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Brand building, improving efficiency and reducing costs are driving forces heading into 2010.
As they head into the new year, PACK EXPO attendees are Attention-grabbing packaging shapes, sizes, features and
trying to counter recessionary forces of 2008 and 2009 by materials increase shelf impact and product differentiation,
focusing on building brands and improving productivity — both of which help convince consumers to buy.
with twin goals of increasing sales and cutting costs.
One new way to differentiate product is the Zip Box, a
In keeping with these goals, sustainability has evolved into hybrid carton/zippered pouch package from T.H.E.M.
a mainstream commitment. Sustainable practices encour- (Marlton, NJ). The rectangular pack opens and recloses
age sales by addressing consumers’ interest easily, stacks better than a pouch and fits more
in “greener” products, and by reducing product per pallet than a canister.
waste and conserving resources, they often Available in a variety of sizes, the Zip Box
generate cost savings. fills like a standard carton on a modified car-
toner from Yeaman Machine Technologies, Inc.
Other trends revealed at PACK EXPO Las Vegas
The carton base and zipper-pouch top of the hybrid Zip
2009 included the increased adoption of digital Box couples easy handling on the packaging line and in
distribution with convenient opening and reclosing for the
printing and safety enhancements. consumer.
TM
(Elk Grove Village, Ill.). T.H.E.M. plans to sell printed blanks
as well as offer contract packaging services.
pick and choose features,” reports McLean. “In fact,” he As a result, Cash predicts, “The x-ray market will be equal
says, “the system is so flexible, customers can supply their or bigger than metal detection in a couple years.”
own parts, if desired.”
Productivity Improvement
In metal detection, the patent-pending Intellitrack XR signal On the productivity continuum, the need to minimize down-
processing technology from Thermo Fisher Scientific time spurs demand for faster changeover and ease of use.
(Minneapolis, Minn.) eliminates product effect instead of Tactics to achieve these goals include higher levels of
compensating for it. Now standard on the company’s Apex automation with increased adoption of servos, software
metal detectors, the signal processor learns the conductive and robotics to speed changeover and reduce faults. The
and magnetic signatures of the product being inspected need to cut downtime also is spurring interest in service
and subtracts those signals from each reading. So, if a and support, automation of manual processes and hygien-
product reads zero, it’s good. It’s especially well-suited for ic designs that require less time to clean.
discrete wet products such as cheese, bread, water and
baby wipes, which change over time and pose a challenge
for traditional phasing methods. Although products with
signals similar to ferrous or nonferrous metal or stainless
steel remain somewhat problematic, detection sensitivity
improves up to 40 percent.
“They’re no longer asking why x-ray, but when,” reports Delkor Systems, Inc. (Circle Pines, Minn.) has launched a
Rick Cash, marketing technology manager, Process more flexible servo version of its Trayfecta carton/tray for-
Instruments for Thermo Fisher Scientific, a supplier of mer. With servomotor drives controlling three axes of
metal detectors, x-ray inspection systems and check- motion (carton blank picking, carton transfer and forming
weighers. “End users are realizing customers will not head action), each function occurs at its optimal rate. The
tolerate low quality in food.” Trayfecta S Series not only runs 10 percent to 12 percent
faster, but also occupies less space, changes over without
Flexibility is readily apparent on the high-speed FSU800 Already viewed by many as the ultimate in flexibility, robot-
aseptic vertical form-fill-seal machine from Fres-Co ic equipment is expanding functionality, ease of use and
System USA, Inc. (Telford, Pa.). It handles a range of refrig- setup with ultra-hygienic designs, vision capability and
erated and shelf-stable products from extended-shelf-life advanced software.
dairy to high-acid aseptic or can be set up to simply hot fill.
The machine maintains overpressure in the form-fill-seal A three-panel printer/applicator from Pro Mach’s ID
area and sterilizes incoming film with ultraviolet light and Technology (Fort Worth, Texas) thermal-transfer prints and
peracetic acid to ensure aseptic conditions. With a 22-inch applies labels to up to three sides of a pallet, reducing the
stroke, potential pouch sizes range from 1.69 ounces to number of applicators needed. Built on the same base as
2.5 gallons with filling speeds from 17 pouches per minute the company’s other printer/applicators, the system fea-
for the 2.5-gallon size to up to 30 pouches per minute for tures a pivoting cam with a tamp-jet pad to apply labels to
the lower volumes. At the 2.5-gallon size, the form-fill-seal leading, passing and trailing sides. A jet of air helps release
process cuts packaging material costs to $0.25 to $0.30 the label for tamp application on the fly or while the pallet
per pouch versus $0.50 to $0.75 for a bag in box. is stopped. The tamp-blow action helps ensure good con-
tact with the stretch wrap frequently used to unitize pallets.
Modular construction of the ALS series of printer/applica-
tors from Avery Dennison, Printer Systems Division Changeover takes only seven minutes on the HFP (Highly
(Framingham, Mass.) simplifies service and integration by Flexible Packer) from Focke & Co. (Whitsett, NC) because
offering several mounting, loading and application options.
Built for heavy-duty use with a cast aluminum housing, the
ALS units feature a dynamic rewind and unwind to adjust
speed and torque for precise, repeatable label placement.
The ALS 306 manages labels up to 6 inches wide at
speeds up to 197 feet per minute. The ALS 309 handles
labels up to 9 inches wide at speeds up to 148 feet per
minute. A CompactFlash card slot makes it possible to
save, share and store configuration settings for several
packaging lines. Other standard connectivity options
With Focke’s two-robot HFP, case packing occupies only 81 square feet
include serial, Ethernet and USB ports. A ribbon-saver (7.5 square meters) of floor space.
Delta robots such as the Adept Quattro s640HS feature a hygienic design
for washdown applications like meat and poultry plants.
vent contact with air hoses and electrical cables, dual seals
and windows at strategic locations so if a seal fails, mois-
ture will be visible. Specially designed surfaces and bolts
prevent accumulation of debris. The high-speed robot also
relies on food-grade grease, operates at 120 cycles per
minute with a 2.2-pound payload, 100 cycles per minute
with an 8.8-pound payload and may be equipped with
visual line tracking.
A growing number of robots, USDA certification is pending for the MPK robot, a similar-
including the MPK from Motoman,
withstand washdown conditions and ly equipped, washdown-compatible, IP67-rated unit from
meet USDA standards for handling
raw meat and poultry.
Taking the measurement effort a step further, Lantech is After offering its InSite Services program to end users for
working to establish standards regarding load containment several years, Rockwell Automation (Milwaukee, Wisc.) has
or holding force and has begun to offer containment extended the program to original equipment manufactur-
workshops to help end users determine proper machine ers, who can sell it as part of their service packages.
settings, improve repeatability and reduce waste and Available on a subscription basis, the program monitors
downtime due to the constant tweaking that occurs on equipment, expedites troubleshooting, signals it’s time for
many packaging lines. preventive maintenance tasks, optimizes performance and
downloads updated information to the controller. It also can
Support maintain a history of the machine and database of support
Support has taken on new importance as packagers have information as well as organize data in standard or custom
deferred new equipment purchases and/or reduced in- formats to create reports or reveal trends.
house technical staff.
At Filamatic (Baltimore, Md.) new one- and two-year serv-
Many packaging machinery manufacturers are publicizing ice agreements can be configured to include a complete
existing programs or expanding service offerings. The six- machinery and procedure assessment along with proactive
month-old Advantage Program at Dorner Manufacturing machine evaluations and tune-ups and operator training in
Corp. (Hartland, Wisc.) includes a Get Fit introduction, Stay
Fit ongoing maintenance, replacement parts kits, same-
day shipment of parts and a 24-hour service line for mat-
top and belted conveyors.
With motors and drives accounting for 68 percent of the In addition, because a fan in the tamp pad holds the label
energy consumed in industrial settings, Bosch Rexroth in place, there aren’t alignment issues or changeover
Corp., (Hoffman Estates, Ill.) takes a multifaceted approach involved when switching from one label size to another. An
to energy conservation. Dubbed 4EE, it consists of energy- all-electric swing-arm model will join the Platinum E-Series
efficient components, energy recovery, energy on demand tamp-on and wipe-on labelers by the beginning of 2010.
and energy-efficient design. On packaging machines, dig-
ital servo-amplifiers on motors eliminate the need for air Adhesive guns also are moving from pneumatic to electric.
conditioning cabinets. A regenerative power supply cuts “With smaller packages moving faster and smaller flaps to
electricity use up to 20 percent by capturing energy gen- seal, higher precision is required,” explains Rick Pallante,
erated during braking and supplying it to other devices, marketing development manager, packaging for the
storing it in a buffer for the next cycle or feeding it into the Adhesive Division of Nordson Corp. (Duluth, Ga.).
electricity supply grid.
Another conservation measure, source reduction, light-
There’s also more attention to optimizing the size of motors weights, downgauges, replaces or eliminates packaging
and drives and replacing pneumatic actuation with electric, materials/components. Eliminating liner waste is the goal
behind a pressure-sensitive label printer/applicator from sumption in half and minimizes downtime related to cleanup,
Arca Automation (Cherry Hill, NJ). The Bi-Fuel Linerless particularly of the drum, where adhesive tends to collect.
Printer/Applicator handles linerless polypropylene or paper
labelstock and offers even greater waste reduction poten- Addressing adhesive buildup another way is the hot-melt-
tial when switched to print linerless paper via a direct repellent Dura Motion finish on the Stay Clean Drum from
thermal process that requires no thermal-transfer ribbon. B&H Labeling (Ceres, Calif.). Available on all new B&H roll-
Capable of reproducing scannable barcodes, the system fed labelers and retrofitable on some older models, the
relies on a Sato S8408 printhead customized for linerless Stay Clean Drum lengthens the uptime intervals between
media and a pneumatic applicator, and its slightly higher stops for cleaning to at least three hours and sometimes as
cost (about $25,000) is offset by material savings. A sec- many as 12 hours.
ond generation machine, scheduled to debut in 2010, will
be able to handle both linerless media and traditional liner- “With standard drums, it’s not uncommon to stop the line
equipped material. for cleaning as often as every 40 minutes,” notes Bob
Adamson, vice president, Sales & Marketing, B&H.
Converting cut-and-stack labelers from open wheel adhesive
pots to closed extrusion systems from Nordson can cut hot Eliminating hot melt entirely, the Roll-Adhesleeve roll-fed
melt consumption 90 percent by eliminating waste and labeler from PE Labelers USA (Cincinnati, Ohio), relies on a
reducing char. The closed system also cuts energy con- label with pressure-sensitive adhesive on the leading and
The PackTiger Hybrid paper system from Sealed Air shapes Characteristic of today’s state-of-the-art digital presses,
single-ply 17-inch by 20-inch sheets into multi-ply pads CSAT’s ITS 600 four-color, drop-on-demand inkjet label
for void-fill. Flipping a switch changes density so pads can printer operates as a standalone unit or integrates with
serve as cushioning. Designed for pack stations rather than labelers or converting equipment as well as vision-based
conveyor applications, the system features a front-loading inspection systems. The model shown at PACK EXPO Las
paper tray and can connect as many individual sheets as Vegas 2009 featured a 9-inch web width with a 4-inch
needed to create the desired length. print area. A model with a 15.75-inch print area is expect-
ed to debut in 2010.
Digital Printing
With the advent of more sophisticated digital presses, the The ITS 600 digital press prints any web-based material
use of digital printing is growing, especially for labels and (film, foil, paper), including die cut and preprinted stock,
shorter runs. Since each impression is generated by the destined for use as labels, shrink sleeves, stick packs or
Safety Enhancements Bosch Rexroth builds safety functions into its drives and
With internal risk assessment initiatives and new safety controllers to reduce monitoring requirements, save on
standards, especially in Europe, some equipment builders certification costs, provide a reaction time of less than 2
are adopting Category 3 safety circuits to provide redun- microseconds and simplify integration. These capabilities
dancy and fast reaction time. also help U.S. packaging machinery manufacturers build
machines to European requirements.
One company that’s standardized on Category 3 safety
components, Columbia Okura LLC, (Vancouver, Wash.) has Safety is receiving more attention — in the United States
built its FL2000 floor-level palletizer with dual-circuit inter- and outside the country. It plays a key role in the European
locks and a discharge light curtain. A sliding tunnel on the Union’s CE requirements, and it’s also part of today’s soci-
infeed provides additional protection and easy access. ety, with its greater levels of litigation and awareness of
injuries, and a higher-value labor force. Further, improved
“Our customers have asked for Category 3 safety circuits safety practices tie in with the lean and sustainable initia-
as an option for several years,” reports Ted Yeigh, sales tives that were so prevalent at PACK EXPO Las Vegas
director, Columbia Okura. “This year, we have standardized 2009. These trends and the others described in this report
on Category 3 circuits across our product line. The compo- will evolve throughout the coming year, and will be on dis-
nents are more expensive but offer a greater level of play next fall at PACK EXPO International 2010.
14 PACKAGING TRENDS 2010
About PMMI
PMMI is a trade association with more than 550 member companies that manufacture
packaging, processing and related converting machinery, commercially-available pack-
aging machinery components, containers and materials in the United States and
Canada. PMMI’s vision is to be the leading global resource for packaging, and its mis-
sion is to improve and promote members’ abilities to meet the needs of their customers.
PACK EXPO
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 in 2010: EXPO PACK México in Mexico City, June 22–25, and PACK EXPO
International, Oct. 31–Nov. 3, at Chicago’s McCormick Place. PACK EXPO Las Vegas
returns to the Las Vegas Convention Center Sept. 26–28, 2011.
Packexpo.com
Packexpo.com is your connection to the packaging and processing supply chain — includ-
ing the exhibitors of PACK EXPO. Around the clock, and around the year. Use the site to
find the suppliers you need, any time, and enjoy the benefits of PACK EXPO all year long.
PMT Magazine
PMT Magazine is the industry’s only publication dedicated to professionals in packaging
operations, purchasing maintenance and training.
Learn more about PMMI and the PACK EXPO trade shows at PMMI.org and Packexpo.com.