Perfectly packaged bit by bit

Food in combibloc and combisafe

Just the way you want it

Food manufacturers have a choice. For long-life foods,

Thanks to their rectangular base and their light weight,

theres a wealth of packaging options they can choose

carton packs are not just hugely convenient in the

from to place their products on the market. Many of

consumers daily routine theyre unbeatably efficient

these options have been around for decades, and their

when it comes to transport logistics as well. And on the

acceptance has developed over time.

warehouse pallets and supermarket shelves of the retail

chain too, carton packs are real space-saving miracles,

However, for any manufacturer looking to select a

permitting an optimal use of shelf space and an efficient

packaging system these days, the smart money is looking

distribution process.

beyond the tried and trusted. What is needed are modern

packaging solutions that provide optimal protection for

With flexible packaging and filling options, high perfor-

the foods they contain, offer flexibility, are convenient to

mance and low wastage rates, food filling machines from

use, have a superlative environmental profile and, at

SIG Combibloc are designed to pave the way to a profit-

the end of the day, are cost-effective as well.

able future for your business, and help you create modern packaging solutions today that will continue in the

This is where carton packs from SIG Combibloc tick

future to give consumers an appetite for your product.

all the boxes: our aseptic combibloc carton packs and the
retortable combisafe carton packs for foods with particulate content, ensure food products are optimally protected
and retain their high quality over a prolonged period.
Carton packs are among the most environmentally friendly
packaging solutions available for long-life foods.

Markus Boehm
Chief Market Officer SIG Combibloc

Welcome to SIG Combibloc

SIG Combibloc is one of the worlds leading system

Each year, SIG Combiblocs packaging plants manufacture

Certified for quality, environment and hygiene

manufacturers of carton packs and filling machines for

more than 25 billion carton sleeves. Palletised to save

For SIG Combibloc as a supplier to the food industry,

beverages and food. The company is part of the Rank

space, the flat carton sleeves are delivered to the food

quality, safety, environmental management and hygiene

Group of New Zealand, and employs around 4,950

manufacturers, where they are filled using filling machines

are essential pre-conditions to enable us to cater to the

people. With production plants and branches in more

designed and manufactured by SIG Combibloc.

needs of our customers across the globe. For this reason,

than 40 countries, we guarantee customer-focused

SIG Combibloc supports its customers every step of the

accredited quality management systems in accordance

cooperation and support wherever you are, and develop

way from market analysis and the development of new

with ISO 9001 and environmental management systems

systems solutions that are optimally tailored to the needs

product concepts right up to designing the carton. The

in accordance with ISO 14001 are implemented at all

of our customers, which we implement together with you.

engineering and installation of the filling equipment,

production sites and at SIG Combiblocs research and

and full after-sales service, are also integral components

development centres. In addition, accredited hygiene

of our offer.

management systems in compliance with the internationally established HACCP (hazard analysis and critical
control points) principles are in place. Since 2013 all
packaging plants have also been certified in accordance
with the BRC/IoP standard.

packs for fo

page 1ib0ilities

ss
All the po
ve portfolio
locs extensi
SIG Combib
foods
for long-life
of products
foods, but
t just liquid
includes no
ducts as
chunky pro
viscous and
s of
day, million
well. Ever y
d buy
nd the worl
people arou
ibloc and
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SIG
rtons from
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lo
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in our asep
ns for this:
good reaso
ks, and
c carton pac
tic combiblo
afe carton
able combis
in the retort

particulate

ods with a

content, fo

very high

od product

are perfect
s
ly protecte
d, have a
long shelf
life and re
tain their h
quality e
igh
ven withou
t refrigerati
and preserv
on
atives. The
key to fillin
long-life fo
g
od product
s containin
particulate
g
s is the slee
ve system
SIG Combib
loc uses.

page 22

page 1
6
Renew

Sustain

able.

able. U
nique.
packs a
r
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more t
an alte
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o
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s jars.
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ment.
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accordance with the criteria of

the Forest Stewardship Council

(FSC) for a continuous product
chain of custody (CoC). This
means we can offer our custom
ers worldwide carton packs

displaying the FSC label.

A real logistical marvel

Thanks to their compact, rectangular
shape, carton packs have a number
of advantages over other packaging
solutions when it comes to transport
and distribution logistics. They stack
extremely well in a truck, in
a warehouse and on a supermarket
shelf. Secondary packaging can be
kept to a minimum, and resources
used efficiently. This reduces, for
example emissions, cuts consumption
of fossil resources, and lowers costs.

4
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nce is a
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page

26

page

28

page

32

page

34

page

36

38
page
40
page
42
page

s
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Renewable. Sustainable. Unique.

combibloc and combisafe
It is in the nature of things that when it comes to long-life

This crucial competitive advantage is set to carry even

foods, carton packs are more than just an alternative to

more weight in the future: without sustainable manufac-

well-known packaging systems such as food metal cans

turing processes that turn out sustainable products, long-

or glass jars. Because no other packaging solution is

term sales success will be difficult and that includes the

made almost entirely from a natural raw material. Our

packaging. By opting for our carton packs, our customers

carton packs are manufactured up to around 75 per cent

are therefore making a sustainable decision: environ-

from wood, a renewable resource. If the wood originates

mentally, and financially.

from forests that are managed properly and responsibly,

this natural raw material is available in a virtually infinite

Of course, our carton packs and closures are fully recy-

supply. And because wood is largely carbon-neutral, it

clable and suitable for all local and national recycling and

does not alter the CO2 balance in the atmosphere. That

waste management options.

makes our carton packs unique in the packaging mix for

long-life foods and beverages, and has a positive effect
on the environmental performance of the products and
the manufacturing processes of our customers.

Our carton packs are made up to 75 per cent

from wood, a renewable resource.

Best environmental
performance
combibloc and combisafe

A Europe-wide, independently verified and ISO-compliant

In the life-cycle assessment, all the key environmentally

life-cycle assessment conducted in 2009 has shown that,

relevant factors and processes that come into play

compared to other packaging solutions for long-life

throughout the product life-cycle of the packaging were

foods, using carton packaging can save CO2 emissions

critically examined and evaluated: beginning with the

and the consumption of fossil resources, respectively, by

extraction and refining of the raw material used to make

up to 60 per cent. In this study, the Institute for Energy

the packaging, through the processes of manufacturing

and Environmental Research (IFEU) compared food

and transporting the finished packages, the packaging of

metal cans, glass jars, carton packs and plastic stand-up

the food, and distribution up to the retailing stage, right

pouches.

up to the recycling or disposal of the packaging after use.

This type of evaluation is the only assessment method
that examines the environmental profile of a packaging
as a whole, rather than just focusing on a single aspect.
In the study, the combibloc aseptic carton pack and the
retortable combisafe carton pack have the best results in
virtually all environmental impact categories in respect
of resource management and emissions. The most
striking findings are the positive results in the impact categories Consumption of fossil resources, Use of primary
energy sources, and CO2 output/climate change. The
study shows that in terms of fossil resource consumption
and CO2 emission, the carton generates up to 60 per cent
less environmental loading than the other packaging
solutions considered in the study.

Using carton packs can reduce CO2 emissions

and fossil resource consumption, respectively, by up to 60%.

Certified. Traceable.
combibloc and combisafe
For food manufacturers, it is a given that many of the

To ensure that this happens, we have had our production

ingredients for their products originate from controlled

sites and sales organisations world-wide certified in

cultivation and are traceable. In our carton packs, these

accordance with the internationally binding criteria of

manufacturers find the perfect partner, because what

the Forest Stewardship Council (FSC) for a continuous

is true for the food should naturally be no different for

product chain of custody. All our suppliers of raw paper-

the packaging. To manufacture our carton packs, we use

board are also certified in accordance with the FSC prod-

only wood fibres originating from certified, responsibly

uct chain of custody standard. This means we are able

managed and other controlled sources.

to offer our customers all over the world carton packs

displaying the FSC label. The label provides a verification
that appropriate quantities of wood originating from

SIG Combibloc is the first manufacturer of carton packs for food products to have

FSC-certified, well-managed forestry or other controlled

all its production sites world-wide certified in accordance with the criteria of the

sources were used to manufacture the raw paperboard.

FSC for a continuous product chain of custody (CoC).

A truck transporting full carton packs is carrying around

95 per cent product, and just 5 per cent packaging.

A real logistical marvel

combibloc and combisafe
The exceptionally good transport and distribution logis-

And even after the carton packs have been filled, a truck

Every saving on space and weight means emissions are

tics properties of carton packs have a beneficial impact

transporting full packages to distributors is carrying

reduced, the consumption of fossil resources is cut, and

on the environment, and at the same time help to lower

around 95 per cent content, and just 5 per cent pack-

costs are lowered.

costs. SIG Combibloc carton packs are transported to

aging. Because carton packs, thanks to their compact,

the food manufacturers production plants as flat folded

rectangular shape and their unbreakableness, stack

And they also make very good use of the space on

sleeves. This means the loading volume of a lorry can be

extremely well and utilise the full capacity of palettes,

the supermarket shelves: Thanks to their rectangular

used to maximum benefit.

and therefore also trucks and warehouse facilities.

form, carton packs need 30 per cent less space than

Compared to glass containers for food products, carton

food metal cans.

packs can reduce package weight by up to 93 per cent

another logistical advantage that speaks for itself.

Maximum convenience
combibloc and combisafe
It is not just food manufacturers and retailers who want

includes carton packs with a complete perforation. The

convenient handling when dealing with food packaging.

complete perforation allows the carton pack to be

These days, convenience is a key consideration for con-

opened all the way across the top, and the food can then

sumers. In this respect, carton packs are ideal for everyday

be emptied out completely.

use: lightweight, space-saving, stackable, unbreakable

and, with perforations and closures, very convenient.

For an easy twist: combiSwift and combiSmart

Optional closures can also be applied to some food carton

Thanks to their light weight and the range

Perforations for even greater convenience

packs. Examples of handy closure solutions on carton

of opening solutions, SIG Combibloc carton

A variety of special partial perforations enables con-

packs are the modern screw caps combiSwift for medium-

packs are 100 per cent user-friendly.

sumers to open our carton packs without the use of

size packages and combiSmart for small-size carton packs.

additional aids such as scissors or knives. The products

Both can be opened and reclosed effortlessly with a single

can be poured out easily. Specifically for chunky food

twist. Thanks to the closure, food products can also be

products, SIG Combiblocs packaging portfolio also

measured out in perfect portion sizes.

Brought to the table, flexibly and efficiently

combibloc and combisafe
The food industry moves at a rapid pace. A packaging

up to highly cost-effective production. The robust, well-

The filling machines from SIG Combibloc offer food manu-

system for food products thus has to offer a high level

engineered design of the filling machines assures the

facturers also great flexibility, enabling them to respond

of production efficiency and competitive manufacturing

food manufacturer of a long, dependable operating life.

to trends quickly and cost-effectively. With the volume,

costs. The modern food filling machines from SIG

The same applies for the applicators used to apply the

design and product flexibility of filling machines from

Combibloc have an output of up to 12,000 carton packs

closures, which are also part of SIG Combiblocs scope

SIG Combibloc, food manufacturers have every option

per hour and consistently low wastage rates. That adds

of delivery.

covered in this respect.

Unrivalled product flexibility

combibloc Food Aseptic
Only with combibloc Food Aseptic:
liquid, viscous or chunky you choose,
we provide the options

The filling flexibility of SIG Combibloc food filling machines

either in one single phase, which is the standard process,

offers food manufacturers the basis for filling a huge

or in two separate phases.

variety of foods: liquid foods and even food products

with a pasty or chunky consistency can be filled and

Two-phase filling means splitting the product into two

packaged for long life, quickly, safely, and using a tech-

components which are processed and filled separately. This

nique that is gentle on the product.

becomes necessary if the product is not viscous enough

to carry its particulate content evenly through the process.

For more than 25 years, SIG Combibloc has been a leader

A typical product which requires two-phase filling is a low

in the aseptic filling of food products. Using our food filling

viscous soup containing large pieces of vegetable. The

machines, food products containing particulates up to 25

vegetable pieces are filled together with a viscous carrier

millimetres long can be aseptically filled in carton packs

liquid in a first step. In a second step, additional water

individual fibres can even be up to 40 millimetres. Products

or broth is filled into the package, adjusting the desired

can have up to 50 per cent particulate content.

viscosity level.

In the aseptic process, the foods are rapidly heated to

Once the product has been filled into the carton pack,

ultra-high temperature using the UHT process, immedi-

the carton top is ultrasonically sealed above the fill level,

ately cooled again, and only then filled into the aseptic

inside the SIG Combibloc filling machine. This makes even

carton packs, which have also been sterilised. Our food

the filling of chunky products safe and easy: there is no

filling machines are equipped with two separate dosing

risk of product ingredients getting caught in the sealed

systems allowing food manufacturers to increase the scope

seam. That is a big plus for aseptic product safety.

of their aseptic food portfolio. Ingredients can be filled

Even more possibilities

combisafe
With the introduction of the heat-resistant combisafe carton pack, the range of options available for the long-life

After the products have been filled into the carton pack, the carton top is sealed ultrasonically. The carton packs

packaging of food products is further expanded. In addition to the aseptic filling process, this packaging system is also

are then automatically conveyed into an autoclave, which can be either static or rotary depending on the product

suitable for particularly chunky foods such as vegetables and pulses, fruit, convenience foods and stews, and for all

requirements and customer preferences. Package and product are sterilised together.

food products that cannot pass through a pumping system and an aseptic process.
In the area of carton packs for long-life food, the use of a rotary autoclave is a world first. Not only do these autoclaves
The tried and tested sleeve system is also used with the combisafe packaging system. Through the use of three

guarantee maximum product quality. Through the continuous movement of the carton packs while they are undergo-

modular filling units, including a high-precision multi-head weigher, a hugely diverse range of products can be filled

ing the effects of heating, they also make it possible to fill and process certain products in the first place particularly

in combisafe the size and quantity of the chunky product ingredients can vary in virtually any respect and can be

highly viscous foods containing extra-large particulates, such as the popular baked beans.

measured out precisely. In the first stage, products that can be pumped are filled, the second deals with dry pieces.
In the third stage, the package is topped up with an infusion. That is a big plus for cost-effective production, because
individual product ingredients can be added to the recipe continuously and in precisely the right quantities, using the
3-stage filling technology. That really adds up in the product calculation too.

Only with the combisafe retortable carton system:

rotary autoclave for optimal product quality;
multi-head weigher for precise portioning and the
ultimate in cost-effective production

Unique volume flexibility

combibloc and combisafe
Food filling machines from SIG Combibloc offer flexibility

An example: two target groups, two volumes. A soup that

that can be controlled smoothly, quickly and safely. When

sells well in the 1-litre family carton pack is supplemented

it comes to volume, for instance, there are many options

with a smaller volume size that is especially suited for

for carton packs with the same base dimensions: in just

one-person households. Promotional carton packs in

a few steps, the filling machines can be adjusted for a

which, for a specified period of time, more content is to

specific volume. There is no need to re-clean or sterilise

be offered than in the standard packs can also be imple-

the machinery.

mented without any difficulty. With the flexibility these

filling machines offer, food manufacturers can select the

The rapid volume change brings with it numerous possi-

Using a single machine: up to seven

different volumes and switching
takes next to no time at all

bilities for positioning products in just the right way

to suit specific target audiences. Up to seven different
volumes can be filled using a single machine.

perfect volume for each product in no time at all.

Unbeatable decor flexibility

combibloc and combisafe
With food filling machines from SIG Combibloc, a change of carton design can be implemented entirely without interrupting the production process, and with no wastage at all. All you need to do is switch the carton sleeves in the filling
machine magazine. This flexibility makes it possible to fill the same product in carton packs with a range of different
designs, for instance, for different brands or for a range of language regions. This means maximum accuracy of fit for
the markets and distribution channels you will be dealing with in each case.

Change the design without interrupting the production process,

and with no wastage

Our service for your efficiency

The unrivalled performance offered by our food filling

Our service always there when you need it

machines is complemented by a wide-ranging service

offer. With our Technical Service team, a network of
experts located around the globe, we support our food
industry customers as part of a reliable partnership: from
installation and commissioning to support with production, plant maintenance and a spare parts service, through
to technical upgrades for the installed filling lines.
Our service ensures a smooth, efficient start to production, the filling lines are constantly operating with a high
degree of efficiency, and you are getting the best out of
the equipment installed at your premises. We also offer
our customers a range of complementary added-value
services that serve directly to optimise the production
processes. The service portfolio is rounded off with a range
of training offers for employees who are already familiar
with the SIG Combibloc packaging system and need even
more in-depth training in specific areas.
As a further additional service offer, the Operational
Excellence Consulting programme focuses on improving
operational performance and, as a consequence, lowering
production costs. In operating this programme, SIG Combibloc
incorporates its many years of experience in handling
production processes with customers across the globe,
together with examples from best practice. Based on these
tools, we develop individual ideas and solutions to further
increase efficiency in our customers factories.

At a glance: combibloc Food Aseptic

Magazine

Sleeve extraction
and opening up
of sleeve

Activating,
folding and
pressing of
carton base

Pre-folding
of carton top

Aseptic zone

The magazine holds the sleeves. The

The individual sleeves are extracted by

The carton base is activated by hot air at

The top of the carton is pre-folded

In the aseptic zone, the packages are

The carton pack is filled with

magazine is filled with sleeves by the

a suction mechanism, opened up into

two stations. While the mandrel conveys

precisely along the grooves, to ensure

sterilised with hydrogen peroxide (H2O2)

sterile product in two stages.

machine operator or by the optional

rectangles and placed on a mandrel. This

the sleeve to the base-pressing station,

the correct top shape after filling.

and dried with heated sterile air.

CAM module (Combibloc Automatic

ensures they are in the correct position

rotating lateral folding arms and a longi-

Magazine).

for the base sealing process.

tudinal folder pre-fold the carton base.

Base-pressing dies and the front face of
the mandrel press and seal the carton base.

Ultrasonic
sealing of
carton top

Top-forming
station

Ejector and
discharge
station

Forming station

Ultrasound tools fold the carton top and

Hot air is used to heat the polymers at the

The carton pack is ejected from the

If combit* packages are filled, the typical

seal it above the fill level. Before it

top triangles and the narrow side of the

filling machine, placed upright and

slanted top of the carton is formed.

is sealed with ultrasonic energy, steam

carton pack. The top triangles are folded

moved onto the discharge conveyor.

is injected into the carton pack, which

down and sealed to the carton.

*provided they have the same base

area, combibloc and the corresponding
combit-format with its distinctive
slanted top can be filled on the same
filling machine.

reduces to a minimum the head space

Application unit

The closure is applied to the carton pack.

volume after cooling.

Applicator

Filling machine

At a glance: combisafe Food Retort

Filling area

Activating, folding
and pressing of bottom
Magazine

Sleeve extraction
and opening up
of sleeve

Ultrasonic
sealing of
carton top

Pre-folding
of carton top

Piston filler

Multihead weigher

Brine dosing

The magazine holds the sleeves. The

The individual sleeves are extracted by

The packaging bottom is activated by hot air

The top of the carton is pre-folded

Filling is done in several stages: Three stages can be

Using ultrasonic equipment, the carton

magazine is filled with sleeves by the

a suction mechanism, opened up into

at two stations. While the mandrel conveys

precisely along the grooves, ensuring

chosen and combined. In the first stage, products that

top is folded and sealed above the fill

machine operator.

rectangles and placed on a mandrel. This

the sleeve to the base-pressing station, rota-

a perfect sealing after filling.

can be pumped are filled (5), while the second deals with

level. Before it is sealed, steam is injected

ensures they are in the correct position

ting lateral folding arms and a longitudinal

dry pieces (6). In the third stage, the package is topped

into the carton pack, which reduces to

for the base sealing process.

folder pre-fold the carton base. Base-pressing

up with an infusion that, depending on product, can

a minimum the head space volume after

dies and the front face of the mandrel press

range from pure water to tomato sauce (7).

cooling.

and seal the carton base.

Top-forming
station

Ejector and
discharge
station

Tray loading
device

Autoclaves
(rotative or static)

Tray unloading
device and
downstream

Hot air is used to heat the polymers

The carton pack is ejected from the

The packages are lined up

The autoclaves are automatically loaded with

The trays are moved to the tray unloading

at the top triangles and the narrow side

filling machine, placed upright and

and put on the trays.

trays by the shuttle. Depending on customer

device where the single packages are

of the carton pack. The top triangles

moved onto the off-conveyor.

demand and product requirements, there can

placed on the belt conveyor. The packages

be rotative or static autoclaves.

are then moved to the traypacker for

are folded down and sealed to the

carton.

optional final packaging.

Our food filling portfolio, your options

Package base
area

Opening solutions

CFA 712 32

63 x 40 mm

Standard perforations

12,000

CFA 712 32

63 x 40 mm

combiSmart

12,000

76 x 47.5 mm

Standard perforations
Complete perforation
combiSmart

12,000

95 x 63 mm

combiLift
combiSwift
Standard perforations

12,000

90 x 59 mm

combiLift
combiSwift
Standard perforations

12,000

72 x 70 mm

combiLift
combiSwift
Standard perforations

12,000

114 x 74 mm

combiLift
combiSwift
Standard perforations

6,000

Complete perforation

12,000

Filling machine

combiblocSmall

combifitSmall

combiblocCompact

150 ml

200 ml

250 ml

300 ml

330 ml

350 ml

200 ml

250 ml

300 ml

330 ml

350 ml

CFA 612 35
CFA 612 36 Food
200 ml

250 ml

300 ml

350 ml

375 ml

400 ml

500 ml

CFA 512 35
CFA 512 36 Food

combiblocStandard

500 ml

500 ml

1,000 ml

1,100 ml

750 ml

1,000 ml

1,100 ml

CFA 812 35
CFA 812 36 Food

combiblocMidi

500 ml

750 ml

1,000 ml

CFA 406 32

combiblocMaxi

combisafe

750 ml

CFA 312 35

combiblocSlimline

1,000 ml

1,500 ml

2,000 ml

CFR 612 35
200 ml

300 ml

400 ml

Filling
machine
output
(packs / h)

500 ml

76 x 47.5 mm

Food 5 2013 en

For any further questions or comments,

please contact info@sig.biz

www.sig.biz

Printed on FSC-certified paper.