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A barrier you can count on Preserve product quality with barrier film you can trust. Charter Films specializes in engineering the right film for your unique application—with up to seven layers—to meet or exceed performance specifications for improved productivity, longer shelf life and a more attractive finished package. Charter’s barrier films are the preferred choice for a wide range of packaging applications. Committed to creating more sustainable, earth-friendly packaging, our films are light, yet strong and durable. For a superior, affordable barrier film that offers customized protection for your products, rely on Charter Films, the specialists in blown film extrusion.
1-877-411-3456 +1 715-395-8258 www.charterfilms.com/barrier cfiinfo@charterfilms.com © 2011 Charter Films, Inc. All rights reserved.
T H E I N D I S P E N S A B L E T O O L F O R C O N V E R T E R S & P R I N T E R S O F FLE X I B LE PA C K A GI N G
Table of Contents ®
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COVER STORY EXECUTIVE OUTLOOK 2011 Recovering with Cautious Optimism Though struggles still ensue, companies are feeling optimistic about the economy and the industry.
30
FEATURES 10 FPA UPDATE
74
2011 Flexible Packaging Achievement Awards Innovations Showcase Honoring 55 years of industry innovation & achievement, the FPA has compiled its list of 56 packaging finalists.
Q&A: ADHESIVES & LAMINATION A Look at Adhesives & Laminations in Packaging The importance of engineering when choosing the right roller and thinking of idler type can make all the difference.
30 DIGITAL PRINTING Checkpoint Label Converting Digitized Three drop-on-demand ink jet printers provide six-webwide coverage at an output of 420 labels per minute.
DEPARTMENTS 6 EDITOR’S FORUM
32 PRODUCTS & EQUIPMENT
32
Converting Success through Technology Upgrades Short runs, rapid turnarounds and attentioncompelling graphics translate to converting success.
18 CONVERTER NEWS Dion Label Installs HP Press…FPA-grade Recycled Resin Available…Converter Installs Solvent Recycler… Arkema Chooses New Additive Supplier…and more.
36 TECHNOLOGY: WEB
44 INDUSTRY INSIGHT
GUIDING & TENSION CONTROL Better Web Process Control through Direct Tension Measurement By retrofitting web converting and printing machinery with direct tension sensing and control equipment, converters can prevent poor quality in finished roll material.
46 SUPPLIER NEWS Flint Group’s New Coating…H.B. Fuller New Hire Announcement…Danafilms Acquired by RKW… OEC’s New Technologies…and News Briefs. 50 HOT PRODUCTS
40 ROUNDTABLE ON EXTRUSION (SPECIAL ADVERTISING SECTION)
56 CORPORATE PROFILES
42 Q&A: SLITTING/REWINDING
68 CLASSIFIEDS
A Dynamic Industry Needs Dynamic Machinery Michael Pappas, president of Catbridge Machinery, has held his position in the industry for 10 years and has the answers to prove it.
72 CALENDAR OF EVENTS 73 AD INDEX
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JANUARY / FEBRUARY 2011
www.flexpackmag.com | FLEXIBLEPACKAGING
one biodegradable resolution
Eco-One® the organic additive that renders plastic products biodegradable
Proud members of National Recycling Coalition, Flexible Packaging Association and Project Network Members of EPA’s Methane-to-Markets Program.
© 2010 EcoLogic LLC. All rights reserved. www.ecologic-llc.com 630.869.0490
T H E I N D I S P E N S A B L E T O O L F O R C O N V E R T E R S & P R I N T E R S O F FLE X I B LE PA C K A GI N G
Online Content ®
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WWW.FLEXPACKMAG.COM FAST ACCESS TO WEB-ONLY FEATURES SUCH AS:
JOB SEARCH epackagingjobs.com, the premier online job search site for packaging professionals. “Unwrap your potential!”
TIMELINE OF INNOVATIONS in Flexible Packaging from the past 10 years.
NEW! FLEXPACKREPORT NEWSLETTER delivers the latest research and business data needed by flexible packaging converters. Includes links to sources of current resin prices. Sign up for your FREE subscription today.
BREAKING NEWS about film manufacturers and converters—get your competitive intelligence here!
CONNECT WITH FLEXIBLE PACKAGING NOW: FACEBOOK AND TWITTER
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www.flexpackmag.com | FLEXIBLEPACKAGING
Advanced Technologies in solvent recycling/reclaim/reuse & water waste treatment
Solvent Recyclers Distillation Columns Water and Solvent Separators Water Evaporators Thermal Evaporators Water Flocculation Systems Contact PPC Technologies & Solutions LLC for more information Ph: (262) 695-7536 Ɣ
[email protected] Ɣ www.ppcts.com/solventrecyclers.htm
Editor’s Forum
THE INDISPENSABL E TOOL F OR CONVERTERS & PRINTERS OF F LEXIBLE PACKAGING
®
SEIZE THE UPTICK am a firm believer in the clichés ‘everything happens for a reason’ and ‘what doesn’t kill you only makes you stronger’. Getting past something can be difficult. You still consider it, it’s on your mind or at the very least in the back of your head, and it can determine the types of future decisions you make. But that doesn’t mean you stand still, allowing the world to pass you by. Lucky for us, executives in the flexible packaging industry are not allowing the world to pass them by. Quite the contrary: They are feeling much more optimistic about the industry and the economy as a whole. I would call it cautious optimism. And that’s not a bad thing. We all must take our past experiences and remember those experiences for future decisions. With that in mind, FP’s Executive Outlook 2011: Trends and Forecasts is appropriately themed, “Recovering with Cautious Optimism.” It is with cautious optimism that the industry will be able to continue on the upswing through innovation, improvements, and of course, a positive attitude. By taking notes and learning from others, we can make this industry extremely successful. For information on how one company improved its digital printing capabilities, turn to page 30. This month’s Technology section includes a very informative piece on Better Web Process Control. If you’re having problems with your web guiding, page 36 contains the article you should read.
I
Publisher Mike Barr,
[email protected] Associate Publisher Randy Green,
[email protected] Senior Marketing Manager Steve Liput,
[email protected] Inside Sales Kristina Lorio,
[email protected] EDITORIAL Editor-In-Chief Erin J. Wolford,
[email protected] Executive Editor Rick Lingle,
[email protected] Associate Editor Jennifer Welbel,
[email protected] Art Director Frank J. Mayeran Advertising/Production Manager Courtney Warnimont EDITORIAL BOARD George Thibeault, Constantia Hueck Foils LLC Michael Impastato, Flint Ink. Fredy Steng, Berry Plastics Marla Donahue, Flexible Packaging Association FPA OFFICERS Chairman John Baumann, Ampac Packaging LLC Immediate Past Chairperson James E. Love, III, Printpack Inc. Executive Vice-Chairman (chairman-elect) William Burke, Nordenia USA Treasurer Michael Impastato, Flint Group President (non-voting member) Marla Donahue, Flexible Packaging Association Executive Committee Members At Large Hans Deamer, Windmoeller & Hoelscher Corp.; Jim Mize, Sealed Air Corp.; Ken Swanson, Berry Plastics Corp.; Rob Tiede, Sonoco Flexible Packaging AUDIENCE DEVELOPMENT Corporate Audience Development Director Rita M. Foumia Audience Development Manager Kourtney Bell Multimedia Specialist Katie Jabour Audience Audit Coordinator Carolyn M. Alexander For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail
[email protected] Innovation, improvements, and of course, a positive attitude will help us recover.
The Roundtable on Extrusion (page 40) includes three top suppliers with the know-how and experience to speak to the sector. And information on proper slitting/rewinding can be found on page 42. And as always, we have our departments, which include industry news separated by Converter and Supplier, as well as our Hot Products section, for new or interesting products on the market now. You may notice our guest columnist, who has been in the industry for years, and understands its experiences. It’s really time to pick ourselves up and pour ourselves into the business that we know and love. Be smart and be resourceful. Take chances, but also think things through. But most of all, never forget what you went through these past couple of years, and how it made you feel. That will keep the determination and drive alive. FP
Sincerely, ERIN J. WOLFORD (847) 405-4042
[email protected] 8
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List Rental Postal contact: Rob Liska at 800-223-2194 x.726
[email protected] Email contact: Shawn Kingston at 800-409-4443 x.828
[email protected] BNP MEDIA CORPORATE OFFICERS Publishing: Timothy A. Fausch Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Conferences & Events: Emily Patten Clear Seas Research: Beth A. Surowiec FOR VOLUME REPRINTS: Reprints Sales Representative Jill DeVries Phone: (248) 244-1726 • Fax: (248) 244-3934 E-mail:
[email protected] CONTACT FLEXIBLE PACKAGING Phone: (847) 405-4000 • Fax: (847) 405-4100 Mail: 155 Pfingsten Road, Suite 205, Deerfield, IL 60015 Internet: www.flexpackmag.com Circulation: (248) 244-6421
BNP MEDIA HELPS PEOPLE SUCCEED IN BUSINESS WITH SUPERIOR INFORMATION. VOLUME 13, NUMBER 1
JANUARY/FEBRUARY 2011
X
WHEN MARKETS
GET TOUGH
WE MAKE FILMS EVOLVE.
From the delicate to the durable, our clients’ products take on the markets. And today’s challenges are significant. That’s why we provide films that continue to evolve with innovation to meet growing demands. When new applications are developed, industries find us to explore beyond barriers—making films that are more effective, more sustainable and more competitive. Look to danafilms.com or call our film experts at 800.634.8289.
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FPA Update | F LE X I B LE PACK AG I N G AS S O CIATION
ASSOCIATION ACTIVITIES UPDATE
2011 FLEXIBLE PACKAGING ACHIEVEMENT AWARDS INNOVATION SHOWCASE Honoring 55 years of Industry Innovation & Achievement
he Flexible Packaging Association is pleased to present the entries of the 55th annual Flexible Packaging Achievement Awards competition. This industry event honors outstanding advancements in printing and graphics, design and structure, consumer convenience, and material innovation. The 57 flexible package entries showcased in this issue of the FPA Update, represent flexible packaging solutions for a wide variety of retail, industrial, and institutional products. Of those, 15 packages will be honored with 20 Achievement Awards. The winning entries of the 2011 competition will be announce during the 2011 Welcome & Flexible Packaging Achievement Awards Dinner, March 9, sort in 2011 at The Ritz Carlton Golf Resort e held in Naples, Florida. The Dinner will be nnual conjunction with the 2011 FPA Annual Meeting (March 9-11, 2011). e Special thanks are given to the judging panel of the 2011 FPA Flexible Packaging Achievement Awards: Larry Ahleman, Master Faculty, Western Michigan University; John Kalkowski, Editor, Packaging Digest Magazine; and, Michael Richmond, Ph.D, Packaging & Technology Integrated Solutions for their time and expertise. The entries of the 2011 competition are presented in alphabetical order by package name. Names of the packages’ or manufacturer are also provided. For more information about the 2011 ent FPA Flexible Packaging Achievement Awards competition, visit FPA at www. ation flexpack.org or contact the association at (410) 694-0800. FP 1
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1. Australian Gold Tanning Set CL&D Graphics, Incorporated 2. Beacon Converters/ ConforMIS Drill and PinKit Wallet Beacon Converters, Inc 3. Beneful Cachorros Saludables Printpack, Inc. 4. Boulder Canyon Kettle Cooked Chips Genpak LP 5. Chicken Bags Flex America Inc. 6. Chip & Dale Snacks Flex America Inc. 7. Chips Ahoy! Navidad Printpack, Inc. 8. Clear Lam Spectrum Marketing Bag Clear Lam Packaging, Inc. 9. Clear-Seal™ Burger Patty Package Berry Plastics Corporation 1 10. Coex Bundling Film AEP Industries, Inc
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FPA Update | F LE X I B LE PACK AG I N G AS S O CIATION
ASSOCIATION ACTIVITIES UPDATE 11
11. Cofler Block Duo Peruplast S.A. 12. Cryovac® Oven Ease™ Bags Sealed Air Corporation, Cryovac Food Packaging
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13. Del Monte Recloseable Apple Slice Package Clear Lam Packaging, Inc.
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14. Dento Peruplast S.A. 15. EnviroPACK MP Master Packaging 16. Food Lion Naturally Brewed Sweet Tea Prime Label & Packaging, LLC 17. Fresh Express® Natursave™ Bag Amcor Flexibles Americas andMedical Europe
15
17 16
18. Fresh N Tasty Produce Pouch Robbie 19. Fresh Step Cat Litter - Clorox Nordenia USA 20. Green Giant® “Steam in the Bag Option” Frozen Food Package Berry Plastics Corporation
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JANUARY / FEBRUARY 2011
TAKE CONTROL
Control your roll quality, speed, workflow and bottom line. Rotoflex Genesis - the newest, most advanced control system in the industry gives you more control. Exclusive to Rotoflex inspection/rewind machines, Genesis guarantees fast, accurate fault recognition and placement, includes 100% matrix and missing label detection, and simplifies set-up and calibration. Best of all it lets you take control of your profits.
www.rotoflex.com
FPA Update | F LE X I B LE PACK AG I N G AS S O CIATION
ASSOCIATION ACTIVITIES UPDATE 21 21. Hellman’s E-Z ZIP Pouch Ampac Packaging LLC 23 22. Henkel Renuzit Crystal Elements Club Store/ Dollar Store Pouch Exopack, LLC
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23. Herr’s Popcorn Printpack, Inc. 24. Hormel® E-Z Zip® Pouch Ampac Packaging LLC 25. Jelly Belly Sonoco Flexible Packaging
25 24
26. John Soules Rotisserie Chicken American Packaging Corporation
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27 Kettle Brand TIAS! Printpack, Inc.
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28. Kroger Meals Made Simple Stand-Up Pouch Bema Inc. 27
29. Liquiflex® Advance™ Films for Bulk Liquids Curwood, Inc., A Bemis Company 30. Masa PrePizza Peruplast S.A. 31. McCormicks Marshmallow Bananas Flex America Inc.
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32. Natural Matte Finish Poultry Pouch Berry Plastics Corporation 33. Nestle ONE Dog Nordenia USA
33 31 32
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JANUARY / FEBRUARY 2011
Pictures:
ICE Europ
e/ICE Asia
MUST ATTEND EVENT North America’s new dedicated paper, film, foil converting show 200+ exhibitors Running machinery Comprehensive 3-day conference Pre-show flexible packaging conference and technical seminars Industry meeting point
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April 6-8, 2011 OCCC • Orlando • Florida ®
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Register today to attend the exhibition and conference and book your hotel
FPA Update | F LE X I B LE PACK AG I N G AS S O CIATION
ASSOCIATION ACTIVITIES UPDATE
34. Next Generation Carpet Wrap P&O Packaging, LLC
36
35 35. Ostasis™ Reinforced Pouch Oliver-Tolas(tm) Healthcare Packaging
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36. Overture® One Rollprint Packaging Products, Inc. 37. P.F. Chang’s Home Menu - Meals for Two American Packaging Corporation 38. Pepperidge Farm Croutons Printpack, Inc.
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39. Pepperidge Farm Stone Baked Artisan Rolls Printpack, Inc. 40. Pharma Pouch Coldpack 41. Popcorn Indiana All-Natural & Reserve Printpack, Inc.
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42. Ruiz El Monterey Burritos American Packaging Corporation
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43. Safeway Frozen Pasta Quad Seal Package Berry Plastics Corporation
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44. Shrink Bundling Film with Optimil™ Technology for Gauge Reduction Berry Plastics Corporation 43 45. Shrink Film Over Film for Easy Release (SFOF) Berry Plastics Corporation
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46 46. Sprout Zippered Retort Pouch Ampac Packaging LLC
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47. Stand Up Pouch with Semi Rigid Recloseable Label Graphic Packaging International
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48. Stein North State Flexibles 49. Stonyfield Farm Multipack Yogurt Clear Lam Packaging, Inc.
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50. Teddy Bear Cookies Flex America Inc. 51. Trail’s End Classic Caramel Popcorn DanaFilms, Inc./ Plastic Packaging Technologies, LLC
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52. Turbo Tubes Ampac Packaging LLC 53. Winter Blend Graphic Packaging International
52 54. Wolfgang Puck® Fractional Coffee Pack with bMET™ II Film Curwood, Inc., A Bemis Company
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55. Wyman’s of Maine Wild Blueberry Juice Printpack, Inc.
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56. Zone Coated Rollstock Oliver-Tolas™ Healthcare Packaging 57. ZUN Energy Supplement Printpack, Inc. 57
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Converter News
DION LABEL PRINTING INSTALLS SECOND HP WS6000 PRESS
he Westfield, Mass-based flexographic and digital label printer installed its second HP Indigo WS6000 digital printing press, replacing its WS4050 model. Providing an increase in printing speed, print width and repeat length, the four-color process press can operate at speeds of 98 feet per minute, has a frame size of 12.48 by 38.58 inches and can print on both thin and thick substrates. “The installation of our second HP Indigo WS6000 press has allowed us to increase the scope of products we can offer to our customers. Our customers will continue to benefit from the highest quality while being able to achieve longer run lengths with the increased productivity of the WS6000,” says Randy Duhaime, general manager.
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Dion Label Printing (413) 568-3713; www.dionlabel.com
FDA-GRADE RECYCLED RESIN AVAILABLE nvision Plastics announced today that it has fully ramped up production of its EcoPrime food grade recycled resin at its Reidsville, North Carolina plant. EcoPrime is the only recycled HDPE plastic resin available in the U.S. to be cleared by the Food and Drug Administration (FDA) for use in packaging foods and beverages. “We have had the technology to produce EcoPrime for some years now,” says Envision’s vice president of sales, Tamsin Ettefagh. “But it has only been recently that demand from consumer products companies has really started to increase. The growing emphasis on sustainability and environmental responsibility has motivated many companies to look at using recycled resins in applications where they would not have before, like food and beverage packaging. With a 67 percent reduction in CO2/Greenhouse Gas emissions over prime resin, EcoPrime enables our customers to reduce their carbon footprint.”
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Made from post-consumer HDPE EcoPrime is produced from curbside collected HDPE (#2) bottles. The bottles are subjected to proprietary and patented cleaning process that not only cleans the plastic but removes anything that could have been absorbed by the plastic as well, making it the cleanest and purest recycled HDPE resin available. “We will produce up to 18 million pounds of EcoPrime this year at our Reidsville, N.C., plant, now that full production scale has been achieved,” says COO Scott Booth. “EcoPrime is now being used in packaging for nutritional supplements, beverages, food storage containers and some personal care products.” Envision Plastics (336) 342-4749; www.envisionplastics.com
US CONVERTING INSTALLS SOLVENT RECYCLER S Converting Inc. has installed an ECOpure SR180V Solvent recycler from PPCTS. The Elgin, Illinois-based flexible converter will use the system to recycle its dirty flexo press wash solvent. Using an electronically controlled distillation process, the ECOpure separates contaminates from the used solvent, resulting in a 95 percent recovery rate and a 90 percent reduction of disposal of toxic waste.
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US Converting, Inc. (847) 985-3833; www.usconvertinginc.com PPCTS (262) 695-7536; www.ppcts.com
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Productivity. Speed. Safety.
®
To a flexible packaging converter, efficiency means lower application temperatures, maximum web speeds, and fast curing and slitting as soon as possible, all while maintaining the stringent safety specifications required by the industry. Through dedicated specialists, customized products, and process expertise, Henkel delivers efficiency that will advance your flexible packaging operation and create advantage for you and your customers. Find out how Henkel’s Liofol® laminating adhesives can deliver for you. 35
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