not only promotes a healthy discovery
process, but the partnership can lead to disruptive
design insights that create a unique point of
dierence. Working together eliminates the typical
stage gate process (and the project hand-o)
and lets ideas evolve quickly, with buy-in from
all stakeholders. Tat evolution allows the most
eective ideas to emerge, giving the entire team
condence and enthusiasm to push their limitations
with new achievable results.
One obvious benet of downstream
collaboration is reducing costly bottlenecks in
production; a critical time that is most likely
already compressed and strained. Losing a week
or two in timing a product launch could cost
a company millions in lost sales opportunities
not to mention costs associated with advertising
and promoting the launch. Getting a product to
market quicker also makes it more di cult for the
fast followers to steal market share or big brands
enough time to react. Te extra time on shelf will
help establish product leadership, capture a bigger
market share and increase overall sales.
Most packaging design projects face similar
di culties in regards to timing and budgets. So how
can these collaborative teams create better design
solutions that are more cost eective and do it in less
time? By allowing teams to work in an environment
that embraces iterative ideation, iterative design
and iterative prototyping. Changes in technology,
material specications, manufacturing and printing
have created complex challenges and diverse
opportunities. You need everyone on board to bring
these industry specic ideas and their experience
to the table and begin a process for co-creation.
Ideation sessions are perfect for that kind of thought
leadership to help ideas take shape.
After artists capture initial ideas on paper,
DESIGNING WITH THE END-IN-MIND reduces production bottlenecks,
speeds time-to-shelf and disrupts the market in the process.
Moving intelligence
upstream aids development
When designers and engineers work together closely in the initial stages, they can create a winning design for brand
owners.
PD1109 038 38 8/31/11 4:30:10 PM
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PD1109 039 39 8/31/11 4:30:16 PM
iterative design and rapid prototyping
takes the subjectivity out of each
concept and creates a concrete
framework for feedback. Te
feedback should include the original
ideation teams, brand and executive
teams and consumers. Tis can be
done concurrently with structural
packaging design, brand packaging
graphics and visual identity. Like the
changing images in a Kaleidoscope,
brand, color, form and function must
align synergistically to be eective
functionally and elicit an emotion.
Sometimes, the packaging innovation
itself is the catalyst for new revenue
streams and dierentiation.
Market makers and
trailblazers
Kraft Foods Oscar Mayer is a
great example of a food brand that
is considered a market maker. One
of the most powerful ways to bring
products to market faster is to create
your own sector through product
innovation or shelf disruption. Oscar
Mayers introduction of Lunchables
was the rst food product of the time
that incorporated moist and dry food
packaged together and was considered
revolutionary at the time. Te overall
concept combined with new packaging
technology created an immediate
barrier to entry for the competition.
Oscar Mayer was also one of the
Design agency Kaleidoscope is
putting its money where its mouth is
by investing to increase capabilities
within its innovation lab. The new
investment is not only in people and
processes, but new equipment that
includes a Digicon packaging nishing
system (for comps and marketing
samples) and computer numeric
controlled (CNC) milling machines for
structural prototyping.
Kaleidoscopes approach to
iterative design utilizing comps and
prototypes to evolve brand packaging
solutions has been a big hit with our
clients says Carrie Mapes, director of
strategy and account planning. Our
Kaleidoscope
doubles
prototyping
capability
A designer may
be tasked with
solving one
problem while
inherently and
unknowingly
creating another
for production.
A milling machine allows
Kaleidoscope to build structural
prototypes of packaging containers
to give clients a 3D preview of a
packaging design.
Presenting the packaging industrys most extensive line of
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technology and fresh ideas help you differentiate and reinvent your
brands. With closure systems from Fresh-Lock and Slide-Rite, your
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See us at
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Fax: (920) 738-1347 E-mail: fresh-lock@reynoldspkg.com
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PD1109 040 40 8/31/11 4:30:20 PM
rst to introduce lunchmeats and
cheeses that were vacuum-formed
and could be merchandised in the
refrigerated section of grocery stores.
Tis innovation took consumers out of
the deli counter and enabled quicker
and easier access to deli products
without waiting in line. Although
there have been many iterations of the
same concept from many other brand
manufacturers, Oscar Mayer is still the
recognized leader.
Other brands rely on eective
design communication and unique
structural packaging to capture
the attention of the consumer. For
example, Method was the rst to create
a structurally revolutionary bottle as
a primary container for its hand soap
line. Tis innovation has given birth to
many fast followers and copycats, but
Method will always own the equity as
the rst brand to leap from the ledge
of standard hand soap packaging.
Whether a brand is launching a
increased capabilities allow our clients
to go from imagining abstract thinking
to handling concrete ideas in 3D form.
Its a powerful tool.
Kaleidoscope wants clients to be
able to make better decisions based
on not just research, but trial and
error prove out. The new equipment
gives the agency the ability to provide
comps and short-run marketing
samples to its clients and other design
rms.
Gary Chiappetta, president and
managing partner, says the real
value in his rms approach to using
iterative prototyping as part of the
design process allows for innovation
through evolution. Rapid ideation,
rapid design and rapid prototyping
allow for ideas to develop quickly,
says Chiappetta. The idea is not
to diminish the strategic thinking
necessary for great design and
strategy to align, but to prove it out
over and over again, and do it within
budget and on time.
new packaging structure or a bold
new design for their products, it is
critical that ideation, design, pre-press
production and manufacturing be a
voice in the process from start to nish.
Without this 360-deg development
of the new product, the window for
launch and inevitably a products
competitive advantage get lost in a
process of working in silos, stage-gate
processes and downstream hand-os.
Moving beyond design intent
In many cases packaging designers
are creating design solutions that
align with a creative strategy while
maintaining brand standards and
packaging architecture. A designer is
tasked with solving one problem while
inherently and unknowingly creating
another for production. Designers
cannot be expected to be IT experts
just because they work on a computer,
as much as they cannot be expected
to be production experts just because
they are designers. Working with
downstream production specialists and
printers can help designers work with
the end in mind.
Another constraint for designers
is digital output as proof of concept.
Although there are many various
forms of output (such as inkjet,
Kaleidoscope uses its new Digicon
system to create marketing samples
of packaging ideas.
For 17 years, PakTech has served all major brands and processors with the most innovative technology in the
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packaging handle appeal and comfort to our state-of-the-art application machinery, we provide turn-key systems
that streamline operations, and create added value. Our green advantage? Low-waste 100% recyclable
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Perception of value begins with quality. Exceptional quality and
great brands go hand and hand. PakTech providing you the
ultimate packaging solution.
Handle & Applicator Solutions
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PD1109 041 41 8/31/11 4:30:38 PM
thermal and laser jet), none of these
technologies oers the ability to print
specialty inks or specialty stocks. And
as much as these print tools are great
for rapid prototyping of color, their
output is only an interpolation of a
print environment.
How can designers envision a
design alternative on foil stock using
transparent inks and custom color
matching? How would they even
know to ask unless they are trying
to mimic a look or eect that has
already been produced? Iterative color
imaging will help solve potential
downstream problems early on in the
design process and the process allows
happy accidents to occur that can
alter the design thinking. In addition,
consulting with separators early on
can be a great help in understanding
how print order, SWAP color and
custom colors need to be addressed to
meet printer specications.
Like brand packaging designers,
structural design teams also face
similar and at times, more complex
challenges. At the same time,
structural ID teams are expected to
be experienced in manufacturing and
deliver beyond design intent. Tis is
why engineering and prototyping are
a structural designers best friend (or
should at least be embraced).
Todays rapid prototyping tools
can help designers and manufacturers
quickly visualize 2D concepts in a
3D form. Tis is an important step
not only for design development, but
also for manufacturers to begin to
assess downstream challenges. Its a
great time to collaborate and meet the
challenges of the market, the goals of
the brand team, and to take market
share from competitors through
innovation. Prototyping should not
be looked at as an end-game process
for visualizing a nal design, but used
as an iterative tool to fail fast forward.
And do it early in the process.
When designers, marketers and
their manufacturing partners work
together, potential problems become
team challenges that are turned into
market-changing opportunities.
Gary Chiappetta, author of this
story, is president and managing partner
of Kaleidoscope, an integrated brand
design rm providing packaging design
solutions for consumer products goods
companies and retailers. To learn more,
visit www.thinkkaleidoscope.com.
Iterative prototyping
as part of the design
process allows for
innovation through
evolution.
Marketers and
designers must
LEARN TO PARTNER
with engineering
and manufacturing
at earlier stages
of concept
development.
PD1109 042 42 8/31/11 4:31:58 PM
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More packaging SUPPLIERS ARE OFFERING DESIGN AND OTHER CREATIVE SERVICES
to help brand owners maximize efciencies and to deliver innovation.
Jennifer Acevedo, Contributing Writer
Its no secret that packaging has become a critical
tool for brands to communicate eectively with
consumers. But with additional investment in
packaging comes the desire to streamline processes
and maximize nancial returns, all the while
maintaining a competitive edge on shelf.
Companies typically face challenges on three
key fronts, explains John Perrin, xpedx vp of
packaging. First, they want maximum visibility
and control of their total packaging costs. Second,
they want to reduce supply chain complexity. Tird,
they want to leverage best practices in package
design because of its large and growing impact on
sales, protability and cost reduction.
Recognizing the opportunity to partner more
closely with their customers, many packaging suppliers
are beginning to swim upstream in the package
development process, oering services like ideation,
brand strategy, and graphic and industrial design that
typically have been oered by standalone advertising
and marketing agencies.
Creativity and feasibility
One signicant benet of consolidating creative
and manufacturing teams under one roof is the
input of experts who understand the equipment on
which the package will ultimately run.
Over the years Ive seen thousands of designs
that were provided by rms whose expertise was not
packaging. Tey were frequently beautiful designs
that couldnt be manufactured or lled. Although
it sometimes provides a starting point, it wastes
time and costs money, explains Craig Sawicki, evp,
design and engineering, TricorBraun.
And when each stakeholder in the development
process has a seat at the table from the start, the
dreaded hand o from one discipline to the next
is eliminated. Tere are no surprises because each
department has been involved and heard from the
beginning.
Te steps in the classic product development
model sequence are dened the same way
organizations dene and divide their human capital
resources. Tere is an opportunity denition phase
led by sales and marketing, a creative phase led by
designers, a production phase led by engineering
and operations, and so forth, explains Scott Jost,
vp, innovation and design, Berlin Packaging.
Smooth transitions between these project
phases require that those involved in the hando
understand each others perspectives. But as we all
know from the proverbial disconnects between right-
and left-brain thinkers, thats easier said than done.
Add to this the fact that, under the traditional
process, development teams typically consist of not
just dierent functions but dierent rms, and it
becomes a challenge to achieve true alignment. But
when creative and manufacturing are on the same
team from the start, the processand the results
can be very dierent.
Combining design and engineering
Bringing designers and engineers together
allows them to focus on complementing each other
rather than their often diering perspectives on how
to approach problem solving, says Jost, adding that
the team can evaluate packaging solutions not only
in terms of their aesthetic appeal, but also in terms
of their functionality, manufacture-ability, and
impact on a brand owners supply chain. When
we show you a next-big-thing package structure,
we follow through by generating volumetrically-
correct models, photo-realistic renderings, and even
prototypes.
Finding the package
development sweet spot
These sketches from Berlin Packagings Studio One Eleven show the various
iterations of the design process from concept to nal packaging.
He who hesitates is lost,
and the rst to market
enjoys the lions share of
that market.
PD1109 043 43 8/31/11 9:57:04 AM

Creative ID: GIL 4 pg Gate
Right Fold
Client: O-I
Printed: 5-3-2011 2:35 PM
Printed Scale: None
Saved: 5-3-2011 2:34 PM
Operator: Piet Halberstadt
Project Manager: Thomas
Art Director: Parsons
Copywriter: Powers
Account Executive: Fullhart
Comments: PAGE 1
Publication:
Packaging Digest - June
Issue
Trim:
10.5 x 13.5
Bleed:
10.75 x 13.75
Safety:
10 x 13
Job Colors: 4CP
Fonts
Helvetica Neue (56
Italic; Type 1)
Trade Gothic (Medium;
Type 1)
Images
Ole_4C.tif (CMYK; 902
ppi; 172.6MB)
TrueFruits_4C.tif
(CMYK; 770 ppi;
98.3MB)
Linus_4C.tif (CMYK;
519 ppi; 64.8MB)
SPellegrino_4C.
tif (CMYK; 876 ppi;
152.7MB)
GoldBottle_4pg_
gate_4C.tif (CMYK;
254 ppi, 181 ppi;
152.7MB)
OI_GLASS_IS_
LIFE_4C.eps (455KB)
Inks
Cyan
Magenta
Yellow
Black
Job Information
Design Studio
200 Varick Street, 11th Floor
New York, NY 10014
212.366.3000
APPROVALS
Proofreader Date
Project Manager Date
Art Director Date
Copy Writer Date
Account Executive Date
Creative Director Date
Quality Control Date
OK for Release Date
Document Name: OIW COR P12809L pg1.indd 1
Stefano Agostini,
Chairman and CEO
of Sanpellegrino S.p.A.
Edson Auricchio,
CEO of
OL Foods
Nic Lecloux,
Co-Founder
of true fruits
Linus, age 2
Saddle-Stitched Center Spread
10
1
3
10.5
1
3
.
5
10.75
1
3
.
7
5
PD1106page28.indd 28 5/27/11 10:05:24 AM

Creative ID: GIL 4 pg Gate
Right Fold
Client: O-I
Printed: 5-3-2011 2:37 PM
Printed Scale: None
Saved: 4-28-2011 1:08 PM
Copywriter: Powers
Comments: PAGE 4
Publication:
Issue
Trim:
10.125 x 13.5
Bleed:
10.375 x 13.75
Safety:
9.625 x 13
Job Colors: 4CP
Fonts
Helvetica Neue (56
Italic, 55 Roman; Type
1)
Type 1)
Images
Bundaberg_4C.tif
(CMYK; 496 ppi;
82.9MB)
Chef_Gate 4C.tif
(CMYK; 498 ppi;
82.9MB)
GoldBottle_4pg_
gate_4C.tif (CMYK;
254 ppi, 181 ppi;
152.7MB)
OI_GLASS_IS_
LIFE_4C.eps (455KB)
Inks
Cyan
Magenta
Yellow
Black
Job Information
Design Studio
New York, NY 10014
212.366.3000
APPROVALS
Proofreader Date
Art Director Date
Copy Writer Date
OK for Release Date
Document Name: OIW COR P12809L pg4.indd 1
John McLean,
CEO of Bundaberg
Brewed Drinks
Chef Geir Skeie,
Bocuse dOr
World Champion
TM
9.625
1
3
10.125
1
3
.
5
10.375
1
3
.
7
5
PD1106page29B.indd 2 5/25/11 4:10:22 PM

Creative ID: GIL 4 page Gate
Right Fold
Client: O-I
Printed: 5-3-2011 4:56 PM
Printed Scale: None
Saved: 5-3-2011 4:56 PM
Copywriter: Powers
Comments: PAGES 2-3
Publication:
Issue
Trim:
20.375 x 13.5
Bleed:
20.625 x 13.75
Safety:
19.875 x 13
Job Colors: 4CP
Fonts
Helvetica Neue (55 Ro-
man, 56 Italic; Type 1)
Type 1)
Images
Cousteau_Gate_4C.
tif (CMYK; 267 ppi;
99.0MB)
GoldBottle_4pg_
gate_4C.tif (CMYK;
254 ppi, 181 ppi;
152.7MB)
OI_GLASS_IS_
LIFE_4C.eps (455KB)
Inks
Cyan
Magenta
Yellow
Black
Job Information
Design Studio
New York, NY 10014
212.366.3000
APPROVALS
Proofreader Date
Art Director Date
Copy Writer Date
OK for Release Date
Document Name: OIW COR P12809L pgs2-3.indd 1
People love glass, and for good reason. Chefs know it
protects avor and freshness. Moms know glass is healthy,
safe food packaging. Environmentalists know its 100%
recyclable, forever. And CEOs know glass says quality.
Honest, pure, iconic glass. Whats not to love?
GlassIsLife.com
Cline Cousteau,
Ocean Advocate,
Environmentalist
makers of beautiful, pure,
sustainable glass packaging
TM
Owens-Illinois, Inc.
19.875
1
3
20.375
1
3
.
5
20.625
1
3
.
7
5
F:10.25 F:10.125
PD1106page29.indd 29 5/27/11 10:04:58 AM

Creative ID: GIL 4 page Gate
Right Fold
Client: O-I
Printed: 5-3-2011 4:56 PM
Printed Scale: None
Saved: 5-3-2011 4:56 PM
Copywriter: Powers
Comments: PAGES 2-3
Publication:
Issue
Trim:
20.375 x 13.5
Bleed:
20.625 x 13.75
Safety:
19.875 x 13
Job Colors: 4CP
Fonts
Helvetica Neue (55 Ro-
man, 56 Italic; Type 1)
Type 1)
Images
Cousteau_Gate_4C.
tif (CMYK; 267 ppi;
99.0MB)
GoldBottle_4pg_
gate_4C.tif (CMYK;
254 ppi, 181 ppi;
152.7MB)
OI_GLASS_IS_
LIFE_4C.eps (455KB)
Inks
Cyan
Magenta
Yellow
Black
Job Information
Design Studio
New York, NY 10014
212.366.3000
APPROVALS
Proofreader Date
Art Director Date
Copy Writer Date
OK for Release Date
Document Name: OIW COR P12809L pgs2-3.indd 1
People love glass, and for good reason. Chefs know it
protects avor and freshness. Moms know glass is healthy,
safe food packaging. Environmentalists know its 100%
recyclable, forever. And CEOs know glass says quality.
Honest, pure, iconic glass. Whats not to love?
GlassIsLife.com
Cline Cousteau,
Ocean Advocate,
Environmentalist
makers of beautiful, pure,
sustainable glass packaging
TM
Owens-Illinois, Inc.
19.875
1
3
20.375
1
3
.
5
20.625
1
3
.
7
5
F:10.25 F:10.125
PD1106page29A.indd 1 5/26/11 3:12:52 PM
We need it yesterday
With lead times shrinking and competitors that
turn on a dime, speed to market is increasingly
critical to brand survival. Tat means manufacturers
need virtually instantaneous development and
execution of new packaging
projects to stay relevant.
Te days of analysis to
paralysis are long gone, says
Sawicki. He who hesitates is lost,
and the rst to market enjoys the
lions share of that market.
Tat means that every day,
every hour, that can be sliced
from the development timeline
can be quantied and assigned
value. Tere is no room for
waste, no time to translate the
concept as it passes through
each stakeholder in the process.
Anyone whos worked under
the old development model
knows that signicant time
must be set aside to convert agency concepts to
production-readiness, sometimes at the expense
of the character and personality of the underlying
design solution, other times meaning delayed or
missed launches, says Jost.
But when design, engineering, and manufacturing
are on the same page from the start, transitions
are much smoother or in some cases absent, so
translation errors and delays are, for the most part,
eliminated, shortening development timelines.
And tools like rapid prototyping allow not only
for the exploration of varying approaches during
the design phase, but also enable consumer testing,
renement and validation of the chosen concept.
Berry Plasticss Design Center, for example, can
reportedly take an idea from sketch to 3D model to
rapid prototype in 24 hours.
Te benet to the brand owner is the
ability to get world class design services that
provide provocative concepts while still having
the pragmatism to design products that can
be manufactured, lled and
marketed, says Sawicki.
With product lifecycles
growing shorter and brand
owners determined to delight
consumers with innovative
packaging, its critical that
brand owners and their
partners take a holistic view
of package development and
are willing to share risks and
rewards.
Collaboration is by far the
best way to avoid problems that
are sometimes inherent in custom
design. From the very beginning a
process that includes conceptual,
product development, engineering
and production from the packaging supplier, the
marketer, the plastic processor and even the retailer
will encompass all those diering perspectives to
avoid catastrophes, says Sawicki.
Berlin Packaging, Studio One Eleven Design,
312-822-0111. www.studio111design.com
Berry Plastics Design Center, 812-306-2000.
www.berryplastics.com
TricorBraun Design & Engineering, 630-758-4600.
http://design.tricorbraun.com
xpedx, a business of Intl. Paper,
513-965-2900. www.xpedx.com
Design studios that are part of a
packaging materials suppliers
services can develop containers to
meet a brand owners specications
while ensuring that the packages also
work in production.
T
R
I
C
O
R

B
R
A
U
N
TricorBrauns studio developed several styles of packaging for Maxides lawn and garden products to conveniently
handle different volumes of product and different ways of spraying the insecticides.
6
Six reasons to use
a suppliers design
services:
During a tour of xpedxs Chicago Package Design
Center, Tony Famiano, general manager of xpedx
Chicago operations, and Beth Powers, vp of sales for
Fidelity Container, a wholly owned business of xpedx,
ticked off the many ways customers can benet
from using in-house design services of a packaging
distributor.
1. Me rst: Augmenting your staff with qualied
professionals will shorten the lead time of project
completion so products get to market as quickly as
possible.
2. Free to choose: Using a substrate-neutral
distributor gives packagers access to a world of
manufacturers so they can pick from all types and
styles of options. This design exibility and freedom
helps ensure that the nal design will use the right
material for the job, not just what the supplier wants
to sell.
3. Been there, done that: Distributors can tap into
their breadth of experience across diverse markets
and technologies to bring in ideas and know-how
from outside a customers regular neighborhood.
Cross-market pollination can be a time- and cost-
effective way to create a game-changer in your
category.
4. Whats in your closet? Just-in-time delivery
from a reliable source can help packagers control the
costs and headaches of packaging materials inventory
management.
5. All together now: Distributors may save
customers money by combining print runs/
manufacturing orders with other clients to reach
economies of scale for niche or lower-volume products
such as limited editions.
6. Can you hear me now? Minimizing the
number of suppliers involved in a project
simplies communications and helps cut down on
misunderstandings. This usually means a better
likelihood that itll be right the rst time.
Smooth transitions
between these project
phases require that
those involved in the
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T
A robotic palletizer at The Scotts Co. simultaneously PALLETIZES 50- TO 60-LB SHIPPERS containing
bags of bird seed packaged on three vertical form/ll/seal machines.
Jack Mans, Plant Operations Editor
Te Scotts Co. LLC plant in Reynolds, IN,
produces more than 150 SKUs of bird seed
products. Last September, the plant installed
a robotic palletizing system to handle product
from three vertical form/ll/seal bag lling lines
simultaneously. Te machines produce 3- to 18-lb
bags of bird seed that are manually placed into
shippers that weigh up to 60 lb.
Scotts installed a four-axis Model MPL160
Master Palletizing robot from Motoman Inc.
that is specially designed for palletizing operations.
We talked to several robot companies, says
Scotts maintenance planner James Staples, but we
had worked with Motoman before, and we really
liked them.
Sophisticated programming
Te MPL 160 features MotoSim
EG-VRC o-line programming software
with virtual robot control that simplies
programming and simulation. It also
includes MotoPallet EG PC-based
palletizing software that works with
MotoSim EG simulation software to
simplify o-line creation of palletizing
patterns.
Motomans control system makes
programming complex pallet patterns quick and easy.
With just a few simple menu selections, operators
can choose from one of more than 200 predesigned
palletizing patterns. Patterns are independent of box
sizes and adjust automatically to changing
box and pallet size.
Te lled shippers pass through
Model Eagle T200 carton tapers from
Berran Industrial Group Inc. Te taper
features top and side drive belts and a
top motor that enables it to handle the
heavy boxes that Scotts runs. A sensor
from Keyence Corp. of America
checks the tops and bottoms of the
shippers to make sure they are secure.
Heavy-duty palletizing
Four-axis robot is
specially designed for
palletizing operations.
A retractable fork-style
gripper picks up four
shippers at a time.
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PD1109 048 48 8/31/11 4:36:43 PM
Te shippers then travel past a
Model Duro 4.5 print-and-apply,
corner-wrap, pressure-sensitive labeler
from In-Line Labeling Equipment
Inc. Te label is printed by a Sato
America Inc. Model M8485 thermal
transfer printer. It is then peeled from
the backing and placed onto a custom
vacuum pad that holds it in place.
When the PLC signals the presence
of a product, an arm swings in, picks
the label from the pad and applies it to
the corner of the shipper. Two brushes,
one standard and one pneumatic,
complete the labeling process. To
ensure the proper application of the
label, the labeler features a through-
beam photo eye for label gap detection
and a photoelectric eye for product
detection.
A worker in the QC o ce inputs
the data that is printed on the labels,
and it is then retained in memory,
says Shane Harbolp, head packaging
technician at Packaging Systems,
which distributes the In-Line labelers.
Te next time Scotts runs this
product, the worker only has to select
the item being run, and the data will
be sent to the labeler automatically.
Systems integrator
for project
Scotts worked with systems
integrator CIM Systems Inc. to design
and implement the project. We had
four contractors come in to review the
project, says Staples. Space was very
limited and there is a low ceiling at
one point, so we were concerned about
getting the cases from the baggers up to
the palletizer.
We also wanted to be able to
expand in the future, so that had to
be included in our planning. After
reviewing the proposals, we liked CIMs
ideas the best, and their o ce was close
to us, which was convenient.
CIMS supplied the conveyors
from the vf/f/s machines, the robot,
the empty and full pallet-handling
systems, the pallet dispenser and all of
the controls.
It was a challenge to come up
with a spot where we could palletize
without interfering with truck tra c,
and there was very little clearance
between the conveyors and the ceiling
beam, says CIM Systems president
Dave Fox.
He added, We presented a design
where the shippers are elevated to a
height that allows fork trucks and
other tra c to pass under the infeed
conveyors. Rather than adding cost
and using valuable oor space to lower
the shippers back to normal conveyor
height, our concept keeps them at 10
ft above the oor. Te Motoman MPL
160 robot has a large vertical reach
allowing us to reach well below the
base of the robot, while palletizing at a
normal level, Fox says. Te end result
solved all of the major obstacles.
Te cell is controlled by an
Allen-Bradley PLC from Rockwell
Automation. Te primary operator
interface is a PanelView HMI, which is
used to start and stop the equipment,
select which product is running on
each conveyor, and display equipment
status and alarms.
Te conveyors are controlled by
variable frequency drives for speed and
acceleration control. Te transfer cart
that handles full and empty pallets
is controlled by a variable frequency
drive (VFD) and uses a laser feedback
system to monitor its position on
oor mounted rails. All of the major
The robot automatically picks up a slip
sheet from a stack and places it between
layers as the load on each pallet is
assembled.
PD1109 049 49 9/6/11 1:54:18 PM
controls equipment communicates via
Ethernet.
Shippers from the three bag-lling
machines travel up individual inclined
conveyors to three separate overhead
infeed conveyors. A sensor at the top
of each inclined conveyor counts the
shippers as they are pushed at a right
angle onto the conveyors that the
robot picks from.
Once an entire row has been
assembled, the robot uses a
pneumatic, retractable fork-style
gripper that was designed and
supplied by CIM Systems to remove a
row of cases (typically three to ve).
Fork-style grippers
Te robot is equipped with a
retractable fork-style gripper that
was designed and supplied by CIM
Systems to remove a row of cases.
We originally wanted to use
vacuum grippers, says Fox, but
some of the boxes were too heavy.
Te forks on this gripper slide
between the rollers on the infeed
conveyor, and a clamp descends to
hold the top of a row of cases as they
are transferred.
Te robot picks sequentially from
each of the three infeed conveyors,
and sensors on each line trigger the
robot to pick up the shippers. Pallets
on three pallet-build conveyors
correspond to the infeed conveyors,
and the robot, which stacks from all
three lines simultaneously, picks up
multiple shippers at a time and places
them onto the corresponding pallet.
As the load on each pallet is
assembled, the robot automatically
picks up a slip sheet from a stack and
places it between layers.
Once a full pallet has been built, a
transfer cart removes the pallet from
the build conveyor, replaces it with
an empty pallet that it has picked up
from an automatic pallet dispenser
and transports the nished pallet to a
stretch wrapper.
Te transfer cart has two on-board
stations: one for the full pallet and
one for an empty pallet.
After loading the stretch wrapper,
the transfer cart transfers the empty
pallet onto the two-station transfer
cart so it can be loaded onto the
pallet-build conveyor the next time it
exchanges pallets.
Te system has worked well, but
we had to do some tweaking, says
Staples. Te rst slip sheets we used
were too thin, and the robot couldnt
handle them. A thicker slip sheet
solved that problem.
Automatic stretch wrapper
Filled pallets are transferred to
a Wulftec Intl. Model WCA 150
automatic stretch wrapper, which is
located in the warehouse. Tis was a
complication, according to Staples,
because the conveyor transporting the
pallet into the wrapper passes through a
re wall, and a re door had to be able to
drop to the oor in case of a re.
Te plant designed the pallet
conveyor with a fold-out section
where it passed through the wall so the
Top-and-bottom taper is designed to
handle heavy cases.
Main
PLC
Cabinet
Track
Cart
Motoman
MPL300 Robot
Pallet
Dispenser
Fire Door
Flow
Slip
Sheets
10
Motoman
Cabinet
Drawing Coutesy of
CIM Systems Inc.
317-773-5600
www.cimrobotics.com
P11
Wulftec
WCA
Stretch
Wrapper
Control
Panel
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PD1109 050 50 8/31/11 4:37:16 PM
conveyor could be moved out of the
way of the door.
Once the pallet is on the wrapper
turntable, it begins to revolve and
picks up the plastic lm, which is
located on a roll. Te lm passes
through a guide and the wrapping
starts at the bottom of the pallet. Te
guide moves upward as the pallet
revolves to apply the plastic lm to
the entire pallet of product.
Te guide then reverses and moves
downward to apply another layer of
plastic. When the guide reaches the
bottom of the pallet, a cutter moves
in and cuts the lm loose, after which
the pallet discharges.
Te wrapped pallet passes by a
Duro print-and-apply labeler identical
to the units used to label the shippers.
A sensor from Keyence Corp. of
America reads the bar code on the
labels applied to the shippers on the
pallet, and the labeler prints the same
label, after which an arm swings in
and applies it to the corner of the
pallet.
Te tapers, labelers and the
Wulftec stretch wrapper were supplied
by Packaging Systems, which is a
distributor for these components.
All of the controls on the
equipment on this line were supplied
by Rockwell Automation.
Te palletizer is doing exactly
what we want it to do, says Staples.
Weve been able to divert one
person from each line, and we run
three shifts a day, so weve been able
to remove nine people per day from
the palletizing operation. Best of all,
weve eliminated the heavy lifting of
the 60-lb boxes and minimized the
chance of injuries.
Motoman was good to work
with and provided excellent service,
Staples continues. In one case,
the wrist on the robot broke, and
Motoman replaced it in two days.
Tey actually took one o of an
existing machine. We call the robot
MOE for Motoman.
Berran Industrial Group Inc.,
330-673-4722. www.berran.com
CIM Systems Inc., 317-773-5600.
www.cimrobotics.com
In-Line Labeling Equipment Inc.,
800-465-4630. www.labeling.net
Keyence Corp. of America,
888-539-3623. www.keyence.com
Motoman Inc., 937-847-3200.
www.motoman.com
Packaging Systems,
800-647-2706.
www.packaging-systems.com
Rockwell Automation,
414-382-2000.
www.rockwellautomation.com
Sato America Inc., 704-644-1650.
www.satoamerica.com
Wulftec Intl., 877-985-3832.
www.wulftec.com
Shippers from the three vf/f/s machines
travel up individual inclined conveyors to
the overhead palletizing robot.
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Linda Casey, Senior Editor
For more than 40 years, 3M Scotchlok electrical
connectors have been used for everything from
audio equipment installations to model train
wiring. While the 403 SKU product lines history
oers 3M strong brand equity, it also came with
outdated packaginga paperboard carton that
crushed easily, did not show the product inside
and was imprinted with hard-to-read information
that sometimes led shoppers to buy the wrong
connectors.
3M embarked on a year-long update project that
resulted in a fresh look and a new labeling system at
the companys New Ulm, MN, plant. Jessica Clark,
packaging engineer for 3M, credits the tenacity of
Lisa Tuer, marketing manager for the Scotchlok
connector line, for recognizing that a new package
would reinvigorate the product lines sales. It
was at her request that this package redesign
happened, Clark remarks. She was the catalyst to
getting this o the ground and all the way through
implementation.
Connecting with partners
To power the project, Clark and Tuer
brought in both internal and external partners.
I solicited support from our sourcing team in St.
Paul, Clark recalls. Te team sent out a request
to a variety of our core suppliersour strategic
suppliers.
Tese suppliers came back with a range of
package components ideas. We had presented
some other wide-mouthed jar options in addition
to an oval canister, recalls John Jones, senior
account executive at Berlin Packaging, one of 3Ms
strategic partners and supplier of the nal package.
After evaluating what was most important to
us, we determined it was speed to market with a
new design change, Clark explains. Although we
originally looked at a more custom design, we went
the alternative route to look at stock containers.
Te oval canister chosen was a 4-in. high
transparent PP stock package thats commonly
used to pack baby wipes. Te decision to not
use a container already in use in the electrical or
hardware markets was deliberate.
It was interesting to see how, even without labels,
we were able to set the stock packages on a table
and identify the product, Clark recalls. Te oval
canister supplied by Berlin Packaging is used out in
the marketplace but not for our electrical industry. Is it
unique? No, its not, but its also not a me-too for our
industry.
Not only was the package a dierentiator for 3M
in the electrical industry, it also had a large label
panel area that enabled easy display of necessary
technical information. Clark explains, Te other
thing is we required a certain amount of area to
print legal requirements on our primary selling unit
package. We also wanted to minimize the amount of
packaging components that were required to support
the 403 products.
Custom complements
Te transparent container is supplied by Berlin
Packagings Plastics Group, and is part of HTI Plastics
Putting stock
in custom
packaging
Dual approaches to both package component selection
and labeling help 3M SPEED TO MARKET REFRESHED
PACKAGING for its 400-plus SKU Scotchlok electrical
component product line.
A stock oval container
gives 3M product
differentiation in the
electrical market.
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PD1109 052 52 8/31/11 4:39:42 PM
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proprietary line of the Option Pak ovals,
which can be made using a range of
resins including HDPE, PP, claried PP,
LDPE and PCR. Te specic claried
PP resin chosen for 3M Scotchloks
canister is Ineos RO1C-00 from Ineos
Olens & Polymers. Tis resin/mold
combination, says Jones, can be run on
various blow molding machines.
For the closure, Berlin and HTI
Plastics took a dierent route. Instead of
using a purely stock item, they chose to
custom design a lid with a new orice
and logo insert. Te lid, which also is
made from PP, is molded on a 250-ton
KraussMaei Technologies GmbH
machine. Te custom closures are made
from a PP resin with added colorants.
Te lid color is based on that
product within the canister, Clark
explains. Red is an indicator for
a particular wire gauge size, as is
yellow and blue. So the red, blue and
yellow lids coincide with an industry
standard for wire gauge size.
One label, hundreds of SKUs
Te common-overlaid-with-custom
theme extends to product labeling for
Scotchloks new packaging.
Our graphic design team at Proof
Advertising in collaboration with 3M
marketing came with the concept of
the preprint label, with everything
thats in color preprinted and most
of the black text to be printed on
demand, Clark remarks.
How to design and print wasnt the
only challenge faced when decorating
the oval canister. WS Packaging
worked with us to come up with a
specic label structure that would
adhere to such a sharp curve in the
bottle and also worked with us to
ensure that the print-on-demand
information that we had to apply onto
the label would be able to withstand
just what these bottles might see out
on a job site, Clark explains. If
you can imagine, these packages are
going into large building installations,
into closets, basements, attics and
everywhere in-between. Tese may not
be the cleanest locations, so we wanted
to ensure that the print stays legible.
Tey chose to print on MACtac
AC9002 60-lb platinum, high-bright
white, semi-gloss paper facestock with
an Acpo thermal-transfer polyester
overlaminate that adds durability. Te
print areas contain all color and some
black elements, with 98 percent of the
black text printed on demand at the
3M packaging facility.
Data printed on-demand
We have an internal IT system to
3M that does all the print-on-demand
that controls all of the variable
data, Clark remarks. A colleague
of mine, senior packaging engineer
Ryann Roberts, is our labeling and
equipment technical expert, and
was in control of all of the design
and tests for the development and
implementation of the label.
We worked with our 3M IT systems
team to run many tests to ensure that the
variable data was properly aligned, that
it downloaded to our plant and that it
was able to talk with the new printer that
we purchased, she adds. We ran many
trials to ensure that all three of those
thingsthe ribbon, the label material
and the print-on-demand lesall
work seamlessly. Ryann also controlled
It (the embossed
decoration on the
closure) was such a
small thing, but what
a huge impact it has
for 3M as a company
and a brand.
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Global Sourcing | Equipment & Service | Speed to Market | Packaging Design
PD1109 054 54 8/31/11 4:40:00 PM
the machine selection, the labeling
structural specications and the ribbon
specication.
With the help of Chris Sawicki
and Rick Isbell, Ryann installed a
wraparound label print-and-apply station
supplied by TEAM Systems Inc. Te
labeling station houses a Label-Aire
Inline 5100 labeling system, which is
a stainless steel cabinet with a variable
frequency drive conveyor and metering
wheel. It can be outtted with the
range of Label-Aire new generation
3100/3000 series applicators for
wipe-on, air-blow or tamp-blow
label placement. 3M chose the
Label-Aire Model 3138-N Merge
Printer Applicator. Te wipe-on label
applicator has a label loop box for the
storage of preprinted labels, automatic
speed following to accommodate
changes in product delivery speed,
advanced user-congurable I/O
connectivity and a digital display to
allow remote operator control.
Te system is used with a resin
thermal-transfer ribbon, for abrasion
resistance. Clark explains, We went
with resin because it basically burns
the image into the label and that was
important for our end user. We knew
it was important for our end user
whether they knew it or not.
Abrasion resistance often is cited
as an important characteristic of
electronic components labeling because
of sometimes harsh environments and
handling that these packages endure.
Customization offers
branding, security
Te robust construction of the
packaging is one of Clarks favorite
features, especially the embossed
decoration on the closures. It was
such a small thing, but what a huge
impact it has for 3M as a company
and a brand, she exclaims. After
the product has been consumed, our
brand is still out therewhether this
canister gets relled with more 3M
Scotchlok terminals and connectors
or buttons, screws, whatever.
In working with Berlin
Packaging, we were also able to
modify the internal design punch-
outs to be 100 percent coverage
at point of purchase, Clark adds.
Terefore the customer would have
to punch a minimum of one out to
get to the product. Teft prevention
was not initially on the list as a
must-have feature, but I was able
to persuade the business team that
it was a value-add to the product
design. And it has been well received
in the market.
Te redesigned package ensures
that 3M Scotchlok customers get the
full value of their purchases while
3M enjoys packaging operation
e ciencies in addition to branding
and marketing benets.
A custom-designed lid provided both
branding (with an embossed logo on the
top) and security (with a inner knock-out
that prevents product pilfering).
Acpo Ltd, 800-793-8273.
www.acpo.com
Berlin Packaging LLC, 800-723-7546.
www.berlinpackaging.com
HTI Plastics, 800-824-0607.
www.htiplastic.com
Ineos Olefins & Polymers USA,
281-535-6600. www.ineos-op.com
KraussMaffei Technologies GmbH,
+49 898 8990.
www.kraussmaffei.com
Label-Aire Inc., 714-449-5155.
www.label-aire.com
MACtac, 866-262-2822.
www.mactac.com
Proof Advertising, 512-345-6658.
www.proof-advertising.com
TEAM (Technology, Equipment,
Applications, Materials) Systems Inc.,
651-450-0100. www.teamsysinc.com
WS Packaging Group Inc.,
800-818-5481. www.wspackaging.com
Zebra Technologies Corp.,
847-634-6700. www.zebra.com
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Two ROBOTS PALLETIZE CONTAINERS of swimming pool
chemicals ranging in size from 2-lb pails to 275-lb drums.
Jack Mans, Plant Operations Editor
As one of Americas largest producers of granular
calcium hydrochlorite for swimming pools and
spas, Arch Chemicals plant in Charlestown, TN,
faced a unique challenge: how to improve speed,
e ciency and ergonomic safety when palletizing
a range of containers rolling down two lines. Arch
Chemicals Inc. is a global biocides company with
more than $1 billion in annual sales, and its HTH
and related brands of pool treatments are among
the most popular in the world.
Te old mechanical system, which could handle
only one container at a time, just wasnt cutting it,
says Dave Sauer, the plants process control engineer.
In addition, vacuum pick-up, which is the process
used in many robotic palletizing operations, could
not handle its various-sized containers, which range
from 2-lb pails to 275-lb drums.
Tats when Arch Chemicals looked to
Automation Project Group (APG) for a
solution. We had worked with APG in the
past, says Sauer. We chose them this time for
their end-of-arm tooling for the robots. Te old
mechanical system could handle a maximum of
nine pails per minute. Our test this time was
based on how fast our lling equipment could
run, which gave us how many items we needed
to palletize every minute.
Two robotic palletizing cells
Arch Chemicals has two similar lines, so
APG installed two robotic palletizing cells, each
incorporating an ABB Inc. model IRB 660 robot.
We have an ABB robot in the plant, so we were
pleased that APG suggested the ABB units for the
new installation, says Sauer. Specically designed
for palletizing operations, the IRB 660 industrial
palletizing robot combines superior speed and reach
with high payload capacity of up to 550 lb, making
it ideal for palletizing Arch Chemicals range of
package sizes.
Te IRB 660 robot has integrated power,
signals, eld bus and air routed to the wrist, and
its IP67 protection rating makes it robust in harsh
environments.
Containers are delivered into each of the robot
cells on a dual-chain conveyor, where they are
picked up by the robot and placed onto a pallet.
Te larger containers are too heavy to use vacuum
grippers, so the robots are equipped with a strong
end-of-arm gripper designed by APG.
Te gripper consists of a bottom metal plate and a
pair of vertical forks with a stationary back plate. Te
robot slides the bottom plate beneath the container
after which the forks descends around the container
and pull it against the back plate. Te robot arm then
transfers the container to the pallet and the procedure
is reversed. Te bottom plate actually supports the
load, while the forks and back plate stabilize it and
keep it from shifting during transport.
Depending on the size of containers being run,
the containers are stacked from four to ve layers
high on the pallets.
In production, a container enters the palletizing
cell and travels to the lifting position. It is then
raised as described. Te next container moves into
position, and the robot lowers the upper container
Robots improve
efficiency
and speed
Arch Chemicals has two similar lines, so it installed two
robotic palletizing cells, each incorporating an ABB robot.
Robots are equipped with robust
end-of-arm grippers designed by APG.
PD1109 056 56 8/31/11 4:42:34 PM
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PD1109 057 57 8/31/11 4:42:47 PM
In an industrial robotic palletizing
operation, the robotic arm provides the
muscle, but the end effectors or grippers
provide the dexterity. Much in the way
that a baseball pitchers arm provides the
velocity on a ball, but his ngers impart the
movement, the grippers are the devices
that actually pick up the packages. While
there are numerous gripper designs, they
generally fall into three main categories:
vacuum, claws and clamps.
Vacuum is the simplest and probably
the most widely used gripper technology. It
is typically used in applications where the
package is not too heavy or too irregular
for the vacuum to be maintained. In this
process, a number of cups are present
to distribute the load over the top of the
package, but the vacuum is applied only
to the cups that are actually contacting
the package. Thus, vacuum grippers can
handle a range of package sizes without
requiring changes.
Claws generally consist of steel ngers
that pass under the package, while a pad
descends on top of the package to hold it
in place. The system may have one set of
ngers that enter from one side or there
may be two sets of ngersone from each
side. The installation at the Scotts bird
seed plant described on page 48 of this
issue, uses a single set of ngers to pick
up cases of bird seed. Fingers were
selected for this application because
the cases can weigh up to 60 lb.
Clamp systems consist of vertical
plates that are pushed in against the
sides of cases. They generally have
short ngers or hooks at the bottom
that help support the cases, and they
may have rubber pads on the sides
to provide additional friction.
Photos of the grippers included here
were supplied by ABB Inc.
Grippers are the key
Vacuum
Claw
Clamp
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PD1109 058 58 8/31/11 4:42:50 PM
onto the lower one, and then lifts
them both into the air. Tis process
continues until a complete stack of
containers is assembled, after which
the stack is shifted to the pallet.
Grippers make adjustments
One of the keys to this operation
is that the grippers adjust themselves
to handle the dierent size containers
automatically using what AGP calls
its servoless servo automatic setup
system. To initiate a change, the
operator selects the product he is
going to run on the specic robot
cells HMI. Te controls then adjust
the spacing of the forks relative to
the vertical back plate so that they t
tightly around the containers.
In this procedure, the controls
unlock the forks, after which the robot
arm pushes them against a bar set into
side of the cell until the forks move
back to a zero position. Te robot arm
then moves the forks around behind
this bar and pulls them open to the
proper spacing for the container that is
going to be run. Te controls then lock
the forks into this position.
As part of the selection process,
the controls also automatically set the
number of containers assembled in
each stack and the number of stacks to
be placed on the pallet. Te robots are
equipped with photo eyes and sensors
that can even discern a wrong pallet.
Te real challenge for APG was
that space at the end of the two lines
was at a premium, Sauer explains.
APG did a great job with its designs.
With our earlier mechanical system,
we could not handle the small
containers; now we can do all sizes.
Te robotic arm sits atop a 6-ft
pedestal that gives it greater reach for
its simple-yet-articulate end-of-arm
tooling, says Sauer.
Calcium hydrochloride makes
for a pretty corrosive environment,
which means regular equipment
purging. However, the ABB robotic
was su ciently robust to handle this
di cult environment.
Besides improving productivity, the
APG solution also removed a major
ergonomic challenge. With the earlier
mechanical system, Arch had to hand-
stack at least 15 percent of the pallets.
Now, all of the containers are
robotically palletized. Mostly the
system goes 24/7, though naturally we
inspect it weekly and shut it down for
one or two days for regularly scheduled
maintenance, Sauer says. Tere was a
lot of skepticism at rst but now most
of our production people really like the
system.
ABB has been here to the plant
for preventative maintenance, and
we have been very pleased with their
service and expertise. And the APG
robotic palletizing system has helped
us reduce repetitive strain injuries
and increase safety. We feel we have a
long-term solution.
The APG robotic
palletizing system
has helped us
reduce repetitive
strain injuries and
increase safety.
We feel we have a
long-term solution.
ABB Inc., 248-391-9000. www.abb.com/robotics
Automation Project Group, 519-746-2537. www.automationprojectgroup.com
PD1109 059 59 8/31/11 4:43:17 PM
A
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Brewerys FOCUS ON QUALITY drives the company to nd an inspection system that
makes sure customers receive a full can of beer each and every time.
At Matt Brewing Co., an uncompromising com-
mitment to quality is the hallmark of the company
and its award-winning Saranac beers. It was this
focus that led it to look for new technology that
would assure every customer received a full can
of beer every time. It searched for an alternative
to conventional gamma ll-level inspection and,
after careful consideration, selected the CM9400
Canweigh checkweigher from Mettler-Toledo
Hi-Speed.
We were looking for a new ll-level monitor
for our canning line, but we were concerned about
the reliability of many of the systems we saw, says
Jim Kuhr, director of brewery operations at Matt
Brewing Co. We visited Mettler-Toledo Hi-
Speed to look at the case weigher we had already
committed to. While we were there, they showed
us the CM9400 Canweigh. Tey gave us a quote
and it was competitive. We thought the Canweigh
would be more accurate and more reliable than
traditional ll-level inspection systems. Compared
to gamma and x-ray systems, it would certainly be
less of a headache from a regulatory point of view.
And it was the right speed for our line.
Matt Brewing Co. became the rst brewer
in the world to install the CM9400 for 100
percent inspection. Food processors are using this
checkweigher for 100 percent inspection and other,
higher volume brewers are using it to inspect a side
stream for continuous sampling.
Te CM9400 is unlike any other checkweigher
on the market, which makes it suitable for some
production lines that historically have not been
good candidates for checkweighing. It is the only
checkweigher that handles a ow of containers
seam-to-seam, without separation. Traditional
checkweighers must accelerate containers prior
to the weighpan, only to be decelerated after, to
create the separation between the containers needed
to achieve the isolated time on the weighpan to
accurately weigh the product.
Stable container handling
One advantage of seam-to-seam weighing is
more stable container handling, which reduces line
jams and maximizes uptime. Another advantage
is fewer equipment components, which reduces
maintenance and sanitation requirements. By
eliminating line-time management components
Checkweigher ensures
all cans are properly filled
Matt Brewing Co. electrician Brian Gubbins checks the
display on the brewerys Hi-Speed Checkweigher, which
they say is highly reliable.
Stand-Alone Servo Controller
Dedicated to the Science of Motion
Aerotech, Inc., 101 Zeta Drive, Pittsburgh, PA 15238
Ph: 412-963-7470 Fax: 412-963-7459 Email: sales@aerotech.com
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Packaging
Applications
Las Vegas Conv Ctr,
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Booth: S-5117
Sep 26-28
See us at the following tradeshow:
PD1109 060 60 9/6/11 1:56:19 PM
REGISTER TODAY at www.myprocessexpo.com | 703.761.2600
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NOVEMBER 1-4, 2011 CHICAGO
McCormick Place South Hall
To get the rst look at next years technology,
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Newmachineryfromthewor|ds|eadingsupp|iers
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PD1109 061 61 8/31/11 4:44:42 PM
like the feedscrew, the CM9400
improves worker safety and speeds
changeovers. Compared to traditional
checkweighers, the CM9400 also
requires less line space.
Te patented CM9400 achieves
seam-to-seam weighing of cans,
bottles and jars by using a weighpan
that is virtually the same length as
the containers being weighted. Tis
is possible because the containers are
supported by two chains positioned
near the outer edges of the container
rather than the middle, which reduces
the perceived length of the container
by two-thirds as it is presented to the
weighpan. Te net eect is accurate
weighing at high production rates.
Te accuracy of the Hi-Speed
Canweigh is very goodit is consistent
down to one or two grams, notes
Rod Jones, packaging maintenance
supervisor at Matt Brewing Co. Were
running 600 containers per minute on
the canning line but the checkweigher
is capable of running 750, so weve got
room to grow.
Last year, Matt Brewing Co.
produced 300,000 barrels of beer,
which was a 20 percent increase
over the previous year. It is now the
seventh largest craft brewer in the
country and the 14th largest brewer
overall in the U.S. Its Saranac and
Utica Club beers are distributed
throughout New England while
some of its private label and contract
brewing customers distribute products
nationwide and overseas.
It has three packaging lines and
operate two at any given time because
the lines share a pasteurizer. To meet
rapidly growing demand, it recently
extended operations from 10 hours
a day, four days a week to 12 hours a
day, ve days a week.
Te CM9400 at Matt Brewing
Co. inspects 12- and 16-oz cans. Line
space is tight and the compact nature
of the checkweigher is critical.
Despite the compact design
despite the shorter weighpanthe
CM9400 actually allows more time to
weigh than traditional checkweighers.
Tis is because traditional check-
weighers accelerate products entering
the scale to achieve separation, and this
faster rate of speed on the scale actually
results in less isolated time.
Looking at a container that is four
inches in diameter on a production
line running 600 packages per minute
(200 feet per minute), a traditional
checkweigher must accelerate the
package to 500 feet per minute,
which allows only 50 milliseconds
on the weighpan. By comparison,
the CM9400 does not accelerate
Cans of Saranac beer line up on
the conveyor before entering the
checkweigher to ensure ll accuracy.
We measure the
success of the
Canweigh based on
the accuracy of the
weigh, the reliability
of the system and
customer service.
PD1109 062 62 8/31/11 4:44:46 PM
the package. Instead, the package
continues through the checkweigher
at a speed of 200 feet per minute,
which results in 58 millisecondsa
16 percent increase in timeon the
scale despite the shorter weighpan.
A lower conveyor speed with more
available time on the scale means
more accurate weighing and reduced
machine maintenance.
Time on scale is critical
Te time-to-weigh is critical
for checkweighers because it is one
variable that contributes to weigh
accuracy. Te absence of acceleration
maximizes the CM9400s time-to-
weigh. It also improves process control
and sortation by enhancing container
handling and improving the reject
systems ability to accurately remove
out-of-tolerance containers. And it
reduces damage to packages. For lines
inspecting open containers after the
ller, it causes less spillage, which helps
maintain a cleaner environment.
Good sanitation is important to the
company and the CM9400 makes it
easy. Te Canweigh is pretty rugged;
we dont need to treat it gently, explains
Rick Swanson, packaging manager at
Matt Brewing Co. We simply rinse it
down once each day and once a week,
we lift the chains to clean underneath.
Changing over the CM9400 is
equally easy, because container-specic
time-management components such
as feedscrews are eliminated. Te
Canweigh takes less than two minutes
to change, including calibration, says
Swanson. Everything is done on the
touchscreen.
Te CM9400 is easy to use.
Everything is right there on the
screenits very visual, adds Jones.
Te checkweigher features a large,
15-in. display that oers at-a-glance
production monitoring. Tis XS
control includes a standard IP69K
user-interface with a cleaning
mode that permits cleaning without
activating the touchscreen.
We measure the success of the
Canweigh based on the accuracy of the
weigh, the reliability of the system and
customer service, concludes Kuhr. Te
relationship we have with a supplier is
very important, especially with a piece of
equipment like the checkweigher because
if it goes down, we shut the whole line
down. If we have a problem, we need a
fast response.
Te CM9400 is the shining star
on our production line, says Jones.
We need to give Don Stewart, our
sales rep from Flo-Dynamics some of
the credit. He is very good at solving
unique production challenges and he
certainly helped us nd an unusual
solution here with the Canweigh.
Matt Brewing Co. has been in
business for over 120 years. Were still
owned and operated by the Matt family.
In all that time, weve been known for
having the highest quality products.
Our Hi-Speed checkweighers help
us maintain our quality reputation,
concludes Kuhr.
Matt Brewing Co.s uncompromising commitment to quality is the hallmark of the
company and its award-winning Saranac beers. This commitment led to a decision to
install a checkwiegh inspection system on its packaging line.
Flo-Dynamics,
978-392-0999. www.flodyn.com
Mettler-Toledo Hi-Speed,
607-257-6000. www.mt.com/hi-speed
SSANOVO - STAALKAT - ITALPROJECT - PROCESS SOLUTIONS - RAME-HART - FOODCRAFT
PART OF PA P RT OF
<HFIE>M> >G= H? EB G> I:<D:@B G@ LHENMB HGL
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<:L>?HKFBG@
<:L>I:<DBG@
I:E>MMBSBG@
LMK>M<APK:II>KL
E:L>K@NB=>=O>AB<E>L
ITALPROJECT del i vers cutti ng edge
end-of-line automation with complete
" pack t o r ack sol ut i ons, made
possible with robotic applications
that offer the highest degree of
customization.
ITALPROJECT USA
15180 Keel Street,
Plymouth Township,
MI 48170
Tel. +1 248 662 0785
Fax +1 248 662 0379
e-mail: ussales@italproject.net
www.italproject.net
www.sanovogroup.com
VISIT US IN OUR ;HHMA.,,+
PD1109 063 63 8/31/11 4:44:54 PM
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Edited by Lisa McTigue Pierce, Editor
Folding carton manufacturer Evergo Packaging
prides itself on being environmentally conscious
and ahead of the curve when it comes to its
printing and packaging technologies.
The company is certified by the Forest
Stewardship Council (FSC), the Programme for
the Endorsement of Forest Certification (PEFC)
and Sustainable Forestry Initiative (SFI). And
70 percent of the paper Evergo buys is made
from 100-percent recycled material. Evergo uses
alternative inks such as soy and vegetable-based
inks. It was on the forefront of using computer-
to-plate technology (CtP), eliminating the use
of chemicals. All of which has resonated with
customers in such diverse markets as the toy
industry, healthcare, food and courier services.
Evergo had one area it was looking to
improve, though. It wanted to nd an alternative
to the solvent-based adhesive it was using on its
folder-gluer production line.
Te solvent adhesive was applied to laminated
Treating
it right
With a plug-and-play solution,
eco-conscious carton maker Evergo
Packaging found a way to switch
from solvent- to water-based
adhesives without compromising
bond strength. MATERIAL COSTS
DROPPED AND PRODUCTIVITY
WENT UP.
The atmospheric plasma surface treater scrubs the paperboard so it can be glued with water-based adhesive.
Metal
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Vibratory
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Eriez New Vibratory Inspection Conveyors
Our new Dual Inspection Vibratory Conveyors offer
precise product control and uniform coverage giving
hand inspectors easy visual recognition of imperfect
product or foreign objects.
Features include:
Vibratory action rotates and flips product
Easy visual inspection
Precise product control
Reduced noise
Safe operation with no
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Sanitary wash down
Green low energy consumption
Visit eriez.com or call 888-300-3743
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Vibratory Selection Guide
& How-to-Use Brochures
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Booth C-1208
PD1109 064 64 8/31/11 4:46:07 PM
glue aps of a paperboard folding
carton. Te interior of the
carton was laminated with PP to
prevent seepage from the product
packaged. Tis variable required an
aggressive adhesive. While a solvent
adhesive did the job in creating
a strong bond, it also emitted
harmful VOCs (volatile organic
compounds), contradicting Evergos
environmental vision.
In the search for an alternative
solution, Ringo Chow, Evergo
director of operations, revisited
the use of an atmospheric plasma
surface treater from Enercon
Industries he saw demonstrated
at a tradeshow. He started by
consigning Enercons Dyne-
A-Mite IT from local Enercon
representative Webconvert Ltd.
Chows goal was to substitute
the solvent-based adhesive with a
water-based adhesive after pre-
treating the glue flaps.
We tested for three days but
knew immediately this was the right
solution, says Chow.
Enercons atmospheric plasma
increases the bond strength of
the PP by cleaning the surface
of contaminants and micro-
roughening, creating more bonding
sites. The unit bombards the
surface with a high-speed discharge
of ions. Positive ion bombardment
creates micro-etching or scrubbing
effect to remove organic and
inorganic contaminants from the
surface.
Plant- and prot-friendly
Te Dyne-A-Mite ITs compact
size made it nearly eortless to
integrate into an existing folding
carton line. Evergo mounted the
treating head above the conveyor
and treats the glue aps prior to
gluing. It also integrated the system
controls so the surface treatment
systems power is in sync with
the rest of the folder-gluer line.
Installation was a breeze. It was
plug-and-play ready, says Chow.
Switching to water-based
adhesive beneted not only the
environment. Evergo was able to
reduce costs substantially. According
to Chow, the water-based adhesive
is much less expensive than the
solvent. Te machine will pay for
itself in no time, says Chow.
Benets dont stop there. Te
wash-up of the machine is much
easier and quicker, increasing
overall productivity. And because
employees dont have to wear
protective masks and gloves to avoid
toxic fumes, they can move more
easily from one project to another.
Installing the carton-treatment
system was just one more stride
Evergo took to be in tune with
its environmental philosophy. It
was able to save some green in the
process, while making its employees
happy and more productive.
Enercon Industries, 262-255-6070.
www.enerconind.com
Webconvert Ltd., 416-252-4462.
www.webconvert-ltd.com
Wash-up is easier
and quicker,
increasing overall
productivity. And,
because employees
dont have to wear
protective gear,
they can move more
easily from one
project to another.
The next evolution in flexible packaging for frozen meals
Frozen food packaging that looks better, ships better,
and fits better than any other frozen package before.
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PD1109 065 65 9/1/11 8:41:41 AM
E
Linda Casey, Senior Editor
Earlier this year, Redhook Brewery celebrated its
30th birthday by unveiling a new lookfrom
bottles to labels and bottle caps to carriers and
cases. Te refreshed packaging is part of Redhooks
eort to get back to its roots.
Tere seems to be a movement within the craft
beer community where a lot of breweries are trying
to out craft each other, says Robert Rentsch,
brand manager of Redhook Brewery. Redhook isnt
about that. Of course were brewing great beer, but
were just as interested in having a great time.
We really wanted to let the personality and
voice and character of Redhook shine through in
everything that we do, Rentsch adds. So thats
New look hooks
production
improvements
Redhook Brewery gets back to basics with UPDATED PACKAGING THAT
BRINGS THE FUN BACK TO EVERYDAY BEER DRINKING while making
improvements to a bottling line thats all about quality.
66
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Redhook receives its empty glass bottles preloaded into
its printed six-pack carriers and shippers. Continued on page 68
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PD1109 066 66 8/31/11 4:59:15 PM
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PD1109 067B 67B 8/31/11 5:00:14 PM
why its a pretty sweeping overhaul on bottle, label,
crowns, six-packs, 12-packs.
To help develop the new packaging, the
Washington State-based brewery turned to design
agency Hornall Anderson, which is headquartered
in Seattle. Teyve been a client of ours since 2005
and so pretty much any brand or design initiative
that comes from their four walls, were usually one of
the rst agencies that theyre talking to, says Patrick
Rowell, strategist at Hornall Anderson. So this is
the natural evolution of our relationship.
Short, stout is what
its all about
Tis whole process really started with a brand
repositioning, Rowell explains. Every agency
[staer] and everyone internally at Redhook
was aligned with the objective in terms of brand
communications. Both the client and ourselves had
thought that it seemed like a natural opportunity
to move to a bottle that was simpler than certainly
their previous bottle, which was tall and custom,
had a split label and all these things that really
didnt seem in line with where they were taking
the brand. Simpler packaging also would be very
dierent from everything else in the craft category.
Rentsch adds, Our previous bottle, which was
more of a traditional long-neck, had barley and
the Redhook logo engraved on the bottle. It felt a
little bit too precious for Redhook. We are really
more about sort of going back to basicsthe
basics of a well-made beer.
Te new bottle is a short, stout glass from
Owens-Illinois (O-I). We worked closely with
O-I in looking at dierent bottle alternatives,
dierent bottle shapes that would we felt again
would kind t within Redhook brand, Rentsch
remarks. Tey were helpful in that process
making sure that everything t togetherthe
bottles t with our labels, were better t with our
crowns, and where we were headed with the brand.
Te labels, supplied by WS Packaging Group
Everything
from bottles
and crowns
to cases
and carriers
received a
facelift.
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PD1109 068 68 8/31/11 4:59:38 PM
Inc., also went through a material change. Tis
might sound counter-intuitive but we dropped
the weight of the paper to get a better adhesion to
the bottle, says Bill Kamp, director of purchasing
and planning for Redhook. With a little bit
thinner label, theres a variable dierence in cost
and this worked a little bit in our favor. But the
cost dierence didnt drive us to a lighter paper. It
was how the lighter weight labels applied to the
bottles themselves.
Kamp explains that while common sense
might dictate that labels made from a thicker
stock should be work better in the packaging
operations arena, Redhooks experience has found
this logic faulty. Te opposite happens when
youre applying labels with our equipment, he
comments. Weve tested this over the years,
weve found that the lighter labels work better,
much better.
Facelift prompts other enhancements
Not content with improvements to Redhooks
package design and packaging structures, the
brewery also took this opportunity to improve its
packaging line. I thank Robert for this opportunity
because it was an excuse to spend money on the
packaging line, jokes Greg Deuhs, master brewer
at the companys Washington Brewery.
On a more serious note, Deuhs says the Krones
Inc. bottling line that was installed in 1995
has served the company well but the packaging
team is always looking for ways to improve the
When Redhook Brewery refreshed its packaging, it also took the opportunity to invest in its Washington bottling line.
While common sense
might dictate that labels
made from a thicker stock
should work better in the
packaging operations area,
Redhooks experience has
found this logic faulty.
PD1109 069 69 8/31/11 4:59:46 PM
production. Although reluctant to
share exactly what was done to the
lling line, Deuhs does say that a lot
of work was in the lling process to
eliminate as much dissolved oxygen
in the beer prior to lling it in the
bottle, the whole process of getting
the beer in the right specications
at the right temperature and the
right carbonation level.
One change he is willing to talk
about is the bottle itself. Te new
bottle actually runs better on our
line, Deuhs exclaims. We had to
make a couple of changes on the ller,
but they were done using standard
change-out parts.
Other changes include
improvements to the labeling and
case-packing operations, but the
line fundamentally is a streamlined
version of its former self.
It starts with a Krones depalletizer,
which sweeps the glass layer-by-layer
onto the bottling line.
Sterile water is used to rinse the
bottles before they are lled by the
Krones ller at speeds averaging 350
bottles/min. Te crowns, supplied by
Crown Holdings Inc., are dumped
into a hopper, where they are picked
up by an airveyor system that right-
sides them and moves them down to
the capper.
Immediately after the crowner,
the bottles are examined by the rst
of several Industrial Dynamics/
Filtec inspection stations. Te line
is very aware of any leaky caps,
Deuhs explains. A leaker is a rare
thing for us. Cap tightness is an
important attribute for Redhook, and
its part of what Deuhs considers are
the top three challenges for bottling
operations.
From the Filtec station, the bottles
enter a race track that provides ve
minutes of accumulation. From the
race track, bottles enter the Krones
labeling station where they receive a
wraparound label from the Krones
labeler and are marked with the date
and brewery name by a Videojet
Technologies Inc. laser coder.
Deuhs explains why laser coding
was chosen for the line: We feel
that having the package date on the
bottle and having it legible where the
consumer can read it is important to
having fresh beer in the marketplace.
Laser prints much clearer on the
bottle.
In addition to using the laser
coding to ensure only the highest
quality product is consumed by
Redhook fans, the brewery uses
a CamPak case packer to gently
place lled, capped bottles into the
secondary packaging.
Many breweries have drop
packers where the oor drops out of
the conveyor and [bottles] drop into
the case, Deuhs comments. We
have a CamPak case packer, which
slides the bottles into the cases using
a rotating cam. Te CamPack is
much easier on the beer. Its easier on
the packagingeasier on the glass,
The case packer
slides bottles into
the case using
a rotating cam.
Compared to drop
packers, this is
much easier on the
beer, as well as on
the glass bottles
and labels. Theres
no jolt.
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PD1109 070 70 8/31/11 5:00:07 PM
and easier on the labels. Its a gentler
process. Teres no jolt like when beer
bottles drop into a case.
Filled and capped bottles are
then repacked into the shippers
and carriers that they arrived at
the brewery in. Another Filtec
inspection system checks for any
missing bottles, and a Videojet
inkjet printer codes the shipper
with the same information as the
bottles inside.
Because the beers are
unpasteurized, they are stored at
38-deg F as not to break the cold
chain. All our beer is fresh, Deuhs
remarks. Its not heat-treated. We
store our beer cold; we ship our
beer cold; we have warehouses that
are kept cold. Tis maintains the
freshness of the beer.
Top three challenges
When Deuhs describes what he
considers the top three challenges
for bottling beer, he starts with
preserving beer freshness.
No. 1 is beer [going stale],
he comments. Air is the worst
for beer. Hence, all the work that
Redhook has done to eliminate
dissolved oxygen in the lling
process.
Te No. 2 challenge is making
sure all the packaging looks right
from a consumer standpoint, he
adds. Te labels need to look good,
on correctly and coded, the six-pack
carriers [supplied by Rose City
Printing and Packaging] shouldnt
get scued and the handles should
work well, and the boxes [supplied
by AllpakTrojan] cant get beat up
in the process. Everything needs to
function correctly.
Te third challenge could apply
to just about any industry. I would
say No. 3 is always chasing constant
improvement, Deuhs remarks.
We have a rigorous packaging
program with a packaging quality
technician on the line. Whenever the
bottle line is running, this quality
person is working with the bottling
line operators. So were constantly
checking all the parameters that go
into making a beer bottle a bottle of
beer, everything.
We also have one person who is
excellent in statistics and maps out
exactly the performance of the bottle
line using that data, he adds. We use
that information to look for trends.
Tese trends drive changes and
improvements to the bottling line.
Early consumer response
is positive
Rentsch says its too early to report on
the packaging redesigns eect on sales.
He does share that anecdotal response
has been positive, which he attributes
to the breadth of the packaging
change. As far as the bottling
improvements impact on beer quality,
he suggests cracking a brew and tasting
the results.
AllpakTrojan, 800-227-7775.
www.allpaktrojan.com
CamPak Inc., 973-597-1414.
www.campak.com
Crown Holdings Inc., 215-698-5100.
www.crowncork.com
Hornall Anderson, 206-467-5800.
www.hornallanderson.com
Industrial Dynamics/filtec,
888-434-5832. www.filtec.com
Krones Inc., 414-409-4000.
www.kronesusa.com
Owens-Illinois Inc., 567-336-5000.
www.o-i.com
Rose City Printing and Packaging,
800-704-8693. www.rcpp.com
Videojet Technologies Inc.,
800-843-3610. www.videojet.com
WS Packaging Group Inc.,
800-818-5481.
www.wspackaging.com
PD1109 071 71 8/31/11 5:00:10 PM
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LOW-MAINTENANCE, HIGH-UPTIME
CIJ coders help this microbrewery
keep productionand prots
owing.
Edited by Lisa McTigue Pierce, Editor
Despite the global recession, Sprecher Brewing
Co. has continued to grow, with demand for its
specialty beers and sodas on the rise. Opened in
1985, the Milwaukee, WI-based microbrewery
crafts 20 high-quality beers, brewed in the
European style, which are distributed in 18 states.
It also makes nine gourmet sodas (root beer is the
companys most popular product now), which are
sold in 40 states.
To keep up with such demand, Sprecher
maintains a high-capacity bottling process that runs
12 hours a day, ve days a week. In the summer
months when demand increases, Sprecher runs six
12-hour shifts. It produces approximately 3,000
cases in an eight-hour shift.
Without the smooth operation of its
manufacturing and bottling processes, Sprecher
would be unable to meet customer demand and
continue its rising protability.
In its early years, Sprecher experienced
some line downtime because its inkjet coding
systems often required maintenance and
printhead cleaning, causing the line to be
slowed or stopped for unplanned periods
of time. Today, Sprecher uses a Videojet
1710 small-character continuous inkjet
printer with pigmented yellow ink to code
its 12- and 16-oz bottles, and uptime has increased
signicantly.
Tom Bosch, brewery production manager,
outlines the benet of the systems Clean Flow
printhead design, which reduces ink buildup and
delivers longer runs without intervention. Te
supervisors on the line are grateful that we have a
coder in which the maintenance sta doesnt
have to regularly be over there trying to clean
it out and get it running again, Bosch says.
Its not only unplanned maintenance that
Sprecher has been able to rein in. Scheduled
upkeep is curtailed, too. Te Videojet
1710 printer can go a full week between
printhead cleanings and 12 months
or 4,000 production hours between
scheduled maintenance. Tis minimal
maintenance is a relief to bottling line
supervisor Greg Fojtik. I have other
things to worry about in my job, and
the printer is not one of them, Fojtik
says. Its great that I can just turn on
the printer and dont have to worry
about it so I can focus on other things.
We cant aord to have something shut
down the line, Bosch says. We have time
constraints and many customers waiting
for our products around the country. So
we must be on time. With our new Videojet
coder, weve had no maintenance problems, so it has
been a great help to our operations.
Encoded quality
For quality control purposes, Sprecher prints
yellow pigmented codes on its amber and blue
bottles that include the date and time of bottling,
sequence number and expiration date. Te Videojet
1710 printer is able to use high-contrast, pigmented
inks to create bright, clean codes on dark surfaces
such as colored glass for which dye-based inks are
not eective.
Te crispness and readability of these codes
communicate more than just numbers and dates,
though. Without a clear code on the bottles,
we are really running blind, says Je Hamilton,
president of Sprecher Brewing Co. Its important
for us to give our customers assurance that we are
Smooth
operator
Sprecher Brewings worry-free coding operation
contributes to the bottling lines uptime, which helps the
plant keep production on schedule.
Sprecher Brewing uses inkjet printers to code
its 12- and 16-oz bottles, as well as its newer
aluminum cans. Yellow pigmented ink provides
good contrast against the amber glass; black
ink is used on concave undersides of cans.
The
supervisors
on the line are
grateful that
we have a
coder in which
the maintenance staff
doesnt have to regularly be
over there trying to clean
it out and get it running
again.
Tom Bosch, brewery
production manager
PD1109 072 72 8/31/11 5:02:19 PM
carefully monitoring the quality of
our products.
Quality is a priority for Sprecher,
and that commitment is recognized
nationwide. In 2010, Sprecher won
second place in the United States
Open Beer Championship. Eight
individual Sprecher brewssuch as
its Dunkel Weiss, Black Bavarian and
Sprecher Mai Bockwon medals
within their categories.
Keeping codes readable for
a longer period of time is also
important because Sprecher ages
some of its beers. Once beer is
brewed, it ferments for about a week
and then goes to an aging cellar for
anywhere from three weeks to three
months. Some specialty beers are
aged for up to a year. Tis means
codes must remain readable even on
a bottle that has been handled and
stored for a long period of time.
For taste-testing around the
country, we take some of our aged beer
samples along with newer batches for
comparison, Bosch says. Tere is a
tendency for codes to wear o over time,
but we dont have that problem. Its nice
for consumers to see that some of our
beers are easily aged for that long.
Paybacks
In day-to-day operations, Sprecher
sees additional benets from its
inkjet coders, including fast and
easy changeover, the ability to print
customer-specic codes and materials
savings from minimal ink waste.
Sprechers gourmet sodassuch
as root beer, cream soda and Orange
Dreamare made, bottled and
shipped out by the next day. Despite
the occurrence of multiple product
line changes every day, changeover
for coding is as simple as selecting
the new product in the printer
interface. All of Sprechers product
codes are programmed into the
system for operators to make quick
changes when needed.
Te printer allows all the dierent
Sprecher brand coding specs to be
preprogrammed, which saves a lot
of time when operators are setting
up in the morning, Bosch says.
It allows them to restart the codes
between brands easily without having
to reprogram the printer. It has been
a big time-saving tool when we do
brand changeovers and bottle line
changeovers. Te operator just touches
the button on the interface, runs a
couple bottles through to make sure its
printing ne, and away we go.
Some distributor-customers
require special codes on their Sprecher
bottles. For example, to sell products
in Florida, Sprecher must include
the letters FL after the sequential
number coded on each container.
Using the Videojet printer to add
this information instead of printing
separate labels has been a cost savings
for Sprecher.
Like the other coders within
the 1000 line of continuous inkjet
printers, the Videojet 1710 leverages
the exclusive Smart Cartridge uid
system. By reading the embedded
microchip, the printer identies
whether compatible uid has been
Line supervisor Greg Fojtik appreciates
the coders easy set up and minimal
maintenance.
PD1109 073 73 8/31/11 5:02:33 PM
installed. Tis prevents errors in ink types or the
switching of make-up and ink uids, saving time
and money. Te Smart Cartridge uid system is
designed to drain completely, wasting no residual
uids. Te needle-and-septum design eliminates the
need for operators to pour ink, thereby preventing
uid spillage and waste.
Te ink cartridges are easy to use, Bosch says. Were
not fumbling with containersthere are no spills, no
messes and no accidents. We just plug and play.
Budding relationship
Bosch notes that Videojet has helped Sprecher
keep its line running by providing equipment on
time and getting it online quickly. It has been a
great relationship, he says. Its not always easy to
say that about other companies and their technical
service. Videojet answers our calls 24/7. We dont
always see that from other companies, especially
since we are a smaller operation. Its nice to get the
best service from a company like Videojet.
Videojet has been a wonderful partner, adds
Hamilton. Tey will always help us and take
care of our needs. Tats what we look for in our
equipment suppliers.
Hamilton foresees further growth for Sprecher.
He anticipates adding more manufacturing
capacity in coming years and perhaps increasing
its canning capabilities (see Transitioning to cans
above). Craft brewing is growing at double digits.
Gourmet sodas are also growing, Hamilton says.
We are fortunate to be in a part of the economy
that is on an upward swing. We expect that to
continue over the next ve years.
Tis was edited from an article written by Drew
Weightman, beverage vertical marketing manager at
Videojet Technologies Inc.
After exclusively using bottles for its products for
the last 26 years, Sprecher has introduced a new
aluminum canning line for its special amber beer and
root beer products. The choice to use cans was driven
by a variety of factors, including environment, cost
and quality.
Cans are the premier containermuch better for
the environment, company president Jeff Hamilton says.
Most aluminum cans get recycled and turned back into
something useful.
The lighter weight of aluminum also reduces shipping
weight, which reduces fuel consumption and shipping
costs. In addition, cans prevent light and air from
contaminating beer and soda. Oxygen and light can get
into a bottle, but cans are dark and hermetically sealed
for ultimate freshness.
For its new can line, Sprecher chose the Videojet
1510 inkjet printer to apply standard black codes to the
concave underside of aluminum cans.
Videojet has always taken good care of us, so it was
a natural decision to go with Videojet when we needed
another coder, Hamilton says.
Transitioning to cans
Videojet Technologies Inc., 800-843-3610.
www.videojet.com
Without a
clear code on
the bottles,
we are really
running
blind. Its
important for us to give our
customers assurance that
we are carefully monitoring
the quality of our products.
Jeff Hamilton, president
IMAGING TECHNOLOGIES
Speak to Sensient today to nd out more about SensiCode
TM
inks.
Sensient Imaging Technologies is a unit of Sensient Technologies Corporation.
Now you CAN choose your own family! Your family of inkjet inks, that is
Introducing the SensiCode
TM
family of inks for
package coding by Sensient. Sensients tradition of
making high quality inks and providing customers
with a variety of products comes together with
the SensiCode range of inks.
The SensiCode family of inks for Thermal Inkjet
applications are designed to work over a wide
range of substrates.
Extended Decap Iimes
High Optical Density
Fast Dry Iimes
5harp Edge Activity
Barcode Readability
Aqueous, 5olvent, Oil based lnks
Dye and Pigment lnks
Food Grade lnks
OEN lnk Cartridges
Bulk lnks
OEN lnk Partnerships
Sensient Imaging Technologies Inc.
2724 Loker Ave West
Carlsbad, CA 92010
Tel: 800.642.2345
Fax: 760.930.1603
www.sensientinkjet.com
email: info@sensientinkjet.com
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PD1109 074 74 8/31/11 5:02:44 PM
Reclosable pouch The Multi-Seal FoldLOK is designed for shredded
cheese applications. The pouchs robust adhesive technology is engineered to enable
consumers of all ages to easily and reliably open and reclose the package multiple
times without needing to completely remove the top or use zippers. To open the Multi-
Seal FoldLOK package, consumers completely peel off a perforated strip, revealing
the opening across the top of the package. When the consumer is ready to store the
remaining product, they simply fold the top of the bag over the strip and the materials
stick together to seal the package. The company says the recloseable pouch can be
reopened and closed more than 10 times and still retain its adhesive qualities.
Sealed Air, 800-845-3456.
www.CryovacFoldLOK.com
Security tag A new holographic security
label protects products and packaging against
counterfeiting and manipulation. A product-specifc
Secutag micro color-code included in the label is
microscopically small, consists of different color layers
and is made in different sizes beginning at 8 m.
Apart from a hologram and a micro color-code, the
label can be provided with additional security features,
including tilting and kinegram effects, along with serial
numbering. Special security stamping further protects
against unauthorized removing of the label.
3S Simons Security Systems GmbH,
+49 2502 23330. www.3SGmbH.com
Coextruded flm Multipeel Flow Wrap, a multilayer
coextruded flm for resealable tubular bags, increases
productivity for resealable fexible packaging, the company
states. The product features DuPonts Surlyn as a sealant,
which is characterized by its ability to seal at very low
temperatures while maintaining high sealing quality. The
sealant also interacts with other components of the multilayer
structure to support the controlled burst-peel behavior of the
fow wrap, in terms of its low initial opening force, its clean
tear propagation and its maintained resealability, the company
claims. Examples of typical applications that could beneft from use with the coextruded flm include small-
piece products such as sweets, nuts, snacks and cheese-cubes, which should not dry up after opening.
Sdpack, 920-738-9877. www.suedpack.com
PD1109 075 75 8/31/11 5:04:39 PM
Anti-counterfeit
technology The co. offers
Prooftags Bubble Seal technology as
an integrated component to its multi-
layered protection solution for the wine
and spirits industry to help overcome
problems of counterfeit product and
authentication in overseas markets.
The protection technology features an
iPhone app that enables distributors
and consumers to verify the product
they are holding is authentic. The
iProof app uses the phones camera
to take a picture of the Bubble Seal,
which then cross-references an online
database of products to confrm
authenticity. Instant offline authenticity
can be achieved with the co.s reveal
detector.
BrandWatch Technologies,
503-285-3890.
www.brandwatchtech.com
Fire-retardant board The
company has received certifcation
from the California Department of
Forestry and Fire Protection for the
fre-retardant (FR) version of its
Falconboard Build display board. The
display board meets the minimum
requirements of fame resistance
established by the states Health
and Safety Code. The FR option
has been engineered to provide
a higher level of performance for
those applications requiring a fre-
rated material. The new grade is
suitable as a display material for
use at theaters, amusement parks,
retail shopping areas and other
environments, which must comply
with stringent fre codes.
Pregis Corp., 877-692-6163.
www.pregis.com
Pallet edgeboard New PerfBoard is budget-friendly laminate
that features standard leg lengths up to 4x4-in., with custom sizes
available and calipers to 0.160. The perforated laminate is safe for
partial shipments and irregular-sized loads; it is designed for use with
automated pallet assembly systems and can be custom-printed to add a
company logo, message or instructions. The recyclable laminate saves
warehouse space by stocking one SKU for multiple lengths.
Laminations, 800-925-2626.
www.lamimationsonline.com
PD1109 076 76 8/31/11 5:04:47 PM
Inkjet printer The new PH
Series small-character, continuous
inkjet printer builds on the success
of the current P-Family printer line.
The new PH Series maintains all of
the benefts of the highly successful
PB and PXR series lines, including
advantaged cost of operation via
innovative ink circulation system and
highest reliability resulting from a more
rigid, durable, cast aluminum printhead
with automatic nozzle and gutter
cleaning, allowing for quick start-ups
and less downtime.
Hitachi America, Ltd.,
800-448-2244.
www.hitachi-america.us
Drives MDrive integrated motor
products are now available for
Ethernet/IP systems, delivering
benefts to manufacturing automation
including low cost, compact size and
high reliability with minimal signal
degradation over long distance. The
motion systems feature an integrated
motor, drive and fully programmable
controller, with a standardized IP
addressing
system.
Ethernet/IP
MDrive systems
communicate
via TCP or UDP
interchangeably
and MDrive
systems allow
up to 254 nodes
on a network while eliminating the
complicated wiring and programming
of traditional multi-drop systems with
RS-422/485 communications, the
company says.
Schneider Electric Motion USA,
860-295-6102.
www.schneider-electric-motion.us
Warning lights The LS7 Series, the latest addition to the
companys family of signal towers, features a slim profle of only 0.78-
in. thick and a 3-in. square footprint for an integrated look in most
any application. Fifteen alarm- and chime-style sounds are available,
with the ability to feld-program the unit using MP3 fles for up to 15
messages with the companys SD card, which is sold separately. The
unit features volume control from zero and sound reduction control.
The unit is available in dark gray, ivory white or silver colors.
Patlite USA Corp., 888-771-0002.
www.patlite.com
IN NORTH AMERICA FOR FANUC
IS NUMBER
ONE
IN PACKAGING
SCHNEIDER PACKAGING EQUIPMENT
ROBOTICS

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CARTONING
CASE PACKING
ROBOTIC PALLETIZING
END OF LINE INTEGRATION
Flexible, rapid ROI, and ready for the future.
P.O. Box 890 | 5370 Guy Young Road | Brewerton, NY 13029
315.676.3035 | fax 315.676.2875
info@schneiderequip.com | www.schneiderequip.com
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PD1109 077 77 9/1/11 4:42:53 PM
Digital cameras The Phantom Miro eX
line is a series of advanced high-speed digital
cameras, which are specifcally optimized for high-
speed machinery testing, including production line
speed-up analysis. All of the cameras in the evolving
camera line are lightweight, untethered and easy to
use. The cameras are equipped with a built-in LCD
screen, allowing for both easy viewing and controlling.
Additionally, the lines integrated batteries enable
portability and mobility for on-demand troubleshooting.
With the cameras, users can take advantage of
maximum, full-resolution frame rates of 500- to more
than 1,200-frames/sec. By reducing resolution, the
cameras can record even faster, reaching speeds of
100,000-frames/sec or more, identifying problems that
would otherwise be missed, the company states.
Vision Research, 866-450-7426.
www.visionresearch.com
Vertical packager The Model 301SF vertical
packager features a new flm loading design, which enables the
operator to more easily load flm on the machine and assists in
roll stock change for additional uptime of the bagging system.
The packager also features a new trim management system
for positive placement of the trim trail and reduced breakage.
The one-piece seal bar design eliminates the joint between the
vertical and horizontal seal bars for reduced maintenance labor
and improved trim tail strength.
Rennco, 800-409-5225.
www.rennco.com
Inkjet printer The Videojet 1710 small-character
continuous inkjet printer is designed for applications that
require easily readable variable data codes on dark or
difficult-to-mark materials. The printer
uses high-contrast, pigmented inks
to create bright, clean codes on
surfaces for which dye-based inks
are not effective, such as colored
glass, rubber tubing, plastic cabling
and dark paperboard. The printer
can apply up to fve lines of high-
resolution print at speeds up to
888-ft/min and it is capable of printing a variety of fonts
in multiple languages, as well as linear bar codes, 2D
DataMatrix codes, custom logos and graphics.
Videojet Technologies, 800-843-3610.
www.videojet.com
Case packer The WCP-35 is a food-
friendly, durable, wraparound servo case packer
that features a fve-panel design and 90-deg
discharge. The machine also features stainless
steel washdown construction that is suitable for food
or pharmaceutical applications. All major motions
are driven via servo motor to improve machine
throughput and simplify changeovers while reducing
air consumption over standard designs. The case
packer loads the product onto the blanks, then forms
and seals the faps around the product before the
case enters the fap detection system to ensure
all sealing is completed. This saves considerable
resources in both materials and operating costs, the
company says.
Schneider Packaging, 315-676-3035.
www.schneiderequip.com
Packaging Competence and Automation
Your Partner For Total Packaging Solutions
Blister Forming and Packaging Machinery
Modular Designed Forming and Sealing Stations
Standard Machine Designs Tailored to Custom Requirements
Product Sorting and Infeed Systems
Fully Integrated Delta Robot Systems
Customized Solutions for Difcult Products
End-Of-Line Cartoning and Case Packing Systems
Package Grouping and Dense Packing Solutions
Flat Blank or RSC-FEFCO Erecting Systems
Simple Lines to Fully Automated Turnkey Systems
Challenge Us To Find The Solution To Your Packaging Needs
KOCH Packaging Systems, LP
44 Indian Lane East
Towaco, NJ 07082
Phone: 973-541-7312
Web: www.KochPackaging.com
E-Mail: Info@KochPackaging.com
Member of the Uhlmann Group
PD1109 078 78 9/1/11 4:43:06 PM
Coder The company releases the
A320i, the frst printer model in its new
A-Series range, which showcases the
i-Tech intelligent technology concept.
The intelligent technology concept
encompasses an array of smart
technologies to decrease maintenance
on production lines, lower cost and
increase efficiency. The system prints
up to four lines of code, text, automatic
serial or batch numbering and features
real-time clocks.
Domino, 847-244-2501.
www.domino-na.com
Vision systems In-Sight
5605 vision systems for high-resolution
applications provide 2448 x 2048 (5
MP) resolution
for high accuracy
gauging, defect
detection and
ID reading,
and allows
accurate
inspection and ID
on larger packages.
Cognex Machine
Vision Systems,
508-650-3000.
www.cognex.com
Thermoforming Create
a transparent package thats never
been done before. Often made with
separate front and back pieces
that are heat sealed together, the
design, tooling and manufacturing
process of custom thermoforming all
revolve around the specifc needs of
your product. The result is a secure
package that delivers a unique visual
punch. Custom thermoformed parts
can also be designed as inserts to
transparent folded cartons.
Transparent Container,
708-449-8520.
www.transparentcontainer.com
Case erector The Supersealer SB20 is a rotary
band sealer designed for use with food and other types
of packaging. It combines stainless steel construction
with proven band sealing technology and operator-
friendly controls for continuous duty in demanding
applications. Options include bag loaders and fllers, bar
coders and printers, as well as bag top trimmers and
trim removers.
OK International Corp., 800-521-2908.
www.okcorp.com
A Different Kind of ProcessFill Testing
Developed for the PET bottling industry, IntegriFill
TM
with Swift Cycle Technology allows you
to heat and dispense water with precision. IntegriFills Swift Cycle Technology duplicates
process-ll applications using short and long burst cycles of stable-tempered water , all within
one to two degrees of the setpoint.
Save Energy
Save Water
Save Time
No Recovery Period
Reduce Maintenance
Smaller Footprint
Portable
Touch Screen Operation
HEAT IT
Hot Water On Demand
800.999.4320 / integrill.com
IntegriFill
TM

with Swift Cycle Technology
INTRODUCING
PD1109 079 79 9/1/11 4:43:21 PM
Limit switches The AEM2G series compact
limit switches feature 35mm-wide die-cast housings
and are equipped with one normally-open and one
normally-closed contact; all units include a three-
meter cable. The IP67-rated series uses standard
25mm hole spacing and a variety of head actuators
is available. Almost all actuator styles are available in
both snap-action and slow-make/slow-break contact
versions.
Automation Direct, 800-633-0405.
www.automationdirect.com
Bag packaging The new
Autofulfllment SPrint bag packaging
system is designed for speed and
fexibility in high-volume mail order
fulfllment applications. The System
is fully customizable for a range
of products, including apparel and
footwear, bed and bath, home decor,
healthcare products, automotive parts, hardware, plumbing, printed materials and anything that will ship in a
poly bag. The Autofulfllment SPrint integrates with Warehouse Management or Order Entry Systems to print,
verify and package up to 15 completed bags per minute with a single operator.
Automated Packaging Systems, 330-342-2000. www.autobag.com
Thermoformers The TFS Thermoformers adhere to the highest standards in sanitation and hygiene,
a must for the medical and food industries. Ease of wash down, quick changeovers and high efficiencies
allow for greater production time. Harpak-ULMA has extensive experience to assist with custom applications
and fully integrated packaging systems.
Harpak-ULMA Packaging, 800-813-6644. www.harpak-ulma.com
PD1109 080 80 9/1/11 4:43:34 PM
packademics
R
Ready, set, action! Students from Michigan State
Universitys School of Packaging, Supply Chain,
Communications and Medical programs are lming
the journey of an IV start kit from material creation
through disposal to highlight the diverse entities that
add value to the kits throughout the supply chain.
IV start kits are found in a variety of medical
settings. Tese include acute-care hospitals, day
surgery centers, nursing homes, doctors and dentists
o ces, ambulances/life ights, battle elds and even
veterinary o ces. Tey cost less than $5 per kit yet
play a critical, foundational role in thousands of
medical procedures, from routine to life-saving.
Te video diary, which they have dubbed the
Incredible Journey, will chronicle the varied
contexts of storage and use of an IV start kit from
Medical Action Industries (Arden, NC; www.
medical-action.com). Te documentary will be
one of the highlights of the Healthcare Packaging
Immersion Experience (HcPIE), an event intended
to raise funds to support research at MSU,
scheduled to be held in East Lansing, MI, on Oct.
5 and 6 (www.msu.edu/~hcpie).
Te video diary will be recorded using cameras
from three diering viewpoints:
1. An eye-tracking camera to provide the user
viewpoint, be they a printing pressman, packaging
line worker, fork lift driver, paramedic or patient.
2. A spy camera to provide the vantage point
of the kit itself.
3. A handheld camera to provide the overall scene.
Te story begins with the creation of packaging
materials, and continues to converter Oliver
Tolas (Grand Rapids, MI), where Tyvek lidstock
is coated. By the end of the journey, multiple
companiesconverters, component manufacturers,
assemblers, sterilizers and distributorslocated in
three dierent countries will have ensured the safe
and sterile delivery of the kits.
Ten early this April, students were granted
access to hospital receiving, central supply and
the emergency department of Ingham Regional
Medical Center in Lansing, MI, where they lmed
its usage on a member of the research team.
As mentioned previously, IV start kits are used
in multiple scenarios, and the learning doesnt stop
there. Ambulances are one of the greatest users of IV
start kits, and for good reason. A patients condition
can deteriorate quickly, and establishing a usable
line for future need is critical. On Aug. 25 (a date
after PDs press deadline), paramedics from Delta
Township, MI, worked with the research team to
stage an automobile accident, extrication of the
driver (a simulated patient) and the storage and use
of the kit.
From production
through disposal, the
Incredible Journey
oers insight for all at
the amount of planning
and eort that goes
into this seemingly
simple product. Tose
who produce materials will
see the varied contexts and
conditions of use and storage. At the end of
the chain, patients and providers will likely be
surprised by the incredible amount of care and
thought that goes into delivering this life-saving
tool in a safe and e cacious manner (all for less
than $5).
Stay tuned for the next installment of
Packademics, which will chronicle the last legs of
the packs Incredible Journey.
This article was written by the School of
Packaging team involved in the Incredible
Journey project: Laura Bix, PhD; Britteny
Bratschi; Doug Furgason; Matt Koss; Jane
Severin; MaryKay Smith; Raghav Prashant
Sundar and Tony Trier.
Hidden camera captures medical packagings
Incredible Journey throughout supply chain
The star of the show: MSU School of Packaging students
are lming the Medical Actions IV start kit during its
entire supply chain journey.
During packaging, a worker dons an eye-tracking camera
to document this step in the process.

Horizontal Conveyorized Model
USDA Approved Rotary Band Sealer
includes bag top trimmer and vacuum
scrap removal. Superior performance and
high speed production for lay-flat packages.
Validatable Model
Medical Pouch Sealer with verification
ports for FDA validation of pressure,
speed, and temperature. Seals Tyvek

pouches at up to 40 feet per minute.
Vertical Conveyorized Model
USDA Approved Rotary Band Sealer
shown with lower support conveyor.
Non-trim models are perfect
for stand-up pouches!
Seal
Seal Only
Dual Heat
and Trim

Pouch and Bag Sealing Machinery
Pouch and Bag Sealing Machinery

i D E S I G N E D F O R A W I D E R A N G E O F A P P L I C A T I O N D E S I G N E D F O R A W I D E R A N G E O F A P P L I C A T I O N S S i
Las Vegas, Nevada
September 26-28, 2011
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PACK EXPO Booth C-1633

PD1109 081 81 8/31/11 5:06:09 PM
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Shoppers react to shrinking
package sizes, higher prices
A new Deloitte survey shows
consumers want healthier foods,
alternative brands, front-of-label
packaging and smartphone access.
And, as food prices escalate, theyre
buying more lower-priced grocery
items and private-label products.
www.packagingdigest.com/
ShrinkingPacks
Continuous retort system could
revolutionize chilled-food packaging
The system being developedknown as a continuous retortshould
increase frms output and deliver huge savings in water and energy use. It
will enable up to 1,200 packs to be processed, per minute, through a single
machine that uses about 50 per cent less energy, in only a quarter of the
factory foor space compared to the same output with batch retorts. The
builder expects to sell complete processing lines in Europe, the U.S. and
Japan by 2013.
www.packagingdigest.com/ContinuousRetort
Windows on Sainsburys new
juice carton help consumers
measure out portions
In a U.K. frst, Sainsburys has launched new 1-L juice
packaging with four see-through windows that allow for
simple portion control and ensure that customers enjoy
their fve-a-day servings. Using the windows on the side
of the carton as a guide, customers can quickly measure
a glass of fruit juice that counts as part of a healthy diet.
www.packagingdigest.com/
SainsburysWindowCarton
Talk back!
Heres what readers of packagingdigest.com are saying:
The new can design is Budweisers 12th since Anheuser-Busch began offering its fagship brand in cans
in 1936. The focal point of the design is Budweisers iconic bowtie, complemented by the time-honored
Budweiser creed and Anheuser-Busch medallion.
www.packagingdigest.com/BudweiserBowtie
Aint that the truth? Even the smallest of
changes can have major impacts. Another
important addition to law of unintended con-
sequences is that you should never [change]
more than one factor at a time. Good luck
fnding the cause of a problem when youve
made multiple changes at one time.
Quality Guy on the new KC Boxbottom, packaging
detective, blog The case of the wrinkly labels
Retail-ready-packaging (RRP) will offer labor savings for the
retailer but will not offer a sustainable advantage over the
current secondary packaging designs used in the U.S. As the
conversation intensifes on expanding RRP into North America,
businesses need to know that material use will increase and
drive sustainable metrics unfavorably.
Todd Van Gordon, packaging engineer, Colgate-Palmolive on
Growth in retail-ready-packaging offers significant opportunities
for suppliers
Kraft, Nestl support
emerging technology
for recycling
laminated packaging
Nestl and Kraft Foods join a consortium to advance Envals patented
material recovery technology as a favorable end-of-life solution for difficult-to-
recycle laminated pouches and tubes.
www.packagingdigest.com/LaminatedPkgRecycling
New P&G packaging center
celebrates employee diversity
Procter & Gamble has opened a new packaging customization facility at its
plant in Auburn, ME. This new FlexiCenter facility will offer local employment
opportunities for the developmentally challenged and disabled veterans.
www.packagingdigest.com/PGFlexiCenter
Budweiser updates packaging
graphics with new bowtie design
PD1109 082 82 8/31/11 5:07:05 PM
For more information, contact Lawrence Nokes at 215/944-9832, lawrence.nokes@ubm.com
info showcase
Literature and other multimedia, product announcements
and websites for packaging machinery, materials,
containers, supplies, and services. Contact supplier directly
or respond online for information.
YUPO Gives You a Sustainable Edge in
Packaging.
Why choose YUPO Synthetic Paper over other label
substrates?
Waste Reduction No Label Liner to Discard r
100% Recyclable Bottle Label r
Starts & Finishes Green 100% tree-free r
Cost-Saving Benefits Compared to other methods r
Diverse Packaging Possibilities r
Blow and Injection Molding r
Clear and Opaque Grades r
Velocity Equipment Solutions is a leading supplier of
Packaging Machinery for over 45 years. Velocity man-
ufactures a full line of equipment including open rail
style chutes, pick off heads, sorters, waterfall sorters,
elevator hoppers and secondary equipment for the
application of caps.
Velocity Equipment Solutions, LLC.
Phone: 800-521-1368 Fax: 724-658-5720
Email: cappingsales@velocityes.com
www.velocitycapping.com
With a PET Resin capacity that has grown tenfold
(to over 3.3 billion lbs/yr) over the last 10 years,
DAK Americas is committed to the global PET Resin
Market. From sustainability to innovative products,
like our Laser+ Family of PET Resins, and state-of-
the-art Melt-Tek and IntegRex PET technologies,
DAK is setting new standards in the industry. For
more information contact: DAK Americas, tel. 888-
738-2002, or visit dakamericas.com
PD1109 083 83 9/1/11 4:37:31 PM
marketplace
Standard classifcations are: Machinery & Materials; Contract Packaging; Career Opportunities.
Other more specifc classifcations may be requested. 2009 rates are $325.00 net per column inch
(1 time frequency), $310.00 net per column inch (3 time frequency), $295.00 net per column inch
(6 time frequency), $285.00 net per column inch (12 time frequency). Add $30.00 net per column
inch for second color. Colors available are: Standard Red, Blue, Green, Yellow and Magenta.
All rates are non-commissionable. Blind Boxes are available for a $25.00 fee. Deadlines:
5th of the month preceding issue. Please send all materials, insertion orders to:
PACKAGING DIGEST
11444 W. Olympic Blvd, Los Angeles, CA 90064 Fax: (303) 265-5286
Attn: Lawrence Nokes at 215/944-9832
Email: lawrence.nokes@ubm.com
Machinery & Materials
Recruitment
Call Us for a Free Quote
800-505-2247 www.polyrol.com
Your Best Bag Price
Pre-opened
Bags-on-a-Roll
Quality Guaranteed
Many Sizes in Stock
Custom Printing
Fastest Delivery
To advertise here, contact
Lawrence Nokes at:
(215) 944-9832
lawrence.nokes@ubm.com
PD1109 084 84 9/1/11 4:38:03 PM
www.packagingdigest.com PACKAGING DIGEST MONTH 20XX 85
marketplace
Contract Packaging
Oriental Packing Co., Inc.
We are a contract packer/distributor, blender
and manufacturer of all types of spices.
We also do contract labeling/packaging for
many other companies including
Simply Jamaican.
Please contact us for more information.
Tel: 305-235-1829 Toll Free: 1800-809-9793
E-mail: dll41212@aol.com
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newsmakers
PACKAGING DIGEST (ISSN 0030-9117) is published monthly, with a special issue in summer, by UBM Canon, 11444 W. Olympic Blvd., Los Angeles, CA 90064-1549; 310-445-4200; FAX 310-445-4299. Periodicals postage paid at Los Angeles, California,
and at additional mailing offices. SUBSCRIPTIONSFree to qualifed subscribers as defned on the subscription card. Rates for non-qualifed subscriptions, including all issues: 1 yr. $150, 2 yrs. $250, 3 yrs. $300. Except for special issues where price changes
are indicated, single copies are available for $10 USA and $15 foreign. For telephone inquiries regarding subscriptions, call 763-746-2792. CHANGE OF ADDRESSNotices should be sent promptly to P.O. Box 47461, Plymouth, MN 55447. Please provide
old mailing labels as well as new address. Allow two months for change. EDITORIAL CONTRIBUTIONSUnsolicited manuscripts should be submitted via e-mail to john.kalkowski@ubm.com. Copy will receive every reasonable care; however, the publishers
assume no responsibility for safety of artwork, photographs, or manuscripts. NOTICEEvery precaution is taken to ensure accuracy of content; however, the publishers cannot accept responsibility for the correctness of the information supplied or advertised
or for any opinion expressed herein. REPRINTSContact Foster Printing Service at 800-879-9144. POSTMASTERSend address changes to PACKAGING DIGEST, P.O. Box 47461, Plymouth, MN 55447. Canada Post: Publications Mail Agreement 40612608.
Return undeliverable Canadian addresses to: BlueChip International,. P.O. Box 25542, London, ON N6C 6B2. Printed in U.S.A. Copyright 2011 by UBM Canon. All rights reserved. Reproduction in whole or part without written permission is prohibited.
Patricia Spinner
Senior Group Publisher
973-808-1250
patricia.spinner@ubm.com
Steve Everly
Associate Publisher
610-705-8705
steve.everly@ubm.com
AK, DC, DE, HI, MD, NC, OH, PA, SC, WV,
Canada (eastern), Europe
Russell Thibeault
781-255-2053 Fax: 877-735-6707
russell.thibeault@ubm.com
AL, AR, CT, FL, IA, IN, KY, LA, MA, ME, MI, MS,
NH, NJ, NY, RI, TN, VA, VT
Steve Slakis
630-990-7429 Fax: 630-990-8894
steve.slakis@ubm.com
AZ, CA, CO, GA, ID, IL, KS, MO, MN, MT, NE,
NV, NM, ND, OK, OR, SD, TX, UT, WA, WI, WY,
Canada (western)
CLASSIFIED/INFO SHOWCASE
Lawrence Nokes
215-944-9832
lawrence.nokes@ubm.com
INTERNATIONAL REPRESENTATIVES:
China | Sylvia Xiao
sylvia@edoomedia.com
Japan | Masayuki Harihara
mail@yukarimedia.com
Taiwan | Robert Yu
sales@wwstaiwan.com
Mary Williams
Marketing Services Manager
630-990-2371 Fax: 630-990-8894
mary.williams@ubm.com
Sales and Marketing Offices
sales staff ad index
Aerotech Inc. ....................................................... 60
All Metric Small Parts (AMSP).............................. 58
All Packaging Machinery Corp. ............................ 81
Ampac Flexibles .................................................. 70
Arpac Group ........................................................ 69
AutomationDirect .................................................. 3
AXON .................................................................. 24
Bivans Corp. .......................................................... 6
Blue Grass Metals ............................................... 78
Blueprint Automation........................................... 48
Bodolay Packaging Machinery ............................. 84
CAMA USA ........................................................... 71
Colordyne ............................................................ 87
Columbia Machine Inc ......................................... 59
Columbia Okura LLC ............................................ 84
Combiscale ......................................................... 10
CTM Labeling ...................................................... 18
DAK Americas ..................................................... 66
Domino Amjet Inc. ............................................... 21
Ecologic .............................................................. 27
Eriez - USA .......................................................... 64
Fallas Automation ............................................... 28
FlexLink Systems Inc. ............................................ 6
Focke & Co. ......................................................... 80
Food Processing Suppliers Assoc. (FPSA) ............. 61
Fort Dearborn Co. ................................................ 68
Fres-Co Systems USA .......................................... 65
HB Fuller ............................................................... 7
Hotset Heizpatronen un Zubehoer GmbH ............... 75
HTI Plastics ......................................................... 29
Iconotech ............................................................ 75
ID Technology ........................................................ 5
IMS Schneider Electric Motion USA ...................... 80
InkJet Inc. ........................................................... 39
Intelligrated Inc. .................................................. 37
ITALPROJECT ....................................................... 63
J.L. Clark............................................................. 32
JW Winco Inc. ..................................................... 84
Keltech ............................................................... 79
Kliklok-Woodman ................................................ 16
Klockner Pentaplast ............................................ 55
KOCH Packaging Systems LP ............................... 78
Leibinger ............................................................. 11
Markem-Imaje..................................................... 42
Milliken & Co. ...................................................... 23
Morrison Container Handling ............................... 50
Motoman ............................................................ 76
NAFM .................................................................. 20
Nordenia USA ...................................................... 35
Owens-Illinois ................................................ 44-45
Paktech ............................................................... 41
Paperboard Packaging Alliance ............................ 26
Patlite ................................................................. 49
Placon Corp......................................................... 31
PolyPack ............................................................ 62
Presto Products Inc. ............................................ 40
Primera Technology ............................................... 9
Printpack Inc. ..................................................... 13
Quality Transmission Components ........................ 58
Rennco LLC ......................................................... 12
RSI Systems ........................................................ 88
Ryson ................................................................. 22
SAS Automation LLC. ........................................... 84
Sato America ...................................................... 17
Schneider Packaging Equipment .......................... 77
Schurtape ........................................................... 36
Sealed Air Corp. .................................................. 53
Sensient Imaging Technologies ............................ 74
Sleeve Seal ......................................................... 14
Squid Ink ............................................................ 25
Squid Ink ............................................................ 57
Temple-Inland ..................................................... 50
The Dickson Company ......................................... 52
US Tsubaki .......................................................... 19
Velocity Equipment .............................................. 73
Verst ..................................................................... 2
Xpedx ................................................................. 54
Yaskawa Electric America Ltd. ............................. 47
YFYJupiter .......................................................... 15
Yupo Corporation America ................................... 51
Page number Page number
MOVERS & SHAKERS
Barry-Wehmiller
Co. Inc. appoints
Dan Jones as
vp of corporate
development.
Sapient
Automation
names William
Fabricino as
Midwest sales
manager.
xpedx names James Connelly as
chief operating officer; Dan Watkoske
as evp, sales; John Biscanti as evp,
operations; and Thomas Lazzaro as
chief procurement officer.
Automated
Imaging
Assn. (AIA)
hires Robert
McCurrach
as director,
standards
development.
SICK appoints
Craig Smith
as president
of SICK Ltd.
Dow names
Glenn Wright
as business vp,
performance
packaging global
business.
Ball Corp.
promotes
Lisa Pauley to
svp, human
resources and
administration and elects Charles
Baker as corporate secretary.
Delkor hires Mike Wilcox as vp of
sales, marketing and aftermarket
services and
Fred Green as
vp of operations.
Domino North
America
appoints Fred
Brunk as svp
of sales and
marketing.
TricorBraun
names Jad
Darsey as
director of sustainability and plastics.
Menasha Packaging promotes
Jonathan McKellips to general
manager of its Neenah complex.
Schawk Inc. appoints Lor Gold to
global chief
creative officer.
O-I names Steve
Bramlage as
president of
its Asia Pacifc
region.
Intelligrated
appoints Greg
Cronin as
executive vp.
Cermex names Marc Ville as
managing director.
MHT USA LLC. appoints Christian
Wagner as CEO.
ITW Muller appoints Rob Payne to
industry manager.
GROWING & GOING
Polyplex USA builds a $187-million
polyester flm plant in Morgan County, AL.
Sonoco builds a $15-million,
120,000-sq-ft rigid plastic container
plant in New Albany, OH.
SATO Corp. changes to a pure holding
company structure. The newly formed
holding company, SATO Holdings,
establishes the following new
subsidiary companies: SATO Corp.,
SATO Communications Co. Ltd., SATO
Printing Co. Ltd., SATO Techno Lab Co.
Ltd., SATO Mechatronics Co. Ltd. and
SATO Quality Assurance Co. Ltd.
Phoenix Closures builds a new
250,000-sq-ft manufacturing plant in
Greencastle, IN.
BUYING & ALLYING
Bemis Co. acquires Mayor Packaging
of Hong Kong.
Nordson Corp. acquires Value Plastics
Inc.
Huhtamaki acquires Brazilian flm
extruder and converter Prisma Pack
Indstria de Filmes Tcnicos e
Embalagens Ltda (Camaari,Brazil).
Wildeck Inc. acquires Ladder
Industries Inc. based in Goodyear, AZ.
Dow and Saudi Aramco plan massive
$20 billion plastics plant in the Jubail
Industrial City in Saudi Arabia.
Craig Smith
SICK
Dan Jones
Barry-Wehmiller
James Connelly
xpedx
Jonathon
McKellips
Menasha
Marc Ville
Cermex
PD1109 086 86 9/1/11 4:38:20 PM
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apart from your competition. Print full process color at throughput speeds
up to 12 inches/second. Join the revolution without breaking the bank.

See Colordyne printers in Action at Pack Expo
Visit our partners to see our high speed digital print solutions.
Special at-show pricing and discounts are available.
CDT - 1600 S
CDT - 1600 C (Continuous Printer)
I t d k t d d t diff ti t
PD1109 087 87 9/1/11 4:39:10 PM
Tell us about your case coding application
at PackExpo 2011 and be entered to win a free iPad!
iPad
1-866-PRINT HP | www.RSIPRO.com | sales@rsipro.com
Visit us at PackExpo 2011 | Booth Number C-159
Your Solution:
The CaseJet Printstation
The CaseJet Printstation
combined with our reliable
HP based inkjet solutions
consistently provides high
resolution images and barcodes.
Talk with an RSI Applications Engineer and nd out how the
CaseJet Printstation can assist you in achieving 100% scannability.
PD1109 088 88 9/1/11 4:38:38 PM

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The LX900 Color Label Printer is Primeras newest, fastest

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