PMMI Media Group editors spread out across the many booths at PACK EXPO in Las Vegas to bring you this innovative report.Here’s what they see in the sustainable packaging category.
There was a time when a review of packaging innovations that debuted at major trade shows like PACK EXPO would focus on examples of improved functionality and performance.Consider enhanced gas barrier properties, antimicrobial properties, improved sliding properties for better machinability, or adding new tactile elements for greater shelf impact.Image #1 in article text.
But as PMMI Media Group editors roamed the aisles of PACK EXPO in Las Vegas last September in search of new developments in packaging materials, as you’ll see in the coverage below, one theme dominates: Sustainability.Perhaps this is not surprising given the level of focus on sustainable packaging among consumers, retailers and society as a whole.Still, it’s worth noting how dominant this aspect of the packaging materials space has become.
It’s also worth pointing out that the development of the paper industry is plentiful, to say the least.Let’s start with the full-paper blister packer (1) on display at the Starview booth, an initiative jointly developed by Starview and cardboard converter Rohrer.
“The conversation between Rohrer and Starview has been going on for a long time,” said Sarah Carson, Rohrer’s director of marketing.“But over the past year or two, the pressure on consumer goods companies to meet ambitious sustainable packaging goals by 2025 has grown so much that customer demand has started to really pick up. That includes one important customer who was very excited about the idea. So serious that it gives us a strong business reason to invest in the R&D that is going to happen. Fortunately, we already have a good partnership with Starview on the mechanical side.”
“We were all going to actually launch this product last year at PACK EXPO in Chicago,” said Robert van Gilse, director of sales and marketing at Starview. COVID-19 has been known to put kibosh in the program.But as client interest in the concept grew, van Gilse said, “We knew it was time to get serious.”
On the mechanical side, a key goal throughout the development process was to provide tools that would enable existing customers already running automated Starview blister machines to obtain the full-sheet blister option by simply adding an auxiliary feeder.One of Starview’s FAB (Fully Automatic Blister) series of machines.With this tool, a flat paper blister is picked from the magazine feed, and thanks to the precise scoring done by Rohrer, it’s erected, ready to receive whatever product the customer happens to pack.Then it is to stick the blister card and the heat seal card on the blister.
As for the cardboard components from Rohrer, in the demo at the PACK EXPO Las Vegas booth, the blister was 20-point SBS and the blister card was 14-point SBS.Carson noted that the original board was FSC certified.She also said that Rohrer, a member of the Sustainable Packaging Alliance, has partnered with the group to make it easy for customers to obtain permission to use SPC’s How2Recycle logo on their blister packs.
Meanwhile, printing is done on an offset press, and if the customer wishes, a window can be die-cut in the blister card to provide product visibility.Bearing in mind that customers using this all-paper blister are producers of products such as kitchen gadgets, toothbrushes or pens, not pharmaceuticals or healthcare products, such a window is certainly not possible.
When asked how much all-paper blistering costs compared to comparable alternatives, both Carson and van Gilse said there are too many supply chain variables to tell right now.
Image #2 in the body of the article.The Syntegon Kliklok topload carton formerly known as ACE – with a particular focus on ergonomics, sustainability and improved efficiency – made its North American debut at PACK EXPO Connects 2020.(Click here to learn more about this machine.) The ACE (Advanced Carton Mounter) was again on display in Las Vegas, but now it comes with a special head that creates a unique divider cardboard tray ( 2), the pallet is certified compostable.Syntegon, for example, sees the new trays as a more sustainable alternative to the plastic trays widely used to package cookies.
The pallet sample shown at PACK EXPO is 18 lb natural kraft paper, but the CMPC Biopackaging Boxboard from which the pallet is produced is available in a range of thicknesses.CMPC Biopackaging Boxboard says the trays are also available with a barrier coating and are repulpable, recyclable and compostable.
ACE machines are capable of forming glued or locked cartons that do not require glue.The cardboard carton introduced at PACK EXPO is a glue-free, snap-on carton, and Syntegon says the three-head ACE system can process 120 of these trays per minute.Added Syntegon product manager Janet Darnley: “Having the robotic fingers form a compartmentalized tray like this is a major achievement, especially when glue isn’t involved.”
On display at the AR Packaging booth is a packaging just launched by Club Coffee in Toronto that takes full advantage of AR’s Boardio® technology.In an upcoming issue, we’ll have a long story on this recyclable, mostly cardboard alternative to today’s difficult-to-recycle multi-layer packaging.
Other news from AR Packaging is the introduction of a cardboard tray concept (3) for modified atmosphere packaging of ready-to-eat, processed meat, fresh fish and other frozen foods.AR Packaging.Image #3 states in the body of the article that the fully recyclable TrayLite® solution provides an efficient and convenient alternative to all-plastic barrier trays and reduces plastic by 85%.
There are alternatives to recyclable or renewable plastics today, but many brand owners, retailers and food producers have set the goal of fully recyclable packaging with maximised fibre content.By combining its expertise in cardboard packaging and flexible high-barrier materials, AR Packaging was able to develop trays with an oxygen transmission rate of less than 5 cc/sqm/24r.
Made from sustainably sourced cardboard, the two-piece cardboard tray is lined and sealed with a high-barrier single-material film to ensure product protection and extended shelf life.When asked how the film was attached to the cardboard, AR only said: “The cardboard and liner are bonded in a way that does not require the use of any glues or adhesives, and it is easy for consumers to separate and recycle after use.” AR says the cardboard tray , liner and cover film – a multi-layer PE with a thin EVOH layer for gas barrier purposes – easily separated from each other by consumers and recycled in separate mature recycling streams throughout Europe.
“We are delighted to offer a new improved paper tray and support the evolution towards more circular packaging solutions,” said Yoann Bouvet, Global Sales Director, Food Service, AR Packaging. “TrayLite® is designed for recycling and is easy to dispose of. , heated and eaten, it is ideal for a variety of products including ready-to-eat meals, frozen meat and fish, and nutritional foods. It is lightweight and uses 85% less plastic, making it a sustainable alternative to traditional plastic trays.”
Thanks to the tray’s patented design, the thickness of the cardboard can be tailored to specific needs, so fewer resources are used while achieving the tightest seal integrity.The inner liner is recyclable as a single material PE with an ultra-thin barrier layer that provides critical product protection to minimize food waste.Thanks to the full surface printing possibilities on the pallet – both inside and outside, the brand and consumer communication is very good.
“Our goal is to work with our customers to create safe and sustainable packaging solutions that help meet consumer needs and our customers’ ambitious sustainability goals,” said AR Packaging CEO Harald Schulz.”The launch of TrayLite® confirms this commitment and complements the broad range of creative innovations offered by our multi-category packaging group.”
Image #4 in the body of the article.UFlex has partnered with flexible packaging, end-of-line and soluble pod equipment manufacturer Mespack, and custom injection molding industry leader Hoffer Plastics to develop a sustainable solution that will address the recycling complexities associated with hot-fill bags.
The three innovative companies have jointly developed a turnkey solution(4) that not only makes hot fill bags and spout caps 100% recyclable with a new monopolymer construction, thus enabling many eco-responsible brands closer to achieving its sustainable development goals.
Typically, hot fill bags are used to package ready-to-eat foods, allowing aseptic packaging of a variety of fresh, cooked or semi-cooked foods, juices and beverages.It is used as an alternative to traditional industrial canning methods.The utility of hot-fill pouches exceeds consumer expectations due to its ease of storage and direct consumption when heated within the package.
Newly designed recyclable single material PP based hot fill bag combines the strengths of OPP (Oriented PP) and CPP (Cast Unoriented PP) in a layered laminate structure designed by UFlex to provide enhanced barrier properties for easy Heat sealing ability, and longer shelf life for non-refrigerated food storage.Sealing is accomplished using Hoffer Plastics’ patented closure in the form of a tamper-resistant, strong-sealing spout cap.Pouch production has the mechanical integrity of the Mespack HF range of filling and sealing machines for efficient filling through the spout of preformed pouches.The new design provides 100% easy recyclability of the laminated construction and spout cover in existing PP recycling streams and infrastructure.The bags, produced at the UFlex facility in India, will be exported to the U.S. market, primarily for packaging edible products such as baby food, food purees and pet food.
Thanks to Mespack technology, the HF series is completely developed and designed to use recyclable materials and, thanks to continuous filling through the nozzle, reduces headspace by up to 15% by eliminating wave effects.
“With our future-proof approach focused on cycle-driven packaging, we are working to deliver products that expand our sustainable footprint in the ecosystem,” commented Luc Verhaak, Vice President of Sales at UFlex Packaging. “Designing using a single material, such as Use this recyclable PP hot fill nozzle bag to create value for the recycling industry and help develop a better recycling infrastructure. Co-creation with Mespack and Hoffer Plastics is a collective for a sustainable future and packaging excellence An achievement backed by a vision, it also marks the beginning of new opportunities for the future, leveraging our respective strengths.”
“One of our Mespack commitments is to focus on developing innovative equipment for sustainable packaging solutions that protect the environment and reduce our carbon footprint,” said Guillem Cofent, Managing Director of Mespack.”To do this, we follow three main strategies: reduce the use of raw materials, replace them with more recyclable solutions, and adapt our technology to these new recyclable, biodegradable or compostable materials. Case, thanks to the collaboration between key strategic partners, our customers already have a recyclable prefab bag solution that contributes to the circular economy while helping to achieve their goals.”
“Sustainability has always been a key focus and driving force for Hoffer Plastics,” said Alex Hoffer, Chief Revenue Officer, Hoffer Plastics Corporation.“Now more than ever, creating products that are fully recyclable and circular by design from the start will not only impact the future of our industry and the environment. We are proud to partner with innovative, responsible partners such as UFlex and the Mespack team Partnering to lead the way forward.”
Sometimes it’s not just new products that debut at PACK EXPO, it’s how those products are coming to market and what industry-first third-party certifications they might be able to tout.While it’s unusual to report this in a new product review, we found it innovative, and it’s an innovation report after all.
Glenroy used PACK EXPO to officially launch its TruRenu sustainable flexible packaging portfolio for the first time (5).But most importantly, it was also able to publish certification in the so-called NexTrex program, a circular economy-conscious program whose output is durable goods.More on that later.Let’s take a look at the new brand first.Image #5 in the body of the article.
“The TruRenu portfolio includes up to 53% PCR [post-consumer resin] content. It also includes store returnable bags, and everything from spouted bags to rolls to our returnable prefabricated STANDCAP bags,” Glenroy marketing Manager Ken Brunnbauer said.”Not only are our store drop bags certified by the Sustainable Packaging Coalition [SPC], but we’ve also just learned that we’ve been certified by Trex.” Of course, Trex is Winchester, Virginia-based alternative wood laminate flooring, Manufacturer of railings and other outdoor items made from recycled materials.
Glenroy said it is the first flexible packaging manufacturer to offer Trex-certified store drop bags for its NexTrex program, with which brands can partner to obtain their own consumer-facing certification.According to Brumbauer, it’s a free investment in the brand.
If the brand’s product is certified by Trex to be clean and dry when the bag is empty, they can put the NexTrex logo on the package.When a package is sorted, if it has the NexTrex logo on it, it goes straight to Trex and ends up being a durable item like Trex trim or furniture.
“So brands can tell their consumers that if they’re using part of the NexTrex program, it’s almost guaranteed that it doesn’t end up in landfill, but ends up being part of a circular economy,” Brunbauer added in the PACK EXPO chat “It’s very exciting. As of early last week, we just got that certification [Sept.2021]. We announced it today as part of a sustainable solution focused on serving the next generation.”
Image #6 in the body of the article.The sustainable packaging initiative was front and center at the North American Mondi Consumer Flexibles booth as the company highlighted three new sustainability-driven packaging innovations specifically for the pet food market.
• FlexiBag Recycle Handle, a recyclable roll bottom bag with an easy-to-carry handle.Each package is designed to capture the attention of consumers – on the retail shelf or through e-commerce channels – and win brand preference among environmentally conscious end users.
Options for all FlexiBag packaging include premium rotogravure and up to 10-colour flexo or UHD flexo.The bag has clear windows, laser scoring and gussets.
One of the things that makes Mondi’s new boxed FlexiBag so compelling is that the bag-in-box is a rarity in the pet food market.”Our qualitative and quantitative consumer research has identified consumer demand for this form of the pet food industry,” said William Kuecker, vice president of North American marketing for Mondi Consumer Flexibles.“There is a need for a package that consumers can easily remove from service and reliably re-close. This should replace the current common practice of dumping pet food in a litter box or tub at home. The slider on the package is also for consumers The key to being interested in our research.”
Kuecker also noted that pet food sold through e-commerce has grown steadily, with SIOCs (owned container ships) all the rage.The FlexiBag in Box meets this requirement.Additionally, it enables brands to promote their products on their product packaging and shipping containers delivered to end-user customers.
“The FlexiBag in Box is designed for the growing online and omnichannel pet food market,” said Kuecker.”The SIOC-compliant box portfolio is based on insights gleaned from extensive consumer research. The packaging provides pet food manufacturers with a powerful branding tool, supporting retailers’ online marketing efforts and reinforcing end-user brand preferences. At the same time, , it helps retailers achieve their sustainability goals while reassuring environmentally conscious customers that the products they buy meet high sustainability standards.”
Kuecker added that the FlexiBags are compatible with existing filling equipment currently handling large pet food side gusset bags, including machinery from Cetec, Thiele, General Packer and others.As for the flexible film material, Kuecker describes it as a PE/PE monomaterial laminate developed by Mondi, suitable for holding dry pet food weighing up to 30 pounds.
The returnable FlexiBag in Box arrangement consists of a flat, roll-on or bottom bag and a box ready to ship.Both bags and boxes can be custom printed with brand graphics, logos, promotional and sustainability information, and nutritional information.
Keep going with Mondi’s new PE FlexiBag recyclable bags, which feature reclosable features including push-to-close and pocket zippers.The entire package, including the zipper, is recyclable, Kuecker said.These packages are designed to meet the shelf appeal and production efficiency required by the pet food industry.These bags are available in flat, roll-on or clip-bottom configurations.They combine high fat, aroma and moisture barriers, provide good shelf stability, are 100% sealed and are suitable for filling weights up to 44 lbs (20 kg).
As part of Mondi’s EcoSolutions approach to helping customers achieve their sustainability goals with new packaging solutions, FlexiBag Recyclable has been approved for use in the Sustainable Packaging Alliance’s How2Recycle store placement program.How2Recycle Store Drop-off approvals are product-specific, so even if this package is approved, brands will need to obtain individual approvals for each product.
Last but not least, the new flexible recovery handle is available in both roll-on and clip-on configurations.The handle makes the FlexiBag easier to carry and pour.
Evanesce, a relatively new player in the compostable packaging space, presented what it calls “breakthrough Image #7 in text.sustainable Packaging technology article” at PACK EXPO in Las Vegas.The company’s scientists have designed a patented molded starch technology(7) that produces 100% plant-based, cost-competitive, compostable packaging.The company expects its dinner plates, meat platters, containers and cups to be available in 2022.
The key to producing these packages is standard food processing equipment from Bühler that has been adapted to make the containers.”Our packaging is baked in a mold, just like you would bake a cookie,” said Evanesce CEO Doug Horne.”But what really sets us apart is that 65% of the ingredients in the ‘dough’ being baked are starch. About a third is fiber, and the rest we think is proprietary. Starch is much cheaper than fiber, so we expect Our packaging costs about half the cost of other compostable packaging. However, it has excellent performance features such as oven-safe and microwave-friendly.”
Horn says the material looks and feels like expanded polystyrene (EPS), except it’s made entirely of organic matter.Starches (such as tapioca or potatoes) and fibers (such as rice husks or bagasse) are both by-products of food manufacturing.”The idea is to use waste fiber or starch by-products that are abundant in any area where packaging is made,” adds Horn.
Horn said the process of ASTM certification for home and industrial compostability is currently underway.Meanwhile, the company is building a 114,000-square-foot facility in North Las Vegas that will include not only a line for molded starch products, but also a line for PLA straws, another Evanesce specialty.
In addition to launching its own commercial production facility in North Las Vegas, the company plans to license its patented technology to other interested parties, Horn said.
Post time: Jun-08-2022