Re Vista Pack

www.packagingdigest.
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GRAIN OF SALT:
Sealing defeats issue of
packaging spices. 50
Perfect
order
Coding provides trail
across supply chain 26
New levels in vial filling 30
SEEDING SALES:
Outdoor display pushes
packets into view. 44
A
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2
0
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REALITY CHECK:
Mobile test can ensure
drug authenticity. 36
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contents
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features
new technology
26
48
30
50
40 OUTSIDE THE BOX New system lets shipper eliminate obsolescence and waste by producing right-sized cases
only when theyre needed.
44 PUSHOVER A weatherproof retail display springs to the aid of Burpee so its seed packets can be sold in outdoor
garden centers.
48 BREAKING THE MOLD Dividing PET bottle manufacturing into two steps can reap signicant savings in
shipping and inventory costs.
50 TOP SHELF Specialty-salt purveyors new packaging line and induction sealing helps project a high level of quality
and freshness.
54 SOFT LANDING Housewares shipper TAG switches to air-pillow cushioning to reduce damage, eliminate mess
and improve its environmental prole.
APRIL 2012 volume 49 no. 4
26 COVER STORY Becton, Dickinson and Co. introduces an end-to-end supply chain bar code system on all
levels of medical packagingprimary, secondary and tertiary.
30 CLEAN SWEEP New aseptic pharmaceutical lling operation utilizes disposable product-contact parts and a
Restricted Access Barrier System (RABS).
34 STEP CHANGE Filling machine manufacturers respond to the need for quick changeovers and exibility
in pharmaceutical operations.
36 CODE RED Mobile technology from Sproxil allows African consumers armed with smartphones to authenticate
the source of their medicines.
Produced and packaged
as promised. Bosch.
Production and packaging lines from Bosch achieve the agreed performance.
Day after day. Year after year. High speed and low material use reduce your
costs per piece and improve your equipment efciency. Experienced employees
with extensive know-how guarantee professional service worldwide. Learn more
at www.boschpackaging.com
s
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staff
departments
Brand Director-Packaging
Steve Everly
610-705-8705
steve.everly@ubm.com
Executive Officers
Chief Executive Officer Paul Miller
Chief Financial Officer Fred Gysi
Vice-President/Executive Director Stephen Corrick
Sr. Vice President, Events Division Mark Snell
Vice President, Operations Roger Burg
Art/Production
Lead Art Director Marco Aguilera
Associate Art Directors Tim Burns, Laura Pappada
Production Director Jeff Tade
Production Manager Martin Schneggenburger
Senior Production Artists Jeff Polman, Derric Treece
Production Artist William Baughman
Production Coordinator Adrienne Davis
Marketing
Marketing Manager Mary Williams
Director of Circulation Sandra Martin
Circulation Manager Xavier Contaoi
Editorial
Editorial Director John Kalkowski
630-990-2364 john.kalkowski@ubm.com
Editor Lisa McTigue Pierce
630-990-7384 lisa.pierce@ubm.com
Senior Editor Jenni Spinner
630-990-7385 jenni.spinner@ubm.com
Plant Operations Editor Jack Mans
630-990-4208 jack.mans@ubm.com
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 60523
630-990-2364 Fax 630-990-8894 e-mail: john.kalkowski@ubm.com
8 PACKAGING CONCEPTS
13 COMMENT At your service
14 NEW EQUIPMENT
20 NEW MATERIALS
24 GO GREEN Triple bottom line?
25 SPC SUSTAINABILITY Material value
57 INDUSTRY INSIGHTS
59 ON PACKAGINGDIGEST.COM
61 INFO SHOWCASE
61 MARKETPLACE
62 NEWSMAKERS
62 AD INDEX
Cover: BD Vacutainer blood collection tubes courtesy Becton, Dickinson and Co. Photo by Jennifer Field.
Vacuum Pumps and Systems
Global Distributor Network
For local distributor contact:
Leibinger
East Troy, Wisconsin
www.leibinger-group.com
262.642.4030
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APRIL 2012 PACKAGING DIGEST www.packagingdigest.com 8
packaging
concepts
www.
mintel.com/gnpd
New Product of the Month
L
aunch pad
With concerns growing about potential side effects from fuoride, researchers have been exploring alternatives. The founders
of Theodent discovered Rennou, a fuoride alternative that blends cocoa bean extract with other minerals, and formulated a
toothpaste purported to deliver the protective qualities of fuoride without the associated risks.
When it came time to launch the product after years of research and testing, the team decided the distinctive toothpaste,
called for special packaging. They turned to World Wide Packaging LLC (www.wwpinc.com), a frm that produces tubes and
other packaging for cosmetic clients. The sophisticated HDPE tubein a rich chocolate-brown tone that evokes the toothpastes
signature ingredientmatches the singularity of the product formulation with a sophisticated, angular shape thats sleek, rather
than round. The head of the one-piece tube is triangular, with dramatic hard edges; the complex cap includes a fexible plug that,
when closed, squeezes into the tubes orifce, and its pintle expands for a tight seal.
The tube is decorated with metallic screened logo and text to further underscore its premium appeal. The productavailable
at Whole Foods nationwide and on the companys website (www.theodent.com)retails for approximately $10.
Toothpastes packaging reflects
key ingredient in its formulation
In the U.S., The Johnson Distilling Co. has
launched the Shine On Georgia Moon brand,
an 80-proof corn whiskey with an especially rustic,
unpretentious and straightforward feel. The brand has a creative
package design that helps tie in with the products moonshine-
style positioning.
The package
consists of 750ml of the
whiskey poured into a
plain blown glass jar
with a screw-on tin-
plate cap, which has
an inner EPE wad
and is sealed with an
outer shrink sleeve.
Product information
is supplied on
two self-adhesive
paper labels,
which are printed
lithographically.
While the
packaging may
look rustic and
old fashioned, the
on-pack claim that
it is less than 30
days old embodies
a modern and topical
trend since it taps into
the consumer demand
for freshness.
Packaging design gives
whiskey a down-home feel
14,000
12,000
10,000
8,000
6,000
4,000
2,000
0
New Products Launched Globally
Source: Mintel Global New Products Database (GNPD)
11
Jun
11
May
11
Jul
11
Aug
11
Sep
11
Nov
11
Oct
11
Dec
12
Jan
11
Feb
12
Feb
11
Mar Apr
11
Food
Beauty & Personal Care
Beverage
Household
Healthcare Healthcare
Beverage
Household
Food
Source: Mintel Global New Products Database (GNPD)
New Products Launched in the U.S.

11
Jun
11
Jul
11
Aug
11
Sep
11
Nov
11
Oct
11
Dec
12
Jan
11
Feb
12
Feb Mar
11
May
11
Apr
11
2,000
1,800
1,600
1,400
1,200
1,000
800
600
400
200
0
Food
Beauty &
Personal Care
Beverage
Household
Healthcare
Food
Healthcare
Beverage Household
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packaging
concepts
Iconic Swedish coffee debuts
in stores with a premium look
Gevalia coffees arent new to American consumers. While the company
was founded in far-off Sweden more than 150 years ago, the coffees
produced by Scandinavias largest roaster have for decades been known to
U.S.-based caffeine fans through its delivery service, which has put various
favors and roasts of the premium beans into U.S. homes via mail order
since 1983. It also launched a retail portal on the Web in 2009.
Last year, current Gevalia brand owner Kraft Foods decided to launch
the coffee on retail shelves. They partnered with Dale Doyle, creative
director of Landor Associates (www.landor.com), to ensure the coffee
package boasted shelf appeal and a high-quality image.
The look we were looking to achieve was an overall premium look and
feel, but also one that told the story of the brands rich history, visually and
verbally, says Doyle. Swedens certainly a country full of dichotomies
traditional and modern, old and newand we brought that together on the
package.
The modern side comes courtesy of the bright yellow background
dominating the metallized layered HDPE pouch. The tradition is evoked
by the old-world feel of the logo font, and a crown symbolizing Swedens
regal history (and the products preferential status as an official coffee of
the Swedish royal court).
Bandage package takes on
role of soliciting donors
Adhesive bandages are used to mend minor cuts, scrapes
and other injuries. Recently, Help Remedies launched a
bandage package that aims to heal on a larger scale.
help Ive cut myself & I want to save a life bolsters a pack
containing Helps standard adhesive bandages with a bone
marrow donor registry kit (consisting of a pamphlet, sterile cotton
swabs and a postage-paid envelope); a rubber band bearing the
kits name is wrapped around the pack alerting shoppers to the
potentially life-saving contents. The idea is to engage shoppers
by inviting them to step up and help others in need.
According to Help CEO Richard Fine, This is a simple and
smart idea: By making registration a part of what people are already doing, we think we can get more people
to register, and in doing so, help save lives.
The package (produced by Plastic Ingenuity, www.plasticingenuity.com) is a paper-pulp clamshell
(composed of 100-percent post-industrial waste) and an overmolded border/clasp of corn-based Plastarch resin.
Energy shot pack
touts health benefits
Energy shots comprise one of the hottest categories in the beverage market.With
new SKUs bursting onto shelves every month, theres a lot of competition for the
attention and dollars of tired consumers. Steaz Energy Shot, offered by a company
best known for its line of tea beverages, promise something more than a simple jolt.
Quick, easy energy boosts are everywhere, but most of them are a little dubious
when it comes to your health, says Danielle Lum with Steaz. Enter Steaz Energy
Shot: a clean, green, healthy way to get the focus and power you need to shine.
The energy shot combines organic green tea with organic yerba mate and
guarana, giving the beverage a plant-based caffeine source. Further, the label
relates that the shot is fair-trade certifed, USDA organic and vegan.
The 2.5-oz PET bottle is supplied by copacker Protica (www.protica.com).
The label is a shrink sleeve manufactured by Brook & Whittle Ltd. (www.
brookandwhittle.com).
Eco-friendly cleaner
adds durable
foaming trigger
PRIDEclean, a company that offers a line of
environmentally responsible cleaning products,
needed a foaming trigger for its product packone
durable enough to last through several container
reflls, and endure the rigors of cleaning work.
The company turned to Global One-Pak (www.
one-pak.co.uk) to provide the device. The GOP
J-Series trigger was selected because of its anti-
clog foaming nozzle technology, which is intended
to deliver leak-free performance. Also, the trigger is
designed to endure several times the usual lifespan of
a conventional cleaning product trigger.
PRIDECleans consumer cleaning products
currently are available through Nugget Markets
retail locations in and around Sacramento, CA;. Its
commercial/industrial offerings are sold through Office
Depot.
A DV E RT ORI A L
Weighing in on the future of packaging
Interview with Mr. Zheng Jinkang, chairman of Guangdong High Dream
Intellectualized Machinery Ltd., China
With the rapid development of the global food industry, the markets demand for food packaging machinery is
increasing rapidly. As a leading manufacturer in the quantitative weighing and packaging industries, Guangdong
High Dream Intellectualized Machinery Co., Ltd. is known for its high quality, unique cultural environment and
excellence in marketing and sales. It is also the largest producer in China of multi-head PC-based weighing
machinery, offering support in multiple languages. Recently, Mr. Zheng Jinkang, chairman of Guangdong High Dream
Intellectualized Machinery Co., Ltd., discussed the companys status and explained his vision for its future.
Could you briey describe High Dreams portfolio of multi-head weighing machines, as well as the companys
recent technological innovations and breakthroughs?
Mr. Zheng: The product portfolio of High Dream consists of IP66 Waterproof Weighers, Dosing Weighers, Standard
Weighers, Double Door Hopper Weighers, Stick-Shaped Weighers and Compact Weighers.. Recently, we launched
the 2012 Version Standard Multi-head Weigher, which is an upgraded product based on the 2.5-generation
technology. First of all, improvements are made in the appearance of the machine. Sand blasting of the round corner
cabin with satin surfaces creates the beautiful appearance and high-end appeal. The weighing bucket is designed
with a rounded corner, making it both fashionable and safe. Secondly, improvements have been made on the
individual chutes, making it faster and easier to assemble and disassemble, improving the packaging speed. Thirdly,
improvements in the electrical circuitry further enhance the machines reliability. Last, but not least, a software
update provides more functionality, such as counting and testing the weight of materials. This product is one of our
major launches in 2012.
What strengths do multi-head weighing machines made by High Dream have for overseas markets?
Mr. Zheng: Our products are exported to markets in Southeast Asia, Europe and the United States. Between 2006
and 2008, our market share in European and American markets reached a level. This was because the price of
our machinery was only about one third that of similar products made in Japan. If compared with products made
in Germany, our price was even lower. However, the product quality is very comparable with those from Japan
and Germany. Our products are characterized by their fast weighing speed and high accuracy. As far as weighing
accuracy, there is no discernable difference from similar products made in Japan, and High Dream products comply
with national standards in the countries where they are sold. It is not surprising that High Dream products have
an absolute advantage in terms of the price-performance ratio overseas market. At that time, 80 percent of the
multi-head weighing products made by High Dream were sold in Europe and North America. Afterwards, because
of the global recession in 2009, sales improved dramatically within Chinas domestic market at a rate of 60 percent
annually for the last three years.
According to our estimates in early 2012, there are about 12,000 High Dream multi-head weighing machines in
operation around the world. Most of these machines have been in continuous operations for more than six years and
continue to run well. This is evidence that products made by High Dream can stand the test of time. In addition, it is
worthwhile to mention that products made by High Dream are represented by agents in more than 80 countries, who
offer convenient after-sales service and prompt satisfaction.
Would you please describe the successes of High Dreams Research and Development team and the new
products planned for international markets?
Mr. Zheng: Our R&D team consists of more than 70 people working in the Mechanical and Software Departments.
High Dream spends nearly $1 million each year on R&D. The high added-value of products from High Dream is
obvious within the industry. However, the technological challenges we face also are very huge. The R&D teams for
multi-head weighers are, therefore, very crucial. The amount invested in software development absorbs as much as
70 percent of the annual R&D cost.
High Dream independently develops and produces highly automated weighing machines that incorporate
advanced technical skills and optimized integration of PC-based multi-head weighers with vertical type bagging,
flling, and packaging operations, which are capable of fulflling metering , feeding, flling, bagging, date-printing
operations. High Dream plans to offer X-ray and metal detection equipment and other associated equipment and
devices in the near future.
What solutions do multi-head weighing machines provide for food processors and what are their application
areas?
Mr. Zheng: Multi-head weighers from High Dream use advanced computers, user-friendly computer interfaces and
powerful automatic data logging functions to record and collect important data such as the total number of bags in
a batch, the rate of acceptance, the average error of every single bag and other data to help solve operational and
maintenance issues. In addition, Chinas manufacturing industry is facing a harsh situation of labor shortage and
rising labor costs. So the advantage of saving the manpower stands out prominently. More companies are asking
us to provide associated equipment to upgrade the automation of their packaging lines. Multi-head weighers from
High Dream are widely used in the quantitative weighing and packaging of such foods as potato chips, puffed foods,
biscuits, and frozen rice dumplings. Our scales have become the frst choice for many trading companies and food
producers all over the world.
At present, quite a few small- and medium-sized companies are phasing out older models of cup-type weighing
machines in the pursuit of precision, speed and production. They are updating their packaging lines high-tech and
highly automated systems. This in turn has brought opportunities for the development of quantitative weighing and
packaging markets. This has also provided High Dream with excellent opportunity for domestic and international
developments. High Dream is frmly grasping this opportunity by constantly exploring and accelerating its own pace
of technological innovation. In particular, we are paying attention to the development of automated machine tools, as
the establishment of diversifed, general-purposed, multi-functional and integrated new packaging systems requires
mechatronics, which is an important direction for future development.
During the short spell of six years, High Dream today has developed into a large manufacturing enterprise that
produces 2,000 units of PC-based multi-head weighing machines annually. The company plans an initial stock
offering in China next year. Today, however, the people of High Dream are working hard for future innovations. We
as always will stand up squarely on the profound basis and commit ourselves to creating the worlds No. 1 brand for
multi-head weighing machines. I am more convinced that in years to come, High Dream will closely follow the pace
of the contemporary revolution in high technologies, while actively developing state-of-the-art automated, intelligent
and networking equipment for packaging applications.
packaging
concepts
Building
products
relaunched in
easy-to-use
packaging
Jewson, a long-standing
supplier of sustainable timber
and building materials to U.K.
consumers, recently launched its
products in redesigned packaging.
The makeover puts the items in
containers intended to be more user-
friendly, offer greater shelf appeal
and boost sustainability.
Natalie Davenport, private label
manager at Jewson, says, The new
packaging uses color-coding, icons
and product information to make it
easy for our customers to recognize
the quality and benefts of the product and choose the correct product for their job.
RPC Containers UK Injection Moulding (www.rpc-blackburn.co.uk) manufacturers the containers, which
include 2.5- and 5-L Paintainer paint cans and 10-L pails. The packs enhanced label decoration is printed using
offset lithography, and each container is designed to offer durability, light weight and effective product protection on
job sites.
Beer brand pours into festival-friendly cans
Germans love beer, and they also are rather fond of open-air festivals. When the two combine, however,
problems can arise. In past years, the streets of cities like Dsseldorf have been littered with broken glass
from bottles dropped by partygoers, which leads to a cleanup problem and poses a safety hazard.
In 2012, Fchschen Alt, the traditional brew
produced by Dsseldorfs Fchschen brewery,
launched in 33-cL cans just in time for the start
of the carnival season. The sleek, striking black
aluminum cans (produced by Ball Corp., www.
ball.com) were designed with the celebratory air of
a street fest in mind. The unbreakable containers
enable people to enjoy a good German brew but
avoid the mess and danger associated with broken
bottles.
A street carnival that is free of broken glass is a
safe carnival, and that is something very important
to me, says Peter Knig, the head of Fchschen.
Thats why I decided to produce the cans. They
also have other benefts: They are lightweight
and can be quickly chilled, and they simply look
fantastic.
Particularly proud of packaging
for a branded product that youve
recently designed? Wed love to
hear about it. Contact our senior
editor, Jenni Spinner, at 630-990-
7385 or jenni.spinner@ubm.com.
Submissions
welcome
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On a continuous roll or fan folded in a
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www.packagingdigest.com PACKAGING DIGEST APRIL 2012 13
John Kalkowski, Editorial Director
comment
S
Services now account for nearly 80 percent of the U.S. GDP,
according to a recent article in the newsletter Future Tinking.
Most companies pay some level of attention to customer service.
Tey might even have a few goals and metrics built around the
idea of service. While packaging is a key step in manufacturing,
perhaps its time for those involved in the process to consider how
important service is to their future.
In packaging, productivity is king. Modern packaging lines
are designed for speed, reliability and repeatable high quality.
Companies rely on materials to protect the product, but also to
not cause downtime. CPGs have little tolerance for downtime
due to material or machinery failures.
Te Packaging Machinery Manufacturers Institute
(PMMI) recently conducted a study on service issues and
expectations in packaging. PMMIs report concludes
that 62 percent of end users are satised with services
provided by North American machine builders.
However, less than half of the end users are satised
with the number of knowledgeable service technicians
and their availability.
Te PMMI study points out that packaging machines
are becoming increasingly complicated. As a result, service
personnel are expected to be be skilled mechanics, system
integrators and savvy computer technicians, too. Tis is
happening at a time when fewer engineers are entering the
manufacturing marketplace, while veteran engineers are retiring at
a faster rate than they are being replaced, the study says.
All too often, companies oer a piecemeal approach to service
without organizing their eorts to maximize the impact.
Forward-thinking original equipment manufacturers (OEMs)
are beginning to realize that providing exceptional after-market
services is a way to dierentiate their oering. A well-developed
service platform not only functions as a dierentiator, but as
Future Tinking points out, it can be relatively inexpensive to
implement and provide recurring revenue.
Te basis for success in service is to really understand your
companys expertise and your customers requirements, and then
build a service platform around your strengths and the customers
needs. Te services a packaging company oers can include many
elements, such as highly skilled and available technicians, operator
training, easily understood documentation, preventive maintenance
programs, online and remote support, extensive spare parts
inventories and quick order turnaround. Most importantly, any
service program must emphasize a high level of responsivenes and
exibility to meet the mission-critical requirements of customers.
Service levels can differentiate packaging OEMs
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45 years of experience in factory automation, Simplimatic keeps your
conveyor systems moving with innovative machinery, efcient layout
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Automatic Lid Press Machinery
1-6 gallONsround or square
Good Solutions for Bad Situations
www.Xpect-Solutions.com
Automatic By Hand
Checkweigher The Thermo Scientifc Versa
RxV checkweigher for track and trace applications
in the global marketplace addresses the needs of
pharmaceutical and other products that require
track-and-trace capability. The all-in-one high-speed
system can process up to 550 bottles or cartons/
min while combining code printing and verifcation
(alpha-numeric and machine readable) with
checkweighing.
Thermo Fisher Scientifc, 781-622-1000.
www.thermofsher.com
Vision sensor The FQ-M vision sensor is designed to
meet the needs of pick-and-place applications. With a processing
speed of 5000 pieces/min, even with full 360-degree rotation, the
new vision sensor comes with Ethernet and EtherCAT embedded
for ease of integration into any environment, and it includes an
incremental encoder for easy tracking and calibration. The vision
sensor is easily confgured for guidance of dynamic pick-and-
place robots using the companys Sysmac Studio software, and
is complemented by the palm-sized TouchFinder console for local
monitoring and access to functions and settings.
Omron Industrial Automation, 866-886-6766.
www.Omron247.com
Welder The DCX Digital Power Supply Series is the companys frst global series of ultrasonic welding
power supplies for automated assembly systems in the packaging, food, automotive and textiles industries.
The new series features a smaller footprint, fexible mounting, more industrial control options and improved
diagnostic and data collection. Offered in three compact sizes and form factors (including horizontal, vertical
with side mount or rear plane mount), the series offers fexible integration and system design.
Branson, 203-796-0400.
www.bransonultrasonics.com
new productsequipment
13,128 hrs.
and still
printing.
Our NEW 1000 Line printers have the longest run times in the market.
With the drastically simplied maintenance requirements of our CORE system, the new
1000 Line lets you print up to an astounding 14,000 hours before preventative maintenance
the longest run times in the market, for more uptime and less cost.
Learn more at 800.843.3610, or visit www.videojet.com/moreuptime and download
a FREE Technical Paper about advancements in continuous inkjet printing.
Scan this QR Code to
download a FREE Technical
Paper about advancements
in continuous inkjet printing
2011 Videojet Technologies Inc. All rights reserved.
T HE NE W VI DEOJ E T 1 0 0 0 L I NE PRI NT E RS.
Vision sensor The new IV Vision
Sensor combines some of the functionality of
machine vision and traditional sensors in a single
system. The vision sensors standard equipment
including high-intensity illumination, high
performance lenses and a selection of eight
different sensor heads enable sharp, clear, stable
images. The systems camera selection includes
close, medium and long range models to suit
many application requirements. The system
complies with the IP67 enclosure rating, which is
based on IEC/JIS standards and it can be used
safely in dusty or wet environments.
Keyence, 888-539-3623.
www.keyence.com
Bottle unscramblers The companys
new range of plastic bottle unscramblers, the
NECOSORT-S3, is more efficient in terms of the
percent of bottles discharged for every revolution of
the unscramblers sorting drum. This improvement in
efficiency directly relates to faster speeds for a given
size unscrambling system. The unscramblers also
feature a small footprint with a 105-in. sorting drum
and the ability to sort a wide range of bottle sizes
and styles.
Nalbach, 708-579-9100. www.nalbach.com
ID reader The DataMan advanced fxed-mount
industrial ID reader is designed to handle difficult
ID code-reading applications, even on high-speed
lines. The new readers increase barcode read
rates and speed with a new 1DMax+ algorithm,
which incorporates groundbreaking new Hotbars
technology. For 2-D matrix and difficult-to-read
DPM (Direct Part Mark) codes, reading performance
has also been signifcantly improved from a major
upgrade of 2DMax to the 2DMax+ algorithm. With
the ID reader, easy set up and deployment features
modular, controllable lighting options and an
intelligent tuning system.
Cognex, 508-650-3000.
www.cognex.com
Embedded computers The company
releases its two new Embedded Automation
Computers, the UNO-3072A and UNO-3074A with
Intel Atom D510 processor. Both models feature 2GB
DDR2 RAM with an integrated RAID 0/1 controller
for two 2.5-in. SATA HDDs and an external SATA
port for additional storage. They are able to work
in temperatures ranging from 14 to 140 deg F and
feature shock/vibration absorbers for data storage
security.
Advantech, 888-576-9668.
www.advantech.com
Color label printer The CX1000 color label printer is designed for
in-house production of professional-quality product labels. The printer
is ideal for producing short- to medium-run jobs from 50 to 5,000
labels/roll in various sizes and 2400-dpi print resolution and
print speed of 16.25 ft/min. The printer prints onto many
different laser-qualifed label materials including pressure-
sensitive plain papers, white and clear polyesters
and more.
Primera, 800-797-2772.
That was then.
This is now.
For 100 years weve been a leader in our
industry, producing superior
packaging printing and converting
for global customers using the
latest label packaging technologies.
Our capabilities include:
cut & stack labels shrink sleeve labels
roll-fed labels foar labels
pressure sensitive labels in-rold labels
For more information
call 585.424.3880
or email us at
sales@hammerpackaging.com
17 www.packagingdigest.com PACKAGING DIGEST APRIL 2012 17
Laser cutter The L-350 high-speed laser
cutters single laser head design enables high-
quality cuts with a 210-micron spot size in a
350-mm cutting feld at speeds as fast as 80 m/
min. The laser cutter automates optimization of
web speed, eliminates quality issues in many
applications that require stitching cuts from two laser
sources, enables job changeovers on-the-fy and is
recognized as operator-friendly technology due to its
intuitive operator interface and behind-the-scenes
sophisticated control engineering software, the
company states.
Spartanics, 847-394 5700.
www.spartanics.com
Weigher The new Dataweigh Omega
multihead weigher emphasizes sanitation and
food safety with an IP67 rating, allowing it to
withstand severe washdown procedures. Improved
polygon-shaped feed pans and weigh buckets
eliminate product build-up, while the system offers
speeds up to 90 weighments/min in single-shift
mode for IQF proteins. Other features include a
rugged load cell design that can withstand up to
150 kg of force and a tapered body for optimum
product fow, speed and improved performance.
Yamato, 262-512-3378.
www.yamatoamericas.com
Controller The company has extended the
functionality of its IRC5 panel-mounted controller
(PMC) to all its robots, including its largest robot
models. Previously, the PMC was only available for
models up to the IRB 1600. Featuring a new, large panel mount drive module,
PMC Large will bring smaller footprint functionality and simplifed internal cabling
benefts to robot models from the IRB 2400 up to the IRB 7600, the company
states. The new PMC variant also will make integrating large robots easier by
allowing machine builders and system integrators the fexibility to create custom
enclosures to protect the electronics by the means appropriate for specifc harsh
environments.
ABB Robotics, 248-391-9000. www.abb.com
Printer-applicator The Model 4300 Pro-
Apply label printer-applicator is an in-line unit
that merges economy with the functionality
often associated with heavier-duty labeling
equipment, the company states. The system
offers a selection of thermal-thermal-transfer
print engines. The units print 203-, 300- or 600-
dpi text barcodes and graphic images at speeds
up to 16-in./sec and will dispense labels up to 6
in. wide and 6 in. in length.
Weber Packaging Solutions, 800-843-4242.
www.weberpackaging.com Filler The company has released its new,
economical performance line of flling machines.
They features rigid steel frame construction,
electronic net weight flling, pneumatic controls,
Rice Lake touchpad weight control for high
accuracy flling, and single or double flling
positions. The machine is compact and portable
easy to position in a manufacturing facility. To
operate, the operator simply places a container
on the scale and pushes a button; the container is
tared and automatically flled by net weight.
Ideal Manufacturing, 608-241-1118.
www.ideal-pak.com
Go Ahead. Change
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Applications
* Compllonce Lobellng
* Cross Dock Lobellng
* Producl lD Lobellng
* Assel lD & Mgml
* VMS
* Loglsllcs lrocklng
* llem Level logglng
Features
* Mulllple CnBoord
Emulollons
* RFlD Reody
* SAlCnel CCMMECl w,
Elhernel or Vlreless lF
* 3Porl Communlcollon:
SB, Porollel, SERlAL
* p lo 10 lps Prlnl Speed
Oxygen analyzer The OpTech
O2 system has a non-invasive oxygen
analyzer capability for headspace
gas testing of pharmaceutical blisters.
The non-invasive, non-destructive
thermoformed blister package
technology is ideal for determining
oxygen headspace and ingress in
fexible and rigid packaging, the
company states.
Mocon, 763-493-7228.
www.mocon.com
VFFS machine The Hawk
evolution VFFS machine features a
small footprint and the ability to make
a bag up to 12 in. wide and 18 in.
long. Its Kollmorgen stepper motor
is maintenance free and designed to
run for hundreds of millions of cycles
with little to no maintenance, the
company states. The VFFS machine
accommodates three bag styles: pillow
bag, typically used in the potato chip
industry; a gusseted bag; and a fat
bottom bag, commonly used for coffee
in 1lb packages. It will run and seal just
about any structure of PE, laminated
or metalized flm or foil.
Sharp Packaging, 800-634-6359.
www.sharppackaging.com
Blister packaging The Z.Pack 8 blister packaging
machine for packaging silicon tube sets features a rapid
changeover design of the machines mold die assembly. The
quick-delivery (QD) mold change system allows for easy and
rapid changeover of mold dies by lowering complete mold die
assembly with cooling platen into the mold cowling, releasing and unlocking
mold cowling, sliding mold cowling out from under forming station, replacing the mold die
and then returning mold platen and new die to the forming station.
Zahoransky, 630-466-1901. www.zahoransky-usa.com
|ntroouclng M8IGL
Coolng ano marklng lntelllgence tbat belps you oo more, tor less.
l-Tecb teatures make coolng ano marklng operatlon easler wltb lower malntenance, less servlclng ano slmpler lnstallatlon.
Contact Domlno to olscuss bow M8IGL can allow you to oo more.
Domlno. Do more. www.oomlno-na.com
1.800.387.7972
g p
D-Serles v-Serles A-Serles
Laser Tbermal Transter |nk jet
Con
Buck-boost
transformers The companys
power product line now includes buck-
boost transformers from Jefferson
Electric. Buck-boost transformers are
designed to maximize the performance
and life of electrical equipment, such
as air conditioners, heating elements,
277-V lighting systems and in-motor
applications. The typical use of the
transformers is to power loads with
specifc voltage requirements that
differ from the available line voltage.
The 60 Hz single-phase buck-
boost transformers, with 50 VA to 2
kVA ratings, are encapsulated with
electrical-grade resin, featuring high-
quality electrical steel cores.
AutomationDirect, 800-633-0405.
Carton inspection The
companys new Carton Inspection
Module is designed for use with a wide
array of pharmaceutical, medical and
food products. The module delivers
three main functions independent of
the cartoner: it inspects for open faps
on cartons, prints lot and date codes
onto cartons and provides a visual
verifcation of the printing. The inspection
module is self-contained, with printer
and vision systems fully integrated and it
can be installed downstream from most
cartoning machines.
MGS Machine Corp., 800-790-0627.
www.mgsmachine.com
Turret rewinder The Model STACRW2-6 automatic turret rewinder for
glueless small-roll fnishing has everything needed to automatically fnish
small roll labels without additional unwinding equipment. Standard features
include: servo drives, touchscreen controls, cantilevered edge guided
unwind, splice table, integral slitter, glueless or coreless start, tail label roll
closure system, semi-automatic core coader, and automatic roll eject with
integral roll tray. The companys popular Tricycle gear caster system is also
included standard.
CTC International, 973-228-2300. www.ctcint.com
new productsmaterials
Pharmaceutical dosage
counter
The e-Dose Counter is a
cost-effective solution that
meets regulatory recommendations for
nasal and sub-lingual spray delivery of
controlled substances, according to its
maker. The use of electronics allows the
counting display to be large and highly
visible, making it suitable for patients of
all conditions and ages. Electronics can
also provide patient comfort features
such as acoustic feedback and fashing
displays to inform and warn.
Aptar Pharma, 845-639-3700.
www.aptar.com/pharma
Plastic tube/can Transparent easy-open
ring pull tube is available as an alternative to metal
cans for dry products. The package is supplied
with the ring-pull closure in place, ready for bottom
flling and subsequent sealing with a tamper-evident
base plug. The container is available with customer
branding for both small and large production runs.
Visican, +44 121 359 8800.
www.visican.co.uk
Grippable large bottles New DeepGrip bottles allow the manufacture of
large size PET containerswith a deep recess for easy handlingas an alternative
to traditional extrusion blow-molded HDPE bottles with integrated handles. Developed
in partnership with Sidel, the bottles can be produced in sizes up to 7 L with a deep
recess on each side, creating an effective integral handle. End markets include dairy,
juice, edible oils, motor oils and home and personal care.
APPE Packaging, +44 1978 317 350.
www.appepackaging.com
Syringes with in-mold labels In-mold
labeling (IML) on a medical syringe barrel can foil
counterfeiters of injectable pharmaceuticals in pre-
flled syringes. In-mold labeling offers a number of
benefts to pharmaceutical brand owners interested
in protecting their intellectual property, including the
ability to create a label with special inks that will only
be revealed under special black lights. The label
can also be coded so that each syringe has its own
identity and the polymer label actually becomes a
part of the syringe barrel, making it impossible to
remove the label and replace it with a counterfeit
one, the company states. Label placement accuracy
is within +/-0.010 in.
CBW Automation, 970-229-9500.
www.cbwautomation.com
Recycle-friendly labels Three
Fasson label constructions have met the protocol
requirements of the Assn. of Post-consumer
Plastic Recyclers (APR) for the recycling of PET
thermoformed containers. The constructions are (1)
54# semi-gloss paper with AT-1 adhesive, (2) 2.0
mil clear BOPP flm with S2001 adhesive and (3)
2.6 mil white BOPP flm with S490 adhesive. The
APR protocol was designed to improve recycling
efficiencies and the quality of post-consumer
plastics. The new protocol evaluates thermoform
labels and adhesives to help advance greater
recyclability by identifying pressure-sensitive
laminates that satisfy the need to adhere and be
removed prior to recycling, the company states.
Avery Dennison, 440-534-4846.
www.averydennison.com
ESD protective packaging
Air-cushioning materials AIRplus and FOAMplus foam
padding are now available in an ESD (electrostatic
discharge) flm version for on-demand protective
packaging of electronic components or other products
that need shielding from static electricity. Previously,
ESD bags or ESD bubble wrap from the roll were
readily available, but there was a lack of products for
use with on-demand systems. These new materials
can be used with the companys equipment solutions,
from single work stations to automated infeed
packaging systems.
Storopack, 513-874-0314. www.storopack.us
Refective designs RefeXions gives
consumer product companies freedom to apply
highly refective design elements to their packaging.
RefeXions uses patent-pending technology in
an in-line printing process to offer a cost-effective
alternative to metallized polyester, metallized transfer or
hot foil stamping. Refective design elements can now
be efficiently and selectively applied in a single process.
AGI-Shorewood, 203-541-8100.
www.agishorewood.com
Anti-counterfeiting software New
anti-counterfeit encryption software, which keeps all
information securely encrypted in a data capacitor, is the
worlds frst micro database-less technology, the company
claims. When applied to products in any data capacitor
(such as 2D bar code or RFID tag), the non-mathematical
encryption has substantial marketing potential,
capabilities in gray market detection and the ability to
track and trace individual items through the supply chain.
Six Degrees Counterfeit Prevention, 818-570-1277.
www.6dcp.com
Cleanroom-made pouches
Pouches are made in the U.S. in a new ISO Class
8 cleanroom from rollstock produced at the same
facility. This vertical integration creates a domestic
supply of packaging for pharmaceutical, medical
device and diagnostic/life-science manufacturers
who are also looking for ways to reduce the number
of contaminants that come in contact with their
products.
Rollprint, 800-276-7629.
www.rollprint.com
Ovenable rollstock New Cryovac Oven Ease rollstock runs on most traditional rollstock
thermoforming equipment and allows easy changeovers. This makes it easier for food processors to offer
consumer-convenient ovenable products without incurring the expense of new equipment. The benefts of
ovenable material are simplifed preparation, faster and unattended cooking, and easier cleanup for busy
consumers. The Oven Ease rollstock material is suitable for poultry and boneless beef and pork roast
cuts, including pre-seasoned or marinated items.
Cooking temperatures can withstand 375 deg F for
a maximum of four hours. With exceptional clarity
and the same vacuum packaging properties as
the existing premade Oven Ease ovenable bag,
the ovenable flm ensures the product is freezer-
ready and accommodates cook-from-raw or reheat
applications. After cooking, Oven Ease rollstock offers
impressive holding time, keeping items hot in the
package long after being removed from the oven.
Sealed Air, 800-845-3456.
www.sealedair.com; www.ovenease.com
Air Cushion Conveyor
for light packaging materials
www.posimat.com
1646 NW 108th Avenue, Miami (Florida) 33172 USA
Ph: (305) 477 2029 / 1-888-Posimax Fax (305) 477 8084 miami@posimat.com
Low cost, minimal maintenance and no
product damage (in comparison to traditional
conveying systems).
Unique exibility / high speeds.
Quick feeding batching system for
product groups to be conveyed from one
to several lanes.
It can handle inclines and declines in limited spaces.
Product sizes: from 60 x 30 x 100 mm. up to 200 x 150 x 400 mm. trays and boxes.
*We can study customized requirements.
Product material: all types of plastic (PET, PP, HDPE, polystyrene, etc...), carton board, alluminium, etc...
Manufactured in USA by POSIMAT
POSIJET
See us in Pack Expo Las Vegas, Booth E 3810
new productsmaterials
Thermal shipper As part
of the companys Chaperon line of
thermal shipping containers, the Sentry
400 FlightSafe unit contains globally
compatible cellular technology that
enables it to communicate from virtually
any location on the globe for track-and-
trace. It transmits the information to a
server where the customer can access
the information through Vision, its secure
web-based portal, and determine the
location and condition of the container in
near-real time. The unit can also detect
lid open/close, ambient temperature,
shock, motion, vibration, pressure and
(optionally) humidity.
Intelligent Thermal Solutions,
888-465-6342.
www.intelligentthermalsolutions.
com
Polypropylene clarifer
The Millad NX 8000 clarifer enables
PP to be processed at signifcantly
lower temperatures vs standard
clarifed PP. These cooler temperatures
allow a reduction in energy use and
associated CO
2
emissions while
maintaining the brighter, cleaner
appearance of clarifed PP. The
product enables broader use of PPa
low-density, easily recycled plasticto
replace less-sustainable materials in
packaging applications.
Milliken, 864-503-2020.
www.milliken.com
Flexible packaging The company offers 10-color process printed
laminations for baking and snack food applications that help maximize a
products shelf-impact through eye-catching colors and high-end designs while
maintaining freshness. For one-time use packages, such as single-serve snack
bags, the company has developed seals that are strong enough to preserve
the product yet are still easy for consumers to open. For reclosable packages,
zipper solutions are available and are easy-to-open while maintaining product
freshness and quality.
Star Packaging Corp., 800-252-5414. www.starpackagingcorp.com
do it on yupo
S Y N T H E T I C P A P E R
For more information,
visit www.yupousa.com/clear
or call 888.873.9876
PRINT PACKAGE LABEL DESIGN
Eliminate bottle-to-label color
matching with YUPO
Clear.
Be at one with your package.
YUPO
Clear is the Clear In-Mold Label

substrate that resists scratching, fading
and f lagging and gives you added control
over your design. Because it has a beautiful,
clear, no label look, you can bring excitingly
unique label sizes and multi-colored bottles
to the table with condence that your
product will clearly shine on retail shelves
and stand out among competitors.
Scan here for an
informational video.
Dispensing cap Tap-The-Cap universal
dispensing bottle cap for supplements offers the ability
to add a vitamin shot to enrich mineral water. The
universal cap-capsule can be pushed on all bottles of
plain water. For a self-made vitamin mixture, a vitamin
can be packed in either a Tap-The-Cap dispensing cap
or any other brand of mineral water.
Tap-The-Cap, 818-472-2311. www.tapthecap.com
Chemical-barrier
containers Baritainers, for
corrosive and difficult-to-contain
liquid chemicals, are a packaging
alternative to fuorinated HDPE
containers that avoids the potential
failure of fuorinated packaging while
reducing a products carbon footprint.
No post-manufacturing treatment is
needed at a secondary facility, so
Baritainers save greenhouse gas
emissions by shipping directly to a
packaging facility. Baritainers combine
Quoral barrier resin and a proprietary
production process. By processing
under well-defned conditions using
specially adapted extrusion equipment,
polyamide (PA) is stretched into thin
lamellas in a PE matrix. This creates
an integrated layered structure, where
a multitude of overlapping PA platelets
guarantee improved permeation
results, the company states.
Barrier Plastics, 949-380-1611.
www.barrierplastics.com
Microfute board MirriNor,
a metallized microfute board, is a
joint venture between Smurft Kappa
and Celloglas that combines Mirri Bio
Film with T-Flute. MirriNor decorative
effects are created
using the Color-Logic
metallic flm printing
process. The product
is targeted at brand
managers in the luxury
goods and gift pack
markets to performance
engineer packaging
while removing cost
because of the light
weight of the board as well as the ease
with which it can be printed.
Smurft Kappa,
954-516-2600.
www.smurftkappa.com
Results from Rexroth: Increase productivity, save energy, grow faster
Successful food and packaging operations need to maximize exibility
without sacricing productivity or increasing costs. Innovative Rexroth
drive and control technology helped Paper Machinery Corporation launch
the rst all servo-driven paper cup forming machine, enabling faster
changeovers while cutting both energy use and machine development
time. Only a technology leader like Rexroth can help its customers, and
theirs, create and sustain that kind of competitive advantage.
All-servo driven PMC 2000S
Speed, time,
efciency all
going up
See what Rexroth
can do for you
www.BoschRexroth-us.com/packagingresults
Order our free Results from Rexroth CD
Go green
Libby Bernick, vp, TerraChoice, said that
consumers are interested in greener products, but
their motivation is what really matters. Learn why
they are interested and deliver on that, she suggests.
Collaborate
Many recent successes in sustainable packaging
development have been built through partnerships
between brand owners and suppliers. PepsiCos
Knoerzer explained that creating value in the
supply chain today requires shared knowledge and a
coordinated strategy which usually involves exclusive
features or services. Brand owners are able to rapidly
move on innovation with suppliers they trust.
Knoerzer also advised attendees: Invest in what
you need to knowwith the right horsepower. If
you think knowledge is expensive, try ignorance.
And dont get stuck protecting intellectual property
but never getting around to using it.
Scott Vitters, general manager of the PlantBottle
packaging platform at Te Coca-Cola Co., shared
a secret to their success: sharing. Te idea was that
development of the technology would accelerate
(which would also drive down costs) if the supply
chain could see the market for PlantBottle was
bigger than Coke. So the company has decided to
partner with other trusted brandssuch as Heinz
ketchupto expand use of PlantBottles.
HPs Boeller added that the size of a supplier
doesnt necessarily matter when deciding to
partner with them or not. Smaller companies can
sometimes act quicker, he says.
It helps, too, for packagers to try to learn about
the upstream and downstream links in the supply
chain. During the Q&A in A World Without
Waste attendee Susan Collins, executive director
of the Container Recycling Institute, reminded
participants that packaging people know as much
about the recycling business as recyclers know
about packaging. Getting all stakeholders in a room
talking is key to nding workable solutions.
Lisa McTigue Pierce, Editor
In its sixth edition, the annual Sustainability
in Packaging Conference sponsored by Packaging
Digest and Pira Intl. demonstrates the evolution
of sustainability in the packaging segment. Held
March 12-14 in Orlando, FL, the conference
highlighted packaging developments and the latest
advances in the science of sustainability.
In summing up the event, conference chairman
John Kalkowski, editorial director of Packaging
Digest, urged delegates to innovate, demonstrate and
collaboratethe three major themes developed in
presentations throughout the conference.
Innovate
Sustainability and innovation go hand-in-hand.
Attendees heard many ideas about sustainable
packaging innovation during the conference.
Speaker Tony Knoerzer, vp advanced research,
food packaging at PepsiCo, advised listeners to fail
early and move on to the next idea.
Lars Lundquist, packaging and environment
expert at Nestl, said there is plenty of drive and
innovation in sustainable packaging, but whats
lacking is direction. And its not about reducing
packaging; its about optimizing. Te risk of under-
packing is higher than over-packing because of the
product waste generated, he says.
Lundquist also said that Gen3 of bioplastics
those that adapt non-food sources (such as wood,
agricultural waste and drought-resistant plastics/
algae) for packaging applicationsare still far
away from commercialization. Te holdup? Te
chemistry often uses more energy to produce the
material than it saves.
In trying to sell your sustainable packaging
innovation internally, Randy Boeller, packaging
engineering manager with Hewlett Packard,
suggested that if two or more departments are
involved in a decision (especially a contrary one,
like spending more in procurement but saving
more in logistics), go up the corporate organization
chart to nd the single executive responsible for
both departments to get needed changes made. He
said HP recently xed its internal policy so that
purchasing agents are no longer evaluated just on
how much they save on purchase prices.
Demonstrate
Teres a lot more science involved in
packaging sustainability nowand thats a good
thing. Alan Blake, associate director corporate
packaging development sustainability at Procter &
Gamble, gave an overview of the Global Protocol
on Sustainable Packaging 2.0, that provides
comprehensive metrics from which users can pick
and choose depending on product and project.
Life-cycle assessment was a major topic.
Lundquist explained how Nestl uses LCA at
the packaging concept phase employing PIQET
(Packaging Impact Quick Evaluation Tool). Tey
have super-users who train others how to use the
online tool. With training, Nestle users can do an
assessment in about 30 min, he says.
But are all LCA tools created equal? Tony
Kingsbury, Dow executive in residence at the
Haas School of Business, UC Berkeley, did a study
comparing ve dierent toolsCOMPASS, GaBi,
SimaPro, Sustainable Minds and the Walmart
Packaging Scorecardand found that results vary
widely, even when the data input is the same.
Still, Ed Socci, R&D director, Advanced
Research Div. at PepsiCo, suggested packagers use
LCA as an improvement tool.
All the right data in the world will take you
nowhere, though, if your customers think it
leads you to a wrong decision. Harry Epstein,
vp innovation, HAVI Global Solutions, warned,
Science doesnt win the day when it comes to
consumer perception.
So whats a packaging designer to do, asked an
audience member, if an LCA tool tells you to make one
improvement, but that isnt the best from a consumer
perception view? P&Gs Blake replied: Communicate
and educateor dont make the change.
Take concentrates, for example. In the U.S.,
consumers expect a nancial incentive, according
to Will Archer, manager of global sustainability
at SC Johnson. Te company recently expanded
its portfolio of concentrated cleaners. Archer
said companies need to communicate what the
sustainable packaging savings mean to consumers.
An addendum to TRIPLE BOTTOM LINE: Innovate, demonstrate, collaborate.
Conference explores
sustainability themes
During the session breaks, Packaging Digest spoke
with a handful of speakers, attendees and sponsors
about some of the topics and findings presented.
Watch these short clips.
Jason Foster, founder and chief reuser, Replenish,
speaks about the challengesand opportunitiesfor
reusable packaging. www.packagingdigest.com/
FosterSustPack2012
Eben Bayer CEO and co-founder of Ecovative,
tells us about recent improvements to the companys
disruptive mushroom-based cushioning, as well
as the products expansion and next steps. www.
packagingdigest.com/BayerSustPack2012
Chandler Slavin, sustainability coordinator at
Dordan Manufacturing, comments on the results of an
intriguing study of various life-cycle assessment tools
by the University of Berkeley. www.packagingdigest.
com/SlavinSustPack2012
Steve Massa, director of marketing at xpedx,
talks about how to help customers save money, be
more productive and cost competitive themselves with
sustainable packaging designs and processes. www.
packagingdigest.com/MassaSustPack2012
Exclusive interviews
Nearly 250 packaging professionals attended the sixth
annual Sustainability in Packaging conference in
Orlando, FL.
sustainability
A
As a brief review of Economics 101, a free market is
one where prices are determined by supply and de-
mand. In the past several years, we have seen a steady
rise in the price of many commodities, most notably
oil, metals and the products that are in turn impacted
by these price increases.
Aluminum also has seen price increases. Worth
between $0.70/lb and $1.00/lb, aluminum cans are one
of the most valuable packaging materials used. So why
did we throw away 1.3 billion pounds of aluminum
last year? Tis is equivalent to the aluminum in more
than 27 Airbus A320s, according to Alcoa. (PSI EPR
Dialogue, Jan. 19, 2010)
Using an average value of $0.85 for baled used
beverage containers, this represents more than $1
billion thrown in U.S. landlls annually. So why
arent we recycling more of them? Isnt that what a
free market would suggest should happen, especially
when we have industries clamoring for these materials?
Because aluminum is such a valuable resource, this is a
prime example of how the free market is not adequately
addressing the value of materials.
Aluminum has been the backbone of many
recycling systems, yet its recycling rates have remained
at below the 50 percent mark over the past ve years,
according to EPA estimates (which do not include cans
imported for recycling). Aluminum Assn. recycling
rates do include growing numbers of cans imported
for recycling purposes, according to the Container
Recycling Institute, and show rising recycling rates over
this same period from 52 percent to 58 percent.
So how can it be when some material pricing is at
market highs, U.S. aluminum can recycling rates are
not increasing proportionately? Where have we gone
so terribly wrong that there
is a disconnect between the
value of a material and our
infrastructure to recapture
that material?
Perhaps we have
done too good a job on selling convenience and
disposability. While our grandparents and great-
grandparents of the Depression Era were radical
savers, the current generations are so far removed
from where things come from that they are also
removed from the value of the materials they buy.
We have encouraged a system where we blame
consumers for not participating in the recycling
system, yet we send signals that products are
disposablenot valuableto make it convenient
for everyone. Marketing
shapes behavior and,
as marketers know,
consumers are Pavlovian.
If consumers are rewarded,
they tend to respond.
To incentivize behavior that
recognizes the true value of resources, the regulatory
response in some states has been container deposits.
But we are still throwing away over $1 billion
of cans a year so this incentive is not enough.
Outside of regulation, there is a role for marketers
who inuence and shape consumer behavior to
get in the game in a coordinated and meaningful
way to develop eective recycling messaging that
drives consumer behavior, such as through the
SPCs Packaging Recovery Label System (www.
how2recycle.info).
Te alternative is to continue bearing the
consequences of some of the lowest recovery rates in
developed countries, which equals money down the
drain. Te idealism that the free market would keep
valuable materials out of landlls is not working, so its
time to think about other market incentives or drivers
to prize aluminum and other materials for the valuable
resources they are.
Anne Johnson is the director for GreenBlues Sustainable Packaging Coalition. For additional information
about the Sustainable Packaging Coalition, please visit www.sustainablepackaging.org.
Market price of recycled material
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IN A PERFECT WORLD, there would be Perfect
Order in our healthcare system, with no errors in
the supply chain and ultimate patient safety.
With that goal in mind, medical device leader
Becton, Dickinson and Co. (BD) implemented
Perfect Order and, along the way, introduced
an end-to-end supply chain packaging bar code
system with its customer, Mercy Hospital, and
Mercys supply chain company, ROi (Resource
Optimization & Innovation). Te solution
described in the illustration at rightis the rst
known instance in the U.S. that a healthcare
provider and a medical device manufacturer have
used the Global Location Number (GLN) and
Global Trade Item Number (GTIN) throughout
both the supply chain and clinical processes.
Data synchronization
Dened by Strategic Marketplace Initiative
(SMI), a consortium of healthcare supply-chain
executives, Perfect Order is an ideal in healthcare
that represents true electronic order processing,
from order placement to delivery and payment,
without human intervention.
BD laid much of the groundwork for this eort
decades ago by implementing bar codes on its
product packages. It eventually transitioned to GS1
global standards: GTINs and GLNs. Today, the
company assigns GTINs to all products at three
levels of packagingprimary (product), secondary
(shelf cartons) and tertiary (shipping cases). Each
subsequent level connects with the prior one in a
child/parent/grandparent hierarchy. Some products
are too small to accommodate a bar code, though,
so codes would just appear on the secondary and
tertiary packs for those products.
BD has studied specic use cases with healthcare
providers to ensure that the data imprinted in bar
codes meets both clinical and supply chain needs.
Te tremendous diversity in products, package sizes
and packaging materials prohibits using a one-size-
ts-all solution to applying bar codes.
As of February 2011, BD established a voluntary
data sync with Mercy/ROi keyed to the GTINs
and GLNs embedded in linear Code 128 bar codes
for nearly 500 products, such as syringes, catheters
and specimen collection tubes. Te data is managed
through BDs enterprise resource planning (ERP)
software from SAP and shared with Mercy/ROi via
electronic data interchange (EDI) and integrated into
its internal IT systems. Tis sharing took place
with help from EDI partner GHX and software
vendor Lawsononly after BD had reconciled all
unique product IDs in its own ERP Master Data le.
Dennis Black, BDs director, e-Business, and
point-man in the collaborative eort with Mercy/
ROi, explains how atypical this data-sync is in the
Using linear bar codes, unique identiers and global standards,
BD has SYNCHRONIZED DATA ON NEARLY 500 PRODUCTS WITH
A SINGLE CUSTOMER to eliminate product errors, ensure patient
safety, reduce stock outs, improve traceability and speed up payments.
RAISING THE BAR
ON SUPPLY-CHAIN EFFICIENCY
Code 128 linear bar codes,
used widely in the pharmaceutical
industry, hold the GTIN data on BDs primary
packs, shelf cartons and (not shown) shipping cases.
26 APRIL 2012 PACKAGING DIGEST www.packagingdigest.com
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Lisa McTigue Pierce, Editor
PHOTO BY JENNIFER FIELD
27 www.packagingdigest.com PACKAGING DIGEST APRIL 2012
healthcare industry. Currently, many product
manufacturer bar codes are covered up with other
codes used at various points in the supply chain,
which can cause errors and ine ciencies.
What we were trying to do is enable the
healthcare provider to get benets from the bar
codes that we put on product packages, Black
says. When we studied the failure points and
challenges in the supply chain, we learned that
many errors and ine ciencies were caused by the
lack of data standards.
Trough this successful case study with
Mercy/ROi, BD is encouraging change in the
industry. Its our hope that this becomes the
norm in the healthcare industry, Black says.
Printing processes
Before BD can share the data, it rst has to
be generated and then added to packages.
Vijay Krishnamurthi, director, worldwide
packaging leader and manufacturing support
for BD Medical-Medical Surgical Systems (the
companys largest business unit), explains that
the Master Data controls the online package
printing, which is how the vast majority of bar
codes are added to products. Tis is done on a
secure network, with all BD locations having
access to the companys ERP system.
Not all the products that ship to Mercy/ROi
are produced in the U.S. (which was another
reason BD went with the GS1 global product ID
standard). BD has 40+ plants worldwide. Over the
years, the company added some online printing
capabilities, which quickly expanded as adding bar
codes and other variable data become the norm.
Andrew Stellon, manager, supply chain compliance
at BD, says, [Bar coding] accelerated the migration
towards on-demand printing for exibility.
For the most part, BD t the online printing
technology to the existing packaging material
rather than changing the substrate. We use
multiple packaging materials, though. Sometimes
it was a challenge, Krishnamurthi says. A good
example is, its much easier to print [on paper]
than when we use Tyvek, which we often use as a
top web. Because it stretches, the equipment we use
to print a bar code on Tyvek has to be able to do
that job much more precisely than paper.
Plus, nearly all products go through some sort
of sterilization (gamma, EtO or steam). Te print
should not only withstand the printing itself, but the
subsequent sterilization processes, Krishnamurthi
says. We have to ensure that, post sterilization, that
we still have a useful, legible, readable code.
Te online printing technology used depends
on the packaging material and the plant where
the product is produced. However, BD typically
uses thermal transfer, some inkjet and, lately, more
and more laser. We are looking at [laser] for the
future, Krishnamurthi says. Tis is an evolution.
We started with some of the older techniques
and then we continue to look for new techniques
that can operate at our speeds. Were looking to
doubleto one thousand parts per minute
manufacturing within BD. We have to work with
the printing equipment vendor to do specic things
Continued on page 28
Every step in the healthcare supply chain
between manufacturer BD and customer
Mercy uses the same bar codes to process
product packages.
ILLUSTRATION COURTESY OF
BECTON, DICKINSON AND CO. (BD)
AND ROI (RESOURCE
OPTIMIZATION & INNOVATION)
to meet those high speeds.
Te data is printed on product packages at various
stages of production, too. For exible packages, bar
codes are typically printed using thermal transfer
on the at web before the pack is formed. Shelf
cartons are often laser-coded just before the product
is loaded. And shipping labels are also printed with
thermal transfer technology at the point of packing.
Codes are veried to ensure readability, with
equipment that varies by facility. Stellon says that
plants have expanded many of their capabilities in
this regard, with more inspection being done online
instead of only o ine sampling.
Additionally, says Keith Racine, director,
worldwide supply chain/supply planning for BD
Medical-Medical Surgical Systems, Since we use
the bar codes in our warehouses, too, theres further
verication of readability as [packages] move through
our supply chain.
The payoff
Because BD introduced product bar coding
and the GS1 standards over a long period (literally
decades), its too hard to say how much it all cost.
But Mercy/ROi paid its own way: It did not receive
subsidies from BD or other suppliers.
Te customer has realized several returns on its
investment, though:
30 percent reduction in days payable outstanding.
73 percent reduction in errors on purchase orders.
Improved sourcing by use of a bar code to
determine the right product and to reorder.
Fewer stock outs due to the simplicity oered to
nursing sta for scanning bar codes at the bedside.
Black says BD is planning to collaborate similarly
with other customers, too. It is our hope that GTIN
and data standards are adopted throughout the
healthcare supply chain, Black says.
Given the benet of experience and time, what
might BD do dierently in implementing bar codes?
We would work closer with the operations on
what the [bar code] verication process should be, and
what controls were needed to ensure that they were
verifying codes correctly, Stellon says. We did have
some struggles up front. But before we went live, we
were monitoring the compliance to our standards. BD uses a variety of online printing technologies in its plants, such as thermal transfer coding on exible webs.
GHX, 800-968-7449.
www.ghx.com
GS1 US, 937-435-3870.
www.gs1us.org
Lawson, 800-477-1357.
www.lawson.com
SAP, 877-727-1127, x11010.
www.sap.com
Strategic Marketplace Initiative (SMI),
781-378-1107.
www.smisupplychain.com
0 More information is available:
What we
were trying to
do is enable
the healthcare
provider to get
benets from bar codes
that we put on product
packages.
DENNIS BLACK,
BDs e-Business director
Looking for end-to-end supply chain solutions
similar to this one from BD and Mercy/ROi that you can
use? Consider attending the GS1 Connect Conference.
Scheduled for June 4-7, 2012, at the Aria Resort and
Casino in Las Vegas, the event shares best practices about
how to use GS1 standards across a variety of markets.
In addition to sector-specic content for apparel,
consumer packaged goods, foodservice, fresh foods,
general merchandise, grocery and healthcare, GS1
Connect will present innovations supporting supply-
chain processes for product and location identication;
inventory efciency; traceability and safety; business-
to-consumer (B2C) communication; trading-partner
collaboration; and data quality/management/
synchronization.
GS1 US, 937-435-3870.
www.gs1connectevent.org
GS1 event helps connect packagers
with solutions for their supply chains
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A
Vetter Development Services USA Inc. has installed a FIRST-OF-ITS-KIND
VIAL FILLER that incorporates aseptic lling, stopper insertion and capping
in a single system to produce pharmaceutical product for clinical trials.
Jack Mans, Plant Operations Editor
A new vial filling system at Vetters U.S. site
called Vetter Development Services USA Inc.
(VDS), Chicagois one of the most advanced
aseptic clinical manufacturing operations
in the world. Te heart of the operation is a
MHI 2020B vial filler from Bosch Packaging
Technology Inc.the first of its
kind specifically developed for
aseptic clinical manufacturing
that allows for highly automated
vial filling and closing, particularly
for the filling of small amounts of
drugs.
Te operation includes disposable
systems and a Restricted Access
Barrier System (RABS) that greatly
reduces the risk of contamination.
Te system fills the vials, inserts
rubber stoppers and applies
aluminum caps.
Vetter Managing Director
Tomas Otto says, In our Chicago
facility, we focus on early-stage
products from preclinical through
phase II, after which we will
scale up and transfer them to
our commercial manufacturing
facilities for phase III filling and
market production. To help ensure
a seamless transition to commercial
manufacture, were replicating
commercial processes at our early-
stage (Chicago) site.
Te Chicago facility is an
expansion of Vetter Development Service. Vetter,
headquartered in Ravensburg, Germany, is an
independent international specialist and contract
developer and manufacturer of aseptically prefilled
syringe systems, cartridges and vials. It has more
than 25 years of experience producing high-quality
aseptically prefilled injection systems.
Te new automated production line at VDS
Chicago is used to fill lyophilized or liquid products
(up to 10,000 units/batch). It features an integrated
monitoring system for the filling and closing
process. Te line can run glass containers ranging
from 0.1mL to 23mL capacity.
Te Restricted Access Barrier System
(RABS), which is supplied by Bosch, is a rigid
wall enclosure equipped with HEPA filtered
unidirectional air to yield an ISO 5 classified
space. All air handling equipment is built into
the system and glove ports, sleeves and gloves
are secured to the walls. Operators at Vetter
are excluded from the RABS during normal
operations. Any operator activities are performed
through the glove ports. Te RABS
at Vetters Chicago site is housed
in a Class 10,000 area and is itself
rated as a Class 100 cleanroom.
Vials for the operation are
sterilized in an autoclave and are then
conveyed onto a turntable inside the
RABS. Te vials leave the turntable in
a single file on a conveyor and travel
to a pickup point. A handling unit
picks up two vials at a time and
swings over and places them on
load cells.
Te load cells weigh each empty
vial, after which fill nozzles descend
and fill the product until it reaches
the set weight of product in the
vial, at which point the filling stops.
Te precision weighing system can
be programmed for dierent filling
volumes and products, allowing for
100 percent in-process control of
the amounts filled.
Disposable parts
Product is pumped from a tank
into the vials by a peristaltic or a
rolling-diaphragm pump. Tese
types of pumps and the associated disposable
product contact components are used to
eliminate the need for cleaning validation
and the long lead times for dedicated product
contact components. After every product run,
every piece of equipment that contacts the
product is disposed of in order to ensure there
is no contamination of the next product to be
run. Peristaltic and rolling-diaphragm pumps
are available with PreVAS single-use sets from
Bosch and so readily fit this requirement.
Te PreVAS family of aseptic single-use
dosing systems is a completely pre-assembled,
and pre-sterilized dosing system that is supplied
with supporting validation documentation.
Tis allows risk free scale up of filling operations
in a single-use format. PreVAS eliminates the need
for complicated cleaning procedures and validation
protocols, and the entire system is quickly installed
and operational in a fraction of the time that
previous systems required.
Rubber stoppers are fed from a vibratory bowl
and travel down a conveyor to a point where a
handling unit picks up two stoppers and places
them on tops of two vials, which are still in the fill
zone. Rods then descend and push the stoppers
tightly into place. If the filler is running lyophilized
products (see below), the rods only partially seat the
special lyo stoppers.
Te vial handling unit then picks up the vials
and places them at another station, where a cap is
applied. Like the stoppers, caps are delivered down
a chute from a vibratory bowl to a point where
another handling unit picks up two caps and places
them on top of the stoppers on two bottles.
Te caps have aluminum skirts attached to them
and the vials are next transferred to another station
where they are spun against rotating horizontal
Precision vial filling
The line can run glass
containers ranging from 0.1mL
to 23mL capacity.
The MHI 2020B vial ller from Bosch Packaging Technology
the rst of its kind specically developed for aseptic clinical
manufacturingallows for highly automated vial lling and
closing, particularly for the lling of small amounts of drugs.
Vials for the operation are sterilized in an autoclave and
are then conveyed onto a turntable inside the Restricted
Access Barrier System (RABS). The vials leave the
turntable in a single le on a conveyor and travel to the
lling pickup point.
Tis operation is repeated until all 10
trays are inserted, after which the unit
is closed and vacuum is applied to the
chamber.
It typically takes about one to
four days (depending on formulation
and fill volume) to complete the
lyophilization, which yields a solid
layer of product in each vial called a
lyo cake.
Te vials containing the lyo cake
are placed back on the infeed turntable
and enter the line. Te vials bypass
the filling and stopper insertion steps,
and the operation resumes at the
point where rods descend to push the
stoppers into the vials.
Otto says, Vetter is the first
company to use the new Bosch
system, designed specifically
for clinical-stage, high-value
pharmaceuticals. Te Bosch filler
uses all disposable drug-contact
components, which eliminates the
need for cleaning validation and thus
saves valuable time and costs.
Otto continues, It is a compact
machine with minimum tubing
lengths for increased API [active
pharmaceutical ingredient] yield,
which is especially important for
the high value products Vetter
wheels that come in against them and
crimp the skirts tightly against the
vials.
Te vials discharge in parallel lanes
and discharge onto a right angle take-
away conveyor.
Lyophilization
Some products require lyophiliza-
tion, which is another term for freeze
drying. Freeze-drying is a method of
choice to remove the liquid reactant
to support stability. Freeze-dried
products will typically have a longer
shelf-life than liquid compounds.
Freeze-drying works by freezing
the compound and then reducing
the surrounding pressure to allow
the frozen water in the material to
sublimate directly from the solid
phase to the gas phase. It is typically
used to dry heat-sensitive products,
because no heat is applied to the
product being dried.
At Vetter, vials are diverted out of
the filling line after the lyo stoppers
have been partially inserted. To
evacuate water vapor, lyo stoppers
have channels in their sides through
which the water vapor can discharge.
In addition, the stoppers are not
pushed completely into the vials.
Te vials are pushed onto an
enclosed platform mounted on the
side of the RABS. When it is filled,
the operator pulls the accumulated
vials onto a tray, which he inserts
into the lyophilizer. Te unit at
Vetter, which was supplied by Hof
Sonderanlagenbau GmbH, can
accommodate 10 trays on five levels.
After two trays have been inserted
side-by-side on the first level, the unit
automatically raises them so two more
trays can be inserted on the next level.
Two vials at a time are placed on load
cells that weigh each empty vial. Fill
nozzles then descend and ll the product
until it reaches the set weight of product
in each vial, at which point lling stops.
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manufacturers for its customers.
One liter of API could easily be
valued at over $1 million and be the
result of several years of eort by
a biopharmaceutical development
team. And the machine includes
a 100 percent check-weight
system. Tats important, because
if the amount of drug in a vial
is inaccurate, that may aect the
outcome of a clinical study, especially
in small, early-stage trials.
Extensive automation
Vetters production line has
elevated clinical manufacturing and
development to a new level. Te MHI
2020B allows for self-monitoring and
self-controlled filling. Te extensive
degree of automation enables a
high level of safety of the filled drug
substances. Te line also has automatic
processes for transportation and in-
process controls as well as filling and
closing.
Vials are filled with high precision
and are closed in conditions that
meet the highest possible cleanroom
classification standards. Tis increases the
protection for both the drug substances
and for the participants in the clinical
tests, an important contribution towards
the successful completion of the early
drug development phases. Rapid
and exible use of various disposable
systems permits Vetter to eiciently
adjust the manufacturing process to
the requirements of the respective drug
substance.
Clinical development of new drugs
is a key challenge for the international
pharmaceutical and biotech industry.
Ever-increasing competition and the
pressure for innovationcombined
with high development costs,
government regulations of quality and
safetyall require new solutions.
Terefore, eiciency combined
with high international standards and
Vial handling units pick up two vials at a time and transfer them to the various stations
in the machine.
Rubber stoppers are applied to the vials while they are still at the lling station, after
which the vial handling unit transfers them two-at-a-time to the next station where a
cap is applied.
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optimal time-to-market is critical.
Often, candidate drug substances
are produced in complex laboratory
processes and are only available
in limited quantities. In addition,
many drug substances are complex
compounds that are extremely
sensitive to environmental inuences.
Vetters vial-manufacturing
line in Chicago provides a
solution to the economic and
technical requirements of clinical
development. Te facility can run
small-scale fillings for testing during
preclinical to phase II stages with
greater eiciency and safety.
Te modular use of disposable
filling system kits allows for faster
and safer preparations for each fill
and also reduces complexity and costs
during the preparatory period. Small-
scale fillings for development studies
(compatibility, informal stability tests)
can be realized on the line. Using
tubes and pumping systems that are
particularly gentle on the product,
as well as automation of the product
from start to end, enables Vetter to
obtain especially high process yield.
Fewer sample removals, avoiding
destructive in-process control (IPC)
testing and reduced loss in the tubing,
all assist in a considerable reduction
in the loss of active drug substance.
Te production line meets high
international standards, contributing
to higher yields of available amount of
drug substance candidates and saving
valuable time and money.
In addition to the automated
vial line, the 24,000-sq-ft Chicago
facility includes a second cleanroom
for semi-automatic filling of a variety
of drug-delivery systems, as well as
chemical analysis lab, microbiology
lab, material preparation and
compounding functions, visual
inspection, cGMP storage area and
administrative oices.
Overall, the site allows the
company to oer a range of services
revolving around the clinical
development of parenteral drugs,
supporting customers from preclinical
development to phase II.
For phase III and commercial
manufacturing, the Chicago facility
provides seamless product transfer
to Vetters large-scale manufacturing
facilities in Europe.
Vials containing products that require
lyophilization are diverted out of the
RABS after the lyo stoppers have been
partially inserted and are placed in
the lyophilizer. When lyophilization is
completed, the vials are transferred back
into the lling machine, and the operation
resumes at the point where the stoppers
are pushed completely into the vials.
Bosch Packaging Technology Inc.,
763-424-4700.
www.boschpackaging.com
Hof Sonderanlagenbau GmbH,
+49 6462-6080.
www.hof-sonderanlagen.de
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A
As pharma companies increase the number of
products on their lling lines, quick changeover and
careful monitoring become critical. Pharmaceutical
companies are handling more products on single
production lines these days, resulting in incredible
demands on lling and packaging lines. For some
companies, smaller batches are the norm, challenging
line operators to execute changeovers quickly and
su ciently. Machinery providers are keeping up,
thankfully, oering a range of solutions.
We are seeing requests to handle more
products on one lling line, in smaller batches,
explains Uwe Kellermann, vp of pharmaceutical
applications, Optima Machinery Corp.
Pharmaceutical companies and contract
manufacturing organizations are handling more
products these days.
Similarly, Walter Langosch, director, sales
and marketing, ESS Technologies Inc., has
been elding requests to build lling and
handling machinery that can support multiple
products. Such high turnover requires expeditious
changeovers.
Disposable society
One of the biggest headaches in changing over
from one product to another is cleaning. Not
only does it take time and eort, but you have got
to follow a validated process, so there can be no
corner-cutting.
Unless you move toward disposable components.
Tere is a denite trend toward use of disposable
pumps and tubing to eliminate the cleaning
validations required. Coupled with CIP and
SIP, disposables can cut turnaround time by 50
percent, says Kellermann.
Disposable nozzles, product bags and tubing
are used with peristaltic lling technology, whose
latest-generation systems can compete better with
positive-displacement pump lling, Langosch says.
Peristaltic pumps are suited for disposables because
the only components that touch the product are the
nozzles and tubing. Changing the product bag-
in-box, the tubing and nozzle takes only minutes.
Tere is no risk of cross contamination, he says.
But the tubing itself must be suitable for the
product, while remaining malleable enough for the
system to work properly, he adds.
At its rst U.S. facility, contract manufacturer
Vetter is using the new MHI 2020 B automated
vial ller from Bosch Packaging Technology.
Located at the Illinois Science + Technology Park
in suburban Chicago, the 24,000-sq-ft site features
three cleanrooms for aseptic lling and visual
inspection (see in-depth article Precision vial
lling on p. 30).
Minimizing contamination
Designed to handle clinical-stage, high-value
biopharmaceuticals, Vetters new automated
vial ller can run up to 10,000 liquid or 6,000
lyophilized vials per batch. Employing a Restricted
Access Barrier System (RABS), the system relies on
automated lling and capping to mitigate risk of
contamination by minimizing human intervention.
It can run a range of ll volumes, from 0.1 to 23
ml, providing exibility.
Vetters intention is to utilize only disposable
liquid path technology for various reasons: reduce
potential of contamination, eliminate cleaning
process of product path and of cleaning validation,
and ability to get to lling customers as quickly
as possible, says David Cousins, director of sales,
pharma liquid, Bosch Packaging Technology Inc.,
pharmaceutical operations.
Tis is the rst MHI 2020 B ller capable of
precise dosing (either through rolling-diaphragm
or peristaltic pump dosing), stoppering and
capping, he adds. Vials move through the
various stations via robotic handling, eliminating
the potential for glass-to-glass contact during the
lling operations.
Vetters managing mirector Peter Soelkner
explained in a statement: Our Chicago facility
provides customers with a top-of-the-line clinical
manufacturing site located in the heart of the
United States. Because Vetter consistently strives to
stay at the forefront of innovation, securing Boschs
new fully automated vial ller was a natural for us.
Multiple lling technologies
Not every product is suitable for peristaltic
pump lling, and users simply may want other
options. Kellermann says that Optima llers can
be developed with options for more than one
technology, such as rotary-piston pumps, time-
pressure ll systems and peristaltic pumps.
We have modied our systems to oer
interchangeability, he explains. Users can take the
whole lling system out in one hour and change
from peristaltic to time pressure, for instance.
Filling a niche
Pharma companies are facing GROWING DEMANDS FOR QUICK
CHANGEOVERS of their lling and packaging lines as the number of
products being run on the lines increase dramatically.
Daphne Allen, Editor, Pharmaceutical and Medical Packaging News
Pharma Tech Industries is using a Ropak Stik Pak 10-up
machine to form, crimp, ll and seal stick packs.
Filamatics Monobloc Fill/Finish Packaging system can accommodate different container sizes and shapes. A chuck-style capping system handles containers ranging in size from
10 to 1,000mL. The llers are digitally controlled with menu-driven programs that electronically adjust operating parameters.
Making the change within a RABS
isnt as easy, however, he explains.
Optima has also made the lling
station accessible from the back of the
machine and added a transport and
lift system for easy access. A roll-up
module is also available to allow users
to switch to peristaltic technology if
needed, Kellermann explains.
ESS Technologies can also oer
two lling or product delivery
systems on one machine. We can
also add a servo-driven auger ller
or even a tablet ller, if requested,
Langosch says. When asked whether
customers have sought equipment
that can regularly switch from liquids
to powders to tablets, he says no,
but theoretically it is possible.
ESS employs 100 percent net-
weigh lling on its starwheel-based
system. As the container enters
the starwheel, it travels over a cell
to capture the tare, then moves
through the lling station, then
indexes to another weighing station
to capture the ll weight, explains
Langosch. We designed the process
to be extremely accurate and have
added a feedback loop to allow
pump adjustment on the y.
Speed limitations
Because of the intermittent motion,
there are speed limitations, and smaller
volumes typically mean faster speeds.
But the number of weigh cells can be
doubled to increase throughput.
Accuracy, however, can be a time
saver. You can greatly reduce the
rework or scrap by addressing issues
inline before containers leave the
machine, and thats where our feedback
loop comes in, Langosch adds.
Optima begins its monitoring
with net-weigh lling, switches to
in-process control and then back
to net weighing. Such sequencing
enables Optima to minimize product
waste during priming, which can be
a concern for high-value biologicals,
says Kellermann.
Optima systems also monitor
seal force/torque, as well as stopper
pressure and crimping in-process.
ESS uses product and component
detection systems throughout lling
and assembly, Langosch reports. We
can verify that the pump has triggered
and cycled, and we can then detect
streams and placement of stoppers,
caps and overcaps.
ESS recently developed servo
torque technology for the nal
torque at a second station. It allows
customers to customize the nal
torque needed, and our in-process
monitoring allows us to track the
torque of every cap, he adds.
Time matters
Langosch reports that changeover
time convinced one customer to opt
for ESS equipment. One customer
picked our HMI-controlled system
with 10-minute changeover over a
system with a 20-minute changeover.
Te HMI controls all servo-driven
functions, which include nozzle
diving, lling, capping and torquing.
Ten minutes may not sound like
a much of deal maker, unless you
hear Langoschs explanation: If one
shift has three changeovers, you save
30 minutes per shift. If you only run
one-shift per day, 250 days per year,
you save enough time to run 15 extra
days of production.
Bosch Packaging Technology Inc.,
763-424-4700.
www.boschpharma-us.com
ESS Technologies Inc., 540-961-5716.
www.esstechnologies.com
Filamatic, 866-258-1914.
www.filamatic.com
Optima Machinery Corp.,
920-339-2222. www.optima-usa.com
Ropak, 256-350-4241. www.ropak.com
I
In Africa, drug counterfeiting is a huge concern.
According to the World Health Organization,
up to 30 percent of all drugs taken by patients
in the developing world arent authentic. Tis
illegal activity drains approximately $75 billion
from the pockets of legitimate pharmaceutical
companies. More importantly, fake drugs
threaten the lives of the patients who believe
the medications theyre taking are real; in 2008,
more than 80 Nigerian children died after taking
counterfeit cold medication that contained
antifreeze.
Mobile Product Authentication (MPA)
technology from Sproxil is designed to combat
the problem. Te technology allows consumers
to verify a products authentication at the time of
purchase or use, using unique identiers or codes
on each package. Response to the technology has
been signicant; in January, the protection service
received its millionth request for drug authenticity
verication.
According to Alden Zecha, Sproxil CFO and
chief strategist, the product succeeds by oering a
unique and necessary service to pharmaceuticals in
the region.
Tis is the rst solution that addresses the
consumer-level verication that is really necessary
in emerging markets, he says.
In the U.S., pharmacists are likely to ll a
prescription bottle for patients at the time of
purchase, but in countries like Nigeria and
Kenya, most pharmaceuticals are sold pre-
With Mobile Product Authentication,
the patient sends the unique
on-pack identier code
via text, web or phone to
determine authenticity.
The MPA system responds to the patients request for
verication with a text message either verifying it is real
and safe, or alerting that there could be a problem.
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Mobile technology
ensures drug
authenticity
In Africa, drug counterfeiting is a prevalentand life-threateningproblem.
Technology puts THE POWER TO VERIFY PACKAGE AUTHENTICITY directly
into the hands of patients.
Jenni Spinner, Senior Editor
packaged. For the consumer to be condent that
the drug is real, Zecha states, authentication
needs to be put in his or her hands; retailers,
clerks or distribution warehouses could be a
source of tampering.
Dr. Paul Orhii, director general of
Nigerias National Agency for Food and Drug
Administration and Control, says, Tis technology
puts the power of detection of counterfeits in the
hands of millions of Nigerian consumers, thereby
enlisting them in the war against counterfeiting.
How it works
Sproxil works with drug manufacturers and
their packaging partners on mass serialization.
Te product gets unique identiers on each
package; this can be performed at the factory
in the manufacturing line, or in a controlled
environment post-manufacturing but prior to
distribution in the supply chain. Having the
manufacturer handle the process in the factory
or a secure location before distribution ensures
the package isnt messed with by an unethical
distributor looking to make a quick buck.
Next, the products move through the standard
retail distribution chain; because the technology is
on the pack and veried by consumers, no change
in distribution practices or behaviors is necessary.
At the time of purchase, the consumer does three
things:
Tey expose or reveal the coating on the
package. While Zecha relates that nearly all clients
to date have used tamper-evident protection over
the code on the pack via a scratch-o code, the
unique code also can be overt.
Te consumer sends the code to Sproxils
system via text message, phone call to the
companys call center or via the web; because in
Africa theres a relatively low market penetration
of data- and web-capable smartphones, text is the
prevalent method of messaging.
Te Sproxil system processes the code to verify
if the product is safe and authentic.
Depending on what Sproxil nds out about
the product when decoding, the message back
to the consumer can be dierent. If the product
is authentic and safe, the user gets a code back
telling them its real and okay to use. Because
literacy rates are low in the markets served by
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Sproxil, the message is usually
simplethe word OK and then
information about the product
(name, dosage and other formulary
info). If the manufacturer chooses,
the basic information can be
supplemented with targeted messages
specic to the drugif its a diabetes
treatment, for example, the user
could be advised to watch his sugar
intake. A phone number is provided
for additional follow-up.
Te product also could be
determined to be authentic, but
the code might have been used.
Te most common reason is user
or phone error: the user might
accidentally have sent the code
twice, or transposed numbers when
typing. In this case, the consumer
receives a message advising them
as such, and encourages him to try
again. Or, the drug could be found
to be authentic, but the package has
passed its expiration date; in that
case, the user receives a message
indicating its use-by date has
passed.
Putting it in place
According to Zacha, the MPA
technology requires only minor
modications to a manufacturing
operation.
We can make it so simple that
the manufacturer doesnt have to
change anything at their factory if
they dont want to, he says. Tere
is no requirement to purchase or
lease equipment, and no capital
equipment required. Te ability for a
pharmaceutical company to put it in
play can be made simple. He adds
that the system on the manufacturing
end requires no specialized software;
if the user chooses, they can opt for
a system that uses a web interface.
However, if a manufacturer wants
to implement a high-end MPA
system, they can opt for high-speed
automated production, printing and
label application equipment. Te
user has a high degree of exibility in
choosing equipment to use with the
Sproxil technology.
BIOFEM Pharmaceuticals is a
large pharmaceutical distribution
rm in Nigeria, importing and
distributing more than 20 name-
brand and generic drugs. Its
oerings include Glucophage, a
popular diabetes drug manufactured
by Merck Sante s.a.s. in France.
In 2009, BIOFEM discovered
its products were plagued by
counterfeiting. Crooks were
leveraging the companys brand
name and reputation to sell false
products, and sales of the companys
legitimate products had fallen 75
percent over the previous year. After
implementing the Sproxil system,
the company saw dramatic results
after just three months. Sales of
Glucophage bounced back more
than 10 percent and, according
to a BIOFEM representative, the
company received a return of 10
times what it invested in MPA.
Additionally, according to
In addition to on-pack messages, in-store displays and other signage communicates the
packaging technology and its benets.
With so many options.
Matrix has built a solid reputation for delivering rugged, well engineered, cost
competitive, easy-to-use packaging systems backed by our outstanding customer
support. And with so many options of sizes, shapes and bag functions that Matrixs
solutions are capable of producing, were sure to find the perfect fit for your needs.
Go to www.MatrixPM.com or call
(262) 268-8300 for more information.
Vertical form-fill-seal solutions
BIOFEM CEO Femi Soremekum,
patients have come to rely on the
technology: No one will buy it now
without the Sproxil label, he says.
Standing out
While other technologies exist to
verify product authenticity, Zecha
says, Sproxils MPA technology is
dierent because unlike RFID, bar
codes and other methodologies,
it doesnt take the power to verify
out of consumers hands, or require
specialized equipment.
Sproxil stands out because it is a
consumer-friendly solution, he says.
Further, the codes and labels
containing them cannot be copied to
defeat the system, unlike holograms.
In addition to providing
consumers with peace of mind,
Sproxil can be used to track down
thieves and bring them to justice.
One customer suspected they had
had a batch of drugs stolen from
them but could not determine
exactly where in the supply chain
the loss had occurred. Zecha says
Sproxil representatives worked
with the company to determine the
product had in fact been stolen, and
they set up a custom message for
the product. When patients entered
their code, they received additional
messaging asking them to contact
the call center.
We didnt want to scare them;
when they called, we just said, We
just want to reassure you the product
is genuine, but we have some market
questionsdo you mind if we ask?
We asked where theyd purchased
the product, so we took that list of
locations where the stolen goods had
been purchased. Te manufacturer
sent investigators and asked
retailers where theyd purchased the
products.
By partnering with Sproxil,
the manufacturer narrowed the
point of theft to a single sourcea
legitimate wholesaler that
unfortunately had gone rogue,
and arrests were made.
Sproxils technology is designed to
be easily adjustable, so that changes
can be made in response to changing
patient behavior or customer needs.
For example, in recent months the
company has made adjustment for
wording messages in markets where
literacy is an issue. Other adjustments
leave greater room for patient error,
and addition of a web portal where
customers can review. Tis feature lets
pharmaceutical companies monitor
data beyond product authentication,
such as how their products are being
tested, checked and sold, how much
time it takes the product to get
from the factory to customers, and
(through Google Maps) how far a
product physically travels to get to
users. After nding out consumers
were contacting the call center with
medical questions (such as dosing,
interaction with other drugs and a
host of doctor-specic queries), the
company added the capability to
pass a call onto the company or a
physician.
The MPA code can be protected with a
scratch-off coating or left uncovered.
Sproxil, 209-877-7694.
www.sproxil.com
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Jenni Spinner, Senior Editor
Ever had to wrap a gift in a box? Its a challenge
nding a corrugated box that ts (or almost ts),
cramming wadded paper or other extra material
to keep the present safe, and making sure the
item is secure before you send it to the recipient.
Now, multiple that one item by hundredsor
thousandsand youll get an idea of why large-
format printing and packaging rm Meisel, made
the switch to on-demand packaging.
Te idea behind the Packsize technology is
enabling packaging operations to make boxes
that are tailor-made to hold the product at hand,
when and where theyre needed. Te concept cuts
inventory costs, frees up warehouse space and
(because less supplementary packing is needed to
keep the product from rattling around a too-big
carton) cuts down materials expenses.
Opportunity knocks
Meisel, based in Carrolton, TX, is a full-service
company that specializes in large-format printing
and packaging for retail products for a diverse roster
of high-prole clients. Its customers range from
outdoorsouttter REI, to shoe giants like Nike and
Puma, to multinational fast-food companies such as
KFC and McDonalds. Te items that the company
is called on to produce packaging for is as varied as
the list of its clients.
According to Meisel evp Hoddy Peck, keeping
stock-size boxes to fulll clients needs was
problematic. Te inventory took up valuable
oor space that could have been used to bring
in other work, ordering boxes for a job required
lead time, gobbled up shipping costs and (because
boxes usually didnt t exactly right) also required
investment in lling material. Peck was, like many
other packaging professionals, frustrated by the
waste in time and material caused by box-making
business as usual.
For many years, people have been packaging
products the same way, says Brandon Brooks, vp
of marketing for Packsize. Teyll make a widget,
then they buy preset sizes of boxes, which theyll
store. Ten, once the widget is made, theyll shove
it into the box. Te system is ine cientits hard
to predict how many boxes youll need, when youll
need them, etc. Its a supply chain nightmare.
Sascha Tietje, cost reduction and packaging
executive at Packsize, approached Peck at
a packaging association event. Peck saw an
opportunity to make a dierence at his operation,
and to meet goals relating to process improvement
and sustainability.
Machine produces
made-to-order boxes
Using on-demand packaging equipment, this large-format printer with
high-prole clients SAVES TIME, MONEY AND FLOOR SPACE by producing
boxes tailor-made to accommodate products as theyre needed.
Distribution manager
Daniel Spencer programs
the box dimensions
required for a project with
the EM-725 touch screen.
Compare for yourself and see how the AutoPilot stacks up against the competition. For more information visit www.squidink.com
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A lot of the attributes of the equipment
and how the workow is tied to the technology
t in with what we were trying to do, Peck
says. Te concept of custom-made boxes that
are right-sized appealed to us. He adds that
because the company is certied as a Sustainable
Green Printing operation, the idea of avoiding
the material waste associated with using added
material to pad items in boxes, or to discard
unused boxes when they become obsolete,
investing in the Packsize system made sense. His
interest increased when a colleague at a Specialty
Graphic Imaging Assn. meeting raved about the
Packsize product. He traveled to a facility to see
the machinery in action, and decided to give it a
try in his own operation.
The technology
Te Packsize system consists of an automated
packaging machine using Windows-based operating
software to create boxes according to custom
dimensions. Corrugated board (supplied by
Corrugated Supplies Co.) feeds into the machine
to construct boxes in widths ranging from 10.63 to
94.49 in., in a range of thicknesses, with no limit on
box length. Te system is able to perform a range of
complex functions, including longitudinal/transverse
cutting, creasing, perforation, and creation of
handles and holes. Meisel uses the multi-faceted EM-
725 model, with the Auto Gluer II automated gluing
module attached; the EM-6, geared toward large-box
production, also is available.
While the block of fanfolded corrugated takes
up some square footage, the tradeo is noteworthy
compared to when Meisel relied on an inventory of
stock boxes.
It opened up a lot of rack space, he says,
adding that the warehouse space previously taken
up by inventoried corrugated boxes now is used
to store replacement parts for equipment around
the plant.
The automated packaging machine produces boxes
within feet of where a packaging operation needs them.
Heat shrink applicators that
Fit your business.
Go to www.AxonSleeves.com or call
1-800-598-8601 for more information.
Whether you need shrink sleeve or tamper evident band
applicators that are flexible and economical or fast and
customizable, Axon has a system that meets your needs.
All systems are backed by ProCustomer service hubs on
the East and West Coasts with leasing programs available
to make it easy to get started today.
More efficient. More precise. More versatile. More reliable.
Axon.
Further, the Packsize system eliminates
problems associated with ordering a large number
of stock boxes in a particular size for a client, only
to nd them gathering dust and eventually tossed
on the recycling pile when the client no longer
needs them.
Obsolescence is no longer a problem, says
Tietje. Waste is brought down to nearly zero,
because you dont make a box unless you need it.
Making a difference
Another benet of the system is that Meisel
can provide its clients with tailored product.
One of the earlier jobs Meisel handled with
its new Packsize system is a project for shoe
retailer Johnston & Murphy. Set to deliver to
200 dierent stores, the job normally would
have called for Meisel sta to order boxes with
dimensions close to their needs, then wait for
them to arrive. Te Packsize system enabled them
to enter the precise dimensions, produce a single
box to determine if the size was appropriate, make
necessary adjustments, then produce containers
that t the project perfectly.
While the machine has only been in place
since the second week of November 2011, Peck
says the companys accounting sta already has
an impact.
Return on investment analysis says were saving
approximately 25 percent of our costs, Peck says.
In December, when we looked at packaging costs
as a bulk item on our prot-and-loss statement,
the numbers seem to be signicantly improved.
Te Packsize system gives us tangible savings in
our packaging costs. Its so much more than just a
better box.
It takes approximately eight seconds from the time
the start button is pressed, to the time the machine
processes the corrugated board to create the box.
Corrugated Supplies Co., 708-458-5525.
www.csclive.com
Meisel, 800-527-5186. www.meisel.com
Packsize, 801-944-4814. www.packsize.com
Stick Packs and Sachets from Start to Finish.
Cartoning and collating machines can be integrated to high speed VFFS ALFA and GAMMA machines, in no time.
The machines and complete line require ONLY ONE OPERATOR.
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Nutraceutical Food & Beverage
3005 State Road I Telford, PA 18969
215.721.4600 I www.fresco.com
B
A new weatherproof pusher tray lets Burpee display its seeds in outdoor garden centers,
keeping its COLORFUL PACKETS IN EASY VIEW of potential customers.
Edited by Lisa McTigue Pierce, Editor
Burpeeone of the countrys biggest garden-seed
companieshas multiple accounts with garden
centers operated by such customers as Lowes and
Home Depot, where its oor-standing retail display
was being used only indoors at the stores.
A customer asked if we could provide an outdoor
oor-standing retail display for our seed envelopes to
go outside in the Garden Center, says Burpees Mike
Wooters, purchasing manager for retail components
and general merchandising. Tis meant developing
a waterproof pusher tray that would retrot into the
outer display panel already in use.
Seed packets are poly-coated for water resistance
but the entire display wasnt designed for wet
environments. Te outer panel holds trays of
seed packets, which are four to six pockets across.
Previously, the seed packets had been pushedor
advancedforward by an injection-molded, metal
coil-spring pusher or anvil so that there is
always a packet front-and-center as customers take
product from the tray. Although the outer panel
was waterproof, the pusher tray with its metal coil-
spring never needed to be until Burpee received the
request. And, since metal will rust when exposed to
outdoor elements such as precipitation and water
hoses, any new design would have to be inherently
weather-proof or metal-free.
But Wooters also wanted the new waterproof
pusher tray to address another concern of an
outdoor display: Keeping the lightweight package
secure. Te previous injection-molded pusher
left a 1/4- to 1/2-in. space in the pocket-front.
In the Garden Center area, the last one or two
seed packets could be blown out by wind, lost
to customer view, possibly aecting sales. We
wanted a pusher-tray design that would hold our
1-oz envelopes in tight and keep seed packets from
blowing away in the wind, Wooters says.
So in spring 2010, Burpee searched for a
thermoformer who could design a retrotted
waterproof pusher-display tray and found Package
Development Co. We visited our customers to
get a directive and then talked to a few dierent
thermoforming companies, Wooter says. Package
Development had the best t and design. Teir
prototype was original, so we partnered with them.
Design breaks new ground
We call it a Retail Articulating Pusher
Display, says Package Development president
Charles (Skip) Schwester. We have an active R&D
Pushing the envelope
A new weatherproof seed display withstands the wet
and, at times, windy environment of outdoor garden
centers.
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department, which had already developed a pusher
(or anvil) design that we thought could work for
Burpees application. It took two or three more
versions before we had a working pusher tray. But
with our rst concept, we were su ciently on-track
to solve the problem so that Burpee supported and
encouraged us to continue.
Prior to this, Burpee and Package Development
had never worked together. But the collaboration
proved fruitful. Burpee was the inspiration for the
Retail Articulating Pusher Display, says Schwester.
Tey had valuable input. Both companies share the
patent thats now pending, and there are many new
patent-pending design modications in the works.
Te ingenuity of the pusher-tray design stems
from its being die-cut and vacuum-formed from
one contiguous piece of Pentaform recycled
polyethylene terephthalate (rPET) rigid lm supplied
by Klckner Pentaplast. RPET is reusable,
says Klckner Pentaplasts business manager for
thermoforming lms, Peter Gianniny. And it can be
streamed back into the recycling loop under the right
waste-management conditions.
Wooters applauds the choice. Te clarity,
functionality and quality of the Retail Articulating
Pusher Display is working ne. No complaints,
Wooters says. Clarity is important because our
seed packets are printed in bright four-colors
meant to grab retail customers. Tey need a good
view. It helps in forming purchasing decisions.
And the clarity of Klckner Pentaplasts lm is
high quality.
Solving a perennial challenge
A oor-standing retail display that leans back and
pushes product forward is not new. But the typical
injection-molded design has always been expensive
because it is comprised of three separate parts,
including a metal coil-spring. Not only is tooling
expensive, injection molding is time-consuming to
manufacture and therefore low volume. (On the
other handBurpee still uses the original injection-
molded design for indoor retail display panels due to
its durability.)
Part of the challenge
was keeping the same panel
structure and having it work
with the redesigned tray that
accommodates various display
iterations. Te display panels
can be up to 5-ft tall, and may
contain from four to 12 vertical
rows of trays. Much also depends
on the type of seed. For example,
pumpkin seeds might ll out the
bottom of a packet to a quarter-
of-an-inch, while celery seeds
are practically at, necessitating
varying tray depths. And width-
wise, trays need to be four-,
ve- or six-pockets wide. Package
Developments design allows us
to tailor the Retail Articulating
Pusher Display to each account.
In fact, we have added more sizes
for the 2012 gardening season, Wooters says.
An upstanding design
With brilliant simplicity and a little physics
what Schwester describes as almost an epiphany
Package Development formed a design that solves
both of Burpees concerns by die-cutting a T at
the head of each long pusher-arm. Tere are four
or six pusher-arms on an extension o the main
An all-plastic tray design
uses a sliding arch behind
the packets to push them
forward.
Any shape. Any size.
Virtually any cap.
Go to www.FowlerMachines.com or call
1-877-549-3301 for more information.
Fowler/Zalkin builds capping machinery for closures of all shapes and sizes. Whether
your caps are screw-on, roll-on, press-on or a combination of all three, we have the
proven technology to apply them at any speed you require. When dependability,
versatility and experience are important, you can rely on Fowler/Zalkin.
tray. Te T slots into a cut-away groove centered
in the middle of each pocket. Schwester says, It
takes a fast 15 seconds to hinge and snap-lock the
pusher-arm extension to the main-tray backside and
u-bend the four or six pusher-arms in place, slotting
the T. Its practically simultaneous.
On both sides of the T slot are thermoformed
utes to prevent bottom sagging or bowing when
loaded. Tese utes also help maintain spacing of the
necessary 5-in. clearance between trays. Te die-cut
front tray wall (double-sided) is further strengthened
with utes at its highest points (5 in.). Tese utes
act as stiening ribs that help prevent deection. Te
wall in front of each pocket is only 3-in. high for easy
reach-in access, accommodating standard seed-packet
dimensions: 4-1/2-in. high x 3-1/4-in. wide.
Wooters says, It is a ne line for the front wall to be
high enough to hold packets in place while also making
them able to be pulled out. Tats also the reason there
are 5-in. of head-space between pusher trays.
Te pusher-arm itself supports the seed packets
vertically with the help of four utes near the T,
providing a at surface with which to advance
them. Advancement takes place because the plastic
pusher-arm is pulled back when the pocket is
lled, but wants to push forward. Te T slides
up as product is depleted. In eect, the bottom of
the pusher-arm acts as a coil that creates energy,
performing like a spring.
Displays assembled manually
Burpee manually assembles each Retail
Articulating Pusher Display at its Pennsylvania
facility, scoring a right-angle bend in the pusher-
arm to further help vertically support seed packets,
which are themselves hand-lled into pockets.
Te pre-loaded Retail Articulating Pusher
Display went into usage at outdoor garden centers
in February 2011, the start of gardening season. In
the end, Package Development also re-engineered
the plastic corrugated outer display using the
same footprint. Tey used a process of concurrent
engineering on the patented pusher display and outer
display to assure both would work well in concert.
For example, thumb recesses thermoformed into
either side of the tray for easy placement inside the
display are then secured with folding side-aps that
are keyed into the display.
Burpee buys the outer plastic corrugated displays
from a paper corrugated supplier who brokers the
panel through a plastic vendor.
Quality savings
Te simplicity of the design relies on the quality
The one-piece trays are thermoformed from a clear sheet of recycled PET.
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Additional solutions at the co-located EastPack, ICSE (International Contract

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of Pentaform rigid plastic lm we
specied from Klckner Pentaplast,
Schwester says. We chose them as
our supplier because we know from
experience that their gauge tolerance
will hold. Klckner Pentaplast
quality allows us to use a thinner
gaugewhich reduces material costs.
Even at 30-thousands-of-an-inch,
the formability of their lm is more
forgiving and its cut-ability reliable.
Not only does the innovative
one-piece Retail Articulating Pusher
Display save on production costs
materials, tooling, time, laborit
reduces shipping costs as well.
Unlike injection-molded product
pusher displays that ship fully
assembled and are limited to a small
number per shipper carton, Package
Developments design allows for each
display to nest together like drinking
cups. Depending on the size and
design, hundreds of displays can
be packed per shipper. According
to Schwester, this saves hundreds if
not thousands of dollars in shipping
cartons, freight and warehousing
with the much welcome benet of
reducing transportation greenhouse
gases.
No rain on this parade
As for wet conditions found
at an outdoor garden center, a
vent allows water to run down
the back of the Retail Articulating
Pusher Display and exit out the at
bottom. Te pusher-arms actually
lean back in a cradle, which acts as
a drain. Package Developments
design exceeded our expectations by
leaps and bounds, Wooters says.
We thought of this project as a
new adventure, and they had the
capabilities and qualities to make a
more e cient oor display.
Package Development continues
to strengthen and adapt its Retail
Articulating Pusher Display for
Burpee, as well as for heavier potential
applications such as candy bars,
pharmaceuticals, cold remedies, liquid
powders, fragrances or cosmetics. As
the company builds its own specialty
equipment and custom machinery,
there is no stopping its push to get
the Retail Articulating Pusher Display
into mass merchandising.
Just think, Schwester says, a
pre-loaded pusher-display panel
could save retail stores hours of labor
in stocking and restocking. And it
could help manufacturers keep their
products in full view of customers at
all times.
Klckner Pentaplast, 540-832-3600.
www.kpfilms.com
Package Development Co. Inc.,
973-983-8500. www.pkgdev.com
The existing stand-up display rack easily
accommodates the new tray design.
Great ideas become great products.
Great products deserve great packaging.
xpedx is packaging expertise
DESIGN | ENGINEERING | MATERIALS | EQUIPMENT | WORKFLOW | LOGISTICS

xpedx.com xpedx, a business of International Paper 2012 E-mail us at packaging@xpedx.com
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F
For decades, producers of PET blow-molded
containers have been shipping bulky bottles and
jars that contained nothing more than air, in many
cases over long distances. Until these containers
are lled with product, they take up valuable space
on cargo pallets and in transport vehiclesnot to
mention warehouse shelves. Tis is particularly true
with wide-mouth, bulk containers that are used to
package a range of products ranging from snacks to
candies and novelty items.
Today, however, a far more e cient two-step
manufacturing process is eliminating the need to
transport and store empty PET containers prior
to lling. In the two-step process, the rst step
begins with the production of uninated plastic
bottles, called pre-forms, which can be nested like
paper cups in space-saving stacks for transport and
storage. During the second step, the pre-forms
are inated to full size using stretch blow molding
equipment that can be purchased or leased for on-
site production, or outsourced to a local vendor.
By breaking the process into two steps, with the
second step performed locally, manufacturers can
enjoy savings in transportation and inventory costs,
along with increased production exibility to create
PET containers essentially on-demand.
Transport capacity increases
Te potential savings become much clearer when
you learn that instead of shipping 5,000 to 10,000
full-size containers in a shipment, a manufacturer could
ship 100,000 pre-forms10 to 20 times as muchat
a similar cost. Of course, that improved e ciency also
means a substantial savings of energy.
Te lead time for transit from distances such
as Asia are also considerably longer than those
required for domestic shipments, possibly six
weeks or more. Tat can translate to big dollars.
Outsourcing PET pre-forms overseas can tie up
hundreds of thousands of dollars in inventory
oating on the ocean while in transit.
Te other major benet of a two-step PET
molding process is the extensive exibility that it
provides for managing inventory.
Te lower cost of shipping makes it aordable
to inventory a larger supply locally. Also, since
the PET preforms are stored in a more compact
manner, you dont require the warehouse space that
you would with full-size, blow-molded containers.
Rez-Tech, for example, oers economical
equipment to manufacture pre-forms, as well as
step-two equipment to complete the bottles. Te
companys step-two equipment is not quite as fast
as more expensive high-volume equipment, but that
can be virtually irrelevant if packagers allow a little
more lead time.
Certain shapes such as handles are not possible
using a preform, and there may be a small trade-o
in the visual quality of the nal product. However,
for most wide-mouth applications, the nal result
is comparable to most conventional extrusion
molding techniques.
For the second step of the PET container
manufacturing process, customers have the option
of purchasing or leasing stretch blow molding
equipment. If a company does not want to
purchase equipment, they can farm it out to a local
supplier to do the work.
This article was prepared by Jack Podnar,
president of Rez-Tech Corp., a Kent, OH, manufacturer
of wide-mouth PET and vinyl plastic containers. For
more information, call 800-673-5277 or visit www.
rez-tech.com.
PET molding takes
two steps forward
A worker shows pre-forms being fed into a stretch blow molder, along with the nal wide-mouth PET bottle.
By DIVIDING THE BOTTLE MANUFACTURING process into two steps
instead of one, manufacturers can experience signicant savings in
shipping and inventory costs.
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I
Jack Mans, Plant Operations Editor
Induction sealers have solved problems with leaking
jars that have plagued SaltWorks, a producer
of gourmet salts in boutique jars, at its plant in
Woodinville, WA. SaltWorks began 10 years ago
as a hobby for Mark Zoske, who created a web site
committed to educating food enthusiasts about the
unique qualities and dierences of gourmet salts.
What started as a hobby rapidly grew into what is
now a company supplying more than 150 varieties
of gourmet salts from around the world.
Zoske says, Ive devoted my life to researching,
importing and packaging the best salts possible and
it takes a tremendous amount of eort.
Himalayan, Kosher, Fleur de Sel, smoked, black
tru e, course, ne, organichave you ever looked
the grocery store shelf overwhelmed by the selection
of salts? SaltWorks has not only mastered the ne
art of artesian salt, but it has also mastered avoring
it with a secret fusion process; and discovered how
an induction sealer provides an air tight seal for
product freshness.
SaltWorks products make up 70 percent of the
artisan salt market share, and today it is the worlds
largest supplier of smoked salts. In late 2011, it
moved to a renovated 100,000 sq-ft warehouse and
factory.
SaltWorks has expanded its product line to
include smoked salts, Fusion avored salts and even
bath salt, all created without chemicals or articial
avoring. Its Fusion collection starts with an all-
natural sea salt base, and then, with a secret process,
infuses the salt crystals with other completely
natural avors, ranging from spicy jalapeno to bold
espresso brava. Zoske says, Our No. 1 rule is that
all of our products are 100 percent natural.
Sourcing salts from the Himalayas to Hawaii,
SaltWorks works closely with farmers, educating
them on how to package the raw minerals to ensure
they arrive safely at its factory in Woodinville, WA.
When the salt reaches SaltWorks factory, it goes
through a thorough, waterless cleaning process.
Te minerals are cleaned with an optical sorter
that uses a high-powered camera to detect and
remove contaminants with jets of air. Tis process
sorts and disposes of matter that does not meet a
prequalied size, shape or color. Every grain of salt
is run through this process twice, making it 99.999
percent pure salt mineral.
Just how precise is the sorter? SaltWorks put it to
test it by adding grains of sand to a batch of salt. It
e ciently removed every last grain of sand.
Packaged to perfection
SaltWorks not only imports and cleans the salt;
it also packages and labels the product. Its packaged
product sizes range from 1 oz to 2,200 lb. SaltWorks
has ve packaging lines, two of which have Enercon
Industries Corp. induction cap sealers.
In 2008, Zoske consigned an Enercon Industries
Corp. handheld system that held him over until his
new high-speed Enercon Super Seal induction sealer
arrived. He liked the handheld system so much that
he purchased it as well. In 2011, he installed a new
packaging line and added another Super Seal cap
sealer to meet the demand for his expanding business.
Zoske says, I knew immediately, when I saw the
Enercon induction sealer at a tradeshow, that it was
what I wanted. We liked the quality of Enercons
construction and the ease of adjustment for our
dierent sizes of jars and caps.
SaltWorks induction seals PET jars ranging from
4 to 32 oz at speeds from 20 to 60 jars/min. Tey
are outtted with 63mm ip-top shaker caps from
Weatherchem Corp.
Zoske says, Prior to induction sealing, we used
pressure-sensitive liners. Due to the nature of salt,
if just one grain got on the jars rim, the pressure-
sensitive liner failed. We also started adding oxygen
scavengers and desiccants to our packaged product.
We decided it would all be a waste if we did not
have an air-tight seal.
By incorporating an induction seal, SaltWorks
now has insurance against inconsistent seals. Its
customers benet from increased product freshness
and tamper evidence.
Enercons induction sealer is designed to be easy
to use. Te induction sealer is comprised of two
main components: the power supply and the sealing
head. Te sealing head produces an electromagnetic
current, heating the induction foil liner tted inside
the capped jar which in turn melts the polymer
coating on the inner seal. Te heat, combined with
the pressure of the cap, causes the inner seal to
bond to the lip of the container, resulting in a tight
Sealed for
success
Induction sealers at SaltWorks
PREVENT LEAKING JARS caused
by grains of salt getting in the seals
of boutique jars. A sealer is part of
a new packaging line installed in
November 2011.
Induction sealer applies air-tight seal to tops of jars, thus ensuring product freshness and tamper evidence.
SaltWorks enjoys 70
percent of the artisan
salt market.
induction seal.
Zoske says, Its the only packaging machine Ive
ever bought that Ive been able to plug in and let it
go. Due to the nature of the salt, we work in a very
corrosive environment, and its never been down a day.
We are very satised with our Enercon sealers.
Tey were easy to set up and install. We had a
couple of questions during installation that they
answered over the phone. I think Enercon is a great
company. Tey really care about their equipment
and their customers.
Packaging line
SaltWorks installed its new packaging line in
November 2011 to run PET jars ranging from 4
to 32 oz at speeds from 20 to 60 jars/min. Jars are
stacked in square rows on pallets, and an operator
sweeps several hundred jars at a time onto the
large infeed table of a jar unscrambler from Inline
Filling Systems Inc. that feeds a 72-in. turntable.
A pallet lifter raises the pallet so that each row of
jars is at the proper height to be pushed onto the
infeed table.
Jars are conveyed to a Model PMB-402-S
twin-head linear scale/ller from Weigh Right
Automatic Scale Co. Te intermittent-motion
PMB net weigher uses vibratory scales that can
deliver 2g to 15 lbs of product into containers. Te
ll nozzles descend into the jars to ll the product,
and then rise when the lling is complete.
Te unit at SaltWorks lls two jars at a time
using the bulk and dribble method of weighing,
in which most of the desired weight discharges
quickly into the weigh bucket (bulk speed) and
the remainder discharges slowly (dribble speed) to
provide an accurate weight.
Te machine features menu driven, touch-
screen controls from AutomationDirect that allow
operators to select the product to be run directly
from the screen, as well as oering help menus and
easy-to-read graphics.
Salt is delivered to the weigher/ller in large
bags, which are lifted into lling position by an
overhead hoist system from Harrington Hoists
Inc. Saltworks loads the amount of salt to be lled
each shift into 500-lb or 2,200-lb super sacks,
which the hoist lifts over the lling machine to
gravity feed into the hopper. Zoske says, We do
this for two reasons. First, our salt is very fragile. By
using gravity and vibratory feeding we create the
least amount of nes.
Te second reason is sanitation. By using
disposable super sacks, we have a clean and sanitary
bulk hopper for every run. We ll more than 150
dierent types of salt. Tere are very few contact
points that need to be cleaned during change over.
We can switch from one type of salt to another in a
matter of minutes. Te company has eight separate
super sack hoist systems throughout the factory.
Capping success
Te lled jars are conveyed to an 8-quill in-line
capper from Pack West Machinery Inc. Te ip-
Salt is delivered to the weigher/ller in 500 or 2,200 lb
super sacks, which are lifted into lling position by an
overhead hoist system. A twin-head linear scale/ller
handles two jars at a time. Continued on page 52
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top caps for the jars are loaded into a oor hopper
and a vertical elevator lifts the caps. Horizontal rails
are sized and slanted so that caps with the open side
facing inward fall back into the feed hopper. Only
caps with the open side facing outward are raised
all of the way to the top. A sensor on the elevator
detects caps without liners and caps with open ip
tops and rejects them.
At the top of the elevator, the caps discharge
down through vertical orienting and spacing
wheels onto a track that carries them down to the
application point in the capper. Jars entering the
capper pick a cap from the discharge shoe at
the bottom of the cap track and pass four pairs of
horizontal rotating rubber wheels that tighten the
caps to the set torque.
In a motion that mimics the way a person
applies a cap to a jar, the rst set of wheels rotates
backwards in order to seat the cap in the threads on
the jar. Te second set of wheels tightens the cap
most of the way, and the third set of wheels nishes
the tightening. Te fourth set of wheels is a fail-safe
in case the cap has not been completely tightened.
A sensor at the outlet of the capper checks that
the caps have been applied properly, after which
the jars are conveyed through the Enercon Super
Seal induction cap sealer and then travel through
a PowerDry Spyder blow-o cleaning and drying
manifold from ITW Paxton Products. Te system
incorporates four exible plastic ducts that can be
adjusted to direct the air to the exact points on the
jars to accomplish the optimum drying.
Top and wraparound labeling
From the dryer, the jars are transported to a
model A107 stainless steel wraparound labeler from
Colamark Asia Ltd. that applies pressure-sensitive
labels. It was custom modied for Saltworks to
also apply pressure-sensitive top labels. Labels are
supplied by Labels West Inc.
Zoske says, We originally purchased an
American-made top and wraparound labeler. It
never worked correctly and we sent it back. We
found Colamark through the internet. We visited
their factory and were really impressed. Tey have
great quality and superior technology. Tis was the
rst Colamark labeler installed in the U.S., and as
far as I know, it is still the only one.
Te labeler applies the top label and then the
wraparound label in two separate operations. Te
jars have a small indent on their base, which is used
to orient them during the labeling operation so that
the top and wraparound labels and the ip top are
all in the same exact orientation.
Te jars enter the labeler and are spun until a
sensor detects the indent, at which point they are
gripped by a unique three-point system that holds
them securely. Zoske says, Tis is one of secrets to
their labeling excellence. It forces the labels to go on
straight and correctly oriented.
Top labels, which are applied rst, are stripped
from a roll mounted over the machine and are
applied to the tops of the jar. Te procedure is
repeated in the wraparound section. Te labeler
is equipped with Sanyo Denki servo drives and
Mitsubishi Electric Automation Inc. controls
and touch-panel HMI that provides user friendly
operation that includes menu-driven memory,
A vertical elevator lifts the ip-top caps to the top of the capper, from which they travel down a cap track to the
application point in the capper. Jars entering the capper pick a cap from the discharge shoe and pass four pairs of
horizontal rotating rubber wheels that tighten the caps to the set torque.
Stainless steel labeler applies pressure-sensitive top and wraparound labels. The manufacturer integrated an ink-jet
printer and a nal rotary accumulation table into the system.
Four plastic ducts can be adjusted to direct the air to the exact points on the jars to accomplish the optimum drying.
intelligent label quantity management, error
messages and help messages for operators.
Te labeled jars travel past a model 9020 ink-jet
printer from Markem-Imaje USA that applies a
production date and lot code and then continue
to a rotary accumulation table from Colamark.
Te labeler, printer and accumulation table were
supplied as a system by Colamark.
Finished jars are manually packed into cases.
SaltWorks sealed for success
Zoske says, Our mission is to oer the most
comprehensive selection of premium specialty salts,
with an emphasis on superior quality, exceptional
value and outstanding customer service. Tis
packaging line supports that mission. SaltWorks
has taken the earths highest quality salts and
blended them with the right combination of
packaging equipment, resulting in a SaltWorks
recipe for success.
AutomationDirect,
800-633-0405.
Colamark Asia Limited,
+852 2634 8011.
www.colamark.hk
Enercon Industries Corp.,
262-255-6070.
www.enerconind.com
Harrington Hoists, Inc.
800-233-3010.
www.harringtonhoists.com
Inline Filling Systems Inc.,
941-486-8800.
www.fillers.com
ITW Paxton Products,
800-441-7475.
www.paxtonproducts.com
Labels West Inc.,
800-540-3009.
www.labelswest.com
Markem-Imaje USA,
866-263-4644. www.markem-imaje.US
Mitsubishi Electric Automation Inc.,
847-478-2100. www.meau.com
Pack West Machinery Inc. 626-814-4766.
www.packwest.com
Sanyo Denki America Inc.,
310-783-5400.
www.sanyo-denki.com
Weatherchem Corp.,
800-680-3412.
www.weatherchem.com
Weigh Right Automatic Scale Co.,
800-571-0249.
www.weighright.com
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T
Trade Associates Group Ltd., (TAG), Woodridge,
IL, was receiving an increasing number of
complaints from its customers regarding the
expanded polystyrene (EPS) loose ll it was using
to protect its shipments.
TAG is a well-known designer and manufacturer
of houseware and giftware products that are sold
through retail channels. For many years, the
company had used EPS to protect its more than
3,000 SKUs while in transit.
Although EPS performs well as a packaging
material, it also has several negatives, explains
David Abraham, director of distribution operations,
TAG. For example, shipments are subjected to
vibration. EPS doesnt block and brace the load, so
products have a tendency to shift during transport.
Tis is especially the case with heavier items, such
as glassware, which tend to migrate to the edge of
the case. Tats when they become most susceptible
to damage.
Additionally, the company had been receiving
consumer complaintsparticularly from smaller
retailers who did not like the mess the EPS
made when the products were removed from the
shipping cases.
Tey would often nd themselves having to
sweep up the particles that had fallen onto the oor.
Empty shipping cases still lled with EPS also took
up a signicant amount of space in their storage
area which is typically small to begin with. On top
of that, they frequently had to incur additional fees
to dispose of it, Abraham says.
In addition to the mess and disposal issues at
the retail level, TAG also had similar clean-up
issues to contend with at its own facility. Using
traditional overhead bins and blow-in delivery
systems with a scissors opening to drop the
loose ll into the cases, EPS particles would
frequently end up on the plant oor, machinery
and work surfaces.
Between the customer complaints and our
own experience, we knew it was time to make
a change. We started to review alternatives in
2010. Our goal was to satisfy our customers
by nding a more environmentally-responsible
option which would eliminate the mess and
make disposal easier for them. Te new system
also needed to protect our products while being
cost-eective, Abraham notes.
In addition to those attributes, the solution
needed to be exible. TAG has both a standard
product oering as well as seasonal. Products vary
widely in size, weight and material.
Our packers deal with everything from tall
outdoor patio torches to small glass objects. It was
important that whatever system we switched to
could protect our entire product line regardless of
the items shape or size, Abraham says.
With many fulllment operations already having
shifted to inatable packaging, TAG felt that was
also the direction they wanted to head in. Te
company then embarked on an extensive evaluation
process to determine which equipment and lm
combination would meet all of its performance and
cost parameters.
Evaluating ll alternatives
Early in 2011, we evaluated machines from
several manufacturers. We actually did test runs
using our packers and products. We hold our
packers to both quality and time standards. So, we
wanted to make sure that the system we converted
to did not negatively impact our productivity,
Abraham says.
Pregis Corp. worked with TAG to review its
packaging requirements. A detailed evaluation of
the products, packing process, current costs and
e ciency (such as speed, shipment weight, cost,
protection and ease-of-use) was conducted.
After the evaluation was complete, we found
that the Pregis system was the most exible and that
its sales and engineering team provided the best
ideas for our situation, Abraham notes.
TAG selected Pregis AirSpeed HC (hybrid
cushioning) Versa system combined with the
companys high-performance, low-density
polyethylene (LDPE) air pillow lm.
Hybrid cushioning diers from traditional void-
ll pillows because it features multiple air chambers
in a horizontal and vertical pattern vs one large cell.
Flat, perforated rollstock is mounted onto the
AirSpeed Versa unit, which creates the rows of small
air-lled pockets as the air is transferred between
the individual chambers. Te new, compact design
positions the roll externally, making it easier for
packers to changeover.
Pregis Versa represents the state-of-the-art in
hybrid cushioning. It can handle multiple roll
widths (up to 32-in.). It has a reduced prole,
which enables the unit to be placed in locations
where space is a premium.
Te AirSpeed HC Versa is also the rst hybrid
Air pillows offer
soft landing for TAG
Housewares and giftwares company reduces damage, eliminates mess,
improves environmental prole by switching to HYBRID CUSHIONING system.
TAG packing station
with Pregis AirSpeed
HC Versa produces
hybrid cushioning for
on-demand protection.
Rolls are removed
from unit and placed
overhead for easy
packer access.
s
h
i
p
p
i
n
g
cushioning unit to produce pads in three dierent
widths: 24-in. wide cushions from 32-in. rolls,
as well as 18- and 12-in. wide sizes. It can also
produce three dierent cell heights: small (3/4
in.), medium (1 in.) and large (1-1/4 in.). Typical
perforation preset is every 6- and 12-in.
TAG is using the unit in conjunction with
Pregis high-performance, recyclable LDPE air
pillow lm that is made with 30 percent less resin
than competitive hybrid inatable cushioning
alternatives.
Not only have we been able to engineer a
space-saving unit, but we have also added to its
capabilities while still retaining industry-leading 75
feet per min speeds. Te speed and small size are
important for tight work spaces and high volume
operations, explains Scott Peterson, business
development manager, packaging systems, Pregis.
It was determined that the 24-in. pads with
medium height bubble would best address TAGs
Left: Packer pulls cushioning off the overhead roll and lines the case. Right: Hybrid cushioning aps are folded over top of contents to create an additional layer of protection before case sealing.
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requirements. A roll winder was added to each unit
to create bundles that could be easily transported
to the pack stations, and mounted on a custom
dispenser for operator use.
TAGs packing protocol mandated protection
on all six sides of the case. So, the solution was
to lay two pads across the top aps of the shipper
in a cross pattern, place the houseware items on
top and allow the pads to sink into the bottom,
enveloping the contents on all sides. Each case
is a master shipper. Multiple products, some
already in small shipping cartons, are co-mingled
in the pack.)
We also like that the hybrid cushioning
material is exible. Tat gives our packers the
ability to also wrap it around individual products
if they think added protection is warranted,
Abrahams points out.
In mid 2011, TAG installed nine AirSpeed
HC Versa units to handle 18 pack stations. (Te
company maxes out at 25 pack stations at the
height of its seasonal packaging.) Te HC Versa also
oers a simple-to-use operator panel which makes it
easy for new or seasonal employees to use.
Providing an eective shipping solution for
our customers is important. We have received
a signicant amount of positive feedback from
our customers since we converted to Pregis
Versa system. Additionaly, we have been able
to eliminate multiple protective packaging
problems, Abraham says.
In addition to positive customer feedback, TAGs
employees say that the systems are easy-to-use and
the need for constant clean up has been eliminated.
Since the Versa units have been installed
we havent experienced any problems. Pregis
maintenance on the machines has been stellar,
as well as the follow-up training. We are pleased
that we now have a leading-edge operation with
an improved environmental prole, concludes
Abraham.
Pregis Corp., 877-692-6163. www.pregis.com
In addition to top and bottom protection,
the cushioning is also used as void-ll.
Find the Latest Innovations and Solutions
to Accelerate Your Packaging Projects
1SPEVDFEBOENBOBHFECZ6#.$BOPOtVCNDBOPODPN
For details on exhibiting or attending, please visit CanonPackShows.com
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February 1416, 2012
Anaheim Convention Center
Anaheim, CA
WestPackShow.com
May 23, 2012
Charlotte Convention Center
Charlotte, NC
SouthPackShow.com
Back in
Charlotte!
March 1415, 2012
Fort Worth Convention Center
Fort Worth, TX
TexasPackShow.com
Coming
in 2012!
Oct. 31 Nov. 1, 2012
Minneapolis Convention Center
Minneapolis, MN
MinnPackShow.com
May 1416, 2013
Toronto Congress Centre
Toronto, ON
PACKEXtoronto.com
May 2224, 2012
Pennsylvania Convention Center
Philadelphia, PA
EastPackShow.com
New
Location!
May 2223, 2012
Philadelphia, PA
PharmapackNorthAmerica.com
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November 1415, 2012
Palais des Congrs de Montral
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C
T
industry insights
Te food industry is beginning to recognize
that food safety is a shared responsibility and
there is a strong need for an end-to-end supply
chain approach to food safety right down to the
packaging of food products.
Over the past few years there has been a great
push in the retail and foodservice industries
toward certication of suppliers against Global
Food Safety Initiative (GFSI)-benchmarked
schemes. Soon, food packaging producers will
be able to earn certication to one of three
packaging schemes up for benchmarking
against the Global Food Safety Initiative. Tese
include BRC Global Standard for Packaging
and Packaging Materials, Food Safety System
Certication 22000/PAS223 and Safe Quality
Food (SQF).
Te GFSI is a business-driven initiative for
the continuous improvement of food safety
management systems to ensure condence in the
delivery of safe food to consumers worldwide.
GFSI allows collaboration between some
of the worlds leading food
safety experts from retailer,
manufacturer and foodservice
companies, service providers
associated with the food
supply chain, international
organizations, academia and
government.
Te initiative was launched
in 2000 following a number of
food safety crises when consumer
condence was at an all-time
low.
GFSI is managed by Te
Consumer Goods Forum, an
independent global network
for consumer goods retailers and manufacturers
worldwide. It serves nearly 400 member
companies in more than 150 countries.
Tis article will help you understand why
certication is important and how you can
start to prepare your packaging facility for
compliance.
Why is certication important?
Contaminated food can have potentially fatal
eects on consumers health. According the
Centers for Disease Control (CDC), food-borne
illnesses cause about 300,000 hospitalizations
and 5,000 deaths every year in the U.S. alone. .
Food recalls are also really, really expensive.
In the U.S., the economy hemorrhages about
$7 billion every year due to these outbreaks,
according to a recent article in the Washington
Times.
Te costs of a food recallwhich include
removing contaminated food from store
shelves, lawsuits and sometimes revamping the
facility that is believed to have produced the
contaminated productreally add up. Not to
mention the loss of sales caused by a bruised
reputation and lowered consumer trust. Everyone
in the supply chain tends to share the burden
retailers and manufacturers alike.
If the food industry is going to avoid these
costly food safety incidents, they will need to
hold each other to higher schemes. Certication
to GFSI-recognized schemes enables food
companies at every link in the supply chain to
achieve best practices and standards that are
recognized globally.
Certication allows a facility to demonstrate
to their customers further down the supply
chain they are committed to food safety,
including packaging.
Why should I earn
certication?
Retailers and foodservice
companies need to be sure the
packaging they are sourcing is
not going to contribute risks
to food safety and quality.
Certication to Global Food
Safety Initiative-benchmarked
schemes enables packagers
to demonstrate to their
supply chain partnersand
ultimately major retailers
that they are a strong partner
in food safety and have quality systems in
place that ensure packaging products will not
have an adverse eect on the safety and quality
of the food products you package.
How can I get started?
An online assessment tool to help facilities
understand their readiness for compliance against
GFSI-recognized schemes is available at http://
bit.ly/xn0rEG.
NSF Intl. also developed a white paper
specically for packagers to help educate them
about the BRC/IOP Global Standard for
Packaging and Packaging Materials. You can
download this white paper at http://bit.ly/
yeun2X.
Author Robert Prevendar has 20 years of experience in public health and food safety. He serves as
director of supply chain food safety at NSF Intl., a leading provider of certication for Global Food
Safety Initiative schemes. For more information, visit www.nsf.org.
Packagers must prepare to comply
with global schemes for food safety
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JUNE 19-21, 2012
Jacob K. Javits Convention Center, NYC
HBA Global is celebrating 20 years!
To mark this very special year, HBA will provide a variety of new onsite
activities, pavilions and tools to assist you and your needs in an ever changing
competitive marketplace, which include:
20 Celebrating years of Creativity, Innovation & Beyond
NEW online appointment making feature for exhibitors and attendees!
Enhanced New Product Showcase in prime location on HBA Globals show floor.
New SPLASH! Pavilion showcasing the best in emerging brands.
Innovation Pavilions, showcasing suppliers, education, networking opportunities all in one area!
Design Hot Spots a new area for inspiration, innovating materials to further develop creativity and ideas.
For more information and
updates visit us online at
www.hbaexpo.com
Celebrate with us and register for your complimentary Exhibits Hall Pass at
www.hbaexpo.com/register with priority code: PPTD
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Sign up for Packaging Digests Daily Packaging News e-newsletter
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Go to www.packagingdigest.com/Daily
Talk back!
Heres what readers of packagingdigest.com are saying:
The household products company has added to its line of concentrated cleaners, which are
designed to be poured into refllable bottles.
www.packagingdigest.com/SCJohnsonReflls
Im all about cause marketing, but this takes
it to a new level. Very insightful and ingenious
packaging. Heres to hoping it helps direct many
people to the registry!
Kayla, blog writer for Container & Packaging Supply, on
Bandage package takes on blood cancer
What is extended producer responsibility supposed to fx? It is
an idea in search of a problem! With two-thirds of all municipal
solid waste in the U.S. not packaging, when all the (unsustain-
able) recycling and take-back propaganda has run its course, the
countrys municipalities still have all that solid waste in need of
disposal.
Tom Dunn, packaging developer, on EPR laws continue
to spread
Cheap, intelligent
item-level RFID
tags now possible
European researchers have made the frst reader-talks-
frst low-temperature thin-flm transistor (TFT) RFID circuit. This
technology will allow the creation of RFID tags that are cheap enough and
have enough performance to be used as intelligent item-level tags on the
packaging of retail consumer goods.
www.packagingdigest.com/CheapRFIDtags
QR code on Budweiser packs
lets consumers Track Your Bud
Budweiser, the iconic global beer
brand, has introduced Track Your
Bud, a digital campaign integrated
with packaging that will allow
consumers to trace the origins of the
beer they hold in their hands to one of
Budweisers 12 U.S. breweries.
www.packagingdigest.com/
BudweiserQRcode
Packaging among factors driving up
private-brand prices
Consumers traditionally have turned to store brands to save money on
their grocery bills. Store brands soon might not be so cheap, though.
Those goods could begin increasing in price to compensate for the
costs of packaging and product improvements.
www.packagingdigest.com/PLprices
Cardinal Health debuts space-
saving packaging
for surgical gloves
Cardinal Healths new half-fold glove
dispenser boxes are at least 30 percent
smaller and use at least 15 percent less
paperboard than competitive products
sold in tall packaging confgurations.
Individual pouches within the half-fold dispenser boxes are said to be at least
48 percent smaller than competitive products.
www.packagingdigest.com/HalfFoldGloveBox
Recycling of non-bottle rigid plastics
soars 72 percent in single year
Nearly 820 million pounds of post-consumer rigid
plastics were collected for recycling nationwide in
2010, an increase of 72 percent from 2009 and
154 percent since 2007, according to a new report
from the American Chemistry Council.
www.packagingdigest.com/
NonBottlePlasticRecycling
SC Johnson expands its line
of concentrated cleaner refills
Ask the Experts
Need a little help? Weve got experts standing by to answer
your questions about Labels, Automation and Sustainability.
http://packagingdigest.canon-experts.com/
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February 1416, 2012
Anaheim Convention Center
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May 2224, 2012
Philadelphia, Pennsylvania
March 1415, 2012
Fort Worth Convention Center
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June 1921, 2012
McCormick Place North
Chicago, Illinois
May 23, 2012
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Charlotte, North Carolina
November 1415, 2012
Palais des Congrs de Montral
Montral, Qubec, Canada
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Reduce your carbon footprint
Head off the regulation blues
Reduce your energy costs
Meet supply chain requirements
Give your product, your customer and
your company something to be proud of.
info showcase
Literature and other multimedia, product announcements
and websites for packaging machinery, materials,
containers, supplies, and services. Contact supplier directly
or respond online for information.
For more information, contact Steve Everly at 610/705-8705, steve.everly@ubm.com
Machinery & Materials
marketplace
PACKAGING DIGEST
11444 W. Olympic Blvd, Los Angeles, CA 90064 Fax: (310) 362-8808
Attn: Steve Everly at 610/705-8705
Email: steve.everly@ubm.com
YUPO Gives You a Sustainable Edge in
Packaging.
Why choose YUPO Synthetic Paper over other label
substrates?
Waste Reduction No Label Liner to Discard
100% Recyclable Bottle Label
Starts & Finishes Green 100% tree-free
Cost-Saving Benefits Compared to other methods
Diverse Packaging Possibilities
Blow and Injection Molding
Clear and Opaque Grades
The Choice For Preforms
Oaklee preforms provide a secure tamper-evident
band for hard to seal and small production run con-
tainers. Simply place the preform over the closure
and container edges then apply heat to gain a snug,
secure fitting seal. No investment in package sealing
machinery or technical expertise. With an inventory
of over 200 preform molds, in a wide array of sizes
and shapes, we can accommodate your packing needs
using clear, custom colors or custom printed film.
Oaklee International Inc.
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Dominos A320i. A revolution in ink jet
coding innovation.
The A320i is the first ink jet printer in the industry
to eliminate the service routine, while guaranteeing
predictable start-up, reduced costs and less waste. See
firsthand how the A320i performs, and discover ink
jet innovation designed to maximize your productiv-
ity.
Domino Amjet Inc.
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Up Your Wow Factor with Vibrant
Printed Shrink!
Convert your multi-packs and bundled items from
paperboard trays, labels or sleeves to 100% printed
polyolefin shrink filmBemis Clysar makes it easy!
Youll wow consumers with colorful 360 brand
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Plus, youll dramatically reduce material usage to
boost sustainability and cost savings.
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Numatics G3 Fieldbus Valve Manifold
The G3 is the next-generation electronic platform that
allows easy access to I/O connections. Its simple to
assemble, install, commission, and maintain. The G3
is the only pneumatic valve manifold that contains a
graphical display used for configuration, commission-
ing, and diagnostics. The platforms electronic modules
can be used for centralized or distributed architecture.
Numatics Incorporated
46280 Dylan Drive, Novi, Michigan, 48377-4906 USA
Phono: 24S-596-S200 Fax: 24S-596-S201
www.numatics.com
newsmakers
PACKAGING DIGEST (ISSN 0030-9117) is published monthly, with a special issue in summer, by UBM Canon, 11444 W. Olympic Blvd., Los Angeles, CA 90064-1549; 310-445-4200; FAX 310-445-4299. Periodicals postage paid at Los Angeles, California,
and at additional mailing offices. SUBSCRIPTIONSFree to qualifed subscribers as defned on the subscription card. Rates for non-qualifed subscriptions, including all issues: 1 yr. $150, 2 yrs. $250, 3 yrs. $300. Except for special issues where price changes
are indicated, single copies are available for $10 USA and $15 foreign. For telephone inquiries regarding subscriptions, call 763-746-2792. CHANGE OF ADDRESSNotices should be sent promptly to P.O. Box 47461, Plymouth, MN 55447. Please provide old
mailing labels as well as new address. Allow two months for change. EDITORIAL CONTRIBUTIONSUnsolicited manuscripts should be submitted via e-mail to john.kalkowski@ubm.com. Copy will receive every reasonable care; however, the publishers assume
no responsibility for safety of artwork, photographs, or manuscripts. NOTICEEvery precaution is taken to ensure accuracy of content; however, the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any
opinion expressed herein. POSTMASTERSend address changes to PACKAGING DIGEST, P.O. Box 47461, Plymouth, MN 55447. Canada Post: Publications Mail Agreement 40612608. Return undeliverable Canadian addresses to: BlueChip International,
P.O. Box 25542, London, ON N6C 6B2. Printed in U.S.A. Copyright 2012 by UBM Canon. All rights reserved. Reproduction in whole or part without written permission is prohibited.
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Steve Everly
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steve.everly@ubm.com
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Russell Thibeault
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AL, AR, CT, IA, LA, MA, ME, MS, NH, NJ, NY, RI,
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steve.slakis@ubm.com
CA, GA, ID, IL, MN, MO, MT, ND, NE, NV, OR,
SD, TX, UT, WA, WI, Canada (West)
Tom Corcoran
215-275-6420 Fax 484-631-0598
tom.corcoran@ubm.com
AZ, CO, IN, KS, KY, MI, NM, OH, OK, UT, WY
INTERNATIONAL REPRESENTATIVES:
Europe/Middle East | Lisa Evans
lisa.evans@ubm.com
China | Sylvia Xiao
sylvia@edoomedia.com
Japan | Masayuki Harihara
mail@yukarimedia.com
Taiwan | Robert Yu
sales@wwstaiwan.com
Mary Williams
Marketing Services Manager
630-990-2371 Fax: 630-990-8894
mary.williams@ubm.com
REPRINTS
Foster Printing Service
800-879-9144
sales@fosterprinting.com
Sales and Marketing Offices
sales staff
Adalet ......................................................................................32
Advanced Antivibration
Components (AAC) .......................................................53
Asco Numatics GmbH ................................................37
AutomationDirect .............................................................3
AXON.........................................................................................42
Berlin Packaging ...........................................................63
Bosch Packaging Technology Inc. ....................5
Bosch Rexroth Corporation ..................................23
Burrow Industries Inc. .............................................61
Busch LLC. ..............................................................................6
Cardinal Packaging .....................................................64
Columbia Machine .......................................................33
Dairy Farmers of America .....................................25
Domino Amjet Inc. ........................................................18
Enercon Industries Corp.........................................55
Fowler .....................................................................................45
Fres-Co Systems USA ................................................43
Groninger ..............................................................................55
Hammer .................................................................................16
HBA Global Expo ............................................................58
Highdream ...........................................................................11
Hitachi ........................................................................................2
ID Technology ...................................................................31
Institute of Packaging Professionals ..........49
Kliklok-Woodman Packaging Solutions ......14
Klockner ................................................................................51
Leibinger ..................................................................................7
Matrix ......................................................................................38
MRI Flexible .......................................................................29
NAFM ........................................................................................19
Overnight Labels Inc. ....................................................6
Paktech ..................................................................................39
Patlite ......................................................................................35
Posimat ..................................................................................21
Primera Technology .......................................................9
Sato ...........................................................................................17
Schneider .............................................................................53
Sharp Packaging ...........................................................12
Simplimatic ........................................................................13
Squid Ink ..............................................................................41
Videojet ..................................................................................15
Xpect Solutions ...............................................................13
xpedx .......................................................................................47
Yupo Corporation America ....................................22
MOVERS & SHAKERS
Adept Technology
appoints Robert
Malley as vp of
global operations.
B & H Labeling
Systems appoints
Rodrigo Melo as
assistant global
feld service
manager.
Ball Corp.
promotes Robert
Miles to svp, North American sales.
Intelligrated hires Tom Sullivan as
national sales
manager for
fulfllment
solutions team.
Key Technology
promotes Steve
Pellegrino to vp
of sales.
TricorBraun
names Charles
Pfster as CFO.
Emerson
Bearing launches
new packaging
division and
promotes Lee Holt
to head it.
The Plastics
Industry Trade
Assn. appoints
Jacqueline Dalzell
as director,
industry affairs.
O-I names
Georgette Verdin as vp of global talent
management and organizational
development and Sergio Galindo as
president of
its Asia Pacifc
region.
PolyOne Corp.
promotes Robert
Patterson to COO
and hires Richard
Diemer, Jr. as svp
and CFO.
Eriez hires
Craig Lorei,
Christopher
Ramsdell and
Jayne Corey as
technical sales
representatives.
Hoover Group Inc.
hires Paul Lewis as
president and COO.
Aaguard Group
LLC hires Jim
Guttridge as key
account and area
sales manager.
Beumer Group names Christian
Matzen as sales manager for
packaging systems.
Nordenia Slavnika, the Russian
subsidiary of Nordenia Int. AG, hires
Oleg Obertinyuk as its general director.
Dymax Corp. appoints Jon Galaska as
territory sales manager.
GROWING & GOING
Intelligrated relocates its Dallas-based
regional operation to Coppell, TX.
BUYING & ALLYING
Triangle partners with Southeastern
Packaging Equipment Sales LLC.
Sato America Inc. acquires Achernar
of Argentina.
Amcor acquires Aperio Group, an Asia
Pacifc producer of fexible packaging,
for $238 million and India-based
Uniglobe for $19.8 million.
Optima Group (Germany) acquires
Doyen Medipharm.
Ardagh Group acquires the Boxal
group of companies from Exal Corp.
for approximately 85 million.
NatureWorks and BioAmber
form AmberWorks joint venture
to commercialize new bio-based
polymers.
Mocon Inc. acquires PBI-Dansensor
A/S (Dansensor) of Ringsted,
Denmark.
H.B. Fuller acquires ForboGroups
global industrial adhesives business.
International Paper completes
Temple-Inland acquisition with total
transaction value of about $4.5
billion.
Mauser Group acquires Varicon
Solutions in North America.
Robert Miles
Ball Corp.
Robert Malley
Adept Technology
Steve Pellegrino
Key Technology
Tom Sullivan
Intelligrated
Rodrigo Melo
B & H Labeling
Systems
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