INSIDEHealth & Wellbeing 2-3

Winners of Alufoil Trophy 2005 4-5

Material of choice for Sustainability 6

Japan’s innovative excellence 6

30 years of pack developments 7

News & statistics 8

EAFA European Aluminium Foil Association

No. 21 Spring 2005

Keepcool at

interpackVisit EAFA in Hall 11,

stand D11To keep you refreshed at interpack 2005

this chewing gum blister pack isproduced using a 20 micron foil hard

temper from mfc aluminiumfoliemerseburg. Hueck Folien produced andprinted the alu-blister foil using a PETheat resistant lacquer with a PVC/PVAccopolymer primer and heat-seal coating.

Alufoil and Recart revitaliseretail shelvesAt the launch Sainsbury’s canned food buying manager

Les Rowse said, “Tetra Recart packs don’t need a tin open-er to open, and fit better in the cupboard and fridge, butthe real advantage is that tomatoes kept in these packssimply taste better.”

Lindroth explained, “What we offer our customers is thepossibility to revitalise slowing product categories andbrands through offering an attractiveplatform of product innovation.”

Among the other installationsare Bonduelle in France for veg-etables, Hormel Foods in the USfor Stagg ready meals and DelFuerte in Mexico for vegetables.There are a number ofother customers atvarious stages ofimplementation.

ALUFOIL is a key component in Tetra Recart, Tetra Pak’spackaging solution developed to challenge canned foodsand currently gaining in popularity for upmarket ‘fresh’products as an alternative to the traditional can.

Aluminium provides oxygen and light barriers to the pack-aging material structure and ensures the 24 month shelf

life. “This is extremely impor-tant when the can is the stan-

dard to which we arecompared,” said ErikLindroth, business

development direc-tor at Tetra RecartAB. “Aluminium is

also necessary toallow the inductionheat sealing of the

pack. “It would be extremely

challenging to reach the linecapacity of 24,000 packs/hour without alufoil,” he added.

Tetra Recart now has four installations operational acrossthe world for a variety of applications. The latest of these isfor Sainsbury in the UK which, at the end of last year, intro-duced Tetra Recart for four varieties of chopped tomatoesand one new Premium chopped tomatoes offering.

In a notable development, the first TetraRecart line using a ‘Hot fill’ processis being operated by Sainsbury’s co-packer Columbus. This means thattomato products are not fullyretorted but rather pasteurised atlower temperatures resulting inexcellent product quality.

Continued on page 2

Flexo printPolypropyleneDuplex boardPolypropylene

PolypropyleneAlufoil

EAFA Infoil 21: Spring 2005 www.alufoil.org

Health & Wellbeing

Bonduelle first introduced a rangeof beans packed in Tetra Recart inItaly in 2003. Based on the excellentproduct quality (as good as home-cooked) and the convenient pack for-mat, the introduction resulted in anincrease in market share forBonduelle in Italy and led to the

launch being extended last year intoGermany, Austria, Switzerland,Benelux and France.

Introduced in 2002, when it wasawarded an EAFA Alufoil Trophy,Tetra Recart is claimed to be theworld’s first retortable carton packagefor food.

It is capable of containing any kindof premium food that cans or jarsusually accommodate and the com-pany feels that it offers the valuechain an alternative with genuineadvantages.

“In short,” says Lindroth, “we usu-ally summarise the benefits in fivewords: convenient, safe, efficient,competitive and innovative.”

It is Tetra Pak’s declared aspirationto support customers in developingproduct concepts and recipes thatwork effectively with the package, themarket and other specific demands.

Continued from page 1

Foil first for freshness and health The buzz words in the European foodmarket are convenience, snacking,health and wellbeing, where possiblemarried to consumer demands forpleasure and indulgence.

The health and wellbeing trend isgoverned by a growing attention tohealth, an ageing population alignedwith an increasing life expectancy,busier more stressful lifestyles, andconsumers taking control of their ownhealth rather than visiting the doctoror pharmacist.

The sector includes a number of dif-ferent definitions, the most usual ofwhich are:� Functional foods – these will havehad something added to the productsuch as vitamins and/or minerals� Nutraceuticals covers functionalfoods but also includes vitamins andherbal remedies� Health – low fat, fat free, low-carbo-hydrate, low salt, reduced sugar, andany number of slimming aid products

According to a report from AroqLimited (www.just-food.com) the cur-rent global functional foods market isestimated to be between US$7bn andUS$63bn, depending on sources anddefinitions, but is expected to grow toUS$167bn by 2010, representingabout 5% of total food expenditure inthe developed world.

One of the most important attributesof packaging in the health & wellbeingmarket is that it should protect thenutritive and medicinal properties ofthe product; and aluminium foil iswell placed to fulfil these demands.

For example, the earliest market fornutraceutical products with health giv-ing benefits was probably the singledaily dose market created by Japan’sYakult Honsha, and quickly taken upby Danone (Actimel, Zen, andDanacol) and Unilever (Benecol). Allthese products feature aluminium foillidding and both product and foil con-tinue to thrive as the market expands.

“Aluminium foil plays a prominentrole in modern food packaging. Themechanical physical and chemicalproperties of aluminium foil such asbarrier effect, deadfold, and food con-tact ability make it particularly suit-

able for health products,” statesProfessor Felix Escher, Professor ofFood Technology at the Institute ofFood Science and Nutrition at theSwiss Federal Institute of Technology(ETH) Zurich.

Other major attributes include:� Light and strong� It can be formed and converted intocomplex shapes� Excellent corrosion and temperatureresistance� High thermal and electricalconductivity� Recyclable without a decrease inquality � Good decorative possibilities

All of these qualities make it a valu-able material for the health and well-being sector.

Applications include aseptic car-tons, pouches, wrapping, bottle cap-sules, blisters, laminate tubes, lids,trays and containers.

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Foil tops for liddingFoil-based lidding can’t be beatenwhen it comes to providing the barrierproperties needed for a variety of mar-garines and dairy products likedesserts and yoghurts.

Laminated lidding materials fromAlcan Packaging have been chosenfor a number of applications in thehealthy foods markets, including DeliReform Active Margarine; ActimelDanone; Froop Müller and Zott Jogolélow-fat yoghurts.

EAFA Infoil 21: Spring 2005 www.alufoil.org

Health & Wellbeing

Cartons take on‘wellness’ mantelSoups, juice and dairy markets are noexception when it comes to capitalisingon the quest for “wellness” productsand aseptic cartons are finding a num-ber of new applications.

The 1000ml SIG Combibloc stan-dard with combitwist closure, forexample, is being used for a range ofbio-milk products from Candia, theleading brand on the French milk mar-ket.

Absolute barrier for products thatare rich in vitamins and minerals, andcontain no artificial preservatives isabsolutely essential and in asepticapplications the aluminium foilensures the carton is both airtight andprovides a barrier to light.

Additionally, SIG’s premium imageslimline CombifitSmall carton witheasy open and reclose Combitwistscrew cap is being used for Actilife“Healthy Plus”, one of Migros’ strate-gic private labels.

The Comifit carton is also beingused for a range of Wellness activeand vital drinks from Pro Health VitalDrink GmbH marketed under the “fitfor fun” slogan, as well as a range ofhealthy vegetable soups with a “newtaste dimension” from the Campbell’sErasco German brand.

Huhtamaki Ronsberg foil laminatedpouches are answering calls for fresh-ness, nutritional value and healthyeating in markets as diverse as chil-dren’s snack foods fromAndros, Knorr Activesoups, and even petfood pouches fromIAMs.

The AndrosPocket PommeNature pouchis designed toencourage chil-dren to enjoyhealthy snack-ing.

The 100gpouches featureattractive 6-c o l o u rr o t o g r a v u r egraphics and atamper evidentspout and cap closure. ThePET/ALU/OPA/PE pouches provide

maximum barrier properties and arehot filled using Form-Fill-Seal

technology. The Knorr range of

dried Activsoups contain30% of thedaily needs ofvitamins B, Cand E per por-tion, plusessential fibrecontent andcome in singleserve gravurep r i n t e dPAPER/ALU/PEl a m i n a t e dpouches. Even pets are

joining in thehealthy eating craze with a laminat-

ed PET/ALU/PP retortable stand uppouch being chosen by IAMs for itsSelect Bites range and Nutro forNatural Choice products.

Providing convenience, pleasure andindulgence as well as healthy creden-tials are these attractively shaped,recloseable sports and energydrinks pouches for CAPs from CapriSun.

The material is provided by AlcanPackaging Italia and is manufactured

from a PE/ALU/PET laminate, gravureprinted in six colours to give a highquality effect at point-of-sale.

The isotonic drink contains the vita-min L-Carnithin that helps maintainendurance, while the energy drinkcomes with added taurin, guarana andcaffeine.

Sun shines on sports enthusiasts

Sensitive yoghurtThe natural health-giving properties ofAloe Vera are being used by Emmi forits one-off novelty Aloe SensitiveYoghurt and Aloe Sensitive Drink.Both products have a fat content ofonly 1.1% and contain 15g of AloeVera in the yoghurt and 25g in thedrink.

The yoghurt features a 38 micronalufoil lid lacquered with PS andprinted in 4- and 5-colour gravurefrom Nyco Flexible Packaging.

The Aloe Sensitive Drink features alaminated lid called Cap Sterilwhich is manufactured from a 50micron foil laminated with 12 micronPET and gravure printed in twocolours.

Pouches answer call for freshness

EAFA Infoil 21: Spring 2005 www.alufoil.orgEAFA Infoil 21: Spring 2005 www.alufoil.org

Alufoil Trophy 2005 Alufoil Trophy 2005

ChocolatPAVOT getsvisual appealAlcan Packaging Singen was awardeda Trophy for a sophisticated, wafer-thin wrapper used for the specialchocolate candy Chocolat Pavot fromStorck.

The candy was developed tocelebrate the company’s 100thanniversary and the packaging had tocomplement the delicate productwhich was finished with a trace of wildpoppy.

The candies are individuallywrapped in a very thin aluminium foiland red tissue paper which, like thepetals on a poppy, can be gentlyunfolded. They are packed in anoctagonal collapsible box which servesas a decorative tray once opened.

“This is a really emotional pack thatreflects the chocolate taste sensationin the pack,” said Professor Büren.

The wafer-thin foil is coated with aspecial protective varnish andembossed with the Chocolat Pavotlogo.

Delivered by Alcan Packaging Singenin 10cm coils, the aluminium foil iscombined with the tissue paper andcut to size at the production facility.

Cool Lifestyle Impress Group’s microwaveable alu-bowl for ready meals with easy peelclosure won a Trophy for what judgesbelieved to be “a system that hitstoday’s lifestyles”.

The pack was adopted by DreisternKonserven in Germany for its range ofsix Hot & Cool ready meals whichextends the use of alufoil packaging toa new group of consumers.

Complete with a plastic over-capfor use during heating and a fork foreating, the pack provides total conven-ience to satisfy appetites of all ages.

As Professor Büren said, “The prod-ucts are presented in an attractive for-mat which can be eaten in the home,in the office or wherever there is amicrowave oven to hand.”

The bowl is produced by Impress inMoelan, France, using six colour pre-distortion printing technology to createa distinctive appearance on the shelf.

The Easy Peel closure is also printedin six colours giving an exceptionalprint quality and is supplied byImpress in Cuxhaven, Germany.

This project demonstrates howexpertise and excellence within theImpress Group can be harnessed toprovide integrated packaging solutionsand create opportunities for cus-tomers, says the company.

Produced using existing seamingand sterilising systems with over-pres-sure, Dreistern-Konserven was sup-ported during the commissioningprocess by the Impress TechnicalService Team, enabling a short con-cept to market development time.

Pouches stand outfrom the crowdA stand-up pouch for wet sauces fromU n i l e v e rBestfoods in theUK won an AlufoilT r o p h yfor HuhtamakiRonsberg. KnorrCreamy ParsleySauce waslaunched last yearin thePET/ALU/OPA/PPgravure printedand matt lac-quered pouchwhich offers excel-lent shelf stand outand protection.

The sterilisablematt lacquer pro-vides excellent opti-cal characteristicsand provides lessspots and less visi-ble creases in theoverall pack.

The high qualityprint design isachieved by 6-colourgravure printing.

Judges felt that thecombination of technical and decora-tive properties demonstrated in thepack meant that stand up pouch tech-nology had been moved forward oncemore.

Huhtamaki Ronsberg has beendeveloping stand up pouch laminatesfor many years and today’s structuresensure attractive appearance, opti-mum barrier properties, high punctureresistance, sterilisability and conven-ient handling.

Nanotechnologyaids quick roastingA technical breakthrough is claimedby Hueck Folien and Cofresco for itsjoint trophy winning entry Quick Alu,a black alufoil used to marketToppits FixGrill (container) & Fix-Brat Alu (household foil) fromCofresco Frischhalteproduckte. By

using nanotechnology, the companyhas come up with a solution to fix ablack coating on alufoil and to makethis physical effect available for heatapplications on foodstuffs.

The black coated alufoil allowsquicker roasting of meat in the ovenand for added convenience it keepsthe meat juicy while preventing theoven from getting covered in fat-splashes. Judges felt this was a veryinnovative solution to a long-standingtechnical challenge.

Normal alufoil reflects the oven heatby more than 90% which prolongs theroasting process, but Hueck Folien’sblack coated alufoil absorbs the ovenheat and conveys it directly to thefoodstuff inside. Meat can be roastedup to 30% faster than previouslywhich also means less energy is usedin the cooking process.

“This is a very convenient andenergy saving solution bringing high-tech developments to the kitchen,”said Professor Büren.

Climatic protectionProtective Packaging received anAlufoil Trophy in this year’s competi-tion for the ProtectAtainer, a barrierfoil ISO Container Liner which allowsusers to switch from individuallypacked products to bulk shipping.

In practice, this allows an increasein shipping volume from 15,000 kilosto in excess of 20,000 kilos.

The aluminium foil lami-nate provides total climaticprotection for any prod-uct that may be suscep-tible to damagecaused by moisture,oxygen, UV light,t e m p e r a t u r eextremes andodour transfer,and liners can betailored to suitindividual cus-tomer specifica-tions.

The judgesacknowledged theexcellent protectionqualities of theProtectAtainer and felt that the con-cept offered worthwhile improvementsin the supply chain.

It also offers environmental benefitsby using less material. And, asProfessor Büren puts it, “Climatedoesn’t count anymore – packagingoffers full protection.”

Excellence in innovationExcellence in innovation, protection, user convenience and environmentalresponsibility are core aspects of the entries from the five winners of an AlufoilTrophy 2005. The competition has rewarded packs across a wide range ofapplications and proven that alufoil is a key element of the packaging mix.

“Although a long established material, these awards highlight the fact thatalufoil is as relevant to modern packaging solutions as it has ever been,” saidProfessor Ingo Büren, of the University of Stuttgart. “Indeed, some forms ofpackaging would not be possible without it.” Independent judges examined the25 entries to the competition and were impressed by the standards achieved.

Hueck Folien and Cofresco’s joint trophy winning entry,Quick Alu

EAFA Infoil 21: Spring 2005 www.alufoil.org

Sustainability

INNOVATION

Japan is internationally renownedas one of the pre-eminent centresof packaging innovation and alufoilpackaging developments are noexception.

Among recent developments isan easy open stand up pouch usedby Nippon Lever K K (Unilever) andProcter & Gamble to refill rigidshampoo bottles. The concept can

also be usedfor powders,pastes, liq-uids andg r a n u l e s .The pouchesare madefrom a PET/ALU/NY/PEfilm lami-nate.

Alufoil hasalso beenadapted tomake it easierto cook thet r a d i t i o n a lJapanese dish

mochi, a stickyrice cake. This

sweet brown rice isvery glutinous, making it difficult toprevent it sticking to conventionalcooking trays.

However, the cooking process hasbeen made easier through thedevelopment of a silicone-coatedaluminium foil release tray.

The shaped tray is manufacturedfrom 70-80 micron coated alumini-um foil and features a series of per-forations in the base of the tray toaid cooking and browning on bothsides of the product.

Maximum performance,minimum use of material

The use of sustainable packagingmaterials is just one aspect ofsociety’s quest to ensure the welfare offuture generations.

The lightness & unique productpreservation properties of aluminiumfoil lead to significant savings in foodwaste, materials and energy.

Production and manufacturing tech-niques have led to significant down-gauging resulting in a 20% decreasein thickness in 10 years at the sametime as maintaining or even improvingmachineability and performance char-acteristics. All of which providesincreased productivity and addedvalue to the conversion process.

The exceptional barrier properties ofaluminium makes it possible to trans-port and store food for long periodswithout energy-demanding refrigera-tion, while also preserving nutritionalvalue and food quality.

Just one example of a market trendwhere aluminium foil’s lightweightand protective properties have beenused to good effect is in the continu-ing move away from rigid to flexiblepackaging. Aluminium can be recy-cled repeatedly at a fraction of its orig-inal energy cost and modern separa-tion techniquesmean alumini-um foil inh o u s e h o l dwaste can beextracted andrecycled.

It is suitablefor both sepa-rate and multi-material collec-tion systemsaccording tonational andlocal condi-tions.

The energy

content of foil laminates can also berecovered by thermal treatment.

Collecting and recycling empty alu-minium packaging makes sound envi-ronmental sense. One of the latestexamples is a new alliance for the col-lection of used aluminium coffee cap-sules forged in Switzerland byNespresso and The IGORA Co-opera-tive for Aluminium Recycling. The aimis to encourage the collection of alu-minium coffee capsules at Nespressopartner outlets, local authority facili-ties and recycling companies.

Thanks to its dense network of col-lection points and success in the col-lection of aluminium drinks cans, petfood trays and tubes, the IGORA recy-cling organisation is in a good positionto support and complement the col-lection system for used aluminiumNespresso capsules.

But it is not just the aluminium thatis recycled, the separated coffeegrounds are converted to fertiliser at acomposting facility.

Nespresso aims to establish anetwork of more than 1,000 collectionpoints and increase the collection ratefrom over 50% to over 60% by the endof 2005.

Japanese styleJust one of the environ-mental credentials forstand up pouches istheir extremely low pack-aging weight which canbe as much as 90% lessthan alternative packs.This also means thatthey are both easy andcheap to transport. Felixcat food pouches fromHuhtamaki Ronsberg arejust one example.

News and innovation

The search for the ultimate in self-heating technology continues withnews of an innovative pouch develop-ment from EPOCA, of Belgium, andits partner KSP Technologies, ofKorea.

Featuring an aluminium layer, thecomplex structure allows the self-heating of a variety of liquids in indi-vidual portions of 100-150ml. Thesystem is already being used in Asiafor herbal teas which are consumedat between 35° and 38°C. However,EPOCA believes that a prototype thatreaches temperatures of up to 60°Cand meets the demands of theEuropean market is about six monthsaway.

The heating mechanism is activat-ed by a button on the side of thepouch that creates a chemical reac-tion. Applications are likely to includesoup, coffee and tea. The pouch isexpected to feature a centrally posi-tioned pour spot and recloseable cap.

Alufoil sales hit all-time highShipments of aluminium foil reacheda record high in 2004 with deliveriesreaching 822,350 tons, an increaseof 1.1% over the previous year(811,400 tons), according to EAFAstatistics.

The growth figures dis-guise an even better pic-ture when the ongoingpractice of down gaugingis considered.

Deliveries were driven asmuch by exports as bysales within EAFAregions*.

Commenting on the eco-nomic outlook presidentBill Morris said: “Weexpect this trend to contin-ue in 2005.

“The level of demand for aluminiumfoil especially for export outside theEAFA region underlines the globalleadership of the European foil indus-try in terms of quality and competi-tiveness.”

EAFA goes from strength to strengthThe inauguration of the RewinderGroup representing 11 household foilmanufacturers and the announcementthat a further six new members havejoined the association as EAFA cele-brates its thirtieth anniversary bringstotal membership to 123 companies.

The association has also made greatstrides in geographic coverage andnow represents 23 countries acrossEurope including new members fromArmenia, Bulgaria, Croatia, CzechRepublic, Hungary, Slovenia, Turkeyand Russia.

New EAFA president Bill Morrissaid, “The past 30 years represent anera of remarkable and rapid evolutionin the European market including theaccession of new Central and EasternEuropean countries to the European

Union. EAFA has played a pivotal rolein assisting its members to adapt notonly to these fast-changing and chal-lenging markets but also by helping toaccelerate technical advance in foilrolling and converting.”

The Association’s groups are:� Converter Group – 71 members� Container Group – 17 members� Roller Group – 24 members� Rewinder Group – 11 membersInterpack 2005Exhibiting with Gesamtverband derAluminiumindustrie in Hall 11 StandD11, EAFA will present its completelist of services. These will include itsAlufoil File series, a dossier on alufoilapplications; information on theAlufoil Trophy 2005 winners, and thework of its specialist groups.

Alcoa Closure Systems Internationalhas begun commercial production ofVino-Lok, its “glass on glass” closuresystem for wine bottles which featuresan aluminium over-cap and neck sleeveto give mechanical protection andtamper evidence.

Alcoa will supply the closures fromits facility in Worms, Germany, to sev-eral wineries in Europe. Applicationsinclude premium wines for Lufthansa,one of the world’s leading airlines.

The Vino-Lok closure, which lookslike a decorative decanter stopper, ismade with rubberised O-rings to pro-vide a sterile seal. The Vino-Lok“Selection” is also being manufacturedin the US under the name VinTegra.

Tops for Tassimo

Winning wayswithwine

Kraft Foods is using die cut lids from Teich for itsTassimo single-serve instant drinks system. Thepartially embossed die-cut lids are UV-flexo print-ed in between 3-6 colours and extrusion coated.

The co-extruded heat sealed lids have to meetstringent demands including producing an unpee-lable seal against the PP pot at minimum retorttemperatures of 121°C. Both the coating and UVinks used are totally solvent free.

The heat is on

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EAFA European Aluminium Foil AssociatioonThe internhational body representing foil rollers, rewinders, converters and container manufacturers www.alufoil.org enquiries@alufoil.org