packaging digest february 2011 issue

8/7/2019 Packaging Digest February 2011 Issue

http://slidepdf.com/reader/full/packaging-digest-february-2011-issue 1/44

www.packagingdigest.c

BAG-IN-BOX:

Packaging prolongsfreshness of wine. 36

LEDs spotlight packaging

Packer bottles up savings

Beachattire

Sun-care product lidresses up its look

BACK TO NATURE:

Compostable bags alignwith brand’s image. 18

F

ebruary 2011

COOL CONCEPTS:

See what’s really new inpackaging design. 8



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http://slidepdf.com/reader/full/packaging-digest-february-2011-issue 4/44www.packagingdigest.com

new technology

features

28

34

30

26

FEBRUARY 2011 volume 48 no. 2

30 PROVEN EQUIPMENT A contract packager fi nds value in

purchasing used machinery to build a new line.

34 DOUBLE QUICK Nestle relies on automation to boost production

of single-serve coff ee portions.

20 COVER STORY A popular line of sun-care products devises a

new look for the beach.

23 BETWEEN FRIENDS New lip balm packaging allows friends tosharejust the product.

26 GOOD TRANSLATION What designers need to consider when

brands adopt a new packaging format.

28 CITY LIGHTS Cosmetic company’s stylish pack evokes

glamor of New York.

36 RIGHT PARTS Innovative components in bag-in-box packaging pay off

for wine and edible oils packaging.

38 SAFE TRAVELS Walmart supplier uses pyramid-shaped paperboard

packing to protect dinnerware packages.

next monthKRAFT FOODS executives

explain their strategy to apply

“open innovation” to their

packaging design process.

BEST OF FLEX T e FPA

Association recognizes 2010’s best

examples of fl exible packaging.

A NEW YORK DAIRY

co-op adds a new fi lling line to

boost productivity in their yogurt

operations.

ROAD SHOW A mobile fi lling

line helps small wineries in Canada

bottle their product without major

capital investments.

contents



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staff departments

Sr. Group Publisher

Patricia Spinner,

973/808-1250

[email protected]

Executive OfficersChief Executive Officer Paul Miller

Chief Financial Officer Fred GysiVice-President/Executive Director, Stephen Corrick

Sr. Vice President, Events Division Kevin O’Keefe

Vice President, Operations Roger Burg

Vice President, E-Media Jason Brown

Art/Production/MarketingLead Art Director Marco Aguilera

Associate Art Directors Tim Burns, Laura Pappada,

Hector Torres

Production Director Jeff Tade,

Production Manager Martin Schneggenburger

Senior Production Artists Jeff Polman, Derric Treece

Production Artists William Baughman, Ricardo

Esparza, Lucia Corona

Production Coordinator Adrienne DavisDirector of Circulation Sandra Martin

Circulation Manager Carlota Valle-Martinez

Marketing Manager Mary Williams

ReprintsFoster Printing Service

800/879-9144, [email protected]

EditorialEditorial Director John Kalkowski

630/990-2364 [email protected]

Editor Lisa McTigue Pierce 630/[email protected]

Senior Editor Linda Casey, 630/[email protected]

Plant Operations Editor Jack Mans

630/990-4208 [email protected]

Associate Art Director Jennifer Field

Corporate Headquarters 11444 W. Olympic Blvd, Los Angeles, CA 90064

310/445-4200 Fax 310/445-4299 www.ubmcanon.com

Editorial: 1200 Jorie Blvd., Suite 230, Oak Brook, IL 60523630/990-2364 Fax 630/990-8894 e-mail: [email protected]

8 PACKAGING CONCEPTS

11 COMMENT Mergers and acquisitions

12 NEW EQUIPMENT

16 NEW MATERIALS

18 GO GREEN Compostable packaging

19 SPC SUSTAINABILITY Life cycle analysis

39 ENGINEERS’ OUTLOOK Career strategies

40 ON PACKAGINGDIGEST.COM

41 INFO SHOWCASE

42 MARKETPLACE

42 NEWSMAKERS

42 AD INDEX



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FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com8

packagingconcepts

wwwmintel.com/gnpd

New Product of the Month Launch pad

Crave launches a dairy revolution with aluminum bottles

Upstate Niagara Co-op. launches Crave chocolate

milk in an aluminum Frost Flow milk bottle that chills

ast and stays colder, longer. Busy amilies can

benef t rom the act that the bottle’s twist-o cap

reseals, making Crave a portable and healthy snack.

And because o the pasteurization process, Crave

is shel-stable. It can be stored and shipped at room

temperature just like soda or juice, making it an instant

hit with national retail buyers across the country.

The graphics are printed directly on the cans, which

are supplied by Universal Can, Japan. The caps are

supplied by NCC Japan Crown Cork Co. Ltd (www.

ncc-caps.co.jp/english).

Crave uses social media tactics and pop-up

2GO drinksSold in sel-heating cans, Fast Drinks’

2GO beverages are an example

o an exothermal process using CaO

(calcium oxide) to produce hot drinks or

immediate consumption most anywhere.

The 2GO drinks are encased in tinplate containers with litho-

printed instructions on wraparound insulating plastic labels. They

can be prepared in as little as three minutes, using a simple

sequence o actions: The consumer f rst removes the bottom

lid rom the can; he or she then presses f rmly into the water

container; the consumer shakes the package until the colored

water disappears, then turns the package over; and he or she

removes the pull-ring on the upper end o the packaging. Three

minutes ater the activation sequence, the packaged product will

be heated and ready to eat or drink.

This product retails in a recyclable 200ml pack, and is

available in f ve varietiesblack coee, cappuccino, chicken

soup, hot chocolate, lemon tea and black coee.

experiential events that Upstate Niagara calls “Craves,”

to engage consumers in unexpected ways. This was

apparent when Upstate Niagara took advantage o the

“Harry Potter and the Deathly Hallows” movie premier

on Nov. 19, 2010, to create a unique product launch on

the University o Nebraska Lincoln campus. Students

who sampled the product were given activation

cards encouraging them to become ans o Crave on

Facebook. The f rst 125 students who became ans and

posted a secret code to the Crave Facebook page won

two ree tickets to an exclusive midnight showing o

“Harry Potter and the Deathly Hallows” at a local theater.

“The UNL Crave event was a huge success

or us,” says Ken Voelker, director o marketing or

Upstate Niagara Co-op. “More than 500 students were

introduced to Crave during our hours o on-campus

sampling, and we were able to give 250 o them an

awesome experience with the Harry Potter premiere. It

our aim to really connect with our consumers through

events like these.”

Crave is the creation o

Upstate Niagara Co-op.

Inc., a group o dairy

armers in western

New York. It is run

at O-AT-KA Milk

Products, Batavia,

NY. Upstate Niagara

is the majority owner

o O-AT-KA.

Source: Mintel Global New Products Database (GNPD)

New Products Launched in the U.S.

10Aug-

10July-

10Sept-

10Oct-

10Nov-

10Dec-

09Nov-

09Dec-

10Jan-

10Feb-

10Mar- May-

1010Apr- June-

10

2000

1800

1600

1400

1200

1000

800

600

400

200

0

Healthcare

Household

Beverage

Food

Pets

Beauty & Personal Care

Food


Beverage

Household

Healthcare

Pets

Source: Mintel Global New Products Database (GNPD)

12,000

10,000

8000

6000

4000

2000

0

New Products Launched Globally

10Aug-

10July-

10Sept-

10Oct-

10Nov-

10Dec-

09Nov-

09Dec-

10Jan-

10Feb-

10Mar- May-

1010Apr- June-

10

Beverage

Food

PetsHousehold

Healthcare


Food


Beverage

Household

Healthcare

Pets




packagingconcepts

10

Bottling a fresh approach to ironingStarBrands Ltd., a U.K.-based manuacturer o household cleaners,

has selected a PET bottle rom RPC Containers Llantrisant

(www.rpc-llantrisant.co.uk) or a private-label ironing water product.

Made by StarBrands or multiple major retailers, the specially ormulated

Fabric Freshener is poured into an iron to give clothing a long-lasting

reshness and ragrance.

StarBrands was looking or a rigid bottle with a dosing eature to enable

ease o pouring. The PET bottle rom RPC Llantrisant oers a tapered

design, leading to an integral lipped spout that ensures a smooth delivery

o product. The bottle is then capped and labeled by StarBrands to meet

customer specif cations. “RPC Llantrisant has devised a highly convenient

solution or this ironing water product that combines durable handling with an

eective pouring mechanism,” comments David Mann, managing director o

StarBrands Ltd.

Seeking a way to extend its proprietary

eervescent technology, Tower Laboratories turned

to strategic branding f rm CBX (www.cbx.com) to

help innovate new product ideas. Through extensive

ideation sessions, CBX helped zero in on the category

o proactive health and hydration or application o

Tower’s technology. The brand that grew out o this

research, which is named YZ (pronounced “wise”),

consists o “All Natural Hydravescent Crystals”

that are added to water to oster good health.

Once the concept was solidif ed, CBX brought the

brand to lie by creating the positioning, logo, name

and package design. Outthink (www.outthink.

com),Tower Brands’ marketing f rm, developed

innovative ways to introduce it to the target audience.

“The name, YZ, speaks to the act that this is an

intelligent choice or health-conscious consumers,”

says Gregg Lipman, managing partner, CBX.

“By placing the YZ name inside a circle logo and

surrounding it with bubbles, we’ve established an

iconic visual that links back to the eervescent nature

o the product.”

Henry McInerney, CEO o Tower Brands, agrees

with this brand positioning. “While there are many

other water-enhancing products on the market, the

eervescent bubbles in YZ are actually better, as

they help to disperse ingredients quickly and evenly.”

YZ avors are packaged in a box f lled with seven

avor “stick” packets. A color-coded logo and benef t

bargreen or the Antioxidant packs, orange or the

Immunity packs and yellow or the Digestive Health

packsmakes it easy to understand the benef ts and

clearly dierentiate the products rom one another.

UV-printed cartoncarries natural appeal

To debut Nature’s Benef ts, a granola-style ood

line targeted to consumers looking or natural products

or their pet birds and small animals, Kaytee Products

Inc. chose paperboard packaging with visual cues

that convey the natural attributes o the product. “We

wanted to create a crunchy-granola eel that was also

very eco-riendly,” remarks Aria Grant, ar t director with

Directions Inc. (www.directions.com), Kaytee’s

design agency. This was achieved by using krat

paperboard as a packaging material and muted tones

in the carton’s graphic design.

The package is UV-printed by Great Northern

Corp. (www.greatnortherncorp.com) using the web-

based StrataGraph process, which utilizes UV inks

and UV curing o inks and coatings. “For the Nature’s

Benef ts boxes, we f rst printed a thin coat o white as a

silhouette o the image to seal the uncoated substrate,”

Don Schroeder, president o Great Northern’s

StrataGraph operations, Oshkosh, WI, explains. “The

white makes the ensuing colors really pop out. As each

color o ink is applied, the substrate moves through

a ast-acting dryer. The dried ink orms a polymer

that sits on top o the paperboard instead o being

absorbed into it and acts as a base or the application

o the next layer o ink. Ater printing, the top sheet is

laminated to the paperboard.”

“The color and style o the package tells the

consumer, even beore seeing the brand name

Nature’s Benef ts, that this is a natural product,” says

Kay Thomson, senior marketing manager, Kaytee Pet

Bird. Nature’s Benef ts is available at Petsmart, Petco

and independent pet retailers throughout the U.S.

Bubbly box shows off effervescent powder



www.packagingdigest.com PACKAGING DIGEST FEBRUARY 20

John Kalkowski, Editorial Director

comment

IL

Like the fi rst robin of spring, an increase in merger and acquisitionactivity can be a harbinger of a changing season. T at appears tobe exactly what is happening across the packaging industry. In thelast few months, there has been an uptick in these activities, withnumerous companies announcing purchases. Could this be a signthat better economic times are blossoming?

Many of the large packaging mergers and acquisitions have beenamong the large converters and materials suppliers. For instance,Rockenn recently announced the purchase of Smurfi t-Stone for$3.5 billion. Even in the fragmented packaging equipment arena,dominated by medium-sized and smaller companies, activity isincreasing. Pro Mach, for example, continues to build its network of integrated equipment brands with its recent purchase of

Shuttleworth, a conveyor company.As the Atlanta Constitution reported, “Rock-enn isbetting consumers will continue to loosen purse strings as

the economy leaves the recession behind. Analysts andeconomists consider packaging a leading economic

indicator, as manufacturers and consumer-productcompanies ship more goods.”

Brian Cornell, senior managing director of Mesirow Financial, an investment bank, says there was a fl urry

of transactions at the end of 2010 because many ownerswanted to take advantage of the Bush tax cuts that were due toexpire, but were fi nally renewed at the last minute.

Investors look highly at packaging, Cornell says, because itperforms better relative to other industries and is not as sensitiveto economic swings. He expects activity to remain strong goinginto 2011, especially with companies valued between $25

million and $500 million (the middle market). “Investors want tobuy good businesses that are well-managed,” Cornell says, and many that have survived the recession fi t that description.

Recently, deals involving equipment makers have slowed becausemany packagers have put capital-intensive purchases on hold duringthe recession. om Egan, PMMI vp of industry services, says hisgroup hasn’t seen even a moderate increase in the acquisition rateamong PMMI members, which average less than $25 millionin annual revenues. He says PMMI membership has remainedrelatively constant, adding that entrepreneurs are always starting new businesses as other established companies are acquired.

One industry insider points out that a number of packagingcompanies have been holding off trying to sell their businesses.Reduced revenues caused by the recession also aff ect the market valueof the companies. “Before they sell, these companies want to buildtheir valuations coming off a couple bad years,” he says.

T omas Blaige, CEO of Blaige & Co., an investment bank specializing in packaging, says about 80 percent of the purchases

are by strategic buyers, who believe an acquisition will strengthenthe acquiring company through better integration of materials ormanufacturing, entering complementary markets or expansion innew territories. Blaige says about 15 percent of purchases are purefi nancial deals, without strategic value.

Cornell points out that private equity investment fi rms are sittingon a lot of money that was raised between 2005 and 2007. T eseinvestors are eager to add performing companies to their portfolios.

Merger activity could be sign of better times

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www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011 13

Portable marking The Mini Mark is a small,

portable dot peen marking system designed or both

handheld applications and integration into existing

or new machinery. The system eatures preloaded

leadscrews and ball slides or machine tool quality

perormance and durability while 12 mounting holes

are provided or exibility in mounting at virtually any

position or angle. The detached controls eature the

latest in embedded technology with CF card storage

and network (LAN) and RS-232 connectivity.

Kwikmark Inc., 815/363-8268.

www.kwikmark.com

Shrink wrapper The co.’s new all-in-one

machines are robotic pick-and-place shrink bundles

with built-in case packers. With quick-change gripper

assemblies and adaptability to handle all types

and sizes o products, the all-in-one system groups

products and places them onto a bucket conveyor

or shrink wrapping. A discharge gantry

automatically places the bundles into an

erected tray/case. The shrink wrapper eatures

one-time handling, product stability, multiple

product conf gurations, minimal changeover,

versatile loading and collation, and a color

touchscreen interace.

Polypack Inc., 727/578-5000.

www.polypack.com

Laser scanner The OS32C Saety Laser

Scanner eatures a 104.5-mm prof le, light 1.3-kg

weight and low 5-W power consumption. Benef ts

o the scanner include ast and easy equipment

commissioning and troubleshooting with patented

individual sector indicators. The scanner eatures up to

our times aster MTTR (mean time to restoration) than

other saety laser scanners with lower maintenance

cost and manuacturing downtime cost rom equipment

damage. Using the scanner’s memory module, a

maintenance technician can get the manuacturing line

running again without using a computer. The scanner

also eatures system monitoring over LAN via the

integrated Ethernet port, low-prof le equipment designs

with a small ootprint and low power consumption, ideal

or battery powered mobile applications, the co. states.

Omron Scientif c Technologies Inc., 800/479-3658.www.sti.com

Bagger The CFS Aquarius SmartPacker TwinTube

C high-speed bagger boasts a bag production output

o up to 500 bags/min., the co. states. The bagger hasthe option o running a single f lm reel or each tube

to simultaneously run packs with dierent sizes and

appearances. It orms bags o 40 to 145 mm, covering

mini treat size bags and overlong narrow bags or party

mixes and calorie packs. The bagger has a product-in-

seal detection system, which has proven to work above

460-bags/min. With the co.’s “CostFox” control system,

the machine boasts eiciencies above 98 percent. The

machine eatures low costs, thanks to low operator

and maintenance requirements. Its net result is a

measurably lower cost per pack, the co. states.

CFS Aquarius/Bainbridge Assoc., 616/583-1458.

www.csaquarius.com

Miniature

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new productsequipment

Cartoner The model CV6-350C

continuous-motion cartoner eatures

a streamlined, modular design,

patented dynamic carton cell chain,

volumetric f ller and integrated vision

system. Ideal or ood, conectionery

and nutraceutical applications, the

cartoner will load a variety o carton

sizes and styles, including theater boxes

With a 4-spindle rotary carton eeder,

the cartoner is designed to operate

at a rate up to 350 cartons/min. The

cartoner eatures a patented product

streaming delivery system to increase

production and uptime, and eliminate

bridging and clogging. The cartoner

also eatures volumetric f llers with

automatic adjustment via eedback rom

the integrated checkweigher, resulting in

less product waste, the co. states.

Z Automation, 847/483-0120.

www.zautomation.com

Case packer The tissue tough

case packer (TTCP) enables versatile

packing o single or multiple rolled and

olded tissue product lines and multiple

SKUs. Ergonomically designed or easy

case removal, quick adjustments and

rapid setup and recovery, the case

packer is a low-cost solution or eicient

side- or end-load RSC or HSC cases.

The design incorporates case erecting,

collation, loading, olding and sealing,

and an be integrated with palletizing,

stretch wrapping, labeling, product

and pallet transport conveyor, pallet

dispensing, and slip-sheet dispensing.

Schneider Packaging, 315/676-3035

www.schneiderequip.com

Cap sealer The co.’s Super Seal Touch induction cap sealer system oers increased

sealing speeds, the industry’s f rst completely integrated cap inspection system, an intuitively

designed touchscreen interace, simplif ed set-up and operation, and a host o capabilities or

internal monitoring and remote network communications. The co. will also unveil its new all-in-

one universal sealing head. This design greatly simplif es setup to ensure operators correctly

position the sealing head across the entire range o cap sizes to be sealed, the co. says. A

positive locking mechanism and dead ront label identiy the correct positioning in a clear and

concise manner. The system is suitable or sealing a range o cap sizes rom 24 to 120 mm.

Enercon Industries Corp., 262/255-6070.

www.enerconind.com

ASME/ANSI Attachment

Corrosion

Resistance Lube Free Plastic Custom/Specialty

U.S. Tsubaki, Inc.www.ustsubaki.com/pdm

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U S A

April 6-8, 2011OCCC • Orlando • Florida




Rigid packaging Cardia Biohybrid ood-

contact rigid packaging products are compliant to

Europe’s Regulation (EC) 1935/2004 and USA’s FDA

CFR 21 or materials and articles intended to come

into contact with ood. The product’s proprietary

technology combines renewable thermoplastics with

polyolef n material to reduce dependence on f nite

petroleum resources, while reducing the packaging’s

carbon ootprint.

Cardia Bioplastics, 888/605-1488

www.cardiabioplastics.com

new productsmaterials

Clear EAS labelsThe co. says its EP Clear

Labels is a f rst-o-i ts kind clear label or placement over

a bar code without jeopardizing bar code scanning. The

enhanced perormance electronic article surveillance

(EAS) labels reportedly oer the smallest-size EAS

label available or protecting small, thin,

un-carded cosmetics and other high-

value merchandise. The labels are

a visual deterrent to thet and have

been proven in retailers’ pilot studies

to reduce thet by more than 15

percent, the co. states. The high-thet

product category o health-and-beauty aids

is one o the key areas to benef t rom these new radio

requency label circuits, as the labels are small in size and can protect items

oten targeted by thieves, such as cosmetics, perumes and other small merchandise.

Checkpoint Systems Inc., 800/257-5540.

www.checkpointsystems.com

Formable paper packaging

FibreForm, a packaging paper with unique elasticity,

enables it to challenge plastic in new areas. The

paper’s ormability creates opportunities or special

eects and personalized packaging based on

renewable raw material that is both compostable and

recyclable, the co. states. This renewable material

can undergo thermoorming in ood packaging

machines and eatures high elasticity. The paper

is made with FSC-cert if ed primary f ber and

meets requirements or traceability certif cation in

accordance with PEFC.

Billerud, +46 8-553-335 00.

www.billerud.com

Wine shippers WineLoc protective wine

shippers are made with 60 percent recycled-content

EPS. The WineLoc packaging uses EcoSix, a

recycled molding bead by RAPAC. The recycled

wine shipping containers are projected to reduce

material introduced into the supply chain by a total

actual weight o 240,000-lbs annually. The high-

perormance protection o EPS reduces supply chain

waste o goods broken or damaged during shipping

and handling. The product also eatures insulating

qualities that protect perishables and f ne wines

during transit.

ACH Foam Technologies, 866/896-1626.

www.achfoam.com

Oxygen scavengersA new series o

oxygen scavenging additives can be dispersed

directly into packaging materials, which the co. says

oers a more convenient alternative to conventional

scavenging techniques such as UV-activated

systems

and oxygen

scavenger

packets.

O2Block

additive is

primarily

designed to maximize shel lie or diverse packagingmade o materials such as LDPE and HDPE, PP,

PET and polylactic acid (PLA) or the ood and

pharmaceutical industries. The technology uses

purif ed and modif ed layered clay as a perormance-

enhancing carrier o the oxygen-scavenging iron.

Oxygen is depleted rom the package by migrating

through the packaging material and reacting with the

dispersed active iron rom the additive. The reaction

is swit and produces iron oxide, which is linked

inside the packaging.

NanoBioMatters, 617/273-8092.

www.nanobiomatters.com

Carry-handle tapeThe co.’s new Easy

Open Carry Handle Tape 8643 is an integrated

carry handle that unctions as par t o the shrink f lm

package. The new tape is applied into the package

on the packaging line using an integrated tape handle

machine. The machine mounts at a r ight angle to

the shrink-wrap tunnel and applies the tape prior to

entering the machine. The tape is reinorced with

continuous PP monof laments in the backing, providing

a straight “zipper-like” easy-open eature. This patented

eature enables consumers to pull the tabs and easily

open the package. Even ater the consumer removes

a ew cans or bottles rom the case, the carry handle is

still unctional, the co. states.

3M, 800/362-3550.

www.3M.com




Secure unit-dose pack MedLock secure unit-dose package

combines a oil-laminated blister card locked within a tear-resistant ormed paper

tray. Based on the co.’s BlisterGuard platorm, the compliance package takes

pharmaceutical package security to the next level with a patent-pending locking

mechanism, resulting in a child-resistant, senior-riendly design, the co. states.

The secure packaging eatures a push-down, pull-out design with a unique

release and locking mechanism. The patient pushes down on a blister cavity that

protrudes through the lid to release the blister card and dispense the dosage.

The blister card is designed to remain intact within the outer protective paper

shell and lock back into place each time the package is closed.

Colbert Packaging Corp., 847/367-5990.

www.colbertpkg.com

Wine closures The new

Select Series coextruded synthetic

closures are tailored to meet the

unique needs o artisan winemakers

and their premium wines. The

closures have a visual appearance

and texture almost indistinguishable

rom natural cork and eature bark-

like roughness and a chamered

(angled or beveled) edge achieved

using advanced cutting technology.

Using a proprietary process that can

replicate more detailed artwork than

the traditional f re-branding used

on natural corks, these are the f rst

synthetic closures that can be end-

printed, the co. states.

Nomacorc, 919/460-2200.

www.nomacorc.com

Food grade polymers

A new amily o products, designated

“FG” (ood grade), meet demanding

requirements or use in ood contact

applications. The new polymers

provide compliance with several

regional ood contact regulations

including FDA (Food and Drug

Administration), European Food

Contact n° 2002/72/EC and GMP (EC)

n° 2023/2006. All FG products are

available globally to give customers the

exibility to design and manuacture in

multiple regions.

DuPont, 800/438-7225.

www.dupont.com




Go greenSnack’s compostable packaging

helps build ‘natural’ image for brand

Learn moreBoulder Canyon’s biodegradable packaging will be the

subject of a presentation by Chris Mitchell, Innovia’s sales

and marketing manager for packaging and sustainable

films, and Bill Reilly, development manager of Genpak, at

the Sustainability in Packaging 2011 conference to be held

Feb. 22-24 in Orlando, FL, for more information and to

register, please visit www.sustainability-in-packaging.com

John Kalkowski, Editorial Director

Healthy, active people often have highexpectations for the foods they eat and thepackaging in which it is sold. Snack makerInventure Group, Phoenix, AZ, aims to meetboth sets of expectations with its Boulder CanyonNatural Foods brand of potato chips and dips. T atis why about a year ago Boulder Canyon adoptedcompostable packaging for its chips.

T ick-cut, kettle-cooked chips such as BoulderCanyon’s have grown in

popularity in

recent years. Many of the people buying theseproducts are concerned about both fl avor andthe nutritional value of the snack, as well as theenvironmental impact of the packaging.

anner Clark, product manager, says BoulderCanyon, which was launched in 1994 in Boulder,CO, has always been very eco-minded. T e earth,he says, plays a central role in their customers’activities.

When Boulder Canyon set out to designcompostable packaging, they wanted to “keepthe integrity of the brand at the forefront,”

he says, adding that they sought to keep thesame look and feel of the packaging they werealready using while adding environmentalbenefi ts.

Genpak, a oronto-based converter thatwas already supplying Boulder Canyon,worked with them to develop the new compostable bags. Bill Reilly, developmentmanager for GenPak, says his company came up with a three-ply laminatedstructure that met stringent requirements.It includes an outside layer made with SFI-certifi ed paper; a middle barrier layer of Innovia’s Naturefl ex metallized cel lophanemade from wood pulp; and an inner layer

made with BASF’s Ecofl ex biodegradableplastic, which has properties similar toLDPE.

T e new packaging had to meetthe American Society for esting andMaterials (ASM) 6400 specifi cationfor compostable plastic, coveringplastic products that are designedto be composted in professionally managed municipal and industrialcomposting facilities. T e standardfocuses on whether those materials willdisintegrate and biodegrade swiftly and safely at a satisfactory rate.

In addition, Reilly says, numerous

other factors were considered, such asthe productivity in Boulder Canyon’spackaging operations, shelf life andsealability.

T e package is also certifi edby the Biodegradable Products

Institute, which involvedextensive testing to ensure

it contains no heavy metals, supports plantlife and breaks down

within six months leaving noharmful materials.

Reilly says the only other

biodegradable option was polylactic acid (PLA)materials. However, he said they were concernedwith some of PLA’s properties, including how well

it machines, its sensitivity to heat and the growingpublic concern that agricultural land is being usedfor packaging and biofuel materials.

Beyond the materials chosen for the packaging,Reilly says that Genpak tries to make the entiremanufacturing process more sustainable usingwater-based adhesives and by using the eight-colorOpaltone printing process, which they say reducessolvent use by 40 percent.

T ere were also concerns about the noiseassociated with some PLA packaging. T ebiodegradable packaging that they chose gives thelook, feel and sound as their earlier packaging, saysBoulder Canyon’s Clark.

T e packaging features a green band across the

top that says, “Compostable Package.” Clark saysawareness of the bag’s environmental benefi ts isgrowing, adding that “People who see it, really like it.”

An enterprising blogger decided to test thecompostability of several types of snack bags. This photoshows the extent of deterioration of Boulder Canyon’sbag (left) after four weeks in a compost heap.

Boulder Canyon Natural Foodshas found wide customer approval for a

biodegradable package it introduced in 2010.



LLinda Casey, Senior Editor

Less than a year after its acquisition of PlaytexProducts Inc. and its health-and-beauty aidbrands, Energizer Holdings Inc. embarked on acomplete redesign of the newly acquired Hawaiianropic suncare line. “It was the summer of 2008,”recalls Chuck Renz, senior manager of packagedevelopment and packaging innovation forEnergizer Personal Care division, “I was headingup the package development group, when theHawaiian ropic marketing head came to meand shared their whole new strategy for brand

positioning.” T e entire line of sunscreens andafter-sun products were to get a luxurious, upscalelook and feel that also would off er more brandconsistency from product to product within theHawaiian ropic line.

o help develop the graphics for the redesign,the Hawaiian ropic product team brought inPhillips Design Group and charged it with thetask of targeting two primary demographics withone look, while maintaining brand equity andeff ectively communicating several messages.

“T ey were talking to the indulgent sun-and-beauty seekers, who want to be out in the sun and

get dark, and the skin-involved age resistors, whoare people that want to be in the sun but don’twant to wrinkle and ruin their skin,” explains StevePhillips, president of Phillips Design Group. “T eseare two diff erent kinds of audiences.”

Because the target markets were so diff erent,the agency created separate image boards for eachdemographic to not only guide their graphic andcontextual messaging for these consumers butalso to look for alignment between the disparateaudiences. “What these two distinct groups have incommon is the desire to pamper and indulge theirskin with something special,” Phillips adds.

Capturing thetropical experience

FEBRUARY 2011 PACKAGING DIGEST 0

health

& beauty

Designers, engineers and marketers collaborate on a PACKAGING REDESIGN that fi nds common ground between

two distinct consumer groups to provide more-consistent branding that also packs big sustainability benefi ts.




T e fi nding set the group off in what Phillips calls“the experiential direction.” He says this directiontries to capitalize on the emotion of the experienceof a sunny day by bringing in the visual remindersof the tropics. T e group’s visual exploration of theexperiential direction is dominated by images of lush tropical fruit, beautiful locations and refreshingwaters. Market research confi rmed the experientialdirection’s appeal.

With a general market target identifi ed, the agency

then charged a team of sixa design directorand fi ve other designersto develop graphicconcepts for the brand. “What we do initially is throw the project at everyone so we get asmany ideas as possible,” Phillips explains.“T e client narrows down the direction,and then we narrow down our team tothe people who worked on the selecteddesigns.”

Developed concepts included thosewith an ingredient focus, more abstractpictograms, masculine shapes, a play onthe Hawaiian ropic palm tree logo and anethereal look that sought to convey how easily the products are absorbed. Simple

more upscale looks and more cosmetics-oriented designs also were considered.

T e Hawaiian ropic group narrowed

down the designs to those created by PhillipsDesign Group senior designers Cara Kingand Angela Kowalczwk. But to determinethe fi nal design direction, Phillips wouldinsist on consumer research. “A lot of usmake subjective decisionsyou couldlike yellow and I could like blue,” Phillipsremarks. “We want to see what our targetaudience selects.”

Consumer testing identifi ed hibiscus

fl ower design as the most eff ective.Phillips attributes this to threecharacteristics of the design. “It’s

reminiscent of the tropics; it’s easily color coded; and it has a strongbull’s eye eff ect on the package,”he explains.

Before the design couldbecome an actual package though,the agency would need to collaboratemore closely with Energizer’s Hawaiianropic team on the look, feel and shape.

Parallel processesbestow benefi ts

King and Kowalczwk worked withVeronica Lewis and Jean Fulfi dio fromEnergizer to fi ne-tune the hibiscus design.

Camilla Medeiros, who held the position of senior global business manager for Hawaiian

ropic at the time, served as the primary decision maker for graphics and color cues.T e agency also collaborated with theHawaiian ropic package development teamto increase the eff ectiveness between thepackage structure and design.

“As marketing was developing graphics,we were developing structures that would go

nicely with the graphics and work with thenew brand image,” Renz recalls.

T e “we” that Renz is referring to includeshim and independent, industrial designerDiana Sierra, who created photorealisticrenderings of the package forms and shapes,using McNeel North America’s RhinoCAD software, a free-form 3-D modelingtool.

Renz then creates more technically specifi cdrawings in Parametric Technology Corp.’s Pro/Engineer (PC) CAD software beforeproducing fused-deposition models (FDM) usinga Dimension Inc. 3-D printer. T e onsite creationof working models made of ABS plastic enabled

the Hawaiian ropic team to quickly test the form,fi t and function of the designs. “Within a day of Continued on page 22Ethereal concept

Masculineconcept

To help defi ne the redesign’s overall direction, image boards were created targeting (left to right) the “indulgent sun seeker,” “skin-involved age resistor” and sunning experience.

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2 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com

having a design, we can have a modelthat is a solid representation of theactual design we’re coming up with,”Renz explains. T e FDM models inABS plastic were the fi rst prototypesto be tested on the fi lling and packinglines.

Production prototypeso further refi ne its understanding of

how the new packaging would impactfi lling and labeling, Energizer workedwith a variety of suppliers to create

production prototypes and identify and obtain package components thatcould be purchased as stock items. T iswas no easy task because the redesignapplied to the entire sun-care productline from oils to aerosol sprays. T erestage involved 205 fi nished goodsacross the U.S., Canada, Latin Americaand Europe.

T e package development teamworked closely with both GrahamPackaging to develop the new, moreshapely tottle structures that can sit

on the cap end. and CCL Containerson the new aerosol cans. Additionally,they worked with AptarGroup Inc.on new Emsar lotion pumps andSeaquistPerfect Creme actuators andtwist-lock actuators; Berry Plastics for a new child-resistant closure;

Polytop Corp. and Zeller Plastik USA Inc. on new fl ip-top closures;and TricorBraun and Gifl or srl onthe latch force and fi tting of a low-profi le closure into the tottle’s revisedorifi ce.

T e components were tested onexisting equipment to optimize themanufacturing process. Energizeralso took this opportunity to installnew packaging lines for the project.In January 2011, it was putting thefi nal touches on a new tottle fi llingline, which will be featured in anupcoming edition of PD.

AptarGroup Inc., 815/477-0424.

www.aptargroup.com

Berry Plastics Corp., 812/306-2000.

www.berryplastics.com

CCL Container Inc., 724/981-4420.

www.cclcontainer.com

Dimension Inc., 866/721-9244.

www.dimensionprinting.com

Giflor srl, +39 0444 380550.

www.giflor.it

Graham Packaging Co. Inc.,

717/849-8500.

www.grahampackaging.com

McNeel North America,206/545-7000. www.rhino3d.com

Parametric Technology Corp. (PTC),

781/370-5000. www.ptc.com

Phillips Design Group, 617/423-7676.

www.phillipsdesigngroup.com

Polytop Corp., 401/767-2400.

www.polytop.com

TricorBraun, 800/325-7782.

www.tricorbraun.com

Zeller Plastik USA Inc.,

847/247-7900.

www.zellerplastik.com

0 More information is available:

The logo-based concept plays on theHawaiian Tropic palm tree to maximizebrand equity across the product line.

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B

Lisa McTigue Pierce, Editor

Balm Chicky Inc. founders Abby Schwalb and

Elizabeth Moskow didn’t take no for an answerwhen one packaging supplier after another saidthe package they envisioned wasn’t possible or they weren’t interested in making it. T e two partnersknew their idea for T e Friend Enda lip balmcylinder with a second stash of balm stored in thebasesolved an unmet consumer need.

“T e Friend End design idea stemmed from asimple act that so many of us balm users encounterpulling a tube of lip balm out of your pocket or bagand having a friend, co-worker or someone else ask if they can borrow your balm for their own chappedlips,” Schwalb says. “We’ve noticed that, like yawning,using lip balm is almost a contagious act and so lipbalm borrowing runs rampant.”

Most people hand it over, some reluctantly,because they don’t want to appear selfi sh oruncaring. But being nice might not be best after

all. What they’re most likely sharing are germs,especially during cold and fl u season. Moskow explains, “T e skin on our lips is very thin andwhen lips are drythe time we’re most likely to

use balmthey often have small cracks or tears inthe skin membrane. Germs more readily enter thebody through these dry lips, making people moresusceptible to germs and infection.”

T e Friend End is a simple, hygienic solution.It’s similar to a typical lip balm tube, where themain compartment holds the product and userstwist the bottom to raise and lower the solid lipsalve. But the bottom of this tube fl ips open toreveal a second small pot of balm inside the base,enough for about 20 uses.

When someone asks to borrow your lip balm,you could, without hesitation, turn it upsidedown, fl ick open T e Friend End and hand themthe tube. T is way, you can share lip relief with

your friends while keeping the main stick pristinefor your lips only.

Finding the right friendsCommercializing T e Friend End has taken

about two and a half years. Schwalb and Moskow fi rst had the idea back in August 2008; thenregistered their company in 2009. T e plan is tolaunch their own branded product this spring,Balm Chicky Balm Balm (inspired by the ‘70s adultfi lm genre), as well as to license T e Friend End toother lip balm or cosmetic companies.

With no prior experience in packaging, thepartners learned as they went, making tweaks alongthe way. “We hardly knew what injection moldingwas two years ago,” Schwalb recalls. “We’ve done all

of our own research via communicating with plasticscompanies, fi lling companies, engineers and fi lling

Hip lip balm…for twoThe owners of Balm Chicky Inc. envisioned an UNUSUAL

TWO-COMPARTMENT TUBE that lets consumers

share their lip balm with friendshygienically. But

engineering and producing The Friend End package

took patience and persistence.

Trays holding The Friend End tubes will be fl ooded withliquid lip balm to fi ll the main compartment. Once theproduct sets, the tubes will be removed from the tray,fl ipped upside down and reinserted so the bottom can be

fi lled, too.

Cutaway view

Top cap snaps on to main body tube

by lip and channel (interference fi t).

When The Friend End portion is

turned clockwise, the main body lip

balm will rise out of the main body

tube.

Interior wheel snaps into main body

and is kept in by lip.

Exterior wheel and interior wheel are

timed by locking teeth and fasten

together by lip and channel.

The Friend End cap snaps into place

by interference fi t of lip of exterior

wheel and channel of The Friend End

cap. The Friend End portion refers to

The Friend End lip balm and wheel,

which is one unit with the cap hinged

to the wheel.

Top cap (PP)

Main body (PP)

Interior wheel (PP)

Riser (PP)

Exterior wheel (PP)

Cap (PP)

(Inset) Living butterfl y

hinge needs to be as

fl ush as possible and

have both an open

and shut state.

Wheel (interior)

Wheel (exterior)

The Friend End cap

Top cap

Riser

Main body

Exploded view

Continued on page 24




returned to the kettle.• ubes will then be fl ipped over, and

T e Friend End fi lled the same way.• Double-fi lled tubes will be

capped (both ends), then labeled,overwrapped and packed 24 or 30to a case.

Schwalb explains why they decidedto package the tubes singly andsimply: “We thought about havingan external box as with other prestigeproducts, but both of us are consciousof the impact Balm Chicky has toour environment and didn’t want togenerate additional waste throughexcess packaging. Also, since T eFriend End feature is such a profoundmarketing tool, we didn’t want toenclose and hide the concept in a box.”

Looking the partIf Balm Chicky Balm Balm

rolls off your tongue like a melody from a campy porno fi lm, that’s no

mistake. T e founders characterizethe company and its branded lipbalm as one of “playful sexiness.”A post on the company’s Facebook page even teases, “T e Friend EndENCOURAGES you to put a fi ngerin our bottom!”

T e brand’s sexy ’70s vibe comesthrough the retro label graphics(by Portland-based freelance artistand graphic designer Ann Storer)and tongue-in-cheek fl avor names:Juicy Melons (cantaloupe), Sticky Bunny (cinnamon/caramel), HugeCucumber (cucumber/mint), Sweet

Baby Ginger (ginger), Hot ChocolateLove (chocolate), Wild MountainHoney (honey/orange), PapaCherry (cherry), Rosie Pomegranate(pomegranate), antric ease (chaimasala) and All Naturals (unfl avored).

T ere’s even a ménage à trois inthe making. “About six months afterthe launch of our brand Balm Chicky Balm Balm,” Moskow tells us, “BalmChicky Inc. plans to roll out vintagetins with a threesome of fl avors, toenhance your lip soothing enjoyment,as well as lip stain, lip gloss, body balms, scrubs and more.”

License to killNo joke: April 1, 2011, is the target

launch date for Balm Chicky BalmBalm. It will be sold for a suggestedretail price of $7 per tube in prestigecosmetic stores, kiosks and upscaleboutiques in Portland, OR, to start,with hopes to distribute across thecountry as soon as possible. T eirplan is to make T e Friend End ahousehold name for everyday balmusers or for anyone who is concernedabout personal hygiene and keeping

their own balm end sanitary.Additionally, Balm Chicky Inc. is

actively seeking an exclusive licenseefor T e Friend End, and is open toother licensing options “if the fi t isright,” Moskow says. T e conceptcould easily be used with otherproducts, too, such as medicatedbrands and ski/surf/sport products.

“We really want to let othercompanies know that T e Friend Endtechnology is a sure-fi re way to bring

attention and increased sales to yourbrand,” Schwalb says. “Diff erentiationis the name of the game in thecosmetics world and it’s not often that

a package feature is not only diff erent,but also serves an important function.”

View additional exclusive photos online at www.packagingdigest.com.

Balm Chicky Inc., 720/475-0979. www.balmchicky.com

McCaskey Design and Development, 503/313-9217. www.jeffmccaskey.com

Ann Storer, 503/270-9282.Wuxi Sunmart Science and Technology Co. Ltd., +86 510-82733182.

www.zmwco.com/sprayers/


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brand

design

BBrand owners know that extending their brandin new directions can provide the impetus forgrowth and, ideally, profi t. But they also know thatif not executed properly their brands can lose theconnection to the consumer.

Years ago, Coca-Cola Co. was faced with animportant challenge: ransitioning their iconicbrand from a glass to plastic bott le. T is was animportant step for Coca-Cola from both strategicand environmental perspectives. Arguably themost important component of the change waswhether or not consumers would accept the new bottle as something that was true to the Cokebrand. T e look, the feel, the weight all required

consideration to ensure consistency of the brandexperience.

T e Coke bottle is as much a part of the brandas the Coke script in the logo and required intensescrutiny because the plastic bottle aff ected fi lling,distribution and the overall brand experience. A few years later, Heinz faced the same challengewith an iconic bottle of their own. T e processof extending your brand into multiple packagingformats can be challenging. Let’s explore the topthree considerations:

1. Brand equityBrand equity is the

No. 1 considerationwhen introducingyour brand in multipleformats. T e exercise of exploring formats that fi tyour strategy will forcean in-depth analysis of the components thattruly encompass yourbrand. Remember, yourbrand is the sum of its parts, not any one

individual component.Brand owners must ask themselves the toughquestions: “If we change this component (printprocess, substrate, color, size), will it still feel likemy brand?”

Brand owners need to understand theirbrand’s equity before ensuring it is consistently communicated across all touchpoints. Color andshape are the easiest targets when assessing brandequity but it’s important to recognize all the

individual elements of your brand todissect it. Once you have dissectedyour brand, you will have a good

understanding of what can and can’t change. T iswill allow you to enhance specifi c elements withoutalienating consumers.

T e debacles widely publicized around designchanges to ropicana and the GAP logo areexamples of what not to do.

2. Brand experienceWhen consumers decide to part with their

money and purchase your brand what kind of experience are they going to have? Does thenew packaging format provide an opportunity

to enhance the brand experience? T ese are thetypes of questions that should be considered whenextending your brand.

Moving to a new format should have some built-in value-added benefi ts to the consumer. Perhapsit’s more convenient, faster to make or easier todispense. Whatever the benefi t is, make sure it i sconsistent with and, if possible, enhances yourbrand’s experience.

And make sure there actually is a benefi t tothe consumer and not just to your organization.Sometimes the lure to extend your brand issimply because it reduces your costs in some way or streamlines distribution. T is has nothing to

When extending a brand to NEW OR ADDITIONAL

PACKAGING FORMATS, consider these three factors.

Multiplepersonalities

When moving from glass (left) to plastic(right), Coca-Cola Co. worked hard tomake sure that the new packaginglived up to the consumer’s brandexpectations.

Coke used its advertising to tell consumers about the glass-to-plastic packaging switch.




do with the consumer and you areputting your overall brand at risk.In fact brand owners must considerwhether their brand is strong enoughto be stretched to new formats. If your brand is not performing wellin the market, it is unlikely thatextending it to new formats willimprove its position.

3. Brand consistencyT is is the most diffi cult

consideration to execute becauseit typically involves many movingparts. Manufacturing, print processes,substrate/materials all need to beconsidered when moving the brandto new formats. Hopefully, you’vealready completed the exercise of

understanding your brand’s equity and know how to deliver the brandexperience, but how do you planto make it all come together? T emanufacturing component aloneusually requires new suppliers, new print processes, new substrates.

All of these elements are new territory for your brand and arecritical to its success. While PMScolors are supposed to be consistent,there are still fl uctuations in colorhue when printing across multiplesubstrates. But the consumer doesn’tknow or care about all of your hardwork in the background. T ey areonly exposed to your brand at thepoint of purchase. T ey care, and willnotice, if the brand they know andlove has changed in some way.

iming is important becauseintroducing a new variant to yourpackaging will require support frommarketing and advertising budgets.

In addition, it is always helpful toengage consumers to validate yourbrand strategy. T ey will probably tellyou something about your brand youdidn’t know or consider.

Understanding your brand’sunique characteristics will assist youin determining which visual directionto take and, assuming the new

packaging format off ers consumerssomething new or better, you canposition yourself for success. T ere’sno question that when executedeff ectively, extending your brandto multiple formats can have anextremely positive impact on profi t.Just make sure you understand yourbrand as well as your consumers do.

John Miziolek is an owner of Reset

Branding, a Toronto-based branding

agency. For more information, visit

www.resetbranding.com.

Even Coke’s most recent plastic bottleharkens back to the brand’s iconicshape from the earlier glass container.

The process of

extending your

brand into multiplepackaging formats

can be challenging.

For 17 years, PakTech has served all major brands and

processors with the most innovative technology in the

marketplace. In fact, it’s our mission to supply clients with

tomorrow’s solutions, today. From our premium

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

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health

& beauty

OLisa McTigue Pierce, Editor

Once you’ve got a winner, it’s hard to follow upwith a good sequel. Keeping the kicks the thirdtime around takes real ingenuity.

When designing the packaging for its Book of Shadows III, California beauty brand Urban Decay knew it had to up the ante for its popular annualeye shadow collection.

asked with the project, product developmentdirector Amy Zunzunegui at Urban Decay says,“We feel like every year we need to make it moreinteresting and more appealing to the customer sowe shine versus our competitors. We’d seen LED

lights in other things, like cards. We’re always tryingto take things that have never been done before inpackaging and apply it to our package.”

BOS III incorporates seven LEDs in a pop-upbox design of a New York City evening cityscape.“New York City is very Urban Decay-ish,” explainsZunzunegui. “Even though we’re not from New York, it’s kind of a quintessential Urban Decay city and feels very much like our brand. We thought thelights in the skyline would be great.”

Urban Decay worked closely with its supplierHCT Packaging on the concept, design andimplementation of this package. Nick Gardner,evp for HC, says, “Having created the two

previous Book of Shadows, as well as the hugely successful Alice in Wonderland pop-up palette, wewanted to take the concept to another level andcreate something with Urban Decay that really stood out from the crowd. New York City is afantastic place, full of atmosphere and characterwhich is what we wanted to capture in this thirdbook of shadows.”

Inspired by the glimmering lights and iconiclandmarks of New York City, the elaborate BOSIII pop up shows hand-illustrated depictions of the city that never sleepsfrom skyscrapers suchas the Empire State building to landmarks like theStatue of Liberty and Central Parkset against abackdrop of a star-fi lled night sky.

A ribbon pull-out drawer holds 16 shades (sevenof which are exclusive to this palette), plus twocolors of Glide-On eye pencils and a 3.7ml travelsize eye-shadow Primer Potion. T is melting potof color, with its unique package, is positioned as acollector’s item.

Artful functionalityStarting with the idea that they wanted to

use LEDs somehow for BOS III, Zunzuneguitalks about designing the NYC theme around thefunctionality of the lights. “It took a long time tofl ush the artwork out, to go back and forth with‘Yes, this side is right, it i sn’t right. Let’s tweak this .

Let’s make the sky look this way, the girl look thisway. We need to make the taxicab move over to theleft because it’s blocking this skyscraper.’ T ere wasa lot of back and forth,” Zunzunegui remembers.“Once we got our artwork, then we had to fi gureout the positioning of the lights. ‘T is light can’tgo in this building because it’s not thick enoughto hold the wire up the back. Or it can’t go herebecause it’s too close to the border. We need morespace.’”

A built-in battery in the lid powers thepack’s seven LEDs, a number selected to make amaximum impression at an aff ordable cost. woof the lights are positioned in buildings printed onthe inside of the lid. T e other fi ve are incorporatedinto pop-ups.

HC had worked with LEDs before, but only by applying them directly onto the pieces. T isdesign needed to be a bit more sophisticated.Gardner explains, “LEDs have a tendency,because they’re so bright, to visually look not very appealing. When you open them, they’re like ‘ooh,’this horrible set of lights, like a being blinded by acar. It’s diffi cult to control the voltage.”

He continues, “So what we did with this was,all the LEDs are covered. T e back section of the lid is covered with a mylar sheet that acts asa light shade, if you will. T e other LEDs on thepop ups are either placed at the back or inside thebuildings so the buildings look as though they’reilluminated. But it’s not a light that would beunnatural, like stuck on them. It’s in them, sowhen you look at them, the buildings are lit fromthe inside.”

When asked about the impact on recyclingor disposal of the package, Gardner says, “Weobviously cannot speak for how the end customerwould dispose of these but in truth it would behard to remove the batteries to allow them to

be placed into a clean recycling stream. We arenot making strong claims for the environmentalfriendliness of this packaging unlike some of the other UD products we make such as ‘T esustainable shadow box’ that is made from bambooand recycled greyboard.”

To keep customers coming back for more, URBAN DECAY LIGHTS UP A

NEW YORK CITY POP-UP CITYSCAPE for its Book of Shadows III eye-shadow

collection through a marriage of package design and function.

UD LEDs

A fi rst for cosmeticspackaging, seven

LEDspositioned inbuildings and on the

bridgelight up UrbanDecay’s latest Book of

Shadows collection.

Urban Decay’s Holiday

2010 Book of Shadows IIIlaunched in October 2010. By being

the fi rst palette to incorporate LEDs

with a pop-up cityscape, it one-upped the

company’s Book of Shadows I from Holiday 2008 (left),

which was the fi rst pop-up design. Book of Shadows II

from Holiday 2009 (right) departed from the

pop-up format to feature a photo

album-style of Urban

Decay images most

popular with customers.

The lid opened to reveal a

trap door where the photo

album was housed.

Buildingon earliersuccess

being

LEDs

.

pop-up or




Making it work Once the design details were worked

out, HC set about bringing thepackage to life. T e main structureof the box is made from die-cutgreyboard, a staple in HC’s inventory.T e recycled paperboard, pressedinto sheets in diff erent thicknesses, isstacked, glued and cut to create theshell of the box and the drawer.

T e box is outer wrapped with artpaper128 grams per square meterthickoff set printed in four-colorprocess, embossed and UV coated. T epop-ups are off set printed in four-colorprocess on white cardstock and die-cut. otal weight of an empty package(minus the product pots) is 400 grams.

Magnets in the box and the topcorners of the lid provide a secureclosure. An activation switch and timerfor the LEDs is in the lid. When lifted,the lights come on by themselves. T ey turn off automatically, too, after about

a minute. T e standard battery providesbetween 5,000 to 6,000 activations.

T e entire package was handassembled at a licensed factory insouthern China, which used about500 people on the line to fi ll theorder for 400,000 packages. Each“book” took about fi ve to six minutesto make. “T e main challenge wasthe sheer complexity of the piece,”Gardner says. “T e large amount of handwork in the assembly, the placingof the lights and ensuring that thepop ups and lights all functioned welllead to very long production times.”

Assembled packages were sent toplants in the U.S. and the DominicanRepublic for fi lling by contractmanufacturer Oxygen Development .T e company formulates the eyeshadows based on Urban Decay’srecipes, opens the drawer, drops in theproducts and closes the drawer. Eachpalette is then packed into a clearfolding carton, made of virgin PE,with an insert card that shows all theproduct colors. Both carton and cardare sourced and supplied by HC.

Crazy for quality

BOS III retails for $54 and is soldat Macy’s, Sephora and ULA storesand online at macys.com, sephora.com, ulta.com, beauty.com andurbandecay.com.

Eye shadow is an important marketat Urban Decay. “Our customersare crazy for the eye shadows,”Zunzunegui says, as they representa higher percentage of businesscompared to competitors, whotypically sell more lip products.

BOS III has been so well-receivedthat Urban Decay has ordered a

second production run. Part of itsdraw is that, like other UD palettes,it contains seven shades not availableelsewhere. T at exclusivityplus thevariety of the collectionappeal tothe brand’s fans, those experimentalMillennials and selective Gen Xersin the 18 to 35 age range with thediscretionary income to be able toaff ord UD’s quality shadows.

It’s overall satisfaction, Zunzunegui

contends, that keeps them comingback for more. “We’ve set a trend withour customers that they’ve come toexpect new and innovative things withour packaging. But it always has tofunction and echo our brand image aswell,” she says. “So we’re always lookingfor diff erent treatments, diff erent waysto do things, diff erent stuff to put inthe palettes. T at being said, we takegreat pride in the fact that we have

high-quality makeup. If you don’t havegood cosmetics behind the scenes, thenyou can sell one palette, but no one’sgoing to buy another one.”


HCT Packaging, 310/260-7680.

www.hctpackaging.com

Oxygen Development LLC,954/480-2675.

http://oxygendevelopment.com

Glass elevates your brand.

The benefits of glass are simply uncanny – allowing the quality to shinethrough while protecting flavor and freshness. When you partner with O-I,we’ll complement glass’ natural allure with eye-catching, functional designsthat help premiumize any product. So if you’ re ready for packaging that movesproduct up and off the shelf, make the clear choice. O-I glass.

“Glass clearly helps us differentiate our product fromcans in the soup aisle.”

– Sean O’Neil, President, Bookbinder Specialties

Bookbinder Specialties got retailers and consumers buzzing when

they partnered with O-I to package their new line of gourmet soups

in glass. See the results for yourself – email or call for the case study.

[email protected] www.o-i.com 567-336-8532




contract packaging

B

Jack Mans, Plant Operations Editor

Black Bear Bottling Group LLC, Oak Creek, WI,specializes in contract packing carbonated beverages.

T e plant has a glass line running 6.3 oz to 1 qtbottles, a plastic line running 10 oz to 3L and aB-I-B operation. Customers include Wit BeverageCo., Goose Island sodas and Deerfi eld raders, whichproduces products for Walgreens. An interestingelement of Black Bear is that almost of all of itsequipment is bought used. “Contract packaging of carbonated beverages is a very cost-sensitive business,so it makes sense for us to buy used equipment whenit meets our needs and is available,” says Black Bearpresident and co-owner Peter Caruso.

“T e key is to fi nd a source for the used equipmentthat you can trust and that has the knowledge andresources to fi nd the equipment you need,” he adds.“For us, that source has been Howard Buckner

at SMB Machinery Systems. Almost all of theequipment I have in my plant has come from Howard.I tell him what I need and he fi nds it for me.”

SMB has a 120,000 sq-ft facility outside of Atlanta, GA, where it maintains an inventory

of used equipment, but if it doesn’t have therequired item in inventory, it will conduct a search.SMB rebuilds equipment as required, althoughthis isn’t always necessary, says Caruso. “T eequipment Howard fi nds us is generally in excellent

condition,” he says. SMB also has electrical andcontrols divisions that did work for Black Bear.T ey built new UL-approved control cabinets anddesigned line controls so that upstream equipmentwill shut down automatically if bottles back up onthe conveyors, and an operator can start all of theequipment on the line from a single cabinet. Mostof the equipment at Black Bear uses RockwellAutomation controls. Black Bear Equipment inthe plant was installed by Pieper Electric.

Running Jelly Belly blueberry drink During PD’s visit, Black Bear was running Jelly

Belly blueberry gourmet soda in 12-oz glass bottlesat a speed of 200 bottles/min for Wit Beverage Co.

(WBC). “Black Bear has been running productsfor us for the past fi ve years, and we have beenvery satisfi ed,” says Paul Kassis, co-founder of WBC. “Quality is a major requirement for us inselecting a contract packer, and Black Bear has done

a great job. T eirSQF certifi cation isa big factor becauseit assures that thehighest levels of

quality are beingachieved and certifi edby an independentthird party. Relationships are also very importantto us, and Pete Caruso has been outstanding towork with. Black Bear has done an excellent job of accommodating our requirements.”

Black Bear receives all of its bottles, which aresupplied by Anchor Glass Container Corp. andO-I, in bulk stacked pallets. T us, the fi rst stepin the glass packaging line is a bottle depalletizer.In this operation, the bottles are swept off onto abulk take-away conveyor on the top level and areconveyed by an Ambec lowerator conveyor fromFleetwoodGoldcoWyard to the fl oor level.

T e bottles travel to a bottle rinser that picksup the individual bottles with rubber grippers,inverts them for a water rinse and then sets themback upright on the outlet conveyor. T e bottlesthen enter a separate room where a monobloc unit

Contract packingcarbonated beveragesBased on what could be termed “sustainable economics,” BLACK BEAR BOTTLING GROUP

MOSTLY PURCHASES USED PACKAGING EQUIPMENT for its operations.

Bottles enter a separate room where a monobloc unit

with 40 fi lling heads and 10 capping heads fi lls and capsthem.

Bottles are li fted for fi lling and then travel to the capper.Rotary labeler has two labeling heads that apply p-s wraparound or front and back labels. As bottles leave the labeler,an inkjet prints date and lot codes on their shoulders.




with 40 fi lling heads and 10 screw capping headsfi lls and caps them. (T e depalletizer, rinser andfi ller/capper were built by companies that are nolonger in business, so those manufacturer’s namesare not included.) Bottles are metered onto thepressure fi ller by a star wheel that places them ontoindividual spring-loaded bottle pedestals.

As the machine rotates, each pedestal raises thebottle up against a seal on the bottom of the gravity-fi ll valve. As the pedestal lifts the bottle, it pushesopen a valve and fi lling commences. T e fi lling cycleis set so that the product reaches the bottom of thevalve sleeve as the fi ller rotation brings the bottle nearthe machine-discharge starwheel. T e bottle pedestaldescends, allowing the fi ll valve to close, and thebottles travel into the discharge starwheel.

T e bottles then enter the capper starwheel andare delivered to the rotating capper. Caps traveldown a chute from the hopper and are placed onthe bottles, after which chucks tighten the capsas the capper rotates. When the magnetic clutchreaches the set torque, it slips and the chuck systemdisengages. Black Bear also has a capper for crowncaps that it uses when running those products.

Black Bear has a newer, faster monobloc 40 fi llhead, eight capping head unit on order to upgradeits operation.

Monobloc fi ller/capperT e bottles are fi lled at 38 deg F, so after leaving

the fi lling/capping room, they enter a bulk heatingtunnel where hot water warms them to about 65deg F to eliminate any condensation on the bottlesthat would aff ect the labeling operation.

T e bottles are then single fi led and enter a

Kosme model op II AD 12-head labeler fromKrones Inc. that applies p-s labels, which aresupplied by Orion Labels LLC. T e labeler is the

only new piece of equipment on the line.T e unit is equipped with two labelingstations that can apply individual frontand back labels or wrap-around labels. Ateach station, a roll of labels is mountedhorizontally and the web is pulled througha series of rollers to a point where the labelis applied to the bottle.

A feedscrew meters the bottles into thelabeler’s infeed starwheel, which, transfersthe containers to individual plates on thecontinuously revolving bottle table. As the

bottle table rotates, the bottle plates alsorotate until the bottle is properly situated to

receive the fi rst label. After this is applied, the bottleplates continue to rotate so the bottle is positionedto receive the second label exactly opposite the fi rstlabel. T e labeled containers then travel through adischarge starwheel onto the discharge conveyor.

As the bottles leave the labeler, an Excel inkjetprinter from Videojet Technologies Inc. prints

date and lot codes on their shoulders. T e bottlesare then conveyed to a Hartness Intl Inc. Model825 case packer. Black Bear packs the bottles intofour- or six-pack carriers, and the carriers andshipping cases are erected ahead of the Hartnessunit by a machine from SWF Companies. T iserector incorporates a Melton hot melt unit fromValco Melton that applies glue to the fl aps. Glue issupplied by Henkel Corp. Black Bear has two of these units to keep up with production.

During PD’s visit, Black Bear was packing theJelly Belly bottles into four-pack carriers. T ecarriers are conveyed from the SWF machines toa packer from Pearson Packaging Systems thatplaces six carriers into a case (four six-pack carriers

into a case when the plant is running those). Black Continued on page 32

Black Bear Bottling Group LLC has become certifi ed under the Safe Quality Food (SQF) Level 2000 food safety

standard that specifi es the quality management system requirements necessary to identify food safety and quality

risks as well as validate and monitor the control measures. The SQF Institute is a division of the Food Marketing

Institute (FMI), which was established to manage the SQF food safety and quality certifi cation program. The SQF

Program is an internationally recognized comprehensive food safety and quality management system to cover theentire food chain. The program is made up of two codes (standards), the SQF 1000 Code for the primary production

sector and the SQF 2000 Code for the food manufacturing and service sectors. The SQF 2000 Quality Code is

a HACCP-based food safety and quality risk management system covering all food chain stakeholders. It covers

the identifi cation of food safety and quality risks, and the validation and monitoring of control measures. These

international standards are designed to be used by any business in the food supply chain operating in domestic or

global markets, from primary producers to manufacturers, and those who offer services to the food industry.

Black Bear Bottling Group achieves SafeQuality Food (SQF) Level 2000 certifi cation

Case packer drops 24 bottles at a time into four-or six-pack carriers, depending on what product the plant is running.




packer. T e cases are then conveyedthrough a SWF top gluer equippedwith a Melton hot melt unit.

T e cases travel past a Label-AireInc. print and apply unit that isequipped with a Sato America Inc.printer. T e printer prints a p-s label andan arm swings out and applies it to theshipping case. T e line is also equippedwith an Arpac Group shrink wrapperthat is used when it is running trays. T ecases are conveyed to a VonGal Corp.palletizer, and Black Bear has a Lantechstretch wrapper on order.

“I do business on the basis of relationships,” says Caruso. “Oursuppliers are great, which takes a lotof the pressure off of our operations.

Bear also runs trays on this line so ithas a Padlocker (now part of SWF)tray former that it uses when it isputting bottles onto trays.

T e cases containing the carriersare conveyed to the Hartness casepacker, where they enter on a low-level conveyor. Bottles enter themachine single fi le on top and thenare separated into four lanes forloading. When the correct number of bottles have accumulated, the empty

case is lifted and the bottles drop intothe case. A Marsh inkjet unit from

Videojet prints the product fl avor onthe sides of the cases as they exit the

Carriers and case fl aps are sealed with hot-melt glue. Shipping cases are conveyed to a high-level machine for palletizin

Anchor Glass Container Corp,

813/884-0000.

www.anchorglass.com

Arpac Group, 847/678-9034.

www.Arpac.com

FleetwoodGoldcoWyard,

630/759-6800. www.fgwa.com

Hartness Intl Inc.,

800/845-8791. www.hartness.com

Henkel Corp., 866/443-6535.

www.henkelna.com

Krones Inc., 414/409-4000.

www.kronesusa.com

Label-Aire, Inc., 714/441-0700.

www.label-aire.com

Lantech, 800/866-0322.

www.lantech.com

O-I, 567/336-5000. www.o-i.com

Orion Labels LLC, 920/833-1173.

www.orionlabels.com

Pearson Packaging Systems,

800/732-7766. www.pearsonpkg.com

Pieper Electric, 414/462-7700.

www.pieperpower.com

Rockwell Automation, 414/382-2000. www.rockwellautomation.com

Sato America Inc., 704/644-1650.

www.satoamerica.com

SMB Machinery Systems LLC,

770/704-2000. www.smbsales.com

Valco Melton, 513/874-6550.

www.valcomelton.com

SWF Cos., 559/638-8484.

www.swfcompanies.com

Videojet Technologies Inc.,

800/843-3610. www.videojet.com

VonGal Corp., 334/261-2700.

www.vongal.com


printing withpride in the U.S.A.



Henkel Corporation10 Finderne AvenueBridgewater, NJ 08807

ADVANTAGE

Creating Henkel is the leader of adhesive and coatings technology

worldwide. Henkel Creates Advantage through a broadrange of high-performance products and process solutions that

drive operational optimization for you and your customers.

To learn how Henkel can Create Advantage for you, and to receive more information,

visit: henkeladhesivesna.com/creatingadvantage21A.

Except as otherwise noted, all marks used are trademarks and/or registeredtrademarks of Henkel and/or its affiliates in the U.S. and elsewhere.® = registered in the U.S. Patent and Trademark Office. © Henkel Corporation, 2011. All rights reserved. 6979 (1/11)

B E S T V A L U E

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Total Process Solutions Our ResourcesYour Success




coffee cup packaging

T

A state-of-the-art, fully automated packaging system at Nestlé

Nespresso’s coffee plant in Lecco, Italy runs 1,260 coffee capsules/min.

T e Nestlé Nespresso SA Co., one of the fastestgrowing operating units of the Nestlé Group, hasfaced an unprecedented increase in customer demandfor its portioned coff ees in induividual serving

capsules. T e company, headquartered in Losanna,Switzerland, pioneered the concept of portionedhigh quality Grand Cru coff ees for use at home, aswell as at out-of-home locations, such as high-endrestaurants, hotels and cafés, premium event caterers,customer care and luxury retail businesses.

In the past several years, the customer demandfor its products has been well above the company’ssustained annual compound growth rate of morethan 30 percent. While presenting a great competitiveadvantage, the customer demand has also requiredNestlé Nespresso to double its packaing productivity.T roughout its growth, Nestlé Nespresso’s key priority has been to not only meet the customerdemand, but also maintain a high quality standard for

its products and processes. Integrity of its productionprocess was thus regarded as critically important andcould not be compromised in delivering the project.

Packaging line upgradeNestlé Nespresso turned to Cama Group, a maker

of high technology secondary packaging systemsand machinery based in Lecco in Northern Italy,to upgrade its existing packaging line and allow thecompany to meet the expanding customer demand.Cama’s outstanding packaging knowledge, combinedwith a unique machine range and robotic loading

units, made it a logical choice for the project.Cama has grown steadily over recent years. T e

company’s turnover has increased from 13.5 millionEuros in 2002 to approximately 43 million Euros

in 2010. In part, this success is due to a strong anddeveloping relationship with Nestlé over the past 20years. T e group’s previous experience in workingwith Nestlé to produce packaging for small cone-shaped ice-creams products, greatly infl uenced Cama’sapproach to the Nespresso project and instilledconfi dence in Nestlé Nespresso that Cama can deliver.

CAMA worked with Rockwell Automation to deliver the project. T e two organizations haveworked together across a number of projects, sotheir collaboration on the Nestlé Nespresso projectrepresented a logical continuation of a successfulrelationship. In addition, Nestlé uses RockwellAutomation for all of its automation needs, whichincreased confi dence in the ability of all parties

involved in the project.Doubling the capacity of the Nespresso packaging

line required Cama to create a robotic wrappingmachine with a dedicated feeding system uniquely designed to meet Nespresso needs. T e project wasintended to set a prototype for all future Nespressofacilities, placing extra pressure on the importance of its success. T e key challenge was to help increase thesafe handling of small cups at varying high speeds.

Tight deadlines“We were under a lot of pressure to deliver this

project swiftly and successfully in order to meetthe rapidly growing demand for ourproduct,” says Enrico Induni, corporate

engineering manager, Nestlé Nespresso. “T e‘devil’s triangle’ of maintaining quality standards,while delivering on a tight deadline and on budget,is always a struggle. In this case, however, Cama

approached the project ‘the Italian way,’ that iswithout any fuss and promptly resolving any issues.T e project was delivered within budget and ontime.”

Cama has been developing robotic packagingsystems since 1988, enabling it to off er a wide rangeof dedicated package loading units equipped withtwo or four-axis robots. T ese units are designed tomeet diff erent packaging requirements for a variety of products, such as fl ow-wraps, bags, thermoformedpacks and cartons.

T e Nespresso automatic line, that was built by Cama, is a state-of-the-art, fully automated packagingsystem that consists of a robotic loading system, aside-loading cartoning machine and a wrapping

machine. T e line runs 1,260 capsules/min. T eloading system is a two-axis robot with picking headsdesigned and tailored by Cama to meet Nespresso’sspecifi c requirements. T e side-loading cartoningmachine places the coff ee cups in sleeves containingup to 10 items per sleeve. Each sleeve is sealed andcodifi ed by a laser after being fi lled. T e wrap-aroundmachine then loads the sleeves into the shippingcases, which contain 20 sleeves. A pallet system picksup the cases and takes them to the outbound line. Allthe production data is transmitted via Ethernet to acentral data collection system.

Cama utilized a range of Rockwell Automationsolutions in building the Nespresso packagingline, including Allen-Bradley ControlLogix and

CompactLogix programmable automation controllers(PACs), Factoryalk View software, PanelView HMI solutions and a Kinetix integrated motionsolution, featuring Allen-Bradley servomotors anddrives. T e Rockwell RSLogix 5000 programmingsoftware package used in the Nespresso line includesstandard program modules for motors, valves,alarms and analog I/O scaling as well as standardprogram modules for PID loops, programs andtasks structures, I/O mapping confi guration, processcontrol sequence examples and safety/processinterlocks structures.

T e Rockwell Automation team in Switzerlandworked with Cama on this project because the Nestlé

System doubles coffee production

The automated packagingsystem consists of a roboticloading system, a side-loading

cartoning machine and awrapping machine.




Nespresso plant is located there.“It is a great advantage to work

with companies such as RockwellAutomation and Cama, who candraw on their subsidiaries in variouscountries,” says Induni. “For a globalcompany such as Nestlé, this is akey competitive advantage, ensuringthat the project can receive promptand effi cient support regardless of itsgeographical location.”

Cama held a week-long workshopfor Nestlé Nespresso technicians atits plant in Lecco to familiarize themwith the technological specifi cationsof the machines. Cama continuedto provide training on the NestléNespresso production fl oor to allow its technicians to learn how to use theequipment.

Close coordinationWhen suppliers team up to deliver a

product to a customer, communicationand information sharing oftenbecomes a challenge, as companies

may sometimes be willing to revealonly partial information about theirequipment and knowledge relevantto the project. As a result, teams,without full knowledge of each other’scompetencies, may not understandhow to fully leverage each other’sequipment and expertise.

T e coordination between theRockwell Automation and Camateams was effi cient and seamless.“Major multinational manufacturersare standardizing with RockwellAutomation’s equipment, because itis hugely innovative, easy to use and

performs impeccably,” says GiovanniAnzani, project manager for theNestlé Nespresso and CAMA Group.“In addition, our teams had a goodknowledge of each other’s equipmentand worked really well together.”

T e project took only eight monthsto complete from start to fi nishavery short timeframe for delivery of such a complex project. “Under suchcircumstances, strong commitmentof resources and will is required fromboth the supplier and the customer tohelp ensure the success of the project,”

says Nespresso’s Induni. “I am happy to report that Cama and RockwellAutomation were able to work togetherand meet all objectives of the project.”

Since the completion of the fi rstproduction line, Cama has delivered18 additional lines and more are beingordered by Nestlé Nespresso. “Our

partnership with Rockwell Automationon the Nestlé Nespresso project was afantastic one, resulting in a completesuccess story for the customer,” saysCama’s Anzani. “Our relationship withNestlé Nespresso continues, as is ourdedication to the partnership withRockwell Automation.”

Cama USA Inc., 201/940-7230.

www.camagroup.com

Rockwell Automation, 414/382-2000.

www.rockwellautomation.com


You need highly

competent people

with specifi c skills,

willing to sacrifi ce a

lot of time and effort

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sustainability

Collaborative effort by packaging technology companies creates packages

that BETTER PROTECT WINES from potential environmental damage.

Research shows boxed wine sales are strong andfuture growth prospects look promising. In theU.S. alone, sales of 3-L boxes of wine have grownat double-digit rates year-after-year since 2003 and

total U.S. consumption from the box, includingboth 3- and 5-L formats, is more than 20 percentby volume (source: AC Nielsen Scantrack Data).

T is momentum among consumers and retailersalike comes as no surprise, given the environmental,cost and taste benefi ts of boxed wines. Unfi lledbags in bag-in-box (B-I-B) wine packaging requireup to 88 percent less storage space than bottles,making them much more economical to warehouseand ship. Boxed wines also are lighter thanbottled wines, less prone to breakage and easier totransport.

Perhaps most importantly, B-I-B packagingminimizes the product oxidation that occurs whenconventional bottles are opened. B-I-B wine can

stay fresh for as long as six weeks after openingversus two to three days for bottled wine.

As a worldwide supplier of bags for the wineindustry with manufacturing locations on fi vecontinents, Scholle Packaging’s products are sold inmore than 60 countries and include fl exible fi lms,fi tments and caps, bags and fi lling equipmentfor the food, beverage and industrialmarkets.

o keep the company at theforefront of bringing fl exiblepackaging technology and trends to life,Scholle hasdeployed

signifi cantresources in theareas of research anddevelopment and packaginginnovation. So when it decided toplace the ethylene vinyl acetate (EVA)based fi lm, it had been using in its B-I-Bpackaging for wine with a new and improved fi lm,Scholle needed a supplier with the capabilities andknowledge to formulate a distinct product thatwould meet its customers’ needs with breakthroughtechnology for the B-I-B wine industry. As a globalcompany, Scholle also needed uniformity of resinsacross geographies.

Bagging material improvementsWith 14 manufacturing locations for PE in four

continents, the Dow Chemical Co. was the perfectfi t. Additionally, the companies could hit the

ground running as Dow as a long-time materialssupplier for Scholle.

“Dow is Scholle Packaging’s No. 1 supplierbecause they really understand the fl exiblepackaging industry and have a tremendous productportfolio,” David Bellmore, manager of globalproduct development, Scholle Packaging, remarks.“T eir multi-source capability [for PE] both inNorth America and other continents enhancethe security of supply that our customers valueimmensely.”

Anand Sundaresan, senior North Americanmarket manager, food and specialty packagingat Dow adds: “As the largest PE producer in theworld, we knew we could develop a resin with

our strong polymer and material science expertise.Collaboration really adds value by getting it rightthe fi rst-time, accelerating the speed to market andhelping our customers rapidly achieve success in the

marketplace. Eff ective collaboration was really the key to successful innovation in

this case.”Scholle

outlinedthree

specifi crequirements

of the new fi lm it sought to

develop: 1) T e new

fi lm needed to haveimproved strength for

better puncture and fl ex-crack resistance which is crucial for

maintaining package integrity toprevent leakage; 2) It should allow

for faster sealability; and 3) It mustdeliver improved organolepticproperties for freshness, tasteand odor.

T is last requirementwas especially important toScholle, as it looked to appealto higher-end and more

specialty wine producers.Dow listened to Scholle’s specifi cations to

identify a variety of ideas to match Scholle’s vision.T e materials supplier then produced variousfi lms in its fabrication facility, and then presentedimportant fi ndings and suggestions to Scholle forconsideration.

T e result of the collaboration was ScholleFlexiech, a single-layer, PE, non-barrier fi lm thatoff ers strong seals and robust package performance.Dow’s in-house reseach and development groupdesigned a resin for Scholle based on Dow’s catalyst

process and product know-how that met Scholle’skey requirements and requests.

T e new fi lm, which serves as the wine contactlayer in B-I-B packaging, off ers durability and fl excrack resistance. Additionally, Flexiech allowsfor consistent sealability which ensures the high-quality of Scholle’s bags. It also helps to provideoptimal taste and odor properties of the wine.

“T e B-I-B wine industry is an importantmarket for Scholleone in which we routinely have seen double-digit growth year-after-year,” saysBellmore. “T e distinct material that Dow createdwith Scholle’s vision and guidance enabled us tomeet the needs of wine manufacturers and vintnerslooking to capitalize on the benefi ts of B-I-B

packaging without compromising the quality of their product.”

Tapping innovations for dispensingScholle says its innovation and leadership in the

boxed wine marketplace does not end with fi lmsalone. T e company designs and sells dispensingtaps, too. Chief among its fi tments is Flexap, anergonomically-designed spigot that off ers pushbutton dispensing of low-viscosity liquids andfeatures easy-on, automatic-off functionality andfl ow rate control. Unlike standard closures foundon conventional bottles and rigid packagingcontainers that allow product-degrading oxygen

Bringing innovation

to bag-in-boxpackaging

Sales of 3-Lboxes of wine havegrown at double-digit ratessince 2003, and total U.S. boxed

wine consumption, including 3- and 5-L formats, hasgrown more than 20 percent by volume.

Unfi lled bags requireup to 88 percentless storage spacethan bottles, makingthem much moreeconomical towarehouse and ship.



37www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011

to enter the container each time thecap is removed, Flexap’s positivefl ow design blocks oxygen fromentering the package, preserving andprolonging the product’s life. Equally important, Flexap is easy to use.

Flexap’s applicability extendsbeyond the wine industry to alsoinclude the water, health drink andjuice markets where consumersappreciate its easy-to-use, stay freshdesign. With Flexap, Scholle alsosaw an opportunity to meet a need inthe edible oil packaging marketplace,particularly among consumers andfood-service operators using cookingoils. T is was because the tap enableseasy, clean dispensing of oils.

Prior to launching into theedible oil market, Scholle’s Globalechnology Laboratory conducted aseries of pre-commercialization teststo ensure a smooth transition into theedible oil market. T is early testing

revealed a challenge: Over time, theedible oils would begin to migratethrough the soft push-button of theFlexap.

o overcome this potentialproblem, Scholle again collaboratedwith Dow. “Dow off ers nearly every product in the polyolefi n industry

and has a variety of grades to selectfrom, so we knew they would beable to help us fi nd a material thatoff ered the density we needed to helpeliminate oil migration from the tapwithout sacrifi cing ease of use,” saysBellmore.

In another very collaborativeprocess, Scholle defi ned the modulusproperties of the existing push-button and the level of fl exibility thatit sought to keep. Dow presentedScholle with samples from itsproduct portfolio, and together they helped identify the grade that hadthe right density and melt index tomeet Scholle’s needs. Scholle thenconducted injection molding trialsand lab testing.

“What we found was that usingdenser materials made the buttonharder to push but provided a betterbarrier,” Bellmore recalls. “Ultimately,Dow and Scholle together identifi ed

the sweet spot that presented theright density with eff ective oil barrierresistance.

“Dow has continually proven itsvalue to Scholle beyond that of resinsupplier,” Bellmore adds. “T ey work hard to understand their customers’business challenges and bring back novel ideas that help drive businessgrowth.”

“Collaborative innovationbetween Scholle and Dow iscontinually driving innovation inthe B-I-B packaging industry andidentifying opportunities to meet

the unique needs of its customerswith opportunities that are desirable,economically competitive andsustainable. T is constant innovationcan be seen in our ever-expandingDowlex, Elite and Attaneportfolio,”says Sundaresan.

Bellmore notes that investmentsin research and development haveenabled Dow to innovate acrossmarket segments to create packagingsolutions for applications from wineto edible oils.

About this article’s authors: Rachael Hopkins is the value chain

manager for packaging sustainability

at The Dow Chemical Co. Dowlex, Elite,

and Attane are trademarks of The Dow

Chemical Co.

Katie Scarpelli is the global

marketing communications manager,

wine & spirits.

Diane Chewning is the global

marketing communications manager,

food and beverage for Scholle

Packaging.Taps with positive fl ow design block oxygen from entering the package, whichcan prolong product life.

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M

protective

packaging

Dinnerware distributor, Ten Strawberry Street, uses interlocking packing

materials to ABSORB SHOCK AND PREVENT SHIFTING of its ceramic

and glass products during shipment.

Linda Casey, Senior Editor

Meeting product protection needs whendistribution streams vary from pallets sent via

dedicated truck systems to case shipments deliveredby package delivery services can be a challenge forpackaged goods companies, especially as consumersand retailer-customers are increasingly voicingconcerns about over-packaging.

T is was the challenge facing en Strawberry Street, Denver, CO, which imports its dinnerware,glassware and fl atware from factories around the globe,including manufacturers in Sri Lanka, Bangladesh,China, T ailand, Poland, Germany and Belgium, andrepackages them for retailer-customers. In additionto repackaging product for shipment to retailers’distribution centers in secured pallets, en Strawberry Street sends product by the case via UPS and FedEx.

Pyramids form nests inside shippersWhen the distributor started having problems

with its shipments to Walmart, it quickly took the retailer’s advice to re-examine its packaging.“en Strawberry Street had some pretty seriousdamage issues and they were actually referred tous through one of their customers,” recalls Jeff Boothman, president of FoldedPak LLC, a supplierof protective, paper-based, packaging material thatforms structures specifi cally engineered to absorbenergy and provide clean unpacking experienceswithout large warehouse space requirements.

When en Strawberry Street fi rst looked at theproduct, which is sold as a fl at material web calledExpandOSshort for expand on site, the packaging

solution was fairly new to the market. “I wasa bit of guinea pig,” Zachary Zucker, COOof en Strawberry Street, comments.

T e distributor was presented with a proof-of-concept that was nearly a literal interpretation

of the pyramid’s nesting capabilities. “ExpandOSsent me a raw egg in a package from New York to Denver, and the egg showed up in one piece,”Zucker exclaims. “We’ve been using it pretty muchexclusively for the last two years.”

A sustainable manufacturing processNot only does the packaging’s functionality harken

back to nature’s own fragile containerthe nestExpandOS is made from eco-conscious materialusing an effi cient manufacturing process. “ExpandOSis made from 100 percent post-industrial waste,”Boothman says. “It’s essentially a waste stream fromthe industrial process that creates beverage cartons. It’sfi rst-quality material that’s just as good as what they’re

actually making beverage cartons out of.”When the beverage carton company cuts the

cartons out of the web, it doesn’t use the entirewidth of the web. T e remaining material typically would be repulped to be used as pre-consumerrecycled fi ber. T e ExpandOS material enablesuse of the scrap material without repulping, thuseliminating the carbon footprint associated with therepulping process.

FoldedPak says that each 1,000 lbs of post-industrial waste ExpandOS averts from therepulping process saves 888 lb of CO2, which is theequivalent of taking 3.9 cars off the road for a week.

Flat-out productivity booster

Additionally, ExpandOS is sold as a web of foldedmaterial, with a small physical footprint and no coreto dispose of. T is web is die-cut so an Expandermachine can create pyramid-shaped packing materialwith 38 “fi ngers” designed to cling together using allthree sides of the pyramid.

“ExpandOS expands at a 25:1 ratio,” saysBoothman. “You don’t have to have a thousand cubicft of storage space right next to the pack-out line. Youcan have a pallet of our paper, which is maybe 4 feettall, and make 1,000 cubic feet of protective fi ll.”

T is lets en Strawberry Street keep its pack-outprocess compact, which currently is a primarily manual endeavor. For example, its dinnerware orders

are manually pulled and staged. Each set arrives atthe plant in primary packaging, so workers need only to cushion these packages for transport. o this aim

worker will manually erect each case, place 1 in. of ExpandOS at the bottom, set the primary packagein the shipper, and fl ow ExpandOS over and aroundthe primary packaging before manually taping thecase closed. Product pallets are built manually, thenwrapped by stretchwrapper supplied by OrionPackaging LLC.

Branded for the futureIn addition to leveraging EspandOS’ protective

properties, en Strawberry Street has started totake advantage of the marketing benefi ts of printedExpandOS triangles versus the plain triangles ithas been using. T is is part of an ongoing brandawareness campaign for the distributor, which isn’t

shy about expanding business off erings. “Whenwe [Zucker’s family] bought the company out of bankruptcy, it had one SKU,” Zucker explains. “Overthe last 15 years, we’ve been able to grow the lineand diversify ourselves in a few diff erent markets.”T e strategy seems paying off : en Strawberry Streetopened its fi rst retail store in 2010.

Packed for

safe travels

Packaging material isdispensed below, around

and on top of a case ofsmall ceramic plates

which otherwisewould be prone

to breakage

An employee wraps a small pallet of product fordistribution.

FoldedPak LLC., 866/909-6266.

www.ExpandOS.com

Orion Packaging LLC, a div. of Pro Mach,

800/333-6556. www.orionpackaging.com


An operator loads the expanding machine with a web offl at, die-cut material.




engineers’ outloo

OOne question often asked during an interview is: “Where do you see yourself in fi ve years?”Your response probably had something to dowith advancement, increased responsibility ormanagement. But do you also recall being askedhow you plan to get there?

I’d wager few of you were asked that, butit’s critical to your career that you give seriousconsideration to and refl ect on creating a strategy to

get there. T at’s not to say that outside infl uenceswon’t impede or hinder your plan, or that yourstrategy will work all the time. Butas this is animportant aspect of addressing most challengingissuesit’s better to have a plan in place fromwhich you can deviate, than to have no plan at all.

Over the years I’ve had the opportunity to holdin-depth discussions with packaging executives

about the traits and characteristics they look forin their employees that they believe make themattractive for advancement. T ese include:1. Personablebe pleasant to be around and easy

to work with. Be likable.2. Demonstrate a passion for your work. It’s been

said, “If you love what you do, you never work a day in your life.”

3. Fit into the organization’s culture. Embody similar goals and values.

4. Be punctual. Arrive at work a little earlier thanexpected and leave a little later.

5. Remain focused on achieving short-term goalswhile working towards long-term strategicgoals.

6. Be well-organized. T at includes having anorganized offi ce and desk, as well as knowing

how to organizea project.

7. Be a team player.Don’t alwaysseek credit for

everything you do. Never make the mistakeof thinking you will look good by makingsomeone else look bad. Be the person your peerslook up to.

8. Seek responsibility and take responsibility foryour actions.

9. Be honest and candid. Lies will come back tobite youhard.

10. Learn the art of public speaking. Make asmany presentations as you can. Volunteer forassignments, keeping yourself visible.

11. Dress a little better than the norm, regardless of “dress-down” days.

12. Learn how to write well. Remember thatspell-check does not correct grammar, usage oralternative spelling.

13. Learn how to listen.14. Learn how to sell, whether it be the company,

the company’s products or your ideas tosomeone else.

15. Learn how to negotiate.16. Don’t make excuses.17. Keep your boss and management informed.

Anticipate and address problems before they arise. Avoid crises by planning eff ectively.

18. Develop a strong network.19. Find a mentor and, if possible, become a

mentor.20. “Act as if.” When you act as if you are the

person you want to become, people willperceive your capability and that you are ready to be in that advanced position.

Rick Pascal, a senior

partner at Adept

Packaging, is a certifi ed

personnel consultant with

more than 25 years of

experience in packaging.

Adept Packaging is an

international packaging

engineering company

headquartered in the U.S. For more information,

visit www.adeptpkg.com

Engineers should create a strategythat will advance their careers

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on

line

Here’s what readers o packagingdigest.com are saying:

Talk back!

cookie trays, expecting to save 150 tons o paperboard.

www.packagingdigest.com/GirlScouts

I question the appropriateness o showing twocracked ootball helmets on the package, consider-ing all the attention being paid in the media to thedanger o brain damage, neck injury or paralysisby using one’s helmet as a battering ram againstanother player. Just ain’t unny.Richard Salcer on “Carrot packaging uses humor to

appeal to football fans”

This competition seems odd considering Cereplast’s

portolio o petroleum-based hybrids.

Steven Prindle on “Contest seeks best ‘bioplastics’ symbol”

Italian winesports white

leather caseAmerican designer Denise Focil and

Italian wine maker Distilleria Bottega

create luxury and stylish packaging or

Amarone Bottega, Il vino Prêt-á-porter

wine. The bottle eatures a white leather

label and is nestled in a white leather

case embellished with debossed black

lettering, which is intended to remind

consumers o a vintage suitcase, and

enriched with metal studs.

www.packagingdigest.com/LeatherWine

Krat Singles packagingdelivers discount orDisney shows

Krat Foods partners with Feld

Entertainment Inc. on a new marketing

campaign or Disney On Ice.

Consumers can redeem any Krat

Singles package wrapper or a pair

o hal-price tickets to any o f ve

Disney On Ice shows playing across

the U.S., including Disney-Pixar’s

“Toy Story 3.” To promote this campaign,

Krat has introduced specially marked packaging.

www.packagingdigest.com/KratDisneyDiscount

Four Loko XXX Limited Edition:Rotating f avors but not UPCs

To acilitate easy distribution and sale, Chicago-based

alcoholic beverage company Phusion Projects uses

one UPC code on all new avors o Four Loko

XXX Limited Edition drinks. New product will rotate

avors every our months, allowing distributors and

retailers to provide a variety o exciting avors to

customers on an ongoing basis.

www.packagingdigest.com/FourLokoXXX

Ralph Lauren fragrances debut in high-performance pumpsL’Oreal expands the company’s Ralph Lauren

Fragrances brand with the worldwide launch o theBig Pony Collection or men. The ragrances are

packaged in crimpless, high-perormance pumps.

The packaging is supplied pre-assembled with the

pump or easy f tting, which the manuacturer says

can increase f lling productivity as much as 40

percent. In addition, it has no rubber gasket, which can aect the ragrance.

www.packagingdigest.com/BigPony

Nutrition Facts to appear on meat, poultryUnder a new USDA rule, meat and poultry will eature nutrition acts panels

either on their labels (ground or chopped) or available or consumers at the

point-o-purchase (whole, raw cuts).

www.packagingdigest.com/MeatFacts

Girl Scouts trim cookie packaging The organization has switched rom paperboard cartons to a f lm overwrap or its Thanks-A-Lot

Outstanding way to reduce carbon ootprint,waste, cost, reight and all! It would be interestingto compare total cost to market or current paper-board, recycled board and the new f lm. Whatresins or f lm could be used that are more green?Eda Englund Murphy on “Girl Scouts trim cookie

packaging”

packagingdigest.comGet these bonus features at



PACKAGING DIGEST11444 W. Olympic Blvd, Los Angeles, CA 90064 Attn: Lawrence Nokes215/944-9832 • Email: [email protected] • Fax: (303) 265-5286

Machinery & Materials

Contract Packaging

Contract Packaging

Recruitment

marketplacenfo showcase

We are a spice manufacturer, distrcontract packer and blender of all ty

spices. Our specialty is curry powdseasoning, jerk seasoning among m

other spice blends. Simply Jamaican

a new label that we will be putting oumarket and would like to have expos

distributors to handle for us. We cucontract labeling/packaging for many

companies.Oriental Packing Co., Inc.

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Interpak, LLCInterpak introduces the new Somic 424 case packer.Capable of producing Shelf Ready Tray, Tray withHood, and Full Wrap Around cases on a singlemachine. Fully servo driven, low ergonomic singlelevel product flow, tool-less changeover, and wideformat range.www.interpakllc.com/424

Vari-Straight Topload Tri-Seal Carton CloserThe Vari-Straight is a straight-line closer for tri-sealcartons that takes Kliklok-Woodman’s revolutionaryvariable pitch technology to a higher level. To providea controlled carton turn without a change in direction,the unique turning bed features “pop-up” turning barsthat capture the cartons and guide them through a 90°turn and into the charlotte closing section. The inher-ent slip and timing issues associated with conventional“lugless” carton closers are eliminated. [email protected] or at (770) 981-5200, or visit ourwebsite at www.klikwoowoodman.com.




newsmakers

Patricia SpinnerSenior Group Publisher973/[email protected]

Steve EverlyAssociate Publisher610/[email protected], DC, DE, HI, MD, NC, OH, PA, SC, WV,Canada (eastern), Europe

Russell Thibeault781-255-2053 Fax: [email protected]

AL, AR, CT, FL, IA, IN, KY, LA, MA, ME, MI, MS,NH, NJ, NY, RI, TN, VA, VT

Steve Slakis630/990-7429 Fax: 630/[email protected], 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

Laurence Nokes215/[email protected]

INTERNATIONAL REPRESENTATIVES:

China | Sylvia Xiao

[email protected]

Japan | Masayuki Harihara

[email protected]

Taiwan | Robert Yu

[email protected]

Mary WilliamsMarketing Services Manager630/990-2371 Fax: 630/[email protected]

Sales and Marketing Offices

sales staff ad indexPage number Page number

A-B-C Packaging Machine Corporation.....31

Automation Direct ................... ..................... ...................3

CAMA USA................... .................... ..................... ................22

Clippard Instrument Laboratory Inc. ...........13

CTM Labeling Systems.................. ..................... ......12

Domino Amjet.................... .................... ..................... ......43

Fogg Filler................... .................... ..................... ................37

Heat and Control Inc. ................... ..................... .........25

Henkel Corp. .................... .................... ..................... .........33

Hitachi America Ltd. .................. .................... ................2

ICE USA ................... .................... ..................... .................... ...15

ID Technology, Div of Pro Mach.................. ......24

Innovia Films ..................... .................... ..................... ......17

INX International Ink Co. .................... ....................21

James Alexander Corp. .................... .................... ...35

Klockner Pentaplast .................... ..................... ..........11

McDowell Label ..................... .................... .....................32

Optima Machinery Corp. ...................... .................37

Overnight Labels Inc. .................. ..................... .............6

O-I.................... .................... ..................... .................... ..............29

PakTech.................... ..................... .................... .....................27

Pillar Technologies .................... .................... ..............39

Primera.................... ..................... .................... ..................... ...9

Quick Label Systems .................. ..................... .............5

Sealed Air Corp. .................... .................... ..................... ...7

Sharp Packaging Systems ................... .................44

Sleeve Seal .................. ..................... .................... .................6

The RB Dwyer Group ................... ..................... ..........19

U.S. Tsubaki Inc. ................... .................... .....................14

Weighpack Systems .................... ..................... ..........10

MOVERS & SHAKERSKraton Performance Polymers

Inc. promotes G. Scott Lee to vp o

operations.

Paperboard Packaging Council

welcomes Metro Packaging &

Imaging Inc.

as a principal

member and

ACTEGA Kelstar

and Marquip

WardUnited

as associate

members.

Piab USA Inc.

names Edwin

(J.R.) Reeser as

area sales manager or a newly ormed

Midwest sales region.

Celplast Metallized Products hires

Marissa DesRochers as a product

development &

process engineer.

Bunting

Magnetics Co.

hires Marvin

Angleton as

manager,

technical services

and quality; Tom

Andrews as metal

detection service

technician;

Ted Curran

as operations

manager; and

Ryan Van Horn

and Jessica

Buchanan

as design

programmers to

its Flexible Die

Division.

Dorner Mfg. COO Rich Ryan is

elected to the Packaging Machinery

Manuacturers Institute (PMMI) board

o directors.

Henkel Corp. names Joseph DeBiase

as senior vp o its North American

general industry business

Packaging Corp. of America names

Charles J. (Jack) Carter as vp,

containerboard.

LMI Packaging Solutions Inc. hires

Gary Morrison as national account

sales manager and JP Moran and

Rosa Wright-Orozco as inside sales

representatives.

Barry-Wehmiller appoints Tom

Patterson, general partner at

investment f rm Madrone Capital

Partners, to its board o directors.

H.B. Fuller hires Michael Olejnik as

business development manager.

Alcoa names Keith Walton as vp,

government aairs.

GROWING & GOINGPalziv North America, a subsidiary

o Palziv LTD, announces the U.S.

manuacturing acility in Louisburg, NC,

to be ully operational in less than 75

days.

BUYING & ALLYINGKörber Group buys Seidenader

Maschinenbau GmbH.

Mid Oaks Investments LLC buys

Plastic Packaging Technologies LLC.

Sealed Air

Corp. acquires

ProAseptic

Technologies.

Pro Mach

Inc. acquires

Shuttleworth Inc.

Alpha

Packaging

acquires

Progressive

Plastics Inc.

BWay Holding Co. acquires Phoenix

Container Inc.

Danaher Corp. aquires EskoArtwork

or $470 million.

Island Acquisitions S.à r.l. buys

Huhtamaki’s

European rigid

plastic consume

goods packaging

operations.

TricorBraun

acquires Penn

Bottle and

Supply Co.

Cardia

Bioplastics

appoints Eco Ventures as exclusive

distributor or Brazil.

The Sterling Group acquires Saxco Intl.

ABB Robotics signs Kleenline o

Newburyport, MA, as a system

integrator.

Group Aktiengesellschaft (GEA)

acquires Convenience Food

Systems (CFS).

Optima Group acquires Metall +

Plastic GmbH.

Automation Tooling Systems Inc.

buys Assembly & Test Worldwide Inc.’s

U.S.-based and German automation

and test systems businesses.

CELEBRATINGFANUC Robotics America sells

its 100,000th robot in North and

South America to Schneider

Packaging.

Rich RyanDorner Mfg.

Michael Olejnik H.B. Fuller

Joseph DeBiaseHenkel Corp.

Tom PattersonBarry-Wehmiller

Marvin AngletonBunting Magnetics

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Stand Out In The CrowdSharp Packaging Systems is a nationwide, innovative manufacturer of quality, flexible packaging solutions, including

film, bags and packaging machinery systems. Sharp Packaging serves the electronics, pharmaceutical, mail order,

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growing into one of the most respected manufacturers of pre-opened bags on a roll, poly film and packaging

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