Food & Beverage Packaging September 2011

AN AIRTIGHT ALLIANCE NEVER LOOKED SO SWEET. While most people associate success with outsidethe-box-thinking, we at Danafilms believe our best achievements include the partnerships we built inside the box. Such is the case with AirLiner, an inflatable, insulating plastic liner featuring leading-edge package design by Coldpack, and a precision-engineered film by Danafilms. Like the trademark hard candy shell

shipped in the box, the film in the AirLiner uses a unique combination of innovations—including a custom film blend, exceptional seal properties, and precision extrusion and barrier technology—to provide maximum protection to the candies. Premium film designed to perform, mixed with the collaboration of leading-edge companies is a recipe for true competitive advantage.

A MEMBER OF RKW-GROUP

Look to danafilms.com or call our film experts at 800.634.8289 ISO 9001 Certified

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End of line packaging: How to finish strong Experts share technology, trends and takeaways to help ensure a strong finish to your packaging operations when unitizing using palletizers, stretch wrappers and other options.

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36 CPG Packaging Thought Leaders: PepsiCo Denise Lefebvre, VP, global beverage packaging, PepsiCo, talks about industry trends including sustainability and the development of a 100% plant-based bottle from unusual sources.

38 A total systems approach: Transforming the way manufacturers approach processing and packaging This roundtable discussion takes a look at how brand owners are increasingly taking a total systems approach to manufacturing to enhance efficiencies and decrease costs.

40

40 PACK EXPO Las Vegas: It’s show time! PACK EXPO Las Vegas 2011 is breaking records and expanding to deliver the largest and most comprehensive packaging and processing trade show experience of the year in North America..

DE PA RT M E NT S 16 New Packages 7UP EcoGreen™ 100% rPET bottle, dualovenable cannelloni package, flat pretzels in revamped bag, SeaDog brews new design, ‘angelic’ snack bar makeover, on-the-go toddler snacks packed in canisters and pouches

48 Sugar and spice and everything…convenient A glimpse into packaging for the condiments market, which helps flavor these products with a healthy dash of convenience.

52 Smoothing out the wrinkles of shrink-sleeve labeling An exploration of customer preferences, problems and solutions in this specialized area of high-impact package decoration.

24 Packager News Food and drink execs expect M&A, Technology that turns poop into bioplastic, Shortcomings in data via smartphones and Internet

56 The package design ‘second moment’ of truth Ensuring your packaging’s ‘signature moment’ stays relevant, in-store, online and beyond.

64 Supplier News Intelligrated opens technology lab, first U.S. Shaka® production retort shipped, Multivac receives Hormel award, Dow Packaging names new VP

58 Green Thoughts: What the packaging industry can learn from Detroit ITW’s move in creating the first ‘Tier 1’ packaging supply company points to an emerging trend.

60 Wrapping it up: Using health claims, nostalgia and the environment to sell sweets A look at key packaging ingredients in the growing market for confectionery products.

70 Metal detectors ensure quality in buckeyes One candy maker learns the importance of a multipoint inspection system.

IN EVERY ISSUE 6

Editor’s Note

10 Calendar

73 Supplier Products 78 Classified Network

FOOD & BEVERAGE PACKAGING Volume 75, Issue 7 (ISSN 1941-8531) is published 9 times annually, Jan/Feb, Mar, Apr, May, Jun/Jul, Aug, Sept, Oct and Nov/Dec, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: FOOD & BEVERAGE PACKAGING, P.O. Box 1080, Skokie, IL 60076. CANADA POST: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O.Box 25542, London, ON, N6C 6B2. CHANGE OF ADDRESS: Send old address label along with new address to FOOD & BEVERAGE PACKAGING, P.O. Box 1080, Skokie, IL 60076. FOR SINGLE COPIES OR BACK ISSUES: contact Ann Kalb at (248) 244-6499 or [email protected]

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Running without water can be dangerous! Unless you know what you are doing

Reducing water usage is an important goal for the Beverage Industry around the world. Eliminating water and lubrication from conveyor systems is a proven method of achieving this goal! Working with System Plast™, the leader in solutions for Dry Running conveying applications, enables a sustainable result. System Plast’s unique expertise and comprehensive portfolio allows you to implement solutions on your conveyor lines that reduce water consumption, energy, QRLVHDQGLPSURYHHI¿FLHQF\ Contact System Plast at 866-765-8744 for more information and visit our web site www.emerson-ept.com www.twitter.com/FoodBevSustain www.facebook.com/FoodBevSustain

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Editor’sNote

SEEKING PACKAGING PREFECTION*

EDITORIAL

To err is human, to forgive, divine—Alexander Pope

MIKE BARR Group Publisher (630) 499-7392 [email protected]

don’t have to tell you that we live in an imperfect world and each of us contributes in his or her own way to that. I am the first to confess that, while we strive for perfection, we all fall short. For example, for the last two issues—my first two at the helm here—I had an incorrect email listed with my signature that has been corrected below. Which may or may not explain the lack of responses to my editorials, though I did receive one that pointed out the error, for which I am grateful. This was particularly frustrating because we put a great deal of effort into each issue, combing over copy and layouts with a fine-tooth editorial comb…and then to overlook the seemingly obvious. We must move on, which is one of the benefits of producing a product—this magazine—that changes monthly, so we get a fresh start every 30 days Thankfully, no one got hurt as a result far as I have heard. That was not the case with a recent incident involving expensive cases of wine and a forklift truck, which prompted this month’s introspective column. You already know this will not end well. It’s a story from Australia regarding a pallet load of rare wine that was dropped to disastrous consequences. You can read the full story here: http://cot.ag/oDXg7M On a happier note and if you truly seek packaging perfection, then you need to attend Pack Expo Las Vegas September 2628. There you’ll find the latest products that the best packaging minds at the leading companies have developed to make them as perfect as possible for you and your company. If you absolutely cannot make the show, check our website where we’ll be posting a few of the developments we come across each day. We’ll also be sending daily eNewsletters from the show so you don’t miss a thing. You can also start immediately with our special Pack Expo coverage that begins on page 38. I suppose I should be grateful for these inaccuracies and stumbles: If we learn the most from our mistakes, then I am far wiser than I would otherwise be. I’d like to hear about any mistakes you may have made or were involved with, perhaps when your (or someone else’s) lemon was turned into packaging lemonade. * But please don’t write me about the headline, that misspelling was intentional this time. I wanted to see if you were paying y g to do so more than ever. attention. I certainlyy am trying

I

RICK LINGLE

Editor in Chief [email protected]

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RICK LINGLE Editor in Chief [email protected] ELISABETH CUNEO Associate Editor [email protected] SCOTT HILLING Senior Art Director FRANK MAYERAN Art Director

ADVERTISING

RANDY GREEN Publisher/Midwest Sales Manager (248) 244-6498 [email protected] GEORGE MISKO East Coast/Southeast Sales Manager (610) 866-6686 [email protected] CRAIG ZEHNTNER West Coast Sales Manager (818) 403-6379 [email protected] KRISTINA LORIO Inside Sales (249) 786-1579 [email protected] ERHARDT EISENACHER International Sales +49-228-2499860 [email protected] CATHERINE WYNN Senior Classified Sales Manager (847) 405-4010 [email protected] BNP CUSTOM MEDIA GROUP Christopher Wilson (248) 244-8264 [email protected] VINCE MICONI Advertising/Production Manager [email protected] CEDRIC BROWN Marketing Coordinator [email protected]

AUDIENCE DEVELOPMENT KOURTNEY BELL Audience Development Manager STACEY NOOCHA Multimedia Coordinator CAROLYN M. ALEXANDER Audience Audit Coordinator For subscription information or service, please contact Customer Service at: Phone: (847) 763-9534 or Fax: (847) 763-9538 E-mail: [email protected] Web: www.foodandbeveragepackaging.com

LIST RENTAL Postal contact: KEVIN COLLOPY at 800-223-2194 x.684 or [email protected] Email contact: MICHAEL COSTANTINO at 800-223-2194 x.748 or [email protected]

CORPORATE DIRECTORS JOHN R. SCHREI Publishing RITA M. FOUMIA Corporate Strategy SCOTT KESLER Information Technology ARIANE CLAIRE Marketing VINCENT M. MICONI Production LISA L. PAULUS Finance MICHAEL T. POWELL Creative NIKKI SMITH Directories MARLENE J. WITTHOFT Human Resources BETH A. SUROWIEC Clear Seas Research BNP MEDIA HELPS PEOPLE SUCCEED IN BUSINESS WITH SUPERIOR INFORMATION For Volume Reprints Contact JILL L. DEVRIES Corporate Reprint Manager Phone: 248-224-1726 Fax: 248-244-3934 E-mail: [email protected] How to contact

FOOD&BEVERAGEPACKAGING Mail: 155 Pfingsten Rd., Suite 205 Deerfield IL 60015 Phone: (847) 405-4000 Fax: (847) 405-4100 Web: www.foodandbeveragepackaging.com

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ry Show ternational Dai Sept.19-21 | In Atlanta, GA .com www.dairyshow entals IoPP’s Fundam Sept. 19-23 | 2 mester 1 and of Packaging Se Atlanta, GA undamentals www.iopp.org/f Forum ble Packaging na ai st Su | 2 Sept. 20-2 Dallas, TX m.com epackagingforu www.sustainabl MidPack Sept. 20-22 | Chicago, IL o/midpack11 shows.com/exp www.canontrade

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Vegas Pack Expo Las Sept. 26-28 | Las Vegas, NV om/pelv2011 www.packexpo.c Oct. 5 | LEAP Chicago, IL forward.com www.leapdesign aging That Sells Oct. 6-7 | Pack Chicago, IL hatsells.com www.packagingt g PP’s Packagin Oct. 10-12 | IO ics Machinery Bas Chicago, IL achinery www.iopp.org/m kaging.com andbeveragepac Visit www.food ve list of events. ensi for a compreh

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YOUR ONLINE COMPANION VISIT US AT

www.foodandbeveragepackaging.com » Breaking News Updated daily news, trends and market studies about packagers and packaging.

» First Look Reveals the newest packages introduced into the market.

» Product Spotlights Spotlights the newest products and includes case studies.

» Supply Side Details the latest vendor-centered news such as acquisitions, expansions, and new managers.

» More Web Exclusives CONNECT WITH US NOW!

Featuring blogs and podcasts from industry experts.

» Food & Beverage Packaging Insights Twice monthly eNewsletter delivers the latest information, news, new packages and Top Developments in a newsy format with hot links.

www.facebook.com/FBPmag

http://twitter.com/FoodPack

WHAT YOU CAN’T SEE CAN HURT YOU!! Don’t take chances with your products. Corbi Plastics introduces Pallet Washing Services at our Chicago Service Center. Our facilities operate by HACCP principles and our cleaning process produces industrially sterile results. 'SRXEGXYWXS½RHSYX just how clean your pallets could be!

CALL (608) 852-8840 www.corbiplastics.com See us at Pack Expo Booth # S-5481

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passion We provide rigid packaging. We have over 100 years of experience in the industry, over 40 offices worldwide, 500 plus employees with specialties ranging from customer service to logistics to global sourcing to design and engineering. While all of that’s important, the real reason to do business with us is not what we do but why we do it. At TricorBraun, we’re passionate about making your life simple. We understand how complex packaging can be so we’re constantly looking for innovative ways to streamline that process for you. Each and every member of the TricorBraun team exists to provide packaging professionals like you with more options for success.

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To get the first look at next year’s technology, be here for this year’s largest all-food processing and packaging equipment show: Ąŕŕ1ŕ'"#(,3ŕ ,)'ŕ."ŕ1),&č-ŕ &#(!ŕ-/**&#,Ąŕŕ/..#(!ŕ!ŕ#(()0.#)(Ąŕŕ0,ŕ÷ûùŕ2"##.),-ŕėŕõôÿôôôĸŕ ))ŕ(ŕ0,!ŕ..(Ąŕŕöýŕ")/,-ŕ) ŕ/.#)(&ŕ---#)(-ŕ )/-#(!ŕ)(ŕ ))ŕ- .3ÿŕ-/-.#(#&#.3ŕ (ŕ).",ŕ#--/-ŕñŕ.#(!ŕ3)/,ŕ ',%.*&ŕĚ#(ŕ(!&#-"ŕ(ŕ*(#-"ě

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NewPackages INNOVATIONS / TRENDS / MARKETING

SOFT DRINK USES 100% rPET epsiCo Beverages Canada has debuted the 7UP EcoGreen™ bottle, Canada’s – and North America’s – first soft drink bottle made from 100% recycled PET (rPET) plastic. The development of the 7UP EcoGreen bottle is a significant achievement for PepsiCo and a breakthrough for the Canadian beverage sector because the company has identified a way to couple existing technology with the best sources of rPET and best-in-class processing techniques to produce a high-quality, 100% rPET food-grade bottle that meets all regulatory requirements. Creating a bottle made from 100% recycled plastic for soft drinks is more challenging than creating a bottle for non-carbonated beverages because of the stress on materials from carbonation pressure. It’s a stepwise development for PepsiCo: The technology is identical to that used for last year’s Naked Juice reNEWa bottle in a non-carbonated application, Denise Lefebvre, PepsiCo’s VP, Global Beverage Packaging, informs Food & Beverage Packaging. “That’s no small technical feat getting to the right quality post-consumer recycle content, particularly for a carbonated soft drink bottle that has so many design requirements from pressure and product retention and utility in the marketplace,”

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The 7UP EcoGreen™ bottle is North America’s first soft drink bottle made from 100% recycled PET plastic.

PACKthAeGE of MONTH

she says. “We see a continued consumer demand for this kind of packaging.” Its use will reduce the amount of virgin plastic used by approximately six million pounds yearly. Studies published by the Association for Post-Consumer Plastic Recyclers in 2010, estimate this reduced use of virgin plastic will lead to a reduction of more than 30% in greenhouse gas emissions and more than 55% in energy use, based on current 7UP production levels. The company invested $1 million in production enhancements in its facilities, including resin handling systems and inspection systems. Although there will be an incremental cost to produce the 7UP EcoGreen bottle, PepsiCo Beverages Canada plans to price 7UP beverages on par with other soft drink brands. The 7UP EcoGreen bottle was available across all 7UP and Diet 7UP package sizes beginning in early August, and will look and feel like any other PET plastic soft drink bottle. The bottle will be produced in multiple PepsiCo manufacturing facilities across Canada. PepsiCo Beverages Canada’s long-term plan is to increase the use of bottles made from 100% recycled plastic. Currently, PepsiCo incorporates an industry-leading average of 10% rPET in its primary soft drink bottles in Canada and the U.S.

CANNELLONI PACKAGE NOW DUAL-OVENABLE livieri, a division of Maple Leaf Foods, teamed with Sealed Air’s Cryovac Food Solutions to create the packaging of their cannelloni. The container has a microwaveand oven-safe thermoformed tray, customized with channels that allow for even distribution of sauce and separation of the cannelloni during cooking. Prior to the redesign, the product was packaged in a rollstock format that required items to be transferred to an oven-safe container before cooking. Olivieri was honored with a Silver Award in the rigid/semi-rigid category for the redesign at the 2011 Packaging Association of Canada (PAC) Leadership Awards.

O

Cryovac Food Solutions 800-391-5645; www.cryovac.com

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s p e c i a l t y

c o n v e y o r s

TODDLER TREATS RECEIVE VIBRANT DESIGN Hain Celestial’s new Earth’s Best Organic Pop Snax is an air popped, rice and potato crisps line designed for toddlers. Smith Design, the New Jersey/California based brand design firm, worked closely with The Hain Celestial Group to design the look for the toddler snacking segment of the organic baby food arena. The graphic design of the line is distinct from their infant foods line, and is packaged in canisters or single serve pouches, for on-the-go convenience. “The packages are playful and strongly color coded by flavor to communicate a fun snack suitable for toddlers as they transition to solid foods,” says Martha Seidner, vice president at Smith Design and account director for Earth’s Best brand. “The objective was to position it away from ‘baby’ infant foods. The large Earth’s Best Organic logo provides the trust of purity and healthfulness to consumers. Vibrant and fresh vegetable photography tells mom which organic veggies are used in each variety.” Pop Snax are fortified vitamins and minerals and are available in two flavors. They retail for $4.40 for a 1.8-ounce container sold at Kings, Whole Foods, Toys r Us, Babies R Us and Shop Rite and other supermarkets and natural food stores. Smith Design 973-429-2177; www.smithdesign.com

TEA AND FRUIT DRINKS RETURN TO A VINTAGE LOOK Cintron Beverage Group teamed up with Strategia Design to develop a branding concept for its new line of premium-ingredient iced teas and fruit ades. The new premium drinks are packaged in 14-ounce eco-friendly glass bottles from Castle Co-Packers and feature vintage sepia-toned images and stylized tropical fruits that evoke Havana in the 1950s. The collaboration yielded a modern take on the 1950s vintage design period to appeal to women and men ages 18-54. “We wanted these premium products to look as good on the shelf as they tasted,” says Donna Davin, Cintron’s chief marketing officer. “These teas and fruit ades are all natural and pays homage to the vibrancy of Latin cuisine, which is always made with simple, fresh ingredients.” Cintron iced teas and fruit drinks are available across the U.S.

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phone (877) 800 1634 • email [email protected]

NewPackages

ANGELIC SNACK BARS UPDATE THEIR PACKAGE ROBAR’s “Sinfully Healthy Snack” HALO product line receives new packaging designs from Boulder, CO-based advertising agency Moxie Sozo. Moxie Sozo set out to entice consumers to indulge their sweet tooth with a snack that’s low in sugar, certified organic, all-natural and “weighs in” at a mere 150 calories. “In terms of design we had an interesting challenge of matching the decadent aspect of a candy flavor with the claims of a nutrition bar,” says Luke Sword, marketing manager of PROBAR. “Clearly we targeted the candy aspect of the spectrum, which sets expectations high for the flavor profile. With that bar raised we had to deliver on taste, and we believe we’ve done so effectively.” What resulted were visually stunning, taste appealing renderings of the elements in each bar. Every logo was individually infused with original illustrations of the ingredients in each snack. Because the snack bar is raw, HALO utilized a vacuummetalized material manufactured specifically for raw

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food. The point-of-purchase corrugated display box is provided by California Packaging and Display. HALO products are sold at Whole Foods, REI and a vast selection of health food and outdoor retail stores, for $1.59 per bar. Moxie Sozo 303-443-1537; www.moxiesozo.com California Packaging and Display 951-787-6706; www.cal-pack.com

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NewPackages

FLAT PRETZELS ADD BOLD FLAVORS, DESIGN nack Factory has revealed new packaging and two new flavors for its Bold & Spicy Pretzel Crisps® line-up: Jalapeno Jack and Chipotle Cheddar join Buffalo Wing in the Bold & Spicy line. To better represent the line, the company revamped the packaging using warmer colors (red, yellow and orange tones), sizzling flame designs and a flaming Bold & Spicy insignia. There is also a black band across the top of the packaging that calls out the Bold & Spicy category. In addition to a revamp to their Bold & Spicy line, the company had a packaging upgrade in 2010, refreshing the entire line with brighter colors, an updated logo and new photography that showcased Pretzel Crisps’ stackability. Also in 2010, the company increased their package size from 6 ounces to 7.2 ounces. According to Jessica Harris, public relations director for Snack Factory, the redesign has been a success, “According to the June 12, 2011 IRI data, Pretzel Crisps is up 115% over four weeks in Total U.S. Food sales from a year ago. The 52 week data reveals a Total U.S. Food sales dollar increase of 83%.” To help determine the new flavors and packaging to beef up their product line-up, Snack Factory reached out to Affinova. Through their IDDEA evolutionary optimization technology, the brand tested various flavors and package combinations. IDDEA II measurement enabled them to evaluate the top concepts in terms of purchase intent, uniqueness, believability, and other key measures against other top concepts as well as competitive products already on the shelf to determine the concepts with greatest market potential. Pretzel Crisps are available in the deli aisle of supermarkets and select specialty retailers nationwide and retail for $2.99 each. There are seven flavors in the Pretzel Crisps Deli Style line-up.

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Affinova 781-464-4700; www.affinnova.com

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Change Film. Transform Sales. Increasing sales and profits may be as easy as changing film. Charter Films uses the latest advancements and proven technologies in creating custom film solutions that make your product stand out like never before—with superior clarity and performance. As specialists in blown film extrusion, Charter Films provides consistent, reliable films for flexible packaging, stand-up pouches, labels, tags, sealants and more. Your product deserves the best. Our history of providing innovative high-quality films and our focus on sustainability make us uniquely qualified to deliver the right solution. Insist on Charter Films. 1- 877-411-3456 +1 715-395-8258 www.charterfilms.com/change cfiinfo@charterfilms.com See us at Pack Expo Booth #S-5714 © 2011 Charter Films. All rights reserved.

NewPackages

BEER PACKAGING UPDATES ITS LOOK ea Dog Brewing Co.’s Sea Dog Bluepaw, Raspberry and Apricot Wheat Ales are the first to launch the company’s new contemporary packaging. The bottles, from O-I, will remain the same, but the label now features bolder, sharper imagery with dramatic colors and emphasizes the Sea Dog brand by incorporating bold block lettering and consistently highlighting the beer style. It has been nearly a decade since the Sea Dog design has changed. wo The packaging design, a collaboration between two ris designers from Portland, ME, Robert Cochran and Chris Hadden, was redeveloped to align with the branding of s. the popular Sea Dog pubs in Maine and Massachusetts. ng Additionally, this summer the company is introducing ges Sea Dog Blonde Ale in 6- and 12-packs. New packages dfor Sea Dog’s full line of year-round and seasonal prodog ucts will be on shelves by the end of the year. Sea Dog beer is available in 12-packs, 6-packs, and on draft.

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Owens-Illinois 567-336-5000; www.o-i.com

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PackagerNews

09/11

BUSINESS / TRENDS / PEOPLE

SHORTCOMINGS IN DATA VIA SMARTPHONES AND INTERNET new report co-authored by GS1 (www.gs1us.org) and Capgemini (www.capgemini.com) cautions companies selling consumer products that much of the digital product information accessible via smartphones and the Internet is incomplete or wrong. The report, titled “Beyond the Label: Providing Digital Information Consumers Can Trust,” addresses a “perfect storm” of three converging forces: consumer demand for more information; increased smartphone usage; and a widening variety of data sources, leading to an explosion of data. Consumers’ interest in researching products is illustrated by the finding that more than two-thirds of consumers want nutrition and ingredient information, while more than 30% of smartphone users have downloaded a bar code scanning application, with usage of these apps jumping 1,600% in 2010. But the results these consumers get frequently let them down, depending on where their searches take them and the incorrect product information often received. The report cites recent research by GS1 UK and the Cranfield School of Management in which 91% of mobile bar code scans returned incorrect product descriptions and 75% returned no data. The report also cites New Yorkbased Scanbuy’s finding that 40% of requests processed through its ScanLife application cannot be authoritatively connected to a product. Available free for download, the report was written by Capgemini, a leading provider of consulting, tech-

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nology and outsourcing services, and several country-based member organizations of not-for-profit standards group GS1, including GS1 US and GS1 UK. “Brand owners – both retailers and manufacturers – and application providers need to understand the severity of this problem,” says Bob Carpenter, president and CEO of GS1 US. “We found that 38% of consumers will not purchase a product if they don’t trust the information they get on a smartphone, and 35% may stop using an app if they get the wrong information.” The authors advise brand owners to begin rigorous data-integrity programs and collaborate with other companies to improve the consumer experience in researching products. “Improving digital product information for consumers requires that all relevant players understand their responsibility to work together collaboratively and in a consistent manner,” says Bob Fassett, vice president, North America Consumer Goods, Retail, and Distribution Leader, Capgemini. “The right solution can help the industry realize the digital data vision: Brand owners can share relevant product information easily, thus building trust with consumers; application providers can ensure they are delivering authentic data; and consumers can feel confident that the digital product information they access is accurate, no matter how or where they shop,” he said.

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SOME 67% OF FOOD AND DRINK EXECS EXPECT M&A OVER THE NEXT TWO YEARS wo out of three U.S. food and beverage executives see their companies being involved in a merger or acquisition over the next two years, as they seek to streamline portfolios and put cash reserves to work. According to a survey by U.S. audit firm KPMG (www.kpmg.com) 67% of executives said it is likely their companies will participate in merger activity over the next two years, with a rough split between likely buyers and likely sellers. One of the main motivations for sellers is that they probably have brands they do not want to invest in anymore, but were unable to unload during the downturn, says Patrick Dolan, the leader of KPMG’s consumer markets and food and beverage practice in the United States. “It’s not like they’re desperate to get rid of them, but they really do want to reinvest the money in some brands that make more sense for their strategy,” Dolan said. Sellers were getting more realistic about the prices their assets were likely to fetch, making it easier for sellers and buyers to agree, he said, adding that buyers were being motivated by pressure from shareholders to make use of cash piles that are otherwise not earning high returns. The consumer goods sector has always been fertile ground for mergers and acquisitions, but mega-deals like Kraft Foods Inc’s purchase of Cadbury have been rare since the economic downturn. And Post cereals maker Ralcorp Holdings Inc. recently rebuffed an offer from ConAgra Foods. “It’s not mega, mega deals, but I think it’s pruning the product and market aspects of their portfolio. Then, they’ll be after geographic expansion, typically in the emerging markets, and using acquisitions to get into new products and services,” Dolan says. About 39% of respondents–senior executives at midand large-cap food and beverage companies such as Coca-Cola Co and Kraft—said they expected to deploy cash this year, with another 39% saying they expected to do so next year. In terms of hiring, 46% of the 101 respondents said they planned to add jobs next year, but 38% are calling for an increase of less than 6%.

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PackagerNews

FROM POOP TO BIOPLASTIC L ‹‹

Samples of microbes that eat nutrients and yield polyesters that can be harvested.

egend has it that King Midas turned everything he touched into gold. The engineers at West Sacramento, CA-based Micromidas (www.micromidas.com) use hungry bacteria to turn something no one wants to touch — solid human waste — into something many people treasure: biodegradable plastic.

Machinery built for quality, dependability, and durability. Systems built for speed, consistency, and precision. 'XGT[VJKPIFGUKIPGFCPFOCPWHCEVWTGFVQſV your recipe, your facilities, and your needs. Robotic Case Packing System

Meet with us at Booth 1229. visit our website at

www.raque.com

11002 Decimal Drive P.O. Box 99594 Louisville, KY 40269 (502) 267-9641 [email protected]

The company’s process holds the promise of mitigating three environmental ills: the ever-increasing amount of solid waste our population generates; the use of potentially scarce, expensive petroleum to make plastic; and the fate of plastic packaging that doesn’t make its way into the recycling stream. What began several years ago as an Environmental Protection Agency award-winning research project under Frank Lope at the University of California–Davis became an independent private enterprise in 2009, and it is already breaking even. “Two years ago, we developed a bench-top-scale proof of concept. We received venture capital backing last spring, and now we’re at the 1,000-L pilot plant stage,” says Ryan Smith, Micromidas’ chief technical officer. “The next step will be to go on site to a municipal waste treatment plant and do a pre-commercial demonstration to show the economies of scale.” Currently, Micromidas runs solid waste through an anaerobic digestion process that breaks it down to the nutrient level. Smith said, “We then feed those nutrients to our ‘superbugs’ in a bioreactor; these microbes eat massive quantities of the nutrients and store polyesters in their cells. At a certain point, we harvest the bacteria, run it through an extraction process to derive the polyhydroxyalkanoate (PHA) resin and sell it to plastics companies.” Smith noted that the resin is similar in function to polypropylene, adding, “At the processing level, it behaves much like polystyrene; it can be made into fibers and may be able to be foamed.” -Heidi Parsons, Senior Editor, Packaging Strategies Source: Packaging Strategies’ July 31 newsletter. For more information, visit www.packstrat.com

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Pack Expo Booth 5640 t a s tU Visi

www.nordeniausa.com

CoverStory

by RICK LINGLE , Editor in Chief

Experts share technology, trends and takeaways to help ensure a strong finish to your packaging operations when unitizing loads with palletizers, stretch wrappers and other options. 28

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here’s a simple, but knowing saying that applies to athletics along with most undertakings in life and in packaging: It’s not how you start, but how you finish. We’ve taken that to heart with our cover story on end-of-line packaging that provides an overview of these crucial systems. It includes ways to improve your operations whether you are considering a new installation or want to optimize an older “workhorse” when new machinery can’t be justified. We asked our experts to set the table by identifying key trends affecting downstream packaging operations for consumer packaged goods companies. One of those is the influence of mass merchandisers, which have gained an ever-stronger voice for packaging that appears in their distribution systems and stores. “Over the past five years there has been an increasingly important role that the mass merchandisers have played in how a food or beverage product is to be packaged for shipment,” offers Dale Andersen, president & CEO, Delkor Systems. “That may be changing the shipper to reduce packaging material content, increasing the variety of product mix and pack patterns, or more recently the addition of a variety of both Retail Ready and Shelf Ready concepts to the mix.

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FOUR WAYS TO IMPROVE YOUR DOWNSTREAM OPERATIONS WITHOUT ADDING MACHINERY

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e solicited our experts for ways that customers could improve their end-of-line operations without the need to add new machinery. Here were some suggestions:

Investigate what retrofits are available for the equipment. It is not unusual for a stretch wrapper to last 15 to 20 years. In that time, numerous advancements have been made that can make the equipment operate more efficiently. There may be simple and affordable ways to increase productivity, reduce maintenance, and minimize film usage without having to invest in new machinery. Field service technicians can perform an audit on your machine and make recommendations on what enhancements can be made to improve performance and keep your machine running for many more years to come. The payback on this type of investment is usually significant. I strongly suggest that the customer contact the equipment manufacturer to find out what is available for their specific equipment. Dan Schmidt, ITW Muller Have the vendor conduct a machine audit. A small up-front investment nearly always pays back many times over in efficiency and speed. Audits of machinery

The result now requires packaging machinery manufacturers to develop a new generation of equipment that is engineered with adaptability and flexibility to handle a much greater range of packaging options.” Footprints matter

Troy Snader, VP of sales for Brenton Engineering div. of Pro Mach, centers the market’s needs on four

can point to faulty or worn parts producing downtime and decreased speed. Companies either don’t have the internal expertise to perform audits, or never take the time. With an audit from the machine manufacturer and implementation of new parts and “tune-up”, the end user not only gets payback for the visit, but increased throughput. Troy Snader, Brenton Companies can modify existing machinery... to provide gentle handling required for today’s reduced packaging and provide additional flexibility to adapt to packaging changes and reduce changeover time. Rodney Erickson, Intelligrated Create packaging standards and a process quality control loop to adhere to the standards. Develop good standards for a shippable product and then test, check, and adjust if necessary. Brian Jackson, Lantech

essential requirements: Space, speed, sustainability and payback. “All companies would rather increase output in the same footprint than expand buildings or build new ones,” he says. “Because of this, increased throughput in the same footprint has become a focus of many companies. Due to constant margin pressures from external influences and trend to ‘go green’, companies are placing a sharp focus on total cost of ownership including utility usage and carbon footprint.” “While more packaging provides billboarding for marketing, food and beverage manufacturers are balancing that with reducing their packaging to cut costs,” says Rodney Erickson, senior beverage account development director for Intelligrated. “Plus there’s a significant push by major retailers to reduce both primary and secondary packaging for ‘green’ initiatives and to reduce packaging and waste handled at the store level. Marketing-driven packaging changes the flow downward through all bottlers. This typically requires equipment changes including new equipment to handle these changes.” Brian Jackson, global account manager, Lantech, distills the market into four drivers: Cost Savings: Reduction of packaging material including corrugated and the use of thin fiber-

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‹‹ High-level palletizers like this are a familiar sight for many packagers, though today’s downstream machines are asked to handle a greater range of packaging formats than ever before.

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CoverStory MachineryTechnology Erickson concurs: “Manufacturers are using more shrink film packaging and reducing corrugate, resulting in more fragile pallet loads. This can present speed and handling issues for a palletizer.” And not only palletizers, stretch wrappers and other downstream operations are likewise affected. “The reduction of primary packaging has had a major impact on stretch wrapping across almost all food and beverage manufacturers,” observes ITW Muller’s Schmidt. “As customers have moved from wrapping product in sturdy corrugated boxes to wrapping the same product in trays or just on

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OTHER OPTIONS: TAPE WRAPPER Robots are finding a place in hazardous duties, such as for placement of corner boards. That’s become a growth market as the use of corrugated shrinks in response to sustainability improvements.

board and conversion to trays; Packaging changes and package quality with different bottle/package designs that are cost- and marketing- driven to make the goods visually exciting/appealing to customer; Eliminating delivered “product waste” including out-of-date and damaged product in the supply chain; Productivity optimization in manufacturing, operations, and distribution. Dan Schmidt, business development manager, ITW Muller, notes that food and beverage manufacturers are seeking to make more data-driven decisions: “This is with the caveat that any solution must also be easy to implement.” “Another driver is the need to change from one packaging format to another quickly, and most importantly, with the ability to immediately return to full production speed,” adds Andersen. “The cost of adjusting a packaging machine post-changeover is too prohibitive in today’s packaging environment.” Materialistic tendencies

Of course, the connection between machinery and materials is an intimate one, and trends on one side of this equation tend to affect the other side. Here are some of the materials changes that these machinery managers point to making an impact. Snader sees reduced materials usage, particularly corrugated, noting examples such as moving to corner boards and stretch wrapping on palletizing for primary packaged goods versus palletizing secondary cases and stretch wrapping. “There is no industry where this is more noticeable than the beverage industry,” he says. “PET is becoming thinner and corrugated is nearly nonexistent in multipacks and in palletizing operations.”

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n intriguing alternative to conventional stretch wrapping is a tape wrapper, which 3M Packaging introduced five years ago. Two years ago it released a new version that enables better ventilation to reduce product cooling times and the amount of pallet handling and wrapping required. The system is said to cut pallet packaging waste by up to 95% by volume, while keeping loads from tipping, shifting and vibrating. The system is designed with semi-automated wrapping, which ensures the proper stretch ratio and consistent banding patterns for optimized load stability, 3M states. Ginny Fox, global product manager, 3M Industrial Adhesives & Tapes Division, says the response has been favorable, especially in snack food and fresh produce markets. “Faced with increasing competition, packagers feel the pressure to deliver fresher product faster and with a focus on cost management and sustainability,” she says. One trend she notes: A growth in the use of highquality graphics on shipping boxes to differentiate products on the shelf and leverage brands. 3M’s adhesive holds loads securely yet can be removed without damaging the corrugate and other materials. Thus, boxes can be reused, providing another benefit. “Sustainability is a driving force for customers to look for alternative ways to unitize their pallets,” says Fox. “A mindset in change is needed because packagers are used to using film. Once customers understand the strength isn’t compromised, their hesitations diminish.”

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3M Packaging 800-362-3550; www.3M.com/packaging

[corrugated] pads, it has made the end-of-the-line stretch wrapping operation much more critical. Customers have been looking for ways to improve load containment. “The other major material trend is the introduction of thinner gauge stretch films in an effort to reduce stretch film costs and waste,” Schmidt con-

tinues. “Often, this can be in direct conflict with food and beverage customer’s need to improve load containment. If not done carefully, customers can increase costs because these thinner films can require additional wraps to get the same load containment or the stability of the load will be negatively impacted and cause an increase in load damage.

ADVICE ON NEW MACHINERY INSTALLATIONS

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e asked our experts for one piece of advice they’d like to share for installs of new equipment. Here’s what they told us:

Consider Total Value of Ownership rather than Total Cost of Ownership To achieve long-term success, a company needs sustainable development, reliable partnerships and a 360 degree perspective. This involves switching the thinking from cost to value. Total Cost of Ownership (TCO) has traditionally been the main focus of business activity. We feel that aside from the highest possible product quality, it is important to include environmental and social factors. That why we propose to follow the Total Value of Ownership (TVO) approach. For example, BEUMER has used water-based-VOC paints in industrial applications since the early 90´s to protect the environment from unnecessary hazards. Only a fraction of customers are including this aspect in their decision-making process. A wider perspective than just investment cost will lead to more satisfied business outcomes. Sven Borghoff, BEUMER Group Allow in-depth training We have developed a two-tier approach to training of new staff for a packaging line. At time of installation we conduct typical line orientation training. But we then follow-up with a customized formal training program about 4 to 8 weeks following the install. This formal training is divided into separate programs for maintenance and operators, and provides the team with an in-depth understanding of the how, why and when of the machinery. We have found that the training is not complete until after this more in-depth training. Dale Andersen, Delkor Systems Allow proper time for proper training What we see more often than not is the customer’s installation team is under a great deal of pressure to bring the equipment up and running deliverable production. If possible, the customer should build enough time into their schedule to allow for training on the fully functioning system. System training is often done while the equipment is being run in a full production mode. This approach doesn’t

allow for training in areas such as situational trouble shooting or preventive maintenance evaluations. Earl Wohlrab, Intelligrated Look at the stretch wrapping system as a whole This means that the packager should understand what is most important to their operations and make sure that the stretch film, equipment and service they get helps them meet their overall goals. Too often, we see different people making the purchasing decisions for the film, the equipment and the service–and each of these people may have different motivations that are in conflict with the other. To maximize performance, minimize film usage, and optimize load containment, the customer must consider the whole system. Dan Schmidt, ITW Muller Provide ample time and materials at Factory Acceptance Testing (FAT) This insures a shorter installation on-site and reduces stress at start-up. If the machinery can be tested thoroughly at a manufacturers site with ample quantity of materials and product, there is a positive cost benefit to quicker installation and a higher efficiency output in a shorter amount of time. Operators and plant personnel have greater confidence in the equipment, which translates to longer-term uptime and higher efficiency on the line. Troy Snader, Brenton Plan ahead Companies should really think about current and potential future packages, and make sure flexibility is built into their systems to handle the unexpected. Rodney Erickson, Intelligrated Do it right the first time Hire qualified, quality installation services and set packaging standards during the new installation process. Brian Jackson, Lantech

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CoverStory MachineryTechnology “However, if done correctly, this can be an effective solution. The real key to minimizing film usage and optimizing load containment is to evaluate the entire stretch wrapping system to ensure the right film and right equipment for your specific application.” The trends of sustainability and downgauged stretch films are global ones, according to Sven Borghoff, senior business development manager, palletising and packaging systems, BEUMER Group GmbH & Co., a supplier of stretch-hood systems. He says, “We have customers in Europe that are operating stretch-hood systems with 40-micron or 50-micron films. We are currently modifying a 2005 system to operate with 30 microns.” He sees this as a trend that will work its way stateside. “The film converters located in the NAFTA region are just starting to ramp up their technical capabilities in order to make those products also

OTHER OPTIONS: ROBOTIC FILM WRAPPER TW GaleWrap’s just-introduced GW-4100 robotic wrapper is a portable system said to be ideal for food and beverage case packed items. That’s according to Michael Klear, market development manager: “The versatility of the machine allows for stretch wrapping in multiple locations, so travel time to and from a stretch wrapper can be eliminated. It’s ideal for customers who are looking to increase productivity, and add automap o uct ty, reduce e uce labor a o costs c tion with minimal expense and without taking up valuable floor space. We find that it works great for customers who have limited space.” The system syst uses GaleWrap Oriented Film Film, which is described as a high-quality high-qualit g qua ty hemmed edge g film with high holding force and post-wrap holdinng contractionn to securely contain loads. It features mast feeatures a telescoping m for accommodating loads to nearly accomm modating nea seven feet high. Klear see sees es the robotic wrapper as offering major maajor labor-saving benefits t over hand wrapping: It permits two w loads to bee wrapped in the time oof one hand-wrapped eliminates hand-wrappped load and eliminate inefficiencies by using just the right cienciees righ amount of film.

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available,” Borghoff reports. “This trend will and has to take place in the U.S. as well, but will be delayed.” A role for robotics

Automation in the form of robots has played a growing role to provide labor reduction, prevent on-the-job accidents, and reduce changeover time, according to Snader. “Our experience has shown that robots are not a solve-all solution for labor issues,” he cautions. “However, there are still many places robots can take the place of potentially dangerous jobs.” One of those mentioned earlier: Placement of corner boards on pallets. “Most companies manually place corner boards onto pallets during the stretch wrapping process,” explains Snader. “That’s an accident waiting to happen. With robotic corner board placers, that has been transformed into managed production and higher efficiency.” Intelligrated cites the case of a major beverage manufacturer as an example of a packager and supplier developing the best solution without trying to force a robot into the equation. The manufacturer wanted to implement a robotic palletizing solution, but the local plant was uncomfortable with the switch from a conventional machine. Also, the robotics-only palletizing solution could not provide the cycle time they required. The team developed a hybrid machine that satisfied the desire to incorporate robotics while providing a conventional palletizing machine that the plant was comfortable with. While your end-of-line operations may not earn your company Line of the Year recognition, improvements are always welcome, even if it’s the satisfaction of spurring more efficiency from a workhorse machine.F&BP

ITW GaleWrap GaleW Wrap 866-425-3727; www.galewrap.com 866-425-3 866-42

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FOR MORE INFORMATION BEUMER Group GmbH & Co. 732-893-2800; www.beumer.com Brenton Engineering Div. Pro Mach 800-535-2730; www.brentonengineering.com Delkor Systems 763-783-0855; www.delkorsystems.com Intelligrated 877-315-3400; www.intelligrated.com ITW Muller 800-628-6787; www.itwmuller.com Lantech 800-866-0322; www.lantech.com

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Proud members of National Recycling Coalition, Flexible Packaging Association and Project Network Members of EPA’s Methane-to-Markets Program.

See us at Pack Expo Booth #S-5808

www.ecologic-llc.com 630.869.0490

SFI – AN EYE ON THE BIGGER PICTURE BY KATHY ABUSOW President and CEO, Sustainable Forestry Initiative

The Sustainable Forestry Initiative® (SFI®) on-product label stands for responsible forest management. But that’s just the starting point. We have a bigger picture at SFI — a picture that embraces conservation, integrity and community. No other third-party forest certification program in North America can match this broad perspective. We start with a rigorous third-party forest certification standard, and build on it so we can accomplish more in the forest, in communities and in the marketplace. We are entrusted with a responsibility we take very seriously. We are the only forest certification program in North America requiring that participants support forest research. The only program that makes sure forest landowners have access to the knowledge and training they need to manage forestlands in a responsible way. Our unique Conservation and Community Partnerships Grant Program is building knowledge, strengthening global supply chains and showing landowners how they can manage forests to enhance wildlife habitat. SFI Inc. has committed $1.1 million to 24 projects to date, and contributions by partners have raised the value to $4.2 million. Our partnerships also help to build strong communities through support for organizations such as Habitat for Humanity. When you specify paperboard packaging from a company with SFI chain-of-custody certification or certified sourcing, you are telling your customers you care about forests and communities. The SFI program may have earned international respect but our roots will always be deep in North American communities — addressing their needs and gaining insight from their knowledge. We also appreciate that the SFI program is part of a bigger picture — that third-party forest certification is just one element of your own corporate responsibility commitments. The SFI label tells your customers a lot about your company’s values. It tells them you are saying yes to responsible forestry, to conservation research, to community outreach, and more.T Kathy Abusow is President and CEO of Sustainable Forestry Initiative Inc. (www.sfiprogram.org), an independent non-profit organization that is responsible for the internationally recognized SFI program. Across North America, more than 180 million acres/ 74 million hectares are certified to the SFI forest management standard, making it the largest single forest standard in the world. SFI Inc. is governed by a three-chamber board of directors representing environmental, social and economic sectors equally.

The SFI program is growing rapidly — we manage the world’s largest single forest certification standard and have 1,000 chain-ofcustody certifications at close to 2,500 certified locations. Our on-product label is recognized across the United States and Canada, and organizations in 23 countries are certified to the SFI standard so our fiber is found in packaging around the world. Learn more at SFIprogram.org

SUPPORT

RESPONSIBLE

FORESTRY.

When you consider that only 10% of the world’s forests are certified, we have a long way to go. The good news is that there are a number of credible forest certification programs. And each one, including SFI, encourages responsible forestry. When you buy or source SFI-labeled paper, packaging or wood products, you increase demand for responsibly managed forests. So look for the SFI label, and source wisely. For more on forest certification and what you can do, visit www.sfiprogram.org.

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BEVERAGE TRENDS AND SUSTAINABILITY Denise Lefebvre, VP, global beverage packaging, PepsiCo, talks about industry trends and sustainability including using plant-based PET bottles. / by RICK LINGLE, Editor in Chief enise Lefebvre’s newly created position in June 2011 makes her responsible for new package formats from concept through commercialization across PepsiCo’s beverage business globally, sharing of Best Practices, technology transfer, and identification of new technologies the company can use to drive either growth or productivity throughout its business.

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F&BP: What trends do you see in beverage packaging? Lefebvre: As consumers move continually toward health and wellness, the packaging requirements are becoming stricter than ever in terms of active packaging, whether that be barrier, enhanced product protection or increased functionality of some nature. While that’s always been a requirement, we’re seeing ove to new ew heightened levels. itt move

the ability to

manufacture our packaging through a closed-loop system is unique to PepsiCo – Denise Lefebvre, PepsiCo

The second “lever” is design, which has long been a familiar theme, but is taken to the next level in terms of packaging. What it can do for the consumer, both functionally and how it pops on shelf to help sell products. The last piece in packaging is sustainability, which is critical. I would tie that in with localization. Consumers are really about getting to authentic products that are local to them and knowing where everything comes from in the supply chain.

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Consumers understand sustainability and want it. There is a “halo” effect to packaging and sustainability in that consumers want something natural and authentic, but not overpackaged. Anything feeling much more organic is very important for them and will continue for some time. Also, the world of [carbonated soft drinks] has had historically great graphics, but I see a big shift at better packaging graphics and structure coming together in that category and others.

F&BP: PepsiCo is taking its PET bottle development into rather unusual sources…what can you comment about that? Lefebvre: The creation of a 100% plant-based PET bottle is a very exciting program for us. We are currently using non-feedstock sources like switch grass and pine bark, so we aren’t diverting otherwise usable food sources for our product packaging. In the future we intend to broaden the renewable sources used to create the bottle to include orange peels, potato peels, oat hulls and other agricultural byproducts from our foods business—the ability to manufacture our packaging through a closed-loop system is unique to PepsiCo and reinforces our “Power of One” advantage by driving a strategic beverage innovation via a food-based solution. We are in the midst of vetting technologies to prepare for our 2012 pilot plant project to introduce some of these bottles into the market. It’s fundamental to the program to really understand things like yield loss and efficiency rates to get the final costing down and to understand the quality and productivity of those products. We’re also aggressively pursuing a commercial pathway in conjunction with determining a pilot plant location. F&BP Next month Lefebvre discusses lessons learned from FritoLay SunChips, standardization and food safety. Also, check the F&BP website for a podcast of our interview.

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PMMICorner

A TOTAL SYSTEMS APPROACH: TRANSFORMING THE WAY MANUFACTURERS APPROACH PROCESSING AND PACKAGING Brand owners are increasingly taking a total systems approach to manufacturing to enhance efficiencies and decrease costs. eading up to PACK EXPO Las Vegas set for September 26-28 at the Las Vegas Convention Center, this year’s largest resource for packaging and processing innovation in North America, we spoke with Jonathan Titterton, director of sales & marketing at Bosch Packaging Technologies (Booth #1423), Brian Barr, packaging sales manager at Heat and Control (Boot (Booth #2433) and Maria Ferrante, vice president, Education & Workforce Development at PMMI, to gain insight into the trend towards integration.

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Services for spare parts, technical support and training are becoming almost as important as the machine itself. – Maria Ferrante, vice president, Education & Workforce Development, PMMI

How have your customers changed the way that they address processing and packaging on the line? Ferrante: The manufacturers that frequently attend the PACK EXPO shows have told us they do not categorize themselves as processors or packagers, per se. They see themselves as professionals within an industry, such as food, confection or pharmaceuticals, so taking a holistic approach to the way they address their processing and packaging operations is important.

Titterton: When we talk to customers about processing and packaging, we tend to focus more on the packaging side. But as we discussed, manufacturers have to address a number of different concerns across their processing and packaging operations – including speed, capacity, sustainability, sanitation and safety. We need to be there for our customers not only at the time of purchase, but later down the road, so engineering and after-market support is important. 38

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Barr:

I agree. Everyone’s looking for added value from their supplier, all the way from the pre-sale stage through the post-sale stage. It’s a simpler, faster and better approach. Brand owners want to have a single point of contact at a supplier that will help them with a broader scope of purchases and carry them from the quote to the engineering phase. They also need a supplier that’s going to be able to provide after-market support to ensure they reap the most benefits from that equipment through its lifetime.

Ferrante: Part of that support – and what our members tell us their customers are demanding – comes with training. End-users need and want as little downtime as possible, and to get that, their employees need to know the machines inside and out. PMMI’s Certified Trainer program helps create leaders within organizations that can teach their colleagues or customers how to use the machinery. We conduct these “train the trainer” sessions all year long, and will conduct a workshop at PACK EXPO Las Vegas.

What is driving the shift to a total system systems approach? What benefits do end-users stand to gain from integrating processing and packaging? Barr:

No matter how far upstream or downstream we’re going with the equipment, our customers have limited resources today. They’re trying to optimize not only their purchasing dollars, but also their staffing. By combining the processing and packaging areas with one supplier or a single source supplier, they’re able to do more with fewer resources. And that’s at the engineering level, it’s at the service level and it’s at the design and implementation levels as well.

Titterton: Manufacturers are also trying to leverage their investment. Capital equipment is the significant piece of our customers’ procurement budgets. With the number of SKUs that are always being developed and presented to the manufacturing floor,

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the ability to seamlessly utilize processing and packaging equipment – even through new installments – is the end goal here. Of course, it’s not as simple as that, but this is the objective that more and more of our customers are sharing with us. They need to be able to leverage their investment over the greatest period of time, to manufacture the greatest number of products so that they see the best possible payback. By combining the efforts and plans of the processing and packaging teams, packagers stand a better chance of getting the right equipment to efficiently meet their production goals.

Barr:

And I don’t know if you’re seeing the same thing, Jonathan, but speaking of payback, our customers want to have a much quicker return on their capital investments. And we’re seeing that across the board.

Titterton: I think that stems a great deal from the short lifecycle that so many products seem to have today. The equipment has to generate return-on-investment at a faster pace. Again, this puts pressure on the equipment manufacturer to provide processing and packaging solutions that offer flexibility and longevity so that the customer can maximize payback on a capital investment. Ferrante:

Capital investment dollars are still being held pretty tightly. As a result, end-users and PMMI members have told us that when companies do decide to invest in equipment, they want and expect to see their investment pay off quicker than ever before. Within two years, even. Another thing we’ve learned is that the “build a better mousetrap” model for technical innovation and marketing is flawed, and in fact, services for spare parts, technical support and training are becoming almost as important as the machine itself. As Jonathan and Brian have said, end-users are trying to get the biggest possible return from their capital investments. And while anyone can mark down a price, it’s a one-time function. With training, parts and tech support you have a “gift that keeps on giving,” in the form of more efficient operations and less downtime.

We know that this September’s PACK EXPO Las Vegas will spotlight processing solutions in addition to packaging technologies. How does an integrated show floor benefit the buying team? Barr: I believe it gives them a venue to view the full spectrum of equipment and solutions that they’re looking for. So many of our customers, especially in this economy, are limited in the number of trade shows they can go to. When they can see processing and packaging solutions in one place, buying teams

Our customers want to have a much quicker return on their capital investments. – Brian Barr, packaging sales manager, Heat and Control

can maximize their time and effort by seeing as many prospective and current suppliers as possible.

Titterton: As buying teams get smaller, they’re always trying to minimize their costs and maximize time. By defining areas specific to certain industries and needs, the show helps attendees manage their time because they know where to find the technologies that they’re looking for. Ferrante: And that’s exactly why we’re doing it. It’s integral to the customer-centric approach we’ve implemented for this year’s event. By providing features and services that hone in on the needs of specific vertical markets, we’re giving those attendees additional resources to draw from, and frankly, making it easier to navigate this very large show. When attendees experience a high return on the time and resources they’ve invested in attending PACK EXPO, everyone wins. For more information about PACK EXPO Las Vegas 2011 or to register, visit www.packexpo.com or contact PMMI’s Show Department at 703-243-8555 or [email protected]. F&BP

By combining their processing and packaging teams, packagers stand a better chance of getting the right equipment. – Jonathan Titterton, director of sales & marketing, Bosch Packaging Technologies

About PMMI.

PMMI organizes the PACK EXPO trade shows: PACK EXPO International, PACK EXPO Las Vegas and EXPO PACK México, connecting packaging and processing equipment and materials suppliers with their customers around the world. Coming Up: PACK EXPO Las Vegas at the Las Vegas Convention Center Sept. 26–28, 2011. Learn more about PMMI and the PACK EXPO trade shows at PMMI.org and Packexpo.com.

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PACK EXPO Show Preview

PACK EXPO LAS VEGAS: IT’S SHOW TIME! PACK EXPO Las Vegas 2011 is breaking records and expanding to deliver the largest and most comprehensive packaging and processing trade show experience of the year in North America.

t’s going to be a really big show, really big: The PACK EXPO Las Vegas 2011 trade show, produced by PMMI, will be at the Las Vegas (Nevada) Convention Center Sept. 26–28, 2011. At press time, the show was outpacing the 2009 Las Vegas show in every category. More than 1,600 exhibitors will be on site, and exhibit space has grown to more than 600,000 net square feet. Special exhibit pavilions, including The Brand Zone, The Processing Zone, The Pharmaceutical Pavilion and The Reusable Packaging Pavilion, are sold out and jampacked with exciting and innovative exhibits. “We’re excited about the way PACK EXPO Las Vegas 2011 is shaping up,” says PMMI President & CEO Charles D. Yuska. “The Las Vegas show has grown considerably over the past 15-plus years, and now it has more to offer than ever. This year, we’re presenting a number of special features, many of them brand new.”

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PACK EXPO attendees will include thousands of packaging professionals and dozens of robots.

• Total systems solutions for precisely integrated production lines • Cutting-edge technologies to apply in all vertical markets • An enhanced conference program presented by key industry players • Dedicated industry pavilions for confectionery, processing, reusable packaging, and pharmaceutical, and an expanded Brand Zone with materials that shape winning brands • Market-specific lounges for networking and education on the show floor: The Candy Bar, The Baking/Snack Break and the Rx Lounge • The premiere of the PACK EXPO Leadership Lecture series, with headliner Gen. Colin Powell • The future of retailing and packaging, as envisioned by Clemson University • Material ConneXion’s display of the newest packaging materials • The Showcase of Packaging Innovations — 300 award-winning packages bound to inspire. • The Sixth annual PACK EXPO Selects Competition Get into the zones

New designated industry pavilions let attendees easily locate the solutions they need. These include: The Baking–Snack Break

This is the place for the latest news and trends on packaging for the bakery and snack industries. Here you can keep tabs on this ever-changing market through news updates, product announcements, people on the move, and a soon-to-come interactive blog. Sponsored by Kliklok-Woodman. The Processing Zone

PACK EXPO Las Vegas 2011 attendees will enjoy a new standard for trade shows with these features and more: • The opportunity to connect with more than 1,600 world-class suppliers and 25,000 colleagues — PACK EXPO Las Vegas is the largest packaging and processing trade show in North America this year

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Find innovative processing solutions for the food, baking and snack industries in this dedicated space. Plus, one out of five PACK EXPO exhibitors on the general show floor will also display processing solutions. That means hundreds of ideas. With packaging and processing under one roof, you can work with

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PACK EXPO Show Preview

Reusable Packaging Pavilion

See how choosing reusable pallets, hand-held containers, bulk containers, dunnage and other transport packaging solutions can raise your productivity and profitability. Learn how you can lower shipping and labor costs while enjoying better product protection and a more efficient flow of goods through distribution channels. Sponsored by the Reusable Packaging Association (RPA). Food Safety Summit Resource Center

Gather and learn from leading industry Subject Matter Experts as the Food Safety Summit invites you to participate at the Food Safety Summit Resource Center, which will help manufacturers and processors respond to the many challenges they face on the job. It is sponsored by BNP Media. Learn about the latest breakthroughs in food safety and gain valuable insight into potential solutions. It’s an opportunity to meet one on one each day with food safety experts. Look for the Food Safety Summit Resource Center in booth # S-6635 in the Processing Zone. For more information, contact Charles Wilson at [email protected] or 630-962-0078.

ways to enhance your equipment’s versatility, minimize changeover time, maximize convenience, guarantee freshness and more. Sponsored by the National Confectioners Association (NCA). The launch of The Candy Bar lounge permits confectionery professionals to network and access resources within their market niche. It will include an “Ask the Expert” resource center and the Innovation Stage program, a series of live, 30-minute seminars. Confectionery manufacturers and suppliers are also invited to a special networking reception hosted by PMMI and NCA in The Candy Bar lounge on Monday, September 26, from 3:30 to 5:00 p.m. You’ll find The Candy Bar lounge in Booth S-7000, within the Confectionery Pavilion in the Upper South Hall, and totaling more than 12,000 square feet of sweet opportunities.

The Processing Zone, another new entry to the PACK EXPO International show floor, was a sellout at the 2010 event.

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suppliers and manufacturers on total system solutions for truly powerful results.

The Brand Zone— Containers & Materials that Shape Winning Brands

See the latest advances in package design for glass, plastic, metal and paperboard packaging, decorating and labeling techniques. The Brand Zone puts the spotlight on packaging technologies to help open innovation executives and brand managers launch new products. Material ConneXion® The Showcase of Packaging Innovations

Sponsored by The Dow Chemical Company, this pavilion features award-winning packaging from around the world. 6th annual PACK EXPO Selects™ awards recognize best-in-class consumer packaging by PACK EXPO Las Vegas exhibitors. Project 2020: The Consumer Experience focuses on the future of packaging with a design competition that forecasts upcoming trends is hosted by EskoArt; Booth #S5449. The Confectionery Pavilion

Candy and snack producers can head to the Confectionery Pavilion for innovations answering your specific packaging and processing challenges. Find

Material ConneXion®, a global leader in materials solutions, will bring its dynamic, interactive materials display to The Brand Zone Sept. 26-28 in Las Vegas. Material ConneXion’s exhibit will introduce new ideas, showcase emerging trends and demonstrate the essential link between material innovation and design. The exhibit’s primary focus will be material innovations for the packaging industry, but will also offer ideas for cross-industry pollination by highlighting materials from all areas of design. “Our interactive Innovation Lab will educate PACK EXPO visitors on the essential material concepts driving innovation today by allowing them to see, touch and experience the materials that are having the greatest impact on the design world,” says Alison Zingaro, Marketing and Communications

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PACK EXPO Show Preview

Manager for Material ConneXion. Material ConneXion, with seven offices around the globe, works with designers and manufacturers to discover materials that will invigorate design, revolutionize industry and create more sustainable environments. The company’s Materials Library is the world’s largest, housing over 5,000 commercially available materials, and its online database offers subscribers comprehensive technical descriptions & complete manufacturer contact information. The AIM Expo and Conference at PACK EXPO

dustry through expanding knowledge and volunteer leadership, and have personally advanced the field of packaging. Join PMMI in celebrating the induction of five career packaging professionals into the Packaging Hall of Fame Class of 2011: Lawrence C. Dull, MS, CPP; Arthur Gustafson; Victor Del Rosso; Thomas L. Schneider CPP; and M.H. “Pete” Wallace. These five outstanding individuals will join a long list of career packagers in a ceremony that will be held Monday, September 26 at 4:15 p.m. in the Ballroom at the Las Vegas Hilton. Individual tickets for the reception and induction ceremony are $75 each.

The Association for Automatic Identification and Keynote speaker: Colin Powell Mobility (AIM) is co-locating There will be plenty of audiAIM Expo 2011 at PACK EXPO ence members at attention lisLas Vegas. tening to keynote speaker Colin The AIM Expo conference Powell, former U.S. secretary of program will include tracks on state and retired Army general. government, healthcare, manuPowell will speak Tuesday Sept. facturing, mobile workforce 27 at 4:30 p.m. at the Las Vegas and retail. “Auto ID in PackagConvention Center on the toping” and “Internet of Things,” ic of “Diplomacy: Persuasion, two new sessions, will idenTrust & Values.” tify state-of-the-art applications DuPont and Morrison Conand solutions for to improve tainer Handling Solutions are operations, streamline producsupporting the lecture as title tion, reduce costs and enhance sponsors. Dorner Mfg. Corp., overall business processes. Eastman Chemical Company The AIM Expo conference will and Fox IV Technologies also complement the existing ConferGENERAL COLIN POWELL, support Powell’s talk. ence at PACK EXPO program, KEYNOTE SPEAKER Single tickets are $125 or which provides valuable insight packages of 10 tickets are available for $1,000. A speinto the trends affecting modern packaging and procial reception, open to all ticket holders, will precede cessing operations. PMMI has partnered with the Rethe speech at 3:30 p.m. usable Packaging Association (RPA), the Institute of Packaging Professionals (IoPP), the international SociPMMI Education Foundation Golf Tourney ety of Beverage Technologists (ISBT), and PMMI’s own PGA Champions Tour golfer Curtis Strange will Alliance for Innovation and Operational Excellence take part in the 2011 PMMI Education & Training (AIOE) to deliver the expert educational experience atFoundation Golf Tournament, an appearance spontendees have come to expect from the Conference at sored by Kodak. PACK EXPO. The conference will feature hot topics in This year’s tournament, scheduled for Sunday, processing and packaging, exploring subjects as diverse Sept. 25, at the Paiute Golf Resort in Las Vegas, as Total Cost of Ownership and The FDA’s new Food will provide backing for student scholarships and Modernization Act over three days of sessions led by continuing education for PMMI member company representatives from companies like Bush Brothers & employees. The biennial event, first held in 1995, Co. and Coca-Cola Co. has funded some $350,000 in education and trainPackaging Hall of Fame ing to date. Schneider Electric is the tournament’s Induction into the Packaging Hall of Fame is the Gold Sponsor. F&BP packaging industry’s highest honor, recognizing a For more information about PACK EXPO Las Vegas lifetime of innovation and achievement. These pack2011 or to register, visit www.packexpo.com aging leaders have dedicated themselves to the in-

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Innovative solutions that simplify the packaging of fresh produce and processed foods.

OctoMation-based solutions are enabling an expanded array of companies to own and operate robotic packaging equipment. OctoMation customers are able to deploy advanced, high-speed packaging solutions with exceptional ease. And with operating costs of less than $5 an hour, OctoMation is delivering the industry‘s lowest total cost of ownerhsip.

WWW.ADEPT.COM 1-800-292-3378 [email protected]

SEE OCTOMATION IN BOOTH S-5411 AT PACK EXPO LAS VEGAS

PACK EXPO Show Preview

HORIZONTAL SHRINK WRAPPER ARPAC will feature the XLR8 ServoDriven Side Seal Horizontal Shrink Wrapper at the Pack Expo 2011 Las Vegas Show at booth # C-1000. The XLR8 side seal horizontal shrink wrapper is capable of wrapping up to 100 packages per minute in clear or print registered film. The seal bar can be converted from a horizontal to vertical configuration to accommodate taller products. The continuous motion XLR8 film folding system eliminates the need for multiple forming heads with its adjustable film former. Unlike conventional film inverters, the XLR8 film path ensures equal transfer of grouped products onto the film without skewing the product configuration making it ideal for multipacks and irregular shaped products. It’s unique film forming and feed method will use up to 2 inches less film than similar competitive machines. In addition, the single wound film requirement increases the film capacity by more than 100% thus improving productivity and reducing downtime caused by film change. ARPAC 847-678-4871; www.arpac.com

ROBOTIC PACKING, UNPACKING, AND PALLETIZING

Visit us at Pack Expo 2011, booth #5485

The Intelligrated booth #3611 will feature two robotic arms operating on a single PLC-based control system performing robotic case unpacking and case packing of bottles. It will also showcase a third robotic arm operating on proprietary robotic controls demonstrating case palletizing. The exhibit will be of particular interest to companies looking to integrate robotics into existing fill lines, including wineries, distilleries and breweries. With quick line changeovers becoming more prevalent, companies are looking to automate processes to avoid downtime and gain efficiencies. Alvey robotics from Intelligrated, operating on industrystandard controls, enable customers to deploy efficient and repeatable robotics solutions that also seamlessly integrate with other equipment on the line. By maintaining a familiar control platform, plant floor personnel can support these Intelligrated robotic applications without being “robotic experts.”

Matrox Imaging 800-804-6243; www.matroximaging.com

Intelligrated 513-881-5239; www.intelligrated.com

SMART CAMERA KEEPS AN EYE ON YOUR PACKAGING PROCESS The Matrox Iris GT smart camera with Design Assistant software has what you need to tackle your next packaging project with confidence. Matrox Iris GT is a powerful smart camera family featuring Matrox Design Assistant, an intuitive, versatile and extendable integrated development environment (IDE). Manufacturing engineers and technicians can easily and quickly configure and deploy machine vision applications on a highly integrated platform without the need for conventional programming. Video capture, analysis, location, measurement, reading, verification, communication and I/O operations as well as a web-based operator interface are all set up within the single IDE.

VERSATILE PRODUCT BLENDING CONVEYOR Accurately mix multiple vegetable, snack, cereal, or frozen food ingredients (and maintain the blend all the way to packaging) using the FastBack blending conveyor. Load cells precisely measure the delivery of each ingredient to maintain blend accuracy better than 1.5% per constituent, depending on the product. Gentle FastBack horizontal motion conveying prevents separation of blended ingredients and reduces product breakage up to

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60% compared to vibratory conveyors. It also reduces coating loss, buildups in the conveyor pan and unscheduled cleaning downtime. Menu-driven recipe selection facilitates fast changeovers while the modular design permits easy expansion and flexibility. A variety of pan surfaces are available for different product applications; learn more by visiting booth #C2433. Heat and Control 800-227-5980; www.heatandcontrol.com

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UNWRAP

BAG See Innovative Packaging / Palletizing Robots at KUKA Robotics booth C-4631 September 26-28th, 2011 www.kukarobotics.com

PACK

STACK

PACK EXPO Show Preview SHELF AND RETAIL READY PACKAGING ON DISPLAY Delkor Systems will dedicate its entire Pack Expo exhibit to Retail Ready and Shelf Ready packaging concepts. In the past year, Delkor has designed eight new machines for various applications of either Retail Ready or Shelf Ready packaging—and all will be highlighted in the Delkor exhibit at booth C-4045 at Pack Expo Las Vegas. Delkor Systems is a leading manufacturer of advanced packaging machines and systems for dairy producers, food processors and manufacturers of consumer products. Delkor Systems 763-783-0855; www.delkorsystems.com

DELTA-STYLE CASE PACKER WITH AUTOMATIC CHANGEOVER The Delta Style Case Packer is a newly engineered case packer with auto-changeover using the BluePrint Automation three- and four-axis Delta robot to case pack flexible packages. The new design simplifies the system mechanically, provides a smaller 4’ wide x 8’ high-footprint, and includes a virtually hands-free changeover between different product and case sizes. The new case packer eliminates fine-tuning that typically takes place after a changeover providing customers with a solution that returns quickly to maximum efficiency after the changeover process is complete. It also eliminates costly change parts (i.e. multiple collation belts, end-effectors and cassettes), maximizes case utilization and packs small bags at 130+ bottles/min. BluePrint Automation 804-520-5400; www.bpa-flexolutions.com

HIGH PERFORMANCE AC DRIVE MODEL Hitachi America, Ltd., Industrial Components & Equipment Division, announces the new SJ700-2200HFU2 model inverter, with a 440 A output current capability. This new model fills in the gap at 300-350 hp in the SJ700 series, which now completely covers the range from ½ to 600 hp. The SJ700 significantly expands on the performance, capabilities and functions of its predecessor, the SJ300. Hitachi reasserts its technological leadership with an improved vector control algorithm and auto-tuning function that enables the open-loop SJ700 (SLV) to develop more than 200% starting torque at 0.3 Hz. Using Hitachi’s unique “0 Hz Domain” open-loop control mode, the SJ700 can develop 150% torque near 0 Hz, ideal for vertical lift applications. Another major new element in the SJ700 is Hitachi’s EzSQ (Easy Sequence) built-in programming function. The user develops EzSQ programs on a PC, and then downloads them to the inverter using the simple-to-use configuration/programming software provided at no charge. Designed to be a product for the global market, the SJ700 carries CE, UL, cUL and c-Tick marks, and is RoHS compliant. Visit Hitachi’s booth, #359, at Pack Expo Las Vegas. Hitachi 914-631-0600; www.hitachi-america.us

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PACK EXPO Show Preview FOOD BAGGING INNOVATIONS Food packaging solutions specialist tna highlights its roflo®VM 3, a vibratory motion transfer and distribution system, unique seasoning system – the new tna intellflav®OMS 3 plus the tna robag®3c RDJ 320 bagger, complete with new tna 314 1 multi-head scale. The innovative tna 314 1 multi-head scale is designed to be seamlessly integrated with vertical form, fill and seal (VFFS) bagger, the tna robag 3c. Amplitude feedback sensor technology increases speed and accuracy to achieve the desired amplitude with minimal power. Weighing speeds are increased by up to 30% and energy consumption reduced by up to 60%. When paired with the tna robag®3c bagger, reaching packaging speeds of up to 200 bpm, the tna weigher-bagger combination delivers a high-speed, high-accuracy packaging solution for improved productivity and reduced waste. For consistent coverage of flavor and seasonings, the company is showcasing the tna intell-flav®OMS 3 on-machine seasoning system. With a responsive variable mass seasoning system that incorporates a dynamic vibratory weigher that responds to variation in product, tna’s latest addition to its intelli-flav®range of seasoning solutions, the tna intelli-flav®OMS 3 optimizes product coverage and flavor dispersion now in a worldwide first with both wet and/or dry applications and allows multiple flavoring on one production line. Visit booth 5135. tna 972-462-6500; www.tnasolutions.com

See us at Pack Expo Booth #S-5279 W W W . F O O DA N D B E V E R A G E PA C K A G I N G . C O M

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MarketTrends

C O ND I M E N T S by ELISABETH CUNEO, Associate Editor

SUGAR AND SPICE AND EVERYTHING…CONVENIENT

A glimpse into packaging for the condiments market, which helps flavor these products with a healthy dash of convenience. ales of condiments of all types including sauces, dressings and spices are on the climb. According to recent research from Mintel, the cooking sauces and marinades category gained 20% in U.S. retail sales between 2005 and 2010 and is expected to increase another 19% by 2015. Why is the market gaining momentum and how are manufacturers responding? There has been an influx of consumers cooking at home and a growing demand for convenience which has manufacturers working harder to introduce new, more convenient products. And a common, crucial ingredient for convenience? Packaging, of course.

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New E-Z Zip pouch takes up less shelf space.

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Cooking with convenience

Sauces and condiment sales are growing as consumers are eating more ethnic and exotic cuisine, and as exotic foods grow in popularity, so does convenient packaging of these food items. Several food brands today allow consumers to purchase homemade quality global foods pre-packaged for home use. Conservas la Costeña offers classic Mexican sauces in the aseptic carton pack, ideal for home use. Tim Kirchen, head of marketing & business development North America and Mexico at SIG Combibloc adds, “During the manufacturing process, foods are rapidly ultra-high heated, quickly cooled again, and then

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filled into sterilized carton packs. Packaged in these cartons, foods are hygienically protected, airtight and impervious to light, and can be kept for a prolonged period without preservatives or refrigeration. The nutrients and vitamins in the foods are retained – and so are the excellent taste and the full, rich flavor.” Consumers are doing more cooking of all types of meals at home. And an increase in home cooking births an increase in shopping for condiments and spices. According to Mintel, 83% of adults who prepare meals at home attest to using sauces, marinades or dry seasonings. Storebought marinades are most popular with 74% of home cooks using them. While cooking at home is on the rise, as is demand for convenience as consumers today have generally less time to prepare meals. In response, McCormick has launched an easy way to create a home cooked meal with its Recipe Inspirations line. Each packet includes a recipe card and premeasured spices to create the ideally spiced dish. There are a dozen recipe flavors, each containing six spices premeasured and self contained in clear plastic so the consumer can see each spice. The spice portions, which peel open from the rear, are exactly matched to the variety and portions required for the recipe. Kikkoman, known for its soy sauce and marinades, has launched a convenient spice packets line as well, a full line of seasoning packets to be used for almost

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Im Imperial is highlighting the product’s ease of use a and prolonged freshness with statements on its packaging, “No Mess, Always Fresh.” Unique packaging attracts consumers

any culinary creation. The company boasts 10 varieties of combination spices in 1-oz paper packets featuring a visually appealing photograph of the desired dish from Broccoli-Beef to Szechwan Shrimp and even Pad Thai. Kikkoman’s website includes recipe options for each variety to ensure easy meal time preparation. Imperial Sugar is meeting demand for convenience with its introduction of its individually portioned brown sugar packets for ease of baking. Every box contains 12 pouches, each containing a ¼ cup brown sugar. In addition to convenience,

With trends toward higher consumption of packages condiments, there’s no wonder that companies are getting more creative with condiment packaging. Heinz temporarily relaunched an American i icon with the release of a new collector’s edition of H Heinz Tomato Ketchup, available in classic octagon 14-oz glass bottles by Owens-Illinois. Absent nal ffrom grocery store shelves for more than 10 years, th limited edition glass bottle of Heinz Tomato the K Ketchup features a vintage-inspired design to bring so some nostalgia to the household name. “While the convenience of our current, squeezab bottles found in grocery stores has been a hit able w with today’s families and their lifestyles, consumer still associate Heinz Ketchup with our iconic ers glass bottle and routinely ask where they can find them,” says Noel Geoffroy, vice president of Heinz Brands. “In response to that consumer demand and to inspire memories of and relive good times from summers past, we wanted to bring back the glass bottle with a limited edition design that gives a nod to the product’s 135-year history.” When Heinz Tomato Ketchup was first introduced in 1876, it was bottled in clear glass to reveal its purity. It was not until several years later

‹‹ McCormick Recipe Inspirations pack in spices and recipe.

A trusted image in salt: The Umbrella Girl laying into nostalgic packaging, Morton Salt has stuck with the same icon for decades, the little girl with the umbrella. The girl has undergone only six slight changes since its introduction in 1914. As a result of keeping the iconic figure, the packaging is recognizable to all, overcoming generational gaps in consumers. In 1911, Morton’s first advertising campaign for a series of ads in Good Housekeeping created the idea for the girl and her slogan, “When it Rains it Pours.” The concept was a hit- an image of a little girl holding an umbrella in one hand to ward off falling rain and a package of salt in the other hand that was tilted back with

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the spout open and salt running out. Morton loved the picture that expressed the Morton message — that salt would run even in damp weather. To accompany the image, eventually the now famous slogan was born, “When it Rains it Pours.” While the icon of the umbrella girl remains ageless, she has continued to change with the times. The first makeover to modernize her looks was in 1921 and then again in 1933, 1941, 1956 and 1968. In spite of slight tweaks to the image, the girl remains a recognizable figure and reminds consumers that Morton has been making salt for over 150 years with the same trusted package and value.

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Morton’s Umbrella Girl transforms over decades. 1914

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Saucy sayings make an impression Available in all Ta Taco Bell stores, and available for purchase online onlin for those sauce enthusiasts, the packets pack have stirred up a lot of attention. Taco Bell, recognizing the te hot sauces’ popularity, created an interactive website allowing consumers to humanize the hot co sauce sauc packets by dressing them up. On the website, visitors can pick a sauce flavor and dress it with choices of clothing, accessories and even a cloth background to place the packet in. The backgro proof is in the sauce (packaging) that humor--and humor--a personification-- is always well received. recei For more information: Denby Creative Cr www.denbycreative.com www.den

aco Bell is leaving a mark (no, not a sauce stain) on consumers with their hot sauce packets, which feature kitschy sayings including; “Do I know you from somewhere?” “We could all use a little squeeze now and then” “Ahhhh we meet again” Designed by Denby Creative, out of San Francisco, these packets are meant to get consumers talking and feed their curiosity and cravings for more hot sauce wisdom. In 2003 Taco Bell rolled out the sauce packets with th witty sayings and then in September 2004 launched nched a contest named “Share Your Sauce Wisdom.” The contest engaged consumers to come up with the he next clever phrase to be printed. Today there aree dozens of different sayings in circulation.

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Taco Bell’s hot sauce packet ‘converses’ with consumers.

that the world-famous octagonal bottle debuted. The glass bottle was sold in stores until the 1990s, when it was replaced with the squeezable plastic bottle that was first introduced in 1983. Capturing the essence and heritage of the Heinz Ketchup brand, the label design of the new limited edition glass bottle was inspired by a vintage packet of tomato seeds. Heinz also released a new look for its individual serving ketchup packages, called the Heinz Dip & Squeeze® Ketchup package. The new package holds three times more ketchup than standard condiment pouches and uses less comparable packaging. Comprised of a peelable flexible lid over a thermoformed pocket, the Dip & Squeeze allows consumers to either tear off the tip and squeeze

FOR MORE INFORMATION Ampac 513-671-1777; www.ampaconline.com Mintel 212-796-5710; www.mintel.com Owens-Illinois 567-336-5000; www.o-i.com SIG Combibloc 610-546-4200; www.sig.ch

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out the condiment, or peel back the lid from the bottom and dip french fries or other finger foods. According to Dr. Michael Okoroafor, VP of packaging R&D/innovation for H. J. Heinz Co., the package was developed in response to consumer demand for a ketchup container that can be used for either dipping or squeezing. It offers better functionality and convenience than typical sachets by providing two different usage options – tearing off the top or “cap” for squeezing, or peeling off the lid for dipping. Another company to improve condiment packets through convenience is Hellmann’s. Hellmann’s released the E-Z ZIP reclosable, stand-up pouch from Ampac for its individually packaged mayonnaise. The flexible package replaces traditional paperboard packaging and holds 75 individual, serving-sized mayonnaise packets. The pouch design reduces the amount of packaging required, stores easily and takes up less shelf space than a paperboard box. It provides a more contemporary billboard for the brand on the retail shelf, and the package is more recognizable and easy to locate for its intended consumer. Packaging today must meet the growing demand for convenience while attracting consumer attention on the shelves. If innovation is born out of demand, expect to continue to see creative and convenient packaging spicing up the condiments aisle.F&BP

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MaterialsTechnology

LAB E L S

SMOOTHING OUT THE WRINKLES OF SHRINK-SLEEVE LABELING An exploration of customer preferences, problems and solutions. / by ELISABETH CUNEO, Associate Editor

ou’ve heard don’t judge a book by its cover, but in this industry, where it would sound more like don’t judge a product by its label, sometimes the label is all you have. The importance of labeling is growing with increasing dietary needs, competition on shelves and labeling regulations. But how do you create an effective label that really gets noticed on shelves? One study found that customers have a strong preference in labels. According to a report from Eastman Innovation, a division of Eastman Chemical Co., 35% of purchase decisions are based on eye-catching product packaging. Between 40% and 70% of brand decisions are made in the store, and consumers decide within three to seven seconds of initial product interaction whether to try a product. The importance of your label is immense. What types of labels are getting noticed by consumers? Shrink-sleeves. Shrink-sleeve labels take advantage of the superior “printability” of polyvinyl chloride, a substrate that works well for flexographic or rotogravure printing. Its high shrink rate makes it perfect for use on contoured containers and a popular choice because of its ability to cover the entire product, increasing canvas size for messaging. A packaging study by AC Nielsen, commissioned by Eastman Chemi-

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‹‹ Pabst Brewing’s shrink-sleeve baseball bat bottles were a hit with Chicago consumers.

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cal Co. to understand consumer preference for label format, demonstrates that shrink-sleeve labels create stronger consumer emotional connections than traditional labels, acting as a key influencer of product trial and sales. This data concludes shrink sleeves, especially combined with high-contour bottles, possess a superior overall appearance, command more shelf attention, and create stronger emotional connections for consumers. As a result, higher product trial rates, long-term sales, and brand loyalty are likely. In addition to customer preference, shrinksleeve labels also offer the manufacturers a larger canvas to relay more ideas. While traditional labels allow on average 40% coverage, shrink-sleeve labels provide up to 100%, 360° package coverage. This translates into 150% more container coverage and greater opportunity for emotional connection with consumers through the use of product information, imagery and nutrition claims. This year Pabst Brewing Co.’s Old Style Beer campaign, reflecting a 61year partnership with the Chicago Cubs, uses a groundbreaking package design utilizing shrink-sleeved bottles to make them look like wooden baseball bats. The collectors’ edition bottles are decorated using a highspeed Fuji Intersleeve applicator from American Fuji Seal Inc. paired with a steam shrink tunnel. Right away the shrink-sleeve labels were noticed by consumers. In just two months after the launch, the company reported a increas in distrib58% year-over-year increase orders a sure hit by any measure. utor orders,

EskoArtwork’s bottle distortion illustrator predicts distortion before the label is applied.

‹‹ Beverage company Tonic from PurBlu, uses shrink labeling to convey its healthy, colorful messaging on it natural health shot drink. Printing partner Multi-Color Corp. utilized reverse printing on shrink film to achieve the dynamic labels. Shrink labeling offered the company a larger platform to relay messaging and a colorful look sure to please consumers. But during the labeling process, Tonic ran into the challenge of designing around the realities of the bottles and creating a distortion-proof design with consistent shrink labeling. A common problem associated with the use of shrink labeling is label distortion. While graphics on shrink labels are printed in a way that compensate for the shrink effect (they appear distorted before shrinking, but settle into their proper configuration once the label is shrunk), distortion can still occur. A distorted label can easily taint your product’s look and message, compromising brand integrity. That’s why new technology has been developed to alleviate this issue.

EskoArtwork and its Studio Toolkit for Shrink Sleeves, creates artwork for shrink-sleeves, and allows designers and prepress professionals to quickly create, test, analyze, communicate and produce designs with 3-D visuals, without the need to conduct physical test runs. Designers create grids on the shrink-sleeve material, wrap it around the container, run it through a shrink-sleeve tunnel, measure the distortion, and try to anamorphically size graphic elements based upon these measurements. The design is tested digitally instead of tangibly, avoiding trial and error methods common to shrink-sleeve labeling. Studio Toolkit for Shrink Sleeves accommodates asymmetrical shapes and multipacks, and works in 3-D from start to finish. The 3-D images accurately predicting the end-result can be used to approve designs faster and cheaper than making and shipping mock-ups. The need to add more content to labels (i.e. nutritional stats, directions for use, not to mention the product name, design and sometimes motto) increases the need for quality control of the labels so that the integrity of the message is preserved, especially with shrink-sleeve labeling.

MaterialsTechnology Avery Dennison Shrink PS is engineered to survive the vacuum-shrink process without wrinkling, providing both shelf appeal and production-related benefits. Avery Dennison Shrink PS labels are applied to shrinkable bags off-line or in-line prior to filling and vacuum sealing. Compared with traditional shrinkbag labeling, the Shrink PS solution offers enhanced labeling flexibility and the opportunity to differentiate products at a later stage in the packaging process. As a result, food processors can reduce or eliminate multiple sets of preprinted shrink bags in inventory, cutting overall costs. The labels exhibit superior aesthetic appeal due to their exceptional shrinking behavior. When submerged in hot water following vacuum sealing, the shrinkable bags and attached Shrink PS labels conform to the packaged product for a smooth finish without the wrinkling sometimes associated with labels applied by hand to the packaging after its been vacuum packed and shrunk. The Shrink PS labels’ water-resistant construction and strong permanent adhesive ensure that the labels stay firmly attached. The labels can be affixed to the bags using automatic label applicators, reducing the need for manual labor.

A label holds invaluable information, represents the brand and product, relays messages and works to attract consumers. The importance of label integrity is obvious. While shrink-sleeves offer packagers a larger canvas and customer preference, be aware of the labeling method’s pitfall–label distortion. With new technology working to avoid this potential shortcoming, shrink-sleeve labeling is a highly viable option in today’s labeling market. F&BP

FOR MORE INFORMATION American Fuji Seal Inc. 800-489-9211; www.fujiseal.co.jp/americas/ Avery Dennison 626-304-2000; www.averydennison.com Eastman Chemical Co. 423-229-2000; www.eastman.com EskoArtwork 937-454-1721; www.esko.com Multi-Color Corp. 513-381-1480; www.multicolorcorp.com

Peel-back label offers more content space: Two companies utilize peel-back labeling cCormick Canada overcame labeling space restriction on its Club House One Step seasoning line with the use of peel back labels. The company pursued this nontraditional option because spice containers do not offer a large label canvas, and due to Canada’s requirement of including both English & French content. All Stick Label, with McCormick, produced the peel-back label, which has three panels and takes advantage of the entire spice bottle. The facestock top sheet carries the prime label, nutrition facts, ingredients list, promotional copy and company information. When the top panel is peeled back, consumers will find six recipes in both English and French, with the latter printed on the backside of the top sheet. The pressure-sensitive base stock bottom sheet wraps the entire bottle and contains the six recipes in English. The three-panel label required switching from paper to biaxially oriented polypropylene (BOPP) film. Both the top and bottom sheets are Fasson® branded pressuresensitive film from the Fasson Roll North America division of Avery Dennison. The backside of the top panel contains a proprietary adhesive that allows the label to be resealed after peeling it back. For more information: All Stick Label 416-798-7310; www.aslprintfx.com

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Koch’s ‘spinning’ packaging allows for 75% more label surface.

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och Foods uses peel-back labeling to overcome space limitations on its line of frozen chicken breast chunks under Aldi’s Kirkwood brand. The new Koch Foods package, partnering with Huhtamaki, Inc. incorporates an innovative oriented polypropylene label, supplied by MPI Label Systems, that is placed over a specially designed round-shaped paperboard Huhtamaki Ultrakan® container. The label carries product photos plus nutrition facts, bar codes and other standard required product data, along with a clear section that reveals additional information when consumers “spin” the outer label. Their innovative “spinning” packaging allows for 75% more label surface while costing no more than traditional plastic bags. For more information: Huhtamaki, Inc. 913-583-3025; www.huhtamaki.com MPI Label Systems 800-837-2134; www.mpilabels.com

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MaterialsTechnology

PACK AG E D E SI GN

ENSURING YOUR PACKAGING’S ‘SIGNATURE MOMENT’ STAYS RELEVANT, IN-STORE, ONLINE AND BEYOND Keep in mind a package’s ‘Second Moment of Truth.’ or most of the fast-moving consumer goods (FMCG) category, packaging still represents one of the strongest key physical connections to the brand. Think of it this way: 100% of a brand’s purchasers interact with the packaging. Outside of tap beer and fountain soda, you literally have to go through the packaging to get the product. While structural packaging is essential to provide protection, security, or freshness, it’s also the perfect moment to reinforce a brand’s “signature.”

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Defining your ‘signature moment’

Brands, keenly focused on driving product lift in-aisle, understand the critical role packaging plays during the “First Moment of Truth.” However, they may not always realize the impact it can also have in the oftenoverlooked “Second Moment of Truth” – the moment when the product is removed from its packaging and used or consumed. A successful Second Moment of Truth can be a defendable structure, an iconic un-boxing moment, or even a powerfully seductive sound that makes the packaging inimitable. Think of popping open a can of Pringles, unraveling a roll of Pillsbury cinnamon rolls, or breaking the wax seal on a bottle of Maker’s Mark. The Second Moment of Truth shouldn’t just be a pit stop along a packaging’s lifecycle. Traditional design elements used to contain, protect, release, and reseal products can be finely crafted to amplify the relationship between brand equity and repeat purchase behavior. For a package to be truly memorable and help drive repurchase, the act FOR MORE INFORMATION of opening needs to be in perfect harmony with the brand’s MWV values – exactly at the moment 804-444-1000; www.meadwestvaco.com of a consumer’s most height-

An example of a Second Moment of Truth: A powerfully seductive sound that makes the packaging inimitable, such as popping open a can of Pringles.

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ened anticipation. Pringles, for example reinforces the concept of “pop” across their website, television commercials, and other online mediums. Maker’s Mark uses the wax seal as a key visual cue across their outdoor ads. Not only does this “signature” help to unify an integrated marketing campaign, it also effectively drives memory recall in-aisle during purchase and brand reinforcement in-home during use. Packaging in the age of digital shopping

As grocery shopping increasingly migrates online, product packaging is more important than ever. While Millennials continue to trade in their physical shopping carts for digital ones, the inability to actually touch and hold products will change how consumers shop. And as marketers and consumers create brand relationships through social networks, packaging is still the strongest key physical connection to a brand and will remain at the epicenter of ever-evolving marketing strategies. Therefore, packaging needs to reinforce the emotional bonds established during product use as powerful visual cues, particularly when the key decision factor relies on a low-resolution image on a website. By establishing these unique, memorable and iconic cues, brand owners can find new avenues to create brand allegiance, even when consumers skip the store entirely. Brands cannot rely solely upon the functional aspects of a package – the package must also evoke the emotional context of the brand to the consumer. Taking the additional step to build a packaging brand strategy before diving into structural design can help brand owners successfully create a memorable Second Moment of Truth for both in-store and online consumers. F&BP

by Steve Kazanjia, VP, Global Creative for MWV

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As A sy your our printing printing n needs eed s c change, hange, so s od does o es H Hitachi’s itachi’s IInk nk J Jet et ttechnology. echnology.

Hitachi has sold more than 85,000 Ink Jet Printers worldwide and remains the industry leader in manufacturing inkjet printers that utilize cutting edge technology and minimize impact on the environment. With every new generation of Continuous Ink Jet Printers, improvements are made to meet the changing needs and requirements of customers globally. Product superiority, reliability and innovation are key components in our new generation Continuous Ink Jet Printer. To learn more about how Hitachi can save you money, visit www.hitachi-america.us/takethechallenge today!

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SustainablePackaging

GREEN THOUGHTS: WHAT THE PACKAGING INDUSTRY CAN LEARN FROM DETROIT ITW’s move in creating the first ‘Tier 1’ packaging supply company points to an emerging trend. by BOB LILIENFELD, guest columnist and Founder, Use-less-stuff.com

bout a year ago, Illinois Tool Works (ITW) came to me with an idea. (If you don’t know ITW, it’s a $16 billion global company consisting of around 900 fiercely autonomous business units.) What if they could align their 45 packaging businesses to provide customers with sustainable packaging solutions, and do so as a single source provider? I lived in the Detroit area for over 20 years, so an automotive analogy immediately sprang to mind: ITW wanted to create the first Tier 1 packaging supply company! By doing so, it could help develop cradle-to-grave packaging systems that would efficiently reduce both environmental and economic waste for customers, distributors, retailers, and even consumers. And the customer would only have to work with one project team and would only have to pay one invoice. I loved the idea and helped them create what’s now known as the ITW Sustainable Packaging Group, or SPG for short (www.itw-spg.com). In less than a year, the SPG

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has caught the attention of the world’s biggest retailers and consumer packaged goods companies. It has many projects in the works, at many links in the value chain. The food and beverage connection

Interestingly, quite a few of the SPG’s initial projects are in the food and beverage space. Why? Because sustainable packaging systems must do more than simply reduce packaging discards. More importantly, they must reduce food waste as well. So, a balance must be struck between what the package delivers and the resources needed to do the job both effectively and efficiently. This new approach requires a very holistic view of packaging, not merely a narrow focus on design or production or conversion or filling. The SPG points to a trend based upon goal setting and problem solving from the top down, not merely at the point of friction. This creates the opportunity to coordinate and optimize the overall result, rather than trying to individually maximize a slew of smaller scale efforts. There is a great moral to this story: Sometimes, the best ideas come from other industries that have similar needs. In this case, the drive for sustainability in the packaging sector has created a need to apply worldclass thinking and technology across complete systems, not just at one point in the value chain. The automotive industry developed this system years ago to solve its own emerging issues regarding the need to provide what customers perceived to be quality vehicles at competitive prices. And over time, quality in Detroit has taken on a new dimension beyond merely reliability and comfort. Thanks to consumer demand and the high price of fuel, it now includes sustainable thinking around material use, recyclability, and energy conservation. Sound familiar? F&BP Robert M. Lilienfeld is a Fox TV environmental commentator and Editor of The ULS (Use Less Stuff) Report, a newsletter dedicated to conserving resources and reducing waste.

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