Flexible Packaging January-February 2011

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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

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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.

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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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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.

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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]

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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

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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

12

14

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

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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.

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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

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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.

30

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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

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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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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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41

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

47

47. Stand Up Pouch with Semi Rigid Recloseable Label Graphic Packaging International

48

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

50 51

54

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

53 55

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.”

E

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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JANUARY / FEBRUARY 2011

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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Liofol® Delivers

Productivity. Speed. Safety. ® 35

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Liofol ® Delivers Answers

A New Generation of Answers. Liofol® Ease-of-Use Production Facts Application Temperature:

35-40°C

Pot Life:

>30 mins.

Cure Time:

48 hrs.

Hot Room Reqs.:

None

Downtime:

Reduced

Solids:

100%

Solvents or Water:

None

Greenhouse Gas Emissions: Low

35

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Liofol ® Delivers Answers

Henkel is anticipating tomorrow’s challenges for flexible packaging manufacturers and is providing answers with a new generation of adhesives. Today, film converters require that their process be as efficient as possible while delivering products that stand up to the functional performance and safety standards that brand owners require. Stay tuned in for what’s coming next from Henkel, the company that has been bringing pioneering products to the flexible packaging industry for over 40 years.

With Liofol® laminating adhesives, substrates of all types can be transformed into high-performance laminates. Throughout the world, flexible packaging converters trust Henkel’s Liofol® adhesives when it comes to producing their laminates. We provide a broad range of laminating adhesives and coatings that meet the highest standards of performance and versatility. The Liofol® product portfolio offers customers the best bonding solutions to cover all of their needs from standard applications to sophisticated laminates for the most demanding performance. Henkel delivers answers to your toughest challenges that will advance your flexible packaging operation and create advantage for you and your customers. Backed by more than 40 years of product innovation, technical experts around the globe are expanding our status as the leader in the development of laminating adhesives and coatings. To learn more about our Liofol® brand of adhesives, call: 1.800.4LIOFOL (454.6365). www.henkeladhesivesna.com/liofolnextgen8c

®

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Liofol ® Delivers Answers Except as otherwise noted, all marks used are trademarks and/or registered trademarks of Henkel and/or its affiliates in the U.S. and elsewhere. ® = registered in the U.S. Patent and Trademark Office. © Henkel Corporation, 2011. All rights reserved. 7051 (1/11)

Converter News

NEW MULTI-PROCESS LAB LINE FOR FILM, COATING, AND LAMINATION he expansion at Extrusion Dies Industries, LLC (EDI) Technology Center consists of a 1.6 meter (63 in.) extrusion line that can be used for cast film, coating or lamination and is fully equipped for laboratory-scale single- or multi-layer production and web converting. The Center also includes a slot die or fluid coating line, a sheet line with six extruders, and other product/process development capabilities. Besides making these facilities available to customers, EDI uses these facilities for its own product and process development research. The new line has five extruders and can produce single- or multilayer cast film up to 1,600 mm (63-in.) wide at thicknesses from 8 to 125 microns (0.3 to 5 mils). Speeds for 8-micron LLDPE/LDPE film average 229 m (750 feet) per minute. Multilayer film can range from standard coextrusions to innovative structures, produced with EDI’s layer multiplier tooling, which can range from a few dozen to over a thousand microlayers.

T

the END RESULT

NEW 360 DEGREE, RESEALABLE PACKAGE FORMAT Zip-Pak introduced its Zip360 – a new flexible pouch format that features a 360-degree zipper that can be resealed in two ways. It also enables graphics around the entire surface area of the pouch and offers pour-spout functionality. Compared to traditional bag-in-box formats, Zip 360 reduces the amount of materials needed to manufacture a bag, lowering greenhouse gas emissions and reducing the energy footprint. Zip-Pak (800) 488-6973; www.zippak.com

The line also includes two unwind stations for converting film made on the process line itself as well as rollstock purchased from other sources. Besides using this and other processing lines at the Center for its own research, EDI rents them to companies looking to do trial runs without tying up their own equipment. Extrusion Dies Industries, LLC (715) 726-1201; www.extrusiondies.com

ARKEMA CHOOSES NEW ADDITIVE MASTERBATCHES SUPPLIER rkema Inc. has selected the Bioplastics Divison of Teknor Apex Company as its preferred supplier of masterbatches. Under its Terraloy bioplastics brand name, Teknor Apex will supply the appropriate masterbatches for Arkema’s Biostrength additives product line, which currently includes a clear impact modifier, an impact modifier for opaque injection molding applications, a melt strength enhancer and a metal release agent. “Arkema is partnering with Teknor Apex as a way to meet the needs of customers for a reliable source of pellet masterbatches for PLA based on our Biostrength additives, which are produced in powder form,” says Peggy S. Sharp, business director packaging and medical markets. “We chose [them] based on their reputation for speed and responsiveness in working with customers,” she adds.

A

Arkema (800) 225-7788; www.arkema-inc.com Teknor Apex (800) 556-3864; www.teknorapex.com

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JANUARY / FEBRUARY 2011

Taking Barrier Films to the Generation

Alpine's X-Die Barrier Film Line

David A. Frecka, CEO

“When we decided to step up to barrier films, our choice was obvious: The Alpine X-Die line”

Superior Film Technology - Most Flexibility - Best Service and Support

Cover Feature: Executive Outlook 2011

RECOVERING OPTIMISM with cautious

While struggles still ensue, companies are feeling optimistic about the economy and the industry. By Erin J. Wolford, Editor-in-Chief

even Æexible packaging industry leaders, including converters, suppliers and association managers, share their insights into the state of the Æexible packaging industry. Against the backdrop of an economic recovery, what they sense is a cautious optimism and what they see are challenges and opportunities.

S

JON MCCLURE: RE:

FLEXIBLE PACKAGING: The economy

ROBERT TEWKSBURY: WKSBURY:

has been at the forefront of business decisions. There are talks of an uptick in growth, but how do you see the economy doing this year? What does that mean for your company and/or the industry as a whole?

If left alone, the he economy ue to recover, but should continue this year will bee impacted by the volatility of oil prices and threat end to be optimistic, of inÆation. I tend he economic outlook regardless of the outlook, as there are always opportunities for continued growth in both up or down markets.

TIMOTHY LEWIS: We are optimistic

that the U.S. economy in general, and our business and industry speciÅcally, is improving, but at a slower growth than we had expected. We anticipate that consolidation, some pent-up demand and more readily available credit will make 2011 an excellent year.

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We witnessed a strong 09 and rebound in 2009 2010 both weree record years for ISO. The Æexible ustry as a packaging industry wn through whole has grown the recession. Over the past O has doubled 24 months ISO its capacity to meet the growing demand of ourr customers.

ART YERECIC: One of the services TLMI provides to members is the TLMI Biannual Index & Trend Report, which closely tracks indicators and economic indices directly relevant to

| www.flexpackmag.com

the North Ame American packaging industry. indus T he Reportt indica The indicates ssustained ustained growth iin p rimary end-use ca primary categories T TLM LMI converters se TLMI serve, in ncluding food, beverage, bever including p ph har maceutical ma and p pharmaceutical personal ccare/cosmetics. ca are/cosmetics. Our re research in ndica catees a slower growth in indicates 2011 and nd resurgence in 22012. 2011 T LMI members cont LM TLMI continue to rreport rep re epo port a general mode of rrecovery. Co C omp mpanies remain cautio Companies cautiously ooptimistic ptimistic as they Åne-tu ne-tune their business strategies and ccapital bu equipment purchasing plans for 2011. MARLA DONAHUE: There appears to be well founded optimism in the Æexible packaging industry. Unlike many industries that experience double-digit declines during the recession, the Æexible packaging industry held its own. There was no growth in Æexible packaging in 2009. However, 2010 saw about 2.5 percent growth and 2011 growth is

JANUARY / FEBRUARY 2011

expected to be back to pre-recession levels of over 3.5 percent.

volume of new projects indicates general and continued economic growth within the industry.

MICHAEL D’ANGELO: From the

perspective of capital equipment supply, as a general statement, the macro-economy trumps the market economy. In other words, buying decisions may be delayed even if the customer’s business is currently doing well. Customers want to have a longer term reassurance before making commitments. The fact that there is optimism in the economy growing and the fear of a double-dip recession is declining gives equipment suppliers good reason to look forward to 2011, as 2010 was already a recovery year as compared to 2009. LARRY LANHAM: We have enjoyed substantial growth in 2010 and are forecasting double-digit growth in 2011. Our outlook is bullish for food packaging and stable for industrial for 2011. For our two major segments, a fairly good barometer of industry demand, this added growth enjoyed is attributed primarily to new projects as opposed to increased market share. While we view the food packaging business as being recession resistant, we feel the increased

FP: What was the biggest surprise or the most unexpected affect on business in 2010? Do you see that happening in 2011? D’ANGELO: Not that it was a surprise, nor is it meant to be a pun, but the elasticity of the Æexible packaging business is noteworthy. As an industry it continues to outperform GDP, outpacing growth in a good cycle and lagging contraction in a bad cycle. The basis of the industry in more stable sectors, such as food and beverage, gives it great strength and a Årm foundation going in to 2011 and beyond. We found the equipment buying in market in North America to be strong in 2010 and this ran contrary to popular opinion. This is likely the result of pent-up demand from those who took a wait-andsee approach in previous years, as well as those customers who became more fortable with the macro economic comfortable macro-economic onment and felt the time to invest environment was right. A lot of panies have companies cash and a lot mpanies of companies ed to take wanted ntage of advantage reat interest the great rate environment.

DONAHUE: The biggest surprise

from the association standpoint was the growth and rapid recovery of the industry from 2009. LANHAM: The biggest surprise was the

magnitude of growth. We outperformed our 2010 projections by nearly double. Moving into 2011, we expect this trend to continue. The activity level and desire for innovative new packaging appears to be back in forefront of marketing departments, driving new projects. Further, the urgency and pressure from Big Box retailers on manufacturers to reduce their carbon footprint and move to more sustainable packaging has created further demand for innovative, valued added, differentiated Æexible packaging. TEWKSBURY: I think what surprised us

the most was incredible growth exceeding our most optimistic projections. Like other companies, we saw it beginning in January and expected it was another sales spike – no different than the same ups and downs we had experienced for several quarters prior. By the second quarter we realized it me a trend, had become ird quarter, and by third eady it was already ng challenging ning, our planning, schedulingg ntory and inventory ment. management. If the Årst eks ooff three weeks

TIMOTHY B. LEWIS

JON T. MCCLURE

ROBERT TEWKSBURY

vice president of marketing and sales CMD Corporation

president and founder, ISO Poly Films, Inc.

vice president, Pearl Technologies, Inc.

years with the company/in the industry: 12 years total

years with the company/in the industry: 20 total

(888) 814-7676 www.isopoly.com

(315) 365-3742 www.pearltechinc.com

years with the company/in the industry: 17 years/24 years (920) 209-0180 www.cmd-corp.com

JANUARY / FEBRUARY 2011

FLEXIBLEPACKAGING

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Cover Feature: Executive Outlook 2011 2011 are any indicator, the answer is a resounding yes, not only is business activity going to be sustained, but there will also be strong continued growth for us worldwide. In fact, for the Årst time in a couple of years we are adding employees, restructuring our organization and implementing a new database to help us to capitalize on the crest of this wave of activity. LEWIS: The converting and packaging

equipment sector of our industry was quite volatile and some of the closings and consolidations among our own competitors and colleagues were surprising. But this scenario was mirrored in sectors throughout the U.S. economy over the past 18 – 24 months, with some areas being hit harder than others. We are optimistic that with the extension of important tax cuts and loosening of available credit, demand and orders will ramp up and the companies left standing after a very rough couple of years will reap the rewards of prudent management and innovative market solutions. MCCLURE: Resin outages. A decade ago there were ten suppliers of base raw materials of low-density and linear lowdensity polyethylene. Today, 4 suppliers control over 87 percent of those materials. One reactor goes down and it creates a ripple effect throughout the industry. With crude oil approaching $100 per barrel, the North American polyethylene producer has a cost advantage with Natural Gas hovering below $5 per million Btu.

the challenges of the marketplace. FP: What do you think will be the biggest asset in this industry for 2011? DONAHUE: Probably the overarching asset is its innovative problem-solving approach to developing packaging solutions. D’ANGELO: The creativity of the printing and converting companies in meeting their customer’s needs remains the industry’s biggest asset and serves as a challenge to the suppliers to the industry to continually innovate. There is dynamism in the Æexible packaging industry that propels it to overcome the challenges of economy, changing trends and competing developments. Virtually any change in the habits of the American public lead to the need for a response from the Æexible packaging market. For example, it wasn’t too many years ago I would travel to Europe and see stand-up pouches everywhere, while here at home, they were nearly unknown. The speed of change in this country demands that everyone involved in the marketplace have creative agility. We’re fortunate as an industry that so many do.

YERECIC: Perhaps it’s not a surprise but I was extremely impressed by the numerous advances made by the narrow web industry. This industry’s printing capabilities continue to make giant strides. Lean manufacturing techniques were also at the forefront of 2010. Increased throughput and waste reduction opportunities were found from prepress solution providers, press manufacturers and in Ånishing operations. One-hundred percent inspection continues to make headway. Successful converters and suppliers will need to continue to invest in making their processes even leaner to meet

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LANHAM:

Understanding customers’ needs and exceeding their expectations with viable Æexible packaging solutions and

alternatives to properly address the pent up demand for revitalized existing SKUs as well as answering the increased sustainability desires. LEWIS: Without a doubt, our industry’s biggest asset is its people. We are fortunate in the converting and printing industries to have a generation of experienced professionals who have worked their way up, learned and developed new technologies, and remain as passionate a group of professionals I have ever known. These same seasoned veterans are eager to train the new, fresh minds of today’s graduates – who will no doubt usher in more efÅcient, productive and sustainable processes and products to ensure the continued health of our industry. YERECIC: One of the greatest assets of the narrow web industry is the sector's ability to withstand market and economic shifts with an unwavering resilience. As run size demands continue to trend downwards and lead times minimize, the narrow web industry is uniquely positioned to exploit these opportunities. Every year TLMI conducts extensive research amongst consumer packaged goods companies; asking packaging buyers about their sourcing trends and forecasted application migrations. One important trend our research has uncovered is how some end-use

ART YERECIC

MICHAEL D’ANGELO

president & owner, Yerecic Label, chairman of the board of directors, TLMI

vice president – business unit web fed, Bobst Group North America

years with the company/in the industry: 35 years total (800) 245-2700 www.yereciclabel.com

years with the company/in the industry: 28 years/12 years (888) 226-8800 www.bobstgroup.com

JANUARY / FEBRUARY 2011

products will migrate from a particular packaging methodology to another. Over the past decade, a common label decoration migration has been away from cut-andstack, or glue-applied, labels to pressure sensitive labels. Our research is indicating that certain end-use product sectors are

going to leapfrog pressure sensitive and go directly from glue-applied to shrink-sleeve applications. This is an ideal scenario for TLMI members, taking market share away from the offset-dominated glue applied market and carving out a niche in converting shrink sleeve applications on their narrow web presses.

TEWKSBURY: Overall, it is the ability to adapt to changing market demands, respond quickly to customers’ urgent needs and produce quality products. I believe the biggest asset is and always has been about customer service. You have to give your customers an experience that stands out among their experiences. If you think

2011 Predictions FP’s sister publication Packaging Strategies has made a few predictions for 2011. Which ones do you think will hit and which ones will miss? • Acquisition activity will accelerate with one or more of the major converting companies, accounting for at least two significant industry acquisitions in 2011. • PET film supply will tighten, leading converters to rapidly find replacement films focused on nylon and polyolefins. Metalized PET films in particular will be targeted. • Liquid flexible packaging will continue to expand with the installation of a high-speed pouch line for beverages. • A national brand will launch an “environmentally friendly” flexible package incorporating 50 percent post-consumer content. • A large European or Asian based flexible packaging company will announce a major new greenfield operation in the US. • Aseptic flexible packaging will continue to expand with a major CPG company introducing a product with a fitmented pouch. Excerpted from 2011 Packaging Outlook, offering predictions and forecasts fom top consultants and packaging organizations. Packaging Outlook is available for sale from Packaging Strategies by contacting [email protected].

JANUARY / FEBRUARY 2011

The Future Of Flexo Esko CDI with inline UV main exposure offers impressive benefits! The future of flexo can be seen today with inline UV exposure technology from EskoArtwork. Digital flexo plates can now receive the UV main exposure within the same device where they are imaged, instead of an offline light frame. Combining these steps in the same unit improves quality and consistency, and reduces operating costs and customers’ environmental impact. Get the future of flexo today, from A&V. Watch and learn about HD Flexo and the new inline UV main exposure at andvre.com/inline_uv.html

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Cover Feature: Executive Outlook 2011 about it business has become less personal, as we went from phones to faxes to emails, it's still all about people and relationships. It's about truly caring for your customer's needs and wants while building a solid relationship; it's not always about the sale. MCCLURE:The North American Market

will continue to grow. FP: There is a lot of talk about the cost

MARLA DONAHUE president, Flexible Packaging Association years with the company/in the industry: 10 years/25 years (410) 694-0800 www.flexpack.org

of materials going up. Are you concerned with these changes in price, and if so, how do you plan to accommodate it? LEWIS: Material prices are a big issue with

our customers, and looking for ways to run thinner, lighter Ålms with unique strength properties is one solution. Running the Ålm on equipment that reliably produces the product at high speeds with very little waste is another. Getting the most out of the resin you run by having a scientiÅc approach to your operating efÅciency is also imperative. We continue to develop technology for

superior sealing quality. MCCLURE: I am not real sure which planet Federal Reserve Ben Bernanke lives on but he was concerned with deÆation last year and instituted Quantitative Easing (QE) to spur inÆation. InÆation on things we consume like food, energy, and basic raw materials have been increasing during the recession. Thus, I see inÆation across the board in every commodity. TEWKSBURY: Rising costs are a reality of running a business in the 21st Century. Therefore, we are always very cognizant of rising material costs and the challenges posed by them. It would be easy to simply pass along increases to our customers, but that only makes us a part of the problem. We need to view it as an opportunity to become part of the solution. We are never satisÅed with status quo, so we're always looking at ways to reduce our costs by improving purchasing practices and manufacturing efÅciencies. When

Melody makes miracles. Sometimes idlers wear out. Sometimes they just get damaged by accident. Whenever you need a replacement idler — and you need it fast — that’s the time to call Melody. As a customer support specialist, Melody Schuelke can deliver Webex idlers with miraculous speed. Thanks to the WebExpress™ emergency roll service, she can ship your precision idlers in as little as 48 hours — guaranteed! Need idlers fast? Call Webex. Get more than just a roll. Get the fastest roll service in town.

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JANUARY / FEBRUARY 2011

we become part of the solution, and our customers become aware that we are trying to maintain costs, it further cements the bond of loyalty and partnership. YERECIC Commodity material cost increases are a reality across the globe. This is a problem that isn’t going away soon. Converters and their suppliers must creatively work together to take out costs in every possible way. Anything that doesn’t add value is waste and must be eliminated or minimized. In the end consumers must bear all costs but it’s our responsibility to make sure we’re not passing on increases that could be eliminated by running our businesses more efÅciently. D’ANGELO: There is inevitability to the cost of materials going up, certainly over the long term with sharper Æuctuations up and down short term, but mainly up. As a press supplier, we have worked diligently and in partnership with printers and converters to assure that materials can be

saved throughout each step of the on press and off press operations, particularly in the startup phase of these processes. These will go far in helping customers level out the impact the inexorable upward march of raw material costs has on them. Such developments can have a huge impact on the bottom line but the fact of the matter is that most material goes out the door in the form of converted Ånished product and that has implications for the packaging buyer and the end user. Presses are becoming more and more efÅcient. The race is on…

LARRY L. LANHAM

LANHAM: Raw material increases are

always a major concern and will be in 2011. While most companies look inwardly and strive to defer the impact of a price increase to the customer, we focus Årst on what the impact of an increase will have on our customer. It begins with excellent communication, understanding and forecasting. While we cannot control global supply and demand, the price of feed stocks, shortages, outages and the plethora

president & CEO Polymer Packaging, Inc. years with the company/in the industry: 25 years/32 years (800) 260-1446 www.polymerpkg.com

Innovative, cost-saving converting machinery optimized for flexible packaging More efficiency, less downtime, less waste Catbridge can help you become more efficient and competitive. We build durable, innovative slitter rewinders that provide immediate cost savings and quality gains. Our unique technology and smart designs significantly increase run time while improving roll quality and minimizing waste. We’ve optimized our machinery for flexible packaging and tailor our equipment to your exact needs. To learn more, visit www.catbridge.com or call us at 973-808-0029.

Standard or custom — we build solutions: slitter rewinders • knife systems • unwinds • perforators • coaters & laminators Catbridge Machinery • 222 New Road, Parsippany, NJ 07054 USA • Tel 973 808-0029 • www.catbridge.com

JANUARY / FEBRUARY 2011

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Cover Feature: Executive Outlook 2011 of components impacting the stability of price, we can communicate, document and help our customers plan for these uncontrollable events. Studying the impact of price increases during ‘peace time’ helps to reduce the anxiety of the dreaded inevitable price increase. FP: What do you think will be the biggest

concern in 2011? LANHAM: Raw material price increases. MCCLURE: InÆation as well as crude oil and energy going crazy.

continue to protect it. YERECIC: Companies that haven’t

invested in new technology or adopted leaner processes during the recent recession and early recovery will struggle to successfully compete. Consolidation of the industry will increase as the economy improves. I believe this is a concern for companies of all sizes but especially for smaller converters and suppliers. Matching up against larger competitors that bring a broader array of solutions to the market will continue to be a challenge. Developing strategic alliances will be critical to the success of smaller companies.

LEWIS: Recruiting bright young

talent to keep our industry invigorated, technologically savvy and moving ahead of the curve.

DONAHUE: The greatest challenge

and concern for 2011 is sustaining the economic recovery.

TEWKSBURY: Maintaining a high level of customer service. We like to think that Pearl has spent a quarter century building its reputation; therefore, we will

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D’ANGELO: A push from the Executive

Branch for increased government regulation, particularly as it relates to recyclability, landÅll and mandates regarding packaging media. This push will potentially be contrary to the desires of the new Congress. The response from competing packaging media will play a role in how this concern turns out as well. I feel there is a looming renewal of the Åght among various forms of packaging for the hearts and minds of the consumer and the food, beverage and consumer product companies. I imagine the lobbying will be intense as the intentions of the Administration relative to regulation become better deÅned. Part and parcel with this is whether the Administration takes a run at Cap and Trade in this legislative year. I sincerely hope not. FP

Web Exclusive Go to www.flexpackmag.com to read the additional responses to questions, including thoughts on sustainability, industry demand, the influence of legislation, and more.

JANUARY / FEBRUARY 2011

Printing: Digital Printing

CHECKPOINT LABEL CONVERTING DIGITIZED Three drop-on-demand ink jet printers provide six-web-wide coverage at an output of 420 labels per minute. heckpoint Systems purchased three Domino K200 piezo ink jet printers to enhance its innovative all-in-one solutions that enable their clients to track and trace their complete logistics chain from production to end user. With its drop-on-demand technology, the K200 is capable of providing fast and accurate 300 dpi print at 90 meters per minute. For Checkpoint, it is an ideal solution for their clients’ variable data demands. Checkpoint Årst encountered Domino at a trade show, and when it was time to equip their existing Gallus 160 labeling machine with a system that could print variable data, logos and text simultaneously, Domino stood out from the crowd. “For us it was crucial to Ånd a supplier that can offer us a complete solution for high-speed digital coding in a variety of formats onto various substrates,” explains Udo Falter, project manager at Checkpoint. “Domino proved very responsive, reacting to our enquiry promptly and organizing a trial installation

C

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The K200 is capable of providing fast and accurate 300 dpi printing at 420 labels per minute.

JANUARY / FEBRUARY 2011

of the K200 at short notice. The trial provided all the proof we needed of the K200’s great Æexibility and the advantages of variable data printing capabilities. “In addition, we really appreciated the teamwork with Domino’s project managers, the ease with which the K200 could be integrated with existing equipment and the software solutions provided with the package – all factors in our decision to choose Domino.”

The three Domino K200 printers have been installed across the web of the Gallus label press and electronically stitched to achieve seamless image composition.

The three Domino K200 printers have been installed across the web of the Gallus label press and electronically stitched to achieve seamless image composition using UVcurable inks. In the current set-up, a maximum of six label webs are imprinted simultaneously. At a full web width a line speed of up to 80 meters per minute is achieved, which corresponds to 420 labels per second. Checkpoint also uses an Editor GT AV-Station which enables them to control data, conÅgurations and print layouts from the ofÅce. It also makes it possible to prepare and queue print jobs even if another job is currently being carried out. “We can produce small orders more effectively thanks to the K200 ink jet printers, as no plate costs arise and setup times are reduced to a minimum,” explains Hans-Peter Horn, department manager of Labels Production at Checkpoint. “Furthermore, the Domino K-Series allows sequential numbering of labels – something that simply isn’t possible with any conventional printing method involving plates.” FP Domino Printing Sciences (847) 244-2501; www.domino-printing.com Gallus Inc. (215) 677-9600; www.gallus-group.com

JANUARY / FEBRUARY 2011

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31

Products & Equipment

CONVERTING SUCCESS THROUGH TECHNOLOGY UPGRADES Short Runs, Rapid Turnarounds and Attention Compelling Graphics

old investments aimed at improving quality and supporting extraordinary service have allowed New Wave Converting Inc. to thrive in what for some is a difficult business environment. The installation of a new flexo press and a move toward printing with solvent-based inks has put distance between New Wave Converting and the competition. In business for more than 30 years, New Wave Converting is family owned and operates from two manufacturing facilities in Fontana, Calif. The company has carefully built a culture around effective customer service supported by short run capability and fast turnarounds. To facilitate a high quality level of service, the company invests in advanced performance technology and maintains a large inventory of materials. According to New Wave marketing and social media manager Jill Hanmer, after receiving an order, work usually begins in 24 hours or less. “Customer service drives every aspect of operation,” she says. “To respond quickly we keep a large inventory of materials.” New Wave is a complete converter; a single source for top quality flexographic printing in 200 lpi process and 4 and 6 color process in both 8 color and 10 color, up to 52 inches wide. The company offers up to 3- and 4-layer laminating, including crystal clear packaging, foil and metalized film, both solvent and solventless, and in-house produced stand-up pouches with or without zippers. Typical products include printed and laminated flexible packaging for the snack and food industries and a growing list of packaging for salads. Capabilities include matte finish and an array of coatings for a wide variety

In business for more than 30 years, New Wave Converting is family owned and operates from two manufacturing facilities in Fontana, Calif.

B

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of barriers, heat seals and fog and atmospheric control. New Wave controls the entire process from plate to finished pouch or roll stock.

New machines for new offerings In the 1990s, New Wave purchased a 6 color Schiavi central impression flexo press from the Bobst Group. Satisfied with their first experience, New Wave turned again to Bobst, ordering an 8 color, 52 inch wide Schiavi CI flexo press when additional production muscle was needed. Installation was completed earlier this year.

We are committed to sustainability and did not shrink from air quality requirements.

“Our entire production team was impressed with the durability and performance of the Schiavi press and the extraordinarily smooth startup and post installation support provided by Bobst,” Hanmer says. “Compared to what we have experienced with other vendors this level of service and support was exceptional.

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“If anything, the latest installation went even smoother than the first,” adds Hanmer. “There were no growing pains and it was as close to plug-andplay as you can get. After startup, in the few times we needed support, Bobst experts were available 24/7. We always had the right person on the phone in under an hour.” In addition to the flexo presses New Wave equipment includes three slitters, including a Bobst Titan SR-6; a Nordmeccanica solventless laminator and a Flint plate making machine. It also includes a Ship and Shore thermal oxidizer recovery unit. The last unit was needed after New Wave moved to solvent based ink a few years ago.

Quality standards met with solvent-based inks The move to solvent-based inks, supplied by Flint, required a substantial investment. However the improvement in the quality of printed images and enhanced production efficiency is more than justifying the investment.

JANUARY / FEBRUARY 2011

Seeing Seeing Savings Savings from your your Tension Tension Equipment? You should be. For defect-free converting install DFE web tension solutions. WebHandler™3 Tension Controller PM Digital closed-loop tension control in an affordable, compact package. Now available in a Panel Mount option for easy installation into your control panel. The WebHandler 3 brings your web process automatic, full-featured control with a simple and stylish touchpanel interface.

! Large 2-line, back-lit LCD display ! Multiple setup storage and recall settings ! Easy push-button setup and calibration from front panel or via PC ! Auto/Manual control modes and E-Stop

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Tension Roll® and Narrow Web Tension Transducers

TwinAmp™ Rack Mount Dual Tension Amplifier ™

Each of these durably constructed tension transducers combines an idler roll and two tension sensors in one unit—for fast, easy installation and high accuracy. No assembly required. Now available in 3 roll diameters, and widths to accommodate webs from 6” wide on up. Choose from several mounting options. ! Narrow web transducers for cantilevered installation on single-frame machines. ! Tension Roll transducers install easily between the sides of a standard machine frame. ! Load ratings from 12 lbs and up, with a wide 50:1 operating range

The TwinAmp Tension Amplifier is a rack-mount transducer interface for monitoring tension in any two tensionsensing zones simultaneously. Two independent, isolated amplifier circuits are included on one card saving you space and money. Each amplifier includes an additional signal output for a tension meter. From transducers in the web path, take both 0-to-10V tension output signals to a PLC, drives or control devices. ! Two separate 0-10VDC isolated tension outputs. ! Quik-Cal™ push-button zero and calibration. ! Choice of 24 Vdc, 115 Vac or 230 Vac power inputs. DFE delivers the most reliable tension control equipment in the industry….. and the fastest turnaround.

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the tension control specialists

Products & Equipment

“Use of solvent-based inks distinguishes our graphics from our competitors’ graphics. Our graphics are noticeably more vivid and give our customers’ products a more compelling presence on the store shelf.” Hanmer says.

What made the change to solvents an especially bold move was the amount of investment required to comply completely with California’s stringent air quality laws, the most demanding in the nation. Key to that compliance was installation of the Ship and Shore thermal oxidizer recovery unit for air quality. “We are committed to sustainability and did not shrink from California’s

demanding air quality requirements. We worked to meet and exceed what was required for compliance and our owners took responsibility for the considerable investment that required,” says Hanmer. With the new press installed, the changeover to solvent based ink complete and a substantial inventory of materials on hand, in house, New Wave Converting is positioned to continue providing their customers with service that exceeds expectations. FP

New Wave Converting's graphics are noticeably more vivid and give our customers’ products a more compelling presence on the storeshelf, according to Hanmer.

Automatic high speed pouch making machines.

Automatic machines for vacuum thermoshrinking sacks.

Automatic machines for bags on roll.

New Wave Converting, Inc. (909) 356-0171; http://nwconverting.com/ Bobst Group (973) 226-8000; www.bobst.com Nordmeccanica +39 0523 596411; www.nordmeccanica.com Flint (800)795-2273; www.flintgrp.com/ Ship and Shore (562) 997-0233; www.shipandshore.com

Universal machines for bags and sacks.

Extruded net plants.

Automatic machines to produce bags with glued patch handle reinforcement.

Automatic machines for T-Shirt bags.

Elba, located in Magnago (MI) Italy, designs and manufactures machines for the production of pouches, bags and sacks. Each machine can be customized according to different production

e in

s

h ac m world more than 2000 machines. To Elba group belong Fiborsin who g kin manufactures extruder plants for plastic nets. a m bag d n a Elba spa - Via Canova, 22 pouch 20020 Magnago (MI) - Italy High speed automatic Tel. +39 0331.305570 - Fax +39 0331.305580 needs to always offer a tailor made solution. Since 1964 Elba installed all over the

E-Mail: [email protected] - www.elba-spa.it

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JANUARY / FEBRUARY 2011

The ECKART effect – added value for brilliant results. PLATINSTAR® Silver, a new solvent-based silver metallic ink for gravure & flexo printing that provides mirror-like effects at greatly reduced costs. This brand new technology gives designs that special touch and makes them real eye-catchers, guaranteeing the most emotional reactions. PLATINSTAR® Silver is especially designed to expand the possibilities of brilliant metallics in applications that were previously off limits. ECKART is the world’s leading manufacturer of metallic pigments for the graphic arts industry. Innovation, research and the constant further development of our products ensure that we remain so! ECKART – take the brilliant way. For further information, please contact: ECKART America Corporation · 830 East Erie Street · Painesville, Ohio 44077 USA Tel: 440-954-7600 · Fax: 440-354-6224 · [email protected] · www.eckart.net

Technology: Web 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, flexible packaging manufacturers can prevent poor quality in finished roll material. By Mark Breen and Glyn Green, Contributing Writers or the Æexible package printer and/or converter who works with extensible Ålms and materials, the Åght to prevent defect-rendering process deviations never ends. The key to reliable defect prevention is the production staff ’s ability to measure and make web machine or press adjustments that eliminate unwelcome deviations, including tension transients. While many Ålm processors are challenged to overcome issues of excess tension, some suffer from slack web conditions. Given the opportunity to diagnose a web process problem, a knowledgeable application engineer at a reputable tension equipment manufacturer can offer solutions to the machinery deviations that lead to deformed or Æawed output.

F

Tension related web problems Loss of color-to-color registration while running at speed, splicing or changing speed, inconsistent repeat length, and slack web that can cause web breaks and wrap-ups around driven rolls are perhaps the most obvious consequences of inadequate tension control on a web press. Others include deformation of web due to stretching or wrinkling; variation of coating thickness; unwind or rewind core crushing; reduction of machine speed to accommodate web handling problems or any of the problems above; hard rolls; soft rolls; telescoping rolls; excessive waste of web material; and the inability to run a wide range of web thicknesses, widths and materials.

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FLEXIBLEPACKAGING

To identify tension measurement or control requirements, the machine can be divided into three tension zones: the unwind zone, intermediate tension zones, and the rewind zone.

Many of these problems are simply accepted as normal and are not attributed to inadequate control of web tension. However, printers and converters experiencing such trouble can improve efÅciency and proÅts by employing better tension control methods. By reducing web scrap and allowing a web press to run at higher speeds with defect-minimized output, a reliable web tension control system will not only improve a press' bottom line performance, but also be an economical solution.

Selecting a web tension control system The determining factors for the level of sophistication necessary for a tension control system on a particular press include: 1) the material nature of the substrate; 2) the level of print quality required of the jobs being run on the press; 3) the

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magnitude of tension transients introduced into the system by the combination of all process variables; and 4) the speed at which the press should be run. When characterizing a process to identify tension measurement or control requirements, the machine can be divided into three tension zones: the unwind zone (one or more), intermediate tension zones (typically multiple), and the rewind zone (possibly one or more). A tension zone is a length of machine in which the web is under the same tension. This occurs between driven rollers, between the unwind stand and the Årst driven roll or nip and between the last driven roll and the rewind stand. To properly control the tension in any of the zones, it must be measured, or approximated, by some means. There are three predominant tension measurement technologies in use today:

JANUARY / FEBRUARY 2011

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Technology: Web Guiding & Tension

Wider-style narrow web printing presses are becoming a popular option.

diameter measurement is less accurate than either of the following technologies. Other open-loop tension control systems, such as roll followers and draw controls, work well in printing/converting applications with forgiving substrates, but they cannot measure the actual tension on a moving web and compensate directly for any deviation from a preset value. Nor can they compensate for speed for speed changes, brake fade, temperature and humidity variations, or nonuniformities in the web, all factors that can affect web tension. roll diameter measurement by optical or ultrasonic sensor; dancer system; and tension transducers, or load cells.

Roll diameter measurement Roll diameter measurement by optical or ultrasonic sensor measure the change in distance from the Åxed sensor head to the roll as it is either building up or winding down. As such, they are not used for intermediate zone applications. Sensor output, usually a 0-to-10 VDC signal, varies as the roll diameter changes at the unwind or rewind station. The sensor output goes to a tensioning device, such as a drive, to trim the line speed. This technology may be suitable for non-critical winding applications, but the inferred tension measurement from

dancers are expensive to design, build and install. They are difÅcult to properly engineer, and are prone to errors caused by mass, damping and friction. And they cannot measure tension directly, nor read out tension or compensate for small but signiÅcant tension transients in the process.

Tension transducers or load cells Tension transducers, or load cells, are the most accurate direct tension-sensing technology available. Using strain-gage based sensors, tension transducers directly measure the force applied by the web on a selected idler roll. The sensors are calibrated

Dancer system option In a dancer system, a controller signals the dancer roll, or dancer arm, to move vertically or horizontally back to a start position in response to a signiÅcant change in position. The initial positional change is almost directly proportional to the variation in web tension. A dancer system allows some forgiveness for web slack by creating web storage in its zone of operation. In an unwind zone, a dancer system supplying web accumulation as needed may help to compensate for out-of-round rolls. But dancers have certain drawbacks. Compared to tension transducer systems, Proper calibration tools can help alleviate tension control headaches, some of which are shown here.

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FLEXIBLEPACKAGING

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against an electronic readout using a known weight over the tension roll in the web path. The transducers are typically used in pairs, with one installed on each end of an ordinary idler roll shaft. Or, on some models, the tension sensors are built into the roller mechanism of a dead-shaft idler roll. The strain gauges detect beam deÆection (of even a few hundred microns) under load and convert the mechanical deÆection into a voltage that is proportional to web tension and highly accurate (~ 1 percent). A transducer pair’s 0-to-500 mV tension output signal is typically ampliÅed to 0-to10 V and displayed on a meter readout. The only way to achieve accurate web tension measurement and control is to use tension transducers combined with automatic tension control electronics in a closed loop system.

customized regional promotions for popular products at the retail level, today's marketing differentiation fever has forced increased demand for shorter print runs, faster time to market, brighter colors, and more new and exciting packaging options in general.

The industry has responded with faster turnarounds, greater process versatility, increasing sub-process capabilities, the ability to print on a wider variety of substrates, and more economical methods of completing short print runs. FP

Slit Roll Protection

Trends in tension control There are a few signiÅcant trends in the Æexible packaging industry that are shaping product developments coming from the tension controls manufacturers. One is derived from the saturated level of business competition in many consumer packaged goods categories. Manifesting itself in the proliferation of brands and

It’s like having a security force protecting your roll products 24/7.

ABOUT THE AUTHORS Mark Breen is the marketing manager, and Glyn Green is the technical support manager and outside sales manager at Dover Flexo Electronics. Dover manufactures components and systems for the measurement and control of process tension in converting and web printing applications.

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Read more on Closed-loop tension transducer systems and other advancing trends in the extended version of this technical article at www.flexpackmag.com/Articles/ Along_The_Supply_Chain

JANUARY / FEBRUARY 2011

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39

Roundtable: Special Advertising Section

ROUNDTABLE ON EXTRUSION Steve DeSpain

Nick Nigro

David Nunes

Executive Vice President Reifenhauser Inc.

Sales Product Manager – Extrusion North America Windmoeller & Hoelscher Corp. 3 years with the company/ 34 years in the industry

President Alpine American Inc.

6 years with the company/ 29 years in the industry (978)412-9700 www.reifenhauser.com

The economic climate has changed the way many do business. What kinds of changes are film extruders seeing? How has that altered the industry overall?

are all in the same situation and that’s regardless of size. And with the recent industry consolidations (Berry/Pliant & Bemis/Alcan), there is additional proÅt strain for every competing entity. Automation and line features that tightly control the process, quicken changeovers, and provide repeatability is the answer. Do it right the Årst time with a minimal amount of waste!

DeSpain: Film extruders are seeing more

Nunes: Margins are razor thin and there

By Erin J. Wolford, Editor-in-Chief

Q:

and more pressure from their customers to lower prices, improve deliveries and maintain quality. This has led to technical innovations such as enhanced cooling devices for increased outputs and the replacement of old outdated nonefÅcient equipment. Nigro: Controlling costs is a constant

priority. As all processors are aware, resin accounts for approximately 80 percent of a product's cost. Along with operations, infrastructure and insurance, it’s a constant battle to stay proÅtable and supply a quality product. This puts the onus on the processors to be as efÅcient as possible. Their competitors 40

(401) 333-2770 www.whcorp.com

FLEXIBLEPACKAGING

24 years with the company/ 27 years in the industry (508) 655-1123 www.halpine.com

is no room for error, and pressure for quick deliveries remains high. Newly developed materials require ultimate Æexibility from Ålm extruders. End-users no longer tolerate any inefÅciencies in the blown Ålm process. Film producers need to operate at higher throughputs than ever before, with impeccable quality, zero tolerance for waste or downtime, and with maximum Æexibility. High Cost barrier materials need to be processed with exacting distribution to allow for thinner layers.

| www.flexpackmag.com

"Windmoeller & Hoelscher recognizes challenges and needs in the market and develops line features to meet them," says Nick Nigro.

PHOTO COURTESY OF: MESSE DÜSSELDORF

JANUARY / FEBRUARY 2011

Q:

What kinds of developments/ changes is your company making to provide the best service to its customers?

Alpine American's Dave Nunes says, "Newly developed materials require ultimate flexibility from film extruders. End-users no longer tolerate any inefficiencies in the blown film process."

Q:

What new development(s) have come about in the film extrusion arena? How have those changes impacted the extruding business? DeSpain: The advent of increased rates

while improving quality is probably the biggest change in the market in the past few years. Processors are aware that their competitors have been adding and/or upgrading their extrusion equipment and they must do so as well in order to stay competitive, things like auto proÅle control are no longer an option but a necessity.

Nigro: The business climate and demands

have also forced processors to retroÅt or replace older obsolete equipment with newer equipment that include improved processes through automation, in a continuous effort to achieve high output with reliability and repeatability. Air ring and IBC improvements, format change capabilities, storage of recipes for quick transition and purging, and constant monitoring of all line conditions, along with deliberate energy efÅciency guarantee consistent Ålm production. Nunes: Film producers need to operate at

higher throughputs than ever before, with impeccable quality, zero tolerance for waste or downtime, and with maximum Æexibility. High cost barrier materials need to be processed with exacting distribution to allow for thinner layers.

DeSpain: Here at Reifenhauser, Inc., we have added staff to support our North American customers in both our service and spare parts groups. In addition Reifenhäuser GmbH has expanded our RQS (Reifenhäuser Quality Service) group to offer a worldwide 24/7 support system to help customers diagnose problems either over the phone or web. RQS is a competent service partner with worldwide customer support. With 12 locations, we are always close to you when you need us. Our hotlines and order service for spare parts can be reached around the clock, 365 days per year. Nigro: W&H recognizes challenges and

needs in the market and develops line features to meet them. Along with different automation features, W&H also focuses on its service and technical assistance. To hold on to a competitive advantage, your partnerships are as important as your equipment modiÅcations and improvements, and service plays a big role in the quality of a partnership. Because of our worldwide presence, W&H has a 24/7/365 hotline where you get a trained extrusion expert who can answer your questions and possible solve your issue over the phone using remote diagnostics. This kind of service is paramount to any company running 24 hour operations and is supported by a $7 million inventory of spare parts in Rhode Island, which usually enable delivery within 24 hours. Nunes: Additionally online

"Film extruders are seeing more and more pressure from their customers to lower prices, improve deliveries and maintain quality," accoding to Reifenhauser's Steve DeSpain.

JANUARY / FEBRUARY 2011

troubleshooting capabilities for both process and equipment issues without having to waste time and money on travel further increases customers’ uptime and production. Alpine’s job is to increase our customers proÅtability and we continue to improve our service and support systems to do just that. FP

FLEXIBLEPACKAGING

| www.flexpackmag.com

41

Industry Q&A: Slitting/Rewinding

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.

Michael Pappas Catbridge Machinery

By Erin J. Wolford, Editor-in-Chief

Q:

How would you characterize this market?

A:

In a word, dynamic, across a number of levels. First, no industry we serve has faster changing, more consumer-driven products than Æexible packaging. Almost monthly innovations in packaging materials and processes dictate new and better materials from converters. The challenges trickle down quickly to machine builders. More precise, more efÅcient and faster labor saving machinery is required. Also, growth overall, combined with little consolidation in recent years, have companies scrambling to update machinery and processes. This presents demands and challenges for machine builders. The focus must be on not just today’s products and features, but in anticipation of tomorrow’s as well.

Third, by the time a roll reaches the unwind of a slitter, a great deal of value has been added/invested. Slitting and rewinding must be to the highest standards to minimize waste of this value and assure that the quality accomplished in coating/ laminating and printing is realized.

Q:

What kinds of trends/ technologies is the slitting/ rewinding sector seeing?

A:

In the last few years there is a clear trend toward focus on two areas: First, reducing downtime between sets. We have done studies for our customers, and regularly assist them in collecting data to tell us both what percentage of a shift their slitters are actually running, versus the percentage they are down between sets (for roll changes, set-up changes, core placement, etc.). The average we have found is in the 25 percent to 35 percent range. This must be improved. Also, as slitter speeds and uptimes increase, more rolls are coming off and the problem becomes what to do with them. They must be removed from the slitter quickly but also in a way that facilitates ease of packing and minimizes operator time and fatigue. These are challenging areas.

Q:

What’s new and exciting at Catbridge?

A:

Q:

Why is slitting/rewinding such an important part of the converting process?

A:

For numerous reasons. First, it is the last opportunity for quality control. Web inspection and removal of bad material at the rewinder assure returns are kept to a minimum. Second, well wound rolls, with excellent edge quality and consistent build throughout, will run well physically on the customers machines and present an image of care and quality to the customer. Badly wound rolls will have the opposite effect. Visit flexpackmag.com/Articles/Slitting_Rewinding

We are presently working on reÅning a new model slitter, one that we expect will revolutionize slitting departments. This model, already in use on Ålms, can outproduce conventional slitters nearly 3 to 1. This helps companies in need of Æoor space get dramatically more through their slitting departments in the same, or even less area. Ease of operation in the form of quick set-ups between and during jobs greatly increases productivity and reduces operator fatigue. Simplicity of core loading and Ånished roll discharge also reduces cycle time and presents Ånished rolls in a way as to be more rapidly oriented to a wide variety of downstream labeling and packaging steps. Pricing will be no more than other conventional winders on the market today making it a great value to companies small to large. FP Catbridge Machinery (973) 808-0029; www.catbridge.com

to read 5 more Q&As with Catbridge’s president.

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FLEXIBLEPACKAGING

| www.flexpackmag.com

JANUARY / FEBRUARY 2011

Circle 106 or visit www.freeproductinfo.net/pff

Industry Insight

CONVERTING DRIVES FLEXIBLE PACKAGING OUTCOMES By Susan Stansbury, Contributing columnist hether you think of converting as the basics of slitting and winding, or the complex layering that can occur when laminating disparate substrates, there are always new developments that impact the latest in flexible packaging. New avenues are appearing often. More exacting converting capabilities are introduced, which translates into flexible packaging also moving to new levels. When converting efficiency and automation happen, flexible packages can more economically sound. If new developments in converting are realized, flexible packages can soar with a new look or offer better protection and convenience.

In the broadest sense, flexible packaging and converting are parts of the important evidence that manufacturing is alive and well in the U.S.

W

Consider the non-traditional converting concepts.

Converting encompasses transforming jumbo rolls of substrates by processes such as slitting, sheeting, flexographic printing, coating, laminating and ultimately, moving toward production of a product or package. On the other side, any film or substrate that is made into a bag, pouch or wrap for the purposes of protecting or carrying a product is flexible packaging. Looking at the nation's top converting corridor stretching from the Green Bay, Wisc., area to metro Chicago, it's apparent that converters are holding their own during the

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FLEXIBLEPACKAGING

rough economic patch the nation hit. The major converting centers in Wisconsin including Green Bay, Appleton and Oshkosh are reportedly 6.9 to 7.2 percent. This is a very impressive number when, since national unemployment has hovered around 9.4 to 9.9 percent in the past 20 months, according to the Bureau of Labor Statistics.

Onward and Upward We must continue to consider non-traditional converting. As an industry, we must also be mindful of and try to develop converting and packaging that are not fully developed or have shortcomings. In the broadest sense, flexible packaging and converting are parts of the important evidence that manufacturing is alive and well in the U.S. Innovation and high-tech efficiency are key reasons this industry remains to be a highly competitive. While quality has been a "given" since the '80s, it has also come roaring back as a reason to buy American. Added to the reasons to source nationally or regionally to cut back on transport costs, it means North American converters have the opportunity to push their advantages. With a goal to tell the industry's converting stories more fully in the flexible packaging arena, Converting Influence is a great resource for Flexible Packaging magazine and its

| www.flexpackmag.com

readers. The group’s Converters Expo will be held on March 3 this year at Lambeau Atrium in Green Bay, Wisc. This event includes participation by leading converters, suppliers and Flexible Packaging magazine. Continue the conversation with your colleagues and take advantage of any networking opportunity. FP

About the columnist: Susan Stansbury is the director of Converting Influence, a group of converters and suppliers of flexible packaging materials. www.ConvertingInfluence.com Contact Susan directly via email at Susan@ConvertingInfluence.com

Converters Expo Mar. 3, 2011 www.convertersexpo.com (920) 265-6407

JANUARY / FEBRUARY 2011

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Display latest equipment and solutions from the integrated sectors of plastic, printing, & packaging Showcase advanced pharmaceutical packaging technologies for the local industry Network with the top industry professionals to form business alliances Gain additional benefit from the concurrent 8th International Food & Technology Exhibition – IFTECH Pakistan

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Supplier News

CAST & CURE COATINGS SUPPORT DECORATIVE PRINTING

H.B. FULLER NEW HIRE TO EXPAND FLEXIBLE PACKAGING TEAM .B. Fuller Company continues to demonstrate its commitment to the flexible packaging industry with the addition of Michael Olejnik as business development manager. Olejnik brings more than 25 years of flexible packaging knowledge and experience to H.B. Fuller. Olejnik held positions in sales and marketing management at Exopack Canada and Genpak. He also worked for Mobil Chemical and BIAX International, where he developed strategic laminations instrumental in developing business for key packaging customers. Olejnik will work with flexible packaging converters in North America to improve their products and processes with H.B. Fuller’s line of high performing adhesives. H.B. Fuller’s wide range of water-based, solvent and solventless lamination adhesives offer key characteristics that have been designed to meet the performance requirements of flexible packaging converters and end users.

H

Cast & Cure, a coating process, combines casting and curing for a holographic finish, shown here.

he Flint Group launches Cast & Cure coatings to support the Cast & Cure decorative process. Designed by Breit Technologies, Cast & Cure is a decorative coating process that integrates “casting” and “curing” techniques to create holographic, ultra high gloss or matte finishes on a variety of substrates. Flint’s three new coatings, the Standard C&C Coating, Low Odor C&C Coating and UV Offset C&C Coating, have been optimized for cure and other functional properties and have been specifically designed to not plug the micro etchings of the film.

T

H.B. Fuller Company Flint Group (734) 781-4600; www.flintgrp.com

DANAFILMS ACQUIRED BY MAJOR EUROPEAN FILM MANUFACTURER RKW KW SE recently announced its acquisition of Danafilms, Inc., a USA-based film producer. This expansion provides RKW and Danafilms the ability to better serve the North American market for plastic films. Danafilms’ president, Sherman Olson, and the management team will remain with the company in their current roles. Danafilms was founded in 1970 in Westborough, Mass., by Sherman Olson and has steadily built a strong reputation for innovation and customer service. The company has continually expanded its manufacturing capacity in Westborough and in a Franklin, Ky., facility built in 2000. Danafilms recently completed a substantial addition to the Franklin plant.

R

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FLEXIBLEPACKAGING

| www.flexpackmag.com

(888) HBFULLER; www.HBFuller.com

Danafilms products include lamination, label, lidding and barrier films. Its principal customers are in the converting segment of the plastics industry, serving the food and beverage, pet food, landscape/gardening and industrial sectors. They also provide custom film for specialized industrial applications. Danafilms is ISO certified and produces both mono- and up to 7-layer co-extruded films. RKW Group is one of Europe’s leading manufacturers of high-quality polyethylene and polypropylene films, nonwovens and nets. Following a careful strategy of growth, RKW has quadrupled in size over the past 12 years, to include 19 facilities throughout Europe, Egypt and Vietnam. The Group operates in five major global business areas: industrial films, industrial packaging, consumer packaging, agricultural films and nets as well as hygiene and medical films. RKW Group +49-6233-8709-136; www.rkw-group.com/ Danafilms (800) 634-8289; www.danafilms.com

JANUARY / FEBRUARY 2011

OEC RELEASES NEW TECHNOLOGIES EC Graphics introduces two new technologies to the North American Market, High Definition In-the-Round (HD-ITR) and Flat Top Dot. HD-ITR combines the company’s seamless photopolymer sleeve technology, Seamex, with high definition flexo imaging and screening technologies. The result is HD imaging with up to 5000 Dpi screening, minimum dot, increased tonal range, smoother tints and sharper copy.

O

JANUARY / FEBRUARY 2011

FLP1207WEBEX.indd 1

Additionally, OEC’s Flat Top Dot technology produces digital plates that have greater surface area and more image structure. Ideal for corrugated printing, it also features reduced fluting, extended gamut, super ink transfer and cleaner reverse type, making it. OEC Graphics, Inc. (800) 388-7770; www.oecgraphics.com

FLEXIBLEPACKAGING

| www.flexpackmag.com

47

12/3/07 2:59:38 PM

Supplier News News Briefs PRATI AUTOMATION APPOINTS NEW SALES MANAGER Prati Automation, a newly established company that manages the sales and service operations of Prati machines in the US and Canada, hires Bryan Ivens as sales manager. Ivens has 33 years of experience in the finishing market, previously working at Arpeco and Rotoflex as worldwide sales manager. Since his appointment, he has already sold his first Prati machine, a Jupiter TC330. Prati Automation (812) 283-8963; www.pratiautomation.com

MAXCESS INTERNATIONAL PROMOTES EMPLOYEE TO NATIONAL SALES MANAGER Maxcess International has promoted Darrell Whiteside to National Sales Manager. Formerly Magpowr’s sales and channel manager, Whiteside will now manage and support local sales efforts for Fife, Magpowr and Tidland products. Whiteside has also worked in International Sales at Magnetek and as a design engineer at Watlwow Process Systems. Maxcess International (405) 755-1600; wwwmaxcessintl.com

AMPAC POISED FOR GROWTH Ampac, a global leader in the retail, food, security and medical packaging markets, announces that a long-term credit facility recently closed with J.P. Morgan Chase and Bank of America. Establishing itself as a global supplier with relationships that support emerging packaging design concepts and technical advancements, Ampac has enhanced the global spectrum of flexible packaging. With roots back to the company’s founding in 1966, Ampac has had inherent growth through company leadership that has developed Ampac as a global change agent and thought leader in flexible packaging. The recent syndication provides significant unused capital to the company and positions Ampac for future organic growth and acquisitions in support of Ampac’s long-standing strategy of relationship-building and partnerships with customers and suppliers. Ampac (513) 671-1777; www.ampaconline.com

48

Protect Your Product

Gain Market Share

Deliver Value

Differentiate Your Product

Reduce Costs

Meet Sustainability Goals

Speed Time to Market

Build the Bottom Line

For the latest equipment, materials, and ideas to innovate your packaging, streamline your process, and accelerate your projects, attend SouthPack this March. Now in Orlando!

March 16–17, 2011 Orange County Convention Center Orlando, FL

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Hot Products

Surface Treating System Increases Profitability Enercon’s new atmospheric plasma surface treating system cleans, etches, and functionalizes surfaces. Unlike corona treaters, the plasma system leverages gas chemistries producing higher and longer lasting treatment levels. Ideal for engineered films and nonwovens, the new system also features automatic gap adjustment for material thickness variations, a wide operating range, and a large operating window. Enercon Industries (262) 255-6070; www.enerconind.com

Hard Flame Sprayed Coatings Available Menges Roller Company has rolled out Marathon Flame Sprayed Coatings, a new product line of hard flame sprayed coatings that give process, idler rollers and parts another dimension. The Marathon Thermal Spray process is where metallic material is sprayed on in a molten condition. These coatings offer the rollers and/or parts different coating dimensions, including release and non-stick, corrosion resistance, wear and abrasion resistance and web tracking and handling characteristics, and extremely hard surfaces can also be attained. Coatings can be added to new or existing rollers. Menges Roller Company (888) 856-1753; www.mengesroller.com

Customizable Core Recycler To accommodate a wide range of roll diameters, lengths, and weights, Appleton Manufacturing’s Safe-Slab Core Recycler is now available in light, medium, and heavy. The compact, blade-free unit automatically removes leftover roll material so the cores can be reused, while the scrap material can be recycled. The product line has variable unwinding speeds and can handle rolls up to 32 inches in diameter, 96 inches in length and 1000 pounds in weight. Appleton Manufacturing (920) 751-1555; www.appletonmfg.com

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FLEXIBLEPACKAGING

HD Flexo Expands Capabilities EskoArtwork further advances 4,000 dpi flexo plate making with the new HD Flexo 2.0. While the original HD Flexo 1.0 provided high rulings and excellent highlights, the HD Flexo 2.0 delivers exceptional printing throughout the entire tonal range. Using new MicroCell screening, the latest version improves solid ink transfer, ink lay-down, increases ink density on final print and creates more vibrant colors on packaging. EskoArtWork (937) 454-1721; www.esko.com

| www.flexpackmag.com

Inspection, Slitting and Rewind System Broadens Reach The Rotoflex VLI has expanded its capabilities with the introduction of Genesis, an advanced motion control system. The touch screen system features missing label and matrix detection, intuitive defect management and multi-shape label inspection – features that converters typically invest in for additional addon inspection systems. In addition to Genesis, the ergonomic Rotoflex VLI also features precision slitting, automated tension management and a high performance web handling system. The Rotoflex is available in increased widths of 17.25 inches and 28.25 inches, along with speeds up to 850 feet per minute. Rotoflex 800-700-6275; www.markandy.com/rotoflex

Nip Measurement Tool The new DigiNip system allows for the quick and easy diagnosis of roller conditions. When the hand-held sensor is placed between rolls, it automatically records the spot nip width at any section of the web or sheetfed process. The device has an ergonomic shell, is water resistant can provide hundreds of readings before replacement. Sensor Expert (973) 884-1755; www.sensorexpert.com

JANUARY / FEBRUARY 2011

GEAR UP FOR FORUM 2011 MAY 1–4 INDIANAPOLIS, IN

Plan now to attend the flexo industry’s premier, PACESETTING event. On the agenda: Seven TURBO-CHARGED technical sessions designed to deliver the technologies, innovations and experiences that will have you operating at PEAK PERFORMANCE in RECORD TIME. ACCELERATE your business. RAMP UP your relationships. BOOST your profits. www.flexography.org

Hot Products

Power System Increases Efficiency In an effort to reduce energy costs and prevent spoiled print jobs, GEW has introduced the latest version of its e-Brick power supplies. Designed to power the e-System, an electronic energy saving UV curing system, the e-Brick incorporates new design elements, which allow customers to select the power level required for the job based on the ink, coating or adhesive properties at the appropriate press speed. GEW Inc. 440-237-4439; www.gewuv.com

BIO-BASED COMPOSTABLE FILMS Toray’s new Ecodear compostable, bio-based films were featured at Pack Expo. Made with renewable resources, the thin, bi-axially oriented films include a metallized heat-sealable film that delivers moisture and oxygen barrier protection and a clear film that can be used as an inner seal layer or a printweb. Ecodear films meet ASTM D4600 standard specifications for compostable plastics and are ideal for food and retail-goods applications. Toray Plastics (America), Inc. (401) 294-4511; www.toraytpa.com

Register NOW and save $100 ) www.PackageDesignAndDevelopment.com

March 1-3, 2011 ) Renaissance Vinoy ) St. Petersburg, FL DEVELOPING PACKAGES IN THE NEW ECONOMY The Package Design & Development Summit brings together package design and development professionals seeking the latest trends, tools and technologies to create packaging that drives product growth.

KEYNOTE PRESENTATIONS Defining Package Innovation from the Consumer Perspective Steve Lannon, Director of Marketing, Innovations, MillerCoors

Shaking the Foundations of Packaging Harry Epstein, Vice President of Innovation, HAVI Global Solutions

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JANUARY / FEBRUARY 2011

Economic Laser System ConverTec Corporation introduces its new TeraLaz CO2 Terahertz Laser System. The compact system creates a beam of light at a very high frequency range enabling it to cut, drill, score, stitch, and weld thick film materials. It is also cost-effective, requiring less energy than traditional knives and dies, which results in improved quality processing. ConverTec Corporation www.coronabeam.com

Offset Press Offers Rapid Changeovers Using a patented sleeve technology, Muller Martini’s Variable Sleeve Offset Printing (VSOP) press allows print sizes to be changed without having to remove a complete offset insert—only two low weight sleeves need to be exchanged to adjust print sizes. The press is ideal for labels, flexible packaging, and folding carton applications, has a maximum print speed of 1200 feet per minutes and is available in two different web widths (20.5 inches and 33.5 inches).

Large Roll Protection

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Economical Coating Repels Adhesives Bunting Magnetics Co. introduces a new coating for its Flexible Die product line. The Repel coating provides a clear, non-stick finish that prevents adhesive or label material from embedding in the cavities of the die. Providing a silicone-based layer of protection, the coating reduces the need to use foam in some applications and helps to reduce cost. Bunting also offers the Diamond and Black Diamond coatings, which increase the hardness of the dies, allowing them to run four times longer. Bunting Magnetics Co. 800-835-2526; www.buntingmagnetics.com

JANUARY / FEBRUARY 2011

Single roll end boards

Give your large rolls real protection during shipping and storage. From single roll solutions to multi-roll shipping systems, Badger Plug unitizes, secures and protects your valuable rolls day and night.

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53

Calendar of Events

Mar. 1, 2011 to Mar. 3, 2011 Package Design & Development Summit Orlando, Fla. www.packagedesignanddevelopment.com

Mar. 9, 2011 to Mar. 11, 2011 FPA 2011 Annual Meeting Naples, Fla. www.flexpack.org/

Mar. 3, 2011 Converters Expo 2011 Gren Bay, Wisc. www.convertersexpo.com/

Mar. 14, 2011 to Mar. 17, 2011 Gulf Print and Pack 2011 Dubai, U.A.E. www.gulfprintpack.com

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For Postal Information Contact: Robert Liska 800.223.2194 x726 [email protected]

For Email Information Contact: Shawn Kingston 800.409.4443 x828 [email protected]

JANUARY / FEBRUARY 2011

Chart Your Course to Real

SUC CESS At Clear Seas Research we develop customized research solutions to identify:

The outlook for new/existing products Customer needs and expectations Optimal product price points Marketing messages with impact Your position in the industry Areas of customer satisfaction Opportunities for new solutions/products . . . and much more

CLEAR SEAS RESEARCH. Making the Complex Clear.

Find out how we can customize a research solution to help your bottom line. BETH SUROWIEC | 248.786.1619 [email protected] www.clearseasresearch.com

An industry-focused market research company

As a CASRO member, we subscribe to the Code of Standards and Ethics for Survey Research established by the Council of American Survey Research Organizations.

CorporateProfiles

CORPORATE PROFILES SPECIAL SECTION

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CorporateProfiles AMERICAN PROFOL

ANDERSON & VREELAND

Photo: Esko 4835

CAST POLYPROPYLENE FILMS CONTAINING ECOPURE™ ADDITIVE:

ANDERSON & VREELAND OFFERS “THE FUTURE OF FLEXO”

• Independent test results show our Ålm with EcoPure™ biodegrades under ASTM D5511-02 (high solids anaerobic) conditions • Film with EcoPure™ is shelf-stable until in prolonged contact with microorganisms commonly found in dirt or landÅlls biodegradation of this Ålm is not dependent upon heat, UV light, or mechanical stresses to initiate the degradation process • EcoPure™ can be added to select American Profol Ålms • FDA compliant grades are available upon request for food contact applications • Clear, white and custom colors are available • Custom low-seal initiation Ålms for improved packaging line speeds

The future of Æexo can be seen today with the newest prepress equipment, materials and software offered by Anderson & Vreeland, Inc. New plate processing equipment includes EskoArtwork digital plate and Ålm imagers, multi-function water-wash and eco-friendly solvent-wash plate processors, and digital prooÅng systems including Epson’s Stylus® Pro WT7900 with white printing technology. New materials from industry leaders including Flint Group with new nyloÆex NExT high-output UV technology, and Toyobo with new Æat dot technology, are also available from A&V, along with color management and prooÅng software like HD Flexo from EskoArtwork The growing sophistication of these products requires the best training and support, otherwise companies are only tapping the basics of feature-rich equipment and software. That’s where A&V experience makes the difference. Our 50 years of Æexo experience provides you with smoother and easier integration of technical advancements affecting Æexo prepress. Anderson & Vreeland’s Training & Technology Group can maximize the effectiveness of your personnel, equipment, software and materials. A&V offers training programs and support designed for every level of experience in Æexography. Take advantage of this training at your location, our location or online with A&V’s seasoned personnel. The best training and support, the most experience, plus state-of-the-art equipment and materials, make for an unbeatable combination that you will only Ånd at Anderson & Vreeland. We’re committed to helping you make the best use of our equipment and materials, and your resources. The future of Æexo can be seen today at Anderson & Vreeland.

AMERICAN PROFOL’S CAST POLYPROPYLENE FILMS: • Substrates for PSA coated tapes • Smooth and embossed Ålms for stationary products, CD and DVD packaging • Films for consumer packaging • White and clear Ålms for In Mold Labels • Graphic substrates for screen printing, lithography and Æexology • Custom Ålms for industrial applications Construction, Automotive and Furniture laminates

American Profol Inc. (319) 731-3316; www.profol.com

Anderson & Vreeland (866) 282-7697; www.AndersonVreeland.com

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CorporateProfiles CHARTER FILMS

CATBRIDGE MACHINERY

LEADING SLITTER REWINDER PERFORMANCE Catbridge Machinery builds durable, innovative slitter rewinders that maximize productivity. Our Model 344 FP dual-turret slitter rewinder, for example, completes cycles more than Åve times faster than a conventional winder. Our versatile Model 902 center winder does the job of two machines, offering duplex slitting as well as large diameter roll log winding. Unique Catbridge technologies and special features signiÅcantly improve performance. Our innovative tabber and enveloper fully automate the roll cut off and transfer process, slashing downtime. Our automatic core placement and knife placement systems increase accuracy, consistency, and repeatability while greatly reducing setup times. Other technologies include an advanced yet intuitive control system, closed-loop tension, operating speed advancements, and a variety of loading and unloading systems. We tailor each machine to your exact material and process.

SPECIALISTS IN BLOWN FILM EXTRUSION

Charter Films, located in Superior, Wis., is a leading manufacturer of extruded blown Ålm. We manufacture an extensive line of polyethylene and polypropylene monolayer and multilayer coex Ålms. Our Ålms are used in many markets including printing and laminating applications, sealant, banner, industrial, surface protection and tag and label.

CONTINUIOUS GROWTH IN CAPACITY AND CAPABILITIES Charter Films has grown continuously since its inception in 1998, predominately in three- layer coex capability. Charter recently installed additional capacity capable of producing EVOH co-extruded barrier Ålms. Primary applications for this new capacity will be high barrier Ålms for food packaging applications such as meat and cheese, seafood, crackers, cookies and nuts.

SUSTAINABILITY Catbridge Machinery 973-808-0029; www.catbridge.com

Charter Films is committed to sustainability and sustainable packaging, beginning with successful source reduction efforts. Each of Charter Films’ extrusion lines is equipped with real time on-line gauge control. This allows an unmatched level of conÅdence that Ålm purchased from Charter will not only process efÅciently through a customers internal operations, but also assures they will not be paying for more Ålm weight than needed. This level of gauge and yield control has allowed many of Charter’s converting customers to take a 3-5% yield advantage and still be within industry tolerances for gauge variation. This, in turn, affords Charter Films’ customers the ability to meet the demands of brand owners for sustainable source reduction and cost control that are so prevalent in today’s Æexible packaging marketplace. Charter Films 715-395-8258; www.charterfilms.com

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CorporateProfiles CMD

DANAFILMS

CONVERTING CONCEPTS INTO PROFITS CMD® delivers Æexible, high-speed converting and packaging equipment empowered with time and moneysaving technology, including: patented overlap bag winders and global drawtape systems, rotary bagmaking systems, bag folders and end-of-line packaging automation.

INNOVATION AND CUSTOMER FOCUS DRIVE GROWTH

THE NEW FACE OF PDI® High performance PDI® pouchmaking equipment is designed for the unique needs of speciÅc market segments including medical, stand-up, protective packaging and security bags. CMD® technology continues to evolve the PDI® line of pouchmaking systems. New Process Driven Innovation includes proprietary quick-change seal dies and tape advance systems and Intelligent Sealing Technology, for precise monitoring and control of the three critical areas of sealing: time, temperature and pressure.

MADE IN THE U.S.A; SOLD AND SUPPORTED GLOBALLY

MULTIPLE LAYERS MULTIPLE PROPERTIES

CMD® bag and pouch converting equipment is designed and manufactured in the United States and is backed by a global network of associates and experienced, in-house service technicians and parts specialists. The CMD® Technology Center is staffed by industry-experienced engineers and is designed for proprietary product development and custom engineering. Put the power of efÅciency in your ands with ProcessIQTM services: data acquisition, machine optimization, process validation, Sysmetric Material Handling Systems and M.R.S. Plasticating Screws and Barrels.

LISTEN, LEARN LEAD® Our mission is to Listen to the changing marketplace, Learn new ways to solve problems and Lead with the best new technology for the bag and pouch converting industry. CMD Corporation +1. 920.730.6888; http://www.cmd-corp.com/

DanaÅlms is a leading supplier of premium polyethylene monolayer and coextruded barrier Ålms for markets including food & beverage, medical & hygiene, industrial, agriculture and energy. Their custom engineered Ålms span a wide variety of Æexible packaging applications while also serving a growing number of specialty markets that demand precision. Coextrusion allows DanaÅlms to provide Ålms that perform multiple feats in a single structure. An outer layer might be designed for special slip characteristics, abrasion resistance, or printability. Other layers might provide barrier properties, formability or temperature resistance. By doing this all with a single Ålm, production steps and the amount of product needed are reduced offering a substantial cost savings.

PARTNERS IN INNOVATION Seeing the opportunity for a lower cost alternative to PVDC-coated PET, the engineers at DanaÅlms have taken their knowledge of resin properties and designed a coextruded EVOH blend Ålm. EvoSealTM provides an oxygen barrier 5 to 10 times greater than that of PVDCcoated PET while being odorless, crystal clear and safe for food contact. It can seal at high production speeds through a variety of contaminants, including crumbs, food particles, moisture, grease and oil.

CUSTOMER SATISFACTION IS HIGHEST PRIORITY

The CMD® stand at K2010 featured the Model 0330HSW Global High-Speed Bag Winder in line with the signature Model 1270GDS Global Drawtape System. Pouch converters were able to view the PDI Shaped Seal/Header Bag combination pouch machine with revolutionary Intelligent Sealing Technology.

By focusing on innovation, DanaÅlms is continuously improving the performance of its products and processes. In today’s competitive marketplace, they understand how important reliability is to the bottom line - orders are delivered with exact speciÅcations on time, every time. Danafilms, Inc. A member of RKW-Group (800) 634.8289; www.danafilms.com

PHO TO C AP TIO N: The C MD ® sta n d at K 2010 feat ure d the M odel 0330H SW Gl obal Hi gh- S peed Ba g Win der in line wit h the si gnat ure M odel 1270GD S Gl obal Dr a wta pe S ystem. P ouch c on verter s were a ble t o vie w the PDI S ha pe d Sea l/ Hea der Ba g combinati on pouch mac hine with revol utionar y I ntelli gent Se ali ng Tec hn ol ogy.

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Con vertin g JANUARY / FEBRUARY 2011 CMD ®

C once pts int o Pr ofits

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CorporateProfiles DOVER FLEXO ELECTRONICS

ECOLOGIC

TENSION MEASUREMENT AND CONTROL BANG FOR YOUR PROCESS IMPROVEMENT BUCK. By adding direct tension measurement your lines will output better Ånished product, and faster, on each job. And it’s one of the least expensive and quick-to-implement process improvements you’ll Ånd anywhere. After installing reliable tension transducers in the web path, your machine operators, or an automated control system, can monitor running web tension at critical points and make necessary drive or winding adjustments before a job is negatively impacted and expensive substrate is wasted. The least costly investment in a new tension measurement system in terms of installation convenience and budget will involve the addition of a Tension Roll® transducer or, for the narrower web cantilevered-style machine frame, a Narrow Web tension transducer. Dover Flexo Electronics (DFE) offers the largest range of transducer sizes and load ratings in the industry to address the growing variation of web substrates that Æexible packaging converters have to deal with. Every Tension Roll or Narrow Web Transducer combines a durably constructed idler roll and two tension sensors in one unit—for fast, easy installation and high accuracy. No assembly is required. Units are available in 3 roll diame-ters and roll widths to accommodate webs from 6” wide on up. Choose from several mounting options and load rat-ings from 12 lbs and up, all with a wide 50:1 operating range. The EasyView™ Indicator is Dover Flexo’s most affordable general-purpose tension measurement and display device. EasyView ampliÅes the web tension signal from a transducer pair and puts out an isolated 0-to-10 VDC ten-sion signal to a PLC, drive, controller and/or to a meter display. It measures 3 ½” x 3” x 4”—small enough to Åt in your hand. Dover Flexo Electronics is ISO 9001 certiÅed and manufactures and services a full line of tension products for the converting industries, all under 5-year warranty. DFE also guarantees faster delivery and more experienced 24/7 technical support than our competition. Call for these product data sheets or download pdf copies at www.dfe.com..

EcoLogic, LLC (www.ecologic-llc.com) owns, manufactures and markets Eco-One® brand of additives for plastic products worldwide. Eco-One® is an organic additive that renders products manufactured from plastic resins biodegradable in landÅlls and composting environments. Biodegradation facilitated by Eco-One® has been conÅrmed using ASTM D5511. Eco-One® is scientiÅcally unique, validated and certiÅed for biodegradation. The addition of Eco-One® does not change the manufacturing process except for the simple step of adding in Eco-One®. Just add approximately 1% Eco-One® into your production process the same way you would add a color concentrate. Products have the same physical properties and tensile strength and hence will perform just as well in their intended applications and usage conditions. These attributes will last until the product is discarded into an active microbial environment (landÅll). Eco-One® only starts to work in this environment breaking down the plastic into inert humus, methane and carbon dioxide. • Products using Eco-One® are 100% recyclable in standard recycle facilities, unlike PLA • Eco-One® is 100% organic and non-starch based • Eco-One® has proven methane off-gassing which allows it to be re-captured for energy • Over 95% of plastics end up in landÅlls plastics with Eco-One® will BIODEGRADE in an ideal landÅll environment • Eco-One® additive is accepted by major national brands EcoLogic, LLC www.ecologic-llc.com

Dover Flexo Electronics www.dfe.com

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CorporateProfiles HOSOKAWA

JEMMCO, LLC JEMMCO, LLC

Alpine American is a leading supplier of Blown Film extrusion systems. These systems are versatile, efÅcient and most importantly, proÅtable. Alpine manufactures blown Ålm lines that produce the most technically advanced multi-layer barrier Ålms to the highest quality lamination grade Ålms and the highest throughput Ålms for commodity products. Alpine’s “X” Die is the most innovative and technologically advanced die in the world. The patented “X” design eliminates “port lines” from the Ålm surface producing exceptional Ålm quality without visual defects, and it is the fastest purging die in the industry. Cooling Systems include our new “V-Ring” which ensures maximum output rates, and performance. The open architecture of our operator friendly Ex-Vis control system allows for customized controls, and “One-Touch” job change to maximize up-time and proÅtability. Alpine’s Web Handling Systems provide maximum versatility and roll conformity. Exacting design and manufacture allows for trimless winding in many applications. Our Machine Direction Orienter speciÅcally enhances Ålm structures providing added barrier protection; tear resistance and many additional exceptional Ånished product properties. MDO tolling is available in the US to stretch your proÅtability. Alpine supports our equipment with the most experienced and respected Technical Engineering team in the industry, providing the most advanced customer support and service excellence. Contact Alpine American to explore a proÅt producing solution for your blown Ålm application.

Jemmco, Inc. is a leading supplier to the extrusion and web converting industries. We offer a complete line of products to help and improve the processing of papers, Ålms and foils. As the leading manufacturer of Dyne Pens, Jemmco, LLC features a full line of Dyne Pens, Dyne Solutions and Dyne Accessories. Our line of Laboratory Equipment and Viscosity Cups adds to our Quality Control Product Line. Our Jemm-Tac Line of Web Cleaning Products includes our unique Jemm-Tac Web Cleaning Sleeve, which is designed to Åt over existing idler rolls. The Jemm-Tac Web Cleaning Systems add automatic cleaning of the Jemm-Tac Web Cleaning Sleeve. Jemmco has developed a full line of Roller Coverings designed to eliminate the need for spare rollers and excessive shipping costs. Our Disposable Roller Coverings are part of a full line of roller coverings we offer. Our JemmTron Treater Roll Coverings include our well known JemmTron Silicone Treater Sleeves, as well as our Epoxy and Ceramic Treater Roll Coverings. Of course Jemm-Tac Web Cleaning Sleeves and Jemm-Tac Bonded Web Cleaning Coverings are able to handle almost any web cleaning application. Our JemmTrac Traction Sleeve is part of our full line of traction roller coverings. Our newest line of roller coverings is our JemmSil Line of High Release Covering. From our JemmSil HS100 FEP TeÆon® Heat Shrink Sleeves to our JemmSil High Release Rubber Sleeves, to our Thermal Sprayed Coatings, the new JemmSil Line of High Release Coatings are ideal for most converting applications. We also offer a wide range of Tapes and Roller Wraps, as well. The JemmStat line of static eliminating products includes Jemmcord Anti-Static Cord and Anti-Static Tinsel and our line of Cleaning Products include JemmClean TR Treater Roll Cleaning Solution, JemmClean CAP Citrus All Purpose Cleaner, and Little Effort All Purpose Cleaner. To learn more about these products visit our website: www.jemmco.com

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CorporateProfiles MAX DAETWYLER CORP.

PEARL TECHNOLOGIES INC.

QSpecialized doctor blades designed to solve print problems such as ink spitting, roll scoring and print chatter. QSpecialty coated blades designed to increase longevity with abrasive inks such as whites and metallics. QComprehensive Flexo Consumable product line— including end seals, cleaning brushes, Ålter/magnet systems, roll covers and more—offers protection and longevity for doctor blades, anilox rolls and cylinders. QUltrasonic cleaning systems as well as cleaning chemistries for all inks and coatings. QTechnical service support and educational seminars customized for your needs. QThe company provides product solutions necessary to improve prepress and pressroom efÅciency and productivity. Max Daetwyler Corp. (704) 875-1200; www.daetwyler-USA.com

For over a quarter century, Pearl has generated innovative converting and extrusion products. Our success and reputation are built upon unparalleled customer service, innovation, quality, value, durability, speed and delivery. We are so conÅdent in our products that all of them come with a 30-day product guarantee. For converters, Pearl can be counted on to provide quality product solutions for any unique application faster and better than anyone in the industry! We have over 50 years of experience within our engineering department, enabling us to design and build custom equipment for any application. Building high-speed machine attachments for punching holes, perforating and slitting is something we do every day. We also carry a full line of punches, slitter blades, air cylinders, ball and die punches, and perforation blades. Most units for handle hole, hanger hole, wicking and hole punching are stocked and ready for shipment. We even offer trade-in and “on-your-line” demo trial programs. For extruders, Pearl has developed innovative products to enhance blown Ålm extrusion. These include low friction collapsing frame wearstrips, gusset boards, bubble guides, pre-nip chillers, turning bars, wrinkle preventer bars and cage arm retroÅts. Furthermore, we strive to keep abreast of challenges resulting from resin technology evolution. Since 1986, Pearl has retroÅtted over a thousand blown Ålm lines for major extrusion equipment manufacturers around the globe. Each retroÅt is implemented to achieve the same goal of improving Ålm quality, increasing output and reducing maintenance. All customers want the same thing - the best possible result so that they can satisfy even their most demanding customers. Have an emergency? Many of our products are built and shipped the very same day. For more information on Pearl’s entire product line, visit our website at www. pearltechinc.com or email us at [email protected]. Pearl Technologies Inc. (315) 365-3742; www.pearltechinc.com

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CorporateProfiles PILLAR TECH

WINDMOELLER & HOELSCHER

Founded in 1966, Pillar Technologies is recognized worldwide as a global leader in the manufacturing of surface treatment equipment. Pillars complete line of surface treatment equipment for the extrusion and converting industries has long assisted both the end user and OEM desiring increased wettability and long term adhesion on a wide variety of substrates. Pillar remains your one stop source for covered roll (non-conductive substrates), bare roll (conductive or non-conductive substrates) or dual dielectric, in narrow, standard or wide web conÅgurations, with your choice of Åxed width or segmented electrode designs utilizing various ground roll dielectrics. If you require surface modiÅcation of your substrate consider our line of controlled gas atmosphere (CGA) or modiÅed gas atmosphere (MGA) equipment. Recently Pillar has introduced the series power supply. Eliminating the need for expensive power supply input transformers, the allows for a wide variation of international supply voltages ranging from 380-515 Volts, 3 phase, 50/60 Hz. The power supply with its advanced IGBT technology and optimized protection circuit has also improved on an astonishing 20:1 turndown ratio. This power supply design comes complete with a user friendly icon style “touch” screen display in full color Q-VGA clarity, with selectable languages in English, Spanish, German and French. Data logging, job storage recipes, US Imperial or Metric units display, along with Help and Information screens throughout assist the user to maximize the experience. Also available, the industry proven P6000 model power supply with selectable digital touch pad for Output Power, Voltage, Current and Frequency. Available in sizes from 0.5 – 30 kW with both CE and ETL agency approvals. Pillar Technologies (262) 912-7200 ; www.pillartech.com

Windmoeller & Hoelscher Corporation of Lincoln, R.I., is distinguished by a heritage of industrial innovation. Founded in 1869, its parent company, Windmöller & Hölscher of Lengerich, Germany, Årst established an international presence by automating the production of paper bags. Since then, the company’s product range has grown extensively. The Rhode Island-based unit, incorporated in 1977, has become a major supplier of advanced Æexographic and gravure printing presses, blown and cast Ålm extrusion systems, multiwall bag making machines, as well as form, Åll, and seal (FFS) equipment for the Æexible packaging industry in North America. W&H’s engineering excellence and advanced concepts have made them the leader in their markets. W&H holds more than 1,500 patents worldwide, including extrusion developments such as oscillating hauloff technology, internal bubble cooling, and automatic die control. The company is well known for many industry “Årsts,” including the introduction of the Årst CI press, the OLYMPIA® 1275, in 1954 and for the 1997 launch of the NOVOFLEX®, the industry’s Årst gearless, direct drive, inÅnitely variable Æexo press, as well as EASYCOL, the Årst color matching system. In addition to the world’s comprehensive machinery range for the Æexible packaging industry, W&H also offers the strongest service and spare parts program that is available 24x7x36, utilizing a comprehensive multi-million dollar warehouse to deliver the vast majority of parts right from our Rhode Island stock. Additionally, W&H’s 43,000 square foot (4,000 square meter) Technology Center in Germany offers the most advanced training and testing labs for printing, extrusion and packaging machinery. Customer satisfaction is our driving force with a primary emphasis on productivity and proÅtability for our customers. Windmoeller & Hoelscher Corp. (800) 854-8702; www.whcorp.com

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CorporateProfiles COMEXI OPEN YOUR MIND TO THE POSSIBILITIES More than half a century ago, the vision of Manel B. Xifra resulted in the formation of a company called Comexi. Today, the Comexi Group, still a family run business, is recognized at the global level as a supplier of quality machinery and services to the Æexible packaging converting industry. Due to the high degree of specialization in each of our product lines and the fact that each of our product lines complements one another, we are able to offer total solutions and exploit synergies to the fullest. The Family business continues to be strong with its success and growth due in large part to its ability to listen and to adapt to our customers’ needs and deliver equipment that will give them the competitive edge they must have. In 2010, we introduced several new product lines including our FPlus+ and F4 EfÅciency Presses which are dedicated to the needs of very different market segments and the Proslit E-Turret, the next generation of slitter/rewinders combining economy, ergonomics, ecology and efÅciency. The Comexi Group is also deeply committed to EB Æexo printing technology because of its high print quality, safety and reduced energy requirements. And, Ånally, in December, Comexi Converting Solutions, an Italian subsidiary of the Comexi

Group, completed acquisition of ACOM, srl., allowing us to offer a complete line of quality gravure printing equipment. Along with the new products listed above, Comexi also offers a full range of Nexus Solventless Laminators for virtually every application including the Nexus Evo, our most popular, which will demonstrated at the ICE USA Exhibition in Orlando, April 6-8. Comexi’s commitment to quality and customer service is unparalleled. With manufacturing facilities and its own foundry in Spain, additional manufacturing operations in Brazil, branch ofÅces in Åve countries and sales representatives in more than 65 countries, Comexi is positioned to support customer needs throughout the world.

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Plot Your Course for Real

SUC CESS Working with Clear Seas Research allows you to competitively position your business within the industry market and ultimately guides your company to make successful and informed decisions, establish a plan for the future and reach its overall objectives.

At Clear Seas Research we develop customized market research solutions.

CLEAR SEAS RESEARCH. Making the Complex Clear.

Find out how we can customize a research solution to help your bottom line. BETH SUROWIEC | 248.786.1619 [email protected] www.clearseasresearch.com

As a CASRO member, we subscribe to the Code of Standards and Ethics for Survey Research established by the Council of American Survey Research Organizations.

January/February Advertisers in this issue

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To place your classified ad in Flexible Packaging call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] CAREER OPPORTUNITY

SALESPERSON/REPS WANTED

LOOKING FOR MANUFACTURER DIRECT REPS/ BROKERS

FOR FLEXIBLE PACKAGING COMPANY

We are looking to join forces with experienced Manufacturers Reps. Our capabilities include: • High-quality 8-color Àexo printing • Laminating • Converting • Inno-Lock and • Pouch making capabilities. Contact:

An expanding company based in the Northeast, with multi-location facilities, is looking to establish relationships with manufacturers’ representatives, brokers and direct representatives (expense & commission) in all regions. Our focus is in developing markets for our Barrier, Thermoforming and other value added products. Our Capabilities include: • 3,5,7 Layer Co-Extruded Film • Printing (8 Color) • Lamination (Solventless, Water, Solvent) • Pouching (Stand-up, Zipper, Center, 3 Side)

Morris Lowy Nap Industries, Inc. phone: 718-625-4949 email: [email protected]

Please direct your inquiries and resume to: [email protected]

RECRUITMENT

SERVICES

LOOKING FOR A BAG/POUCH CONVERTER?

Since 1977, KLEER PAK has specialized in manufacturing of custom bags and pouches for the converting industry

Equipment to sell? Services to provide? Positions to fill? Advertise in Flexible Packaging's Classified Network

[email protected] • www.kleerpak.com • 1-630-543-0208 320 S. La Londe Ave. Addison, IL 60101

AIB CERTIFIED EXCELLENCE THROUGH DILIGENCE

Contact Diana Rotman at 847-405-4116 or [email protected]

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JANUARY / FEBRUARY 2011

To place your classified ad in Flexible Packaging call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] CAREER OPPORTUNITY

MATERIALS WANTED

PRODUCTION MANAGER, SALES MANAGER AND SALES REPRESENTATIVE St. Johns Packaging Ltd., a vertically integrated flexible packaging manufacturer that has been supplying the food and personal care industries for more than 50 years, is seeking to hire a Production Manager, a Sales Manager and a Sales Representative for its recently acquired North State Flexibles LLC subsidiary in Greensboro, North Carolina. North State Flexibles specializes in high-impact pre-press graphic development, state-of-the-art flexographic printing, environmentally-friendly laminating and converting of various film materials into an array of pouches, bags and roll stock products.

PET / BON / PLA FILM

Production Manager • At least 10 years of experience managing production for an established flexible packaging company. • Theoretical and practical knowledge of flexographic printing, solventless lamination and pouch making processes. • A Bachelor’s degree (preferably in Engineering) from a North American university.

Sales Manager • Bachelor’s or Master’s degree(s) in Business. • At least 10 years of sales experience with an upper management position, preferably focused in the printing/laminating, converting arena. • Must be a strong communicator with excellent decision and problem solving skills. • Strong strategic planning skills and market knowledge.

Sales Representative • Bachelor’s degree in Business with Sales, Marketing/Communication specialization. • At least 5 years of sales experience. • Flexographic printing, lamination, pouch market sales experience.

Interested candidates are invited to email their resume to [email protected]

320 Remington Blvd., Bolingbrook, IL 60440 Phone: 630-226-9800 / Fax: 630-226-9400 Toll Free: 1-888-PET-FILM Website: www.PetFilm.com

BUSINESS WANTED

WANTED TO BUY!!! Established Converted Paper or Nonwoven Product Business is seeking to buy an existing Film or Flexible Business or Converting Line. Information discussed will be strictly confidential

Contact Bernie Dahlin, owner 920-606-3424

SUPPLIES

EQUIPMENT FOR SALE

Lotar LLC Tel: 920/465-6678 Fax: 920/465-7262 [email protected] www.lotarenterprises.com 1221 Bellevue St., Green Bay, WI 54302

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To place your classified ad in Flexible Packaging call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] ROLLERS

Does the Inside of Your Heat Transfer Roll Look Like This?

SUPPLIES If So, Your Rolls Will Be Running Slower to Achieve the Heating or Cooling Your Process Requires We can remove the shell and re-engineer and repair your roll to run as good as new. Depending on its age and engineering, we can make it run Better than New at a cost of 25-40% less than a new roll.

Before

Aluminum Foil Gauge: from 0.00022” to 0.157” Dingsheng Aluminum USA Office: Raymond Xu Tel: 804-690-3483 Email: [email protected] www.dingshenggroup.com

After

Menges Roller is an all inclusive Rubber Covering and New Core Manufacturer

Toll Free: (888) 856-1753 / Fax: (847) 487-8897

www.mengesroller.com ADVERTISE HERE IN FLEXIBLE PACKAGING'S CLASSIFIEDS Contact Diana Rotman at 847-405-4116 or email: [email protected]

WWW.PAPERTUBEANDCORE.COM PATERSON, NEW JERSEY, USA 973-977-8823 Serving the Flexible Packaging Industry In Business over 50 years • No Minimums/Pre-Cut Sizes Available • Samples upon Request • Worldwide Service

EQUIPMENT FOR SALE

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JANUARY / FEBRUARY 2011

To place your classified ad in Flexible Packaging call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] SUPPLIES

SERVICES

OOPS... Roll Printers, Have You Ever Left Out a New Wt. or Some Other Printed Image and Rendered Your Otherwise Perfect Print Job Worthless? We Will Add This For You in Register and Restore the Job to its Original Value. Cover-up and Reprint Also Possible.

Roll-Fed SOLUTIONS

Cincinnati Convertors, Inc.

Post-Print Dept. • 1730 Cleneay Ave. Cincinnati, OH 45212 • (513) 731-6600 www.cincinnaticonvertors.com

••• Don J. Kemps LLC ••• Exclusive Agent in the U.S. and Canada for M.A.L.I. Hole Punching Apparatus "MALI is the world leader for punching holes in poly, paper or foil" N5949 Cordy Road Cell: 920-850-3546 Hilbert, WI 54129 Fax: 920-439-1253 Email: [email protected]

E-3 Epoxy CORONA TREATER ROLL COATING +++ +++ ++ + + + GUARANTEED + Call us or send your rolls to:

Quality, Experience &Value ALL ROLLED INTO ONE! At Contract Converting, we’re focused on anticipating your needs to professionally deliver quality converting solutions at a moment’s notice. Custom slitting. Roll finishing. Distribution and packaging. We have the experience, products and capabilities to handle your most complex challenges. (On time. Anytime.) Papers, film, foil, laminates, tissue, non-wovens, plain or printed...let Contract Converting’s experienced professionals provide solutions to your specialized converting needs. Boost your bottom line with services and solutions designed exclusively for you. Visit www.ContractConverting.com or call us toll-free at 800-734-0990.

SOLO SYSTEMS, INC. 4001 Industrial Street Rowlett,TX 75088

800/259-5570 • fax: 972/475-5128

JANUARY / FEBRUARY 2011

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To place your classified ad in Flexible Packaging call Diana Rotman at 847-405-4116 Fax: 248-502-9083 E-mail: [email protected] SUPPLIES Eliminate problems caused by uneven nip-pressure with Roller Nip Impression Paper. Uneven Nip Pressure Causes-Wrinkling; Uneven Winding; Poor Laminating and Poor Coating - Simple to Use - Takes Minutes Includes Instructions and White Paper for Solving ems ems Uneven Nip Problems

We take Visa 847-487-8877

Impex International Group, Inc. Importer/Exporter/Converter/Distributor of all types of Industrial, Packaging and Specialty Films.

✷ ✷ ✷ “Excellent Customer Service, Prompt Deliveries & Competitive Pricing”✷ ✷ ✷ POLYESTER FILMS Corona / Chemical treated Industrial Grades Packaging / Metallizing Thermal Lamination / Matte Graphics / Antistatic Coated Wire and Cable Wrap PVDC Coated Milky and Opaque White Hot Stamping / Roll Leaf Metallized / Pigmented Sealable / Ovenable

BOPP FILMS Coextruded Plain / Tape Pearlized / White Anti Fog Metallizing / Metallized PVDC Coated / Acrylic Print Lamination/ Matte Labels / Decals Holographic Thermal Lamination Synthetic Paper/Teslin

BIAX NYLON FILMS Clear Metallized PVDC Coated CAST NYLON FILMS Thermoforming Non Forming HOLOGRAPHIC FILMS Polyester / BOPP Patterns METALLIZED LACQUERED FILMS Polyester / Polypropylene

FILM BOARD LAMINATES Cosmetics Gift Boxes POP Chocolate Boxes CPP FILMS Metallized Lamination Retort Twist Soft Blister Textile grade

• Thickness range: 20-1400 gauge (5 - 350 micron) • Width range: 3/8 inch - 88 inches Converting Capabilities: Custom Slitting, Custom Sheeting, Label Printing & Packaging/Board Laminations. Warehouses: Bedford Park, IL; Atlanta, GA; Simpsonville, SC; Trenton, NJ; Milbury, MA; Houston, TX

CORPORATE OFFICE: 2801 W. SAM HOUSTON PKWY, N., SUITE 100, HOUSTON, TX 77043 USA PH: (281) 416-4449 • FAX: (281) 416-4989 • EMAIL: [email protected] • WEB SITE: WWW.IMPEXFILMS.COM ----- SEEKING NATIONWIDE

WORLDWIDE SALES REPS -----

SERVICES

PLASTIC CORE PLUGS

flexpackmag.com

WANTED TO BUY

FILM

WE BUY LAMINATE SCRAP




Polyester Film 48 GA-1400 GA

Plain, Coated, Metalized, Slit, Sheet & Warehousing (877) 838-1702 www.plasticconnections.com

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• FOIL SCRAP • FILM SCRAP • PAPER SCRAP

We Also Buy Surplus Rolls CONNECTICUT METAL INDUSTRIES (203) 736-0790 • [email protected] • www.foilfoil.com

JANUARY / FEBRUARY 2011

Ad Index COMPANY NAME

American Profol, Inc. Anderson & Vreeland Inc. Badger Plug Canon Communications Catbridge Machinery Charter Films CMD Corporation Converting Influence Danafilms Dover Flexo Electronics Eckart American Corporation Ecologic, LLC Elba SPA Fives North America Henkel Hosakawa Alpine America INFO*FLEX 2011 Jemmco, LLC Mack Brooks Exhibitions Inc. Mark Andy Inc. Max Daetwyler Corp. Pearl Technologies Pillar Technologies Plasti & Pack PPC Techonologies & Solutions Totani America, Inc. Webex Windmoeller & Hoelscher

PAGE

WEB SITE

31 25 39, 54 49 27 2 29 48 9 33 35 5 34 38 19, BC 15 53 43 15 13 30 3 28 45 7 37 26, 47 75

www.americanprofol.com www.AndersonVreeland.com www.badgerplug.com www.southpackshow.com www.catbridge.com www.charterfilms.com www.cmd-corp.com www.ConvertersExpo.com www.danafilms.com www.dfe.com www.eckart.net www.ecologic-llc.com www.elba-spa.it www.fivesgroup.com www.henkelna.com/liofoldelivers2 www.halpine.com www.flexography.org www.jemmco.com www.ice-x-usa.com www.markandy.com www.daetwyler.com www.pearltechinc.com www.pillartech.com www.plastipac.com.pk www.ppcts.com www.totaniamerica.com www.webexinc.com www.whcorp.com

Reader & Marketing Services LETTERS Rick Lingle Mail: Flexible Packaging 155 Pfingsten Road Deerfield, IL 60015 E-mail: [email protected] SINGLE COPY SALES BACK ISSUES Ann Kalb E-mail: [email protected] Call: (248) 244-6499 VOLUME REPRINTS Deb Soltesz E-mail: [email protected] Call: (248) 786-1596

PRINT & INTERNET ADVERTISING Mike Barr E-mail: [email protected] Call: (630) 801-4152 Randy Green E-mail: [email protected] Call: (248) 244-6498 CUSTOM PUBLISHING John Schrei E-mail: [email protected] Call: (248) 786-1637 SUBSCRIPTIONS P.O. Box 1080 Skokie, IL 60076 E-mail: [email protected] Call: (847) 763-9534

LIST RENTAL For postal information: Rob Liska E-mail: [email protected] Call: (800) 223-2194 ext. 726 For e-mail information: Shawn Kingston E-mail: [email protected] Call: (800) 409-4443 ext. 828 CLASSIFIED SALES Diana Rotman E-mail: [email protected] Call: (847) 405-4116

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 F L E X I B L E PA C K A G I N G

®

BNP Media 155 Pfingsten Road, Suite 205 Deerfield, Illinois 60015 (847) 405-4000 Fax: (847) 405-4100

Also publishers of: Beverage Industry, BrandPackaging, Candy Industry, Dairy Foods, Food & Beverage Packaging, Food Engineering, Food Master, Industria Alimenticia, The National Provisioner, Nutrasolution, Prepared Foods, Private Label Buyer, Refrigerated & Frozen Foods Retailer and Snack Food & Wholesale Bakery.

FLEXIBLE PACKAGING (ISSN 1535-0797) is published 10 times annually, Jan/Feb, Mar, Apr, May, Jun/Jul, Aug, Sept, Oct, Nov, and 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: FLEXIBLE PACKAGING, P.O. Box 1080, Skokie, IL 60076.Change of address: Send old address label along with new address to FLEXIBLE 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.For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected]

JANUARY / FEBRUARY 2011

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Industry Q&A: Adhesives and Laminations

A LOOK AT ADHESIVES AND LAMINATIONS IN PACKAGING An exclusive interview with Guenther Hering, vice president, flexible packaging adhesives, North America, for Henkel Corp. Henkel is the largest adhesive manufacturer in the world with sales close to $8bn and more than $1.5bn in packaging adhesives. By Rick Lingle, Executive editor

Q:

What are the major trends and drivers in the flexible packaging market?

A:

There have been unforeseen increases in raw materials prices, which have put a lot of pressure for cost reduction measures. There has been a lot of innovation over the past few years. And there is a lot of added d pressure agfrom imported materials and converted packaging from Asia. When you add in the mergers in positions and consolidation, there are a lot off different dynamics occurring.

Q:

or cellophane. These materials are based on natural resources, but also have performance limitations. Longer-term, perhaps companies will alter—lower—their existing speciÅcations or Ålm providers may be able to increase the performance of these Ålms without sacriÅcing the sustainable aspect.

Q:

There is some of that activity as some people look at this from a source reduction point of view and sometimes s from a cost-reduction view to eliminate a layer or eliminate a lamination e by b having a monolayer material. Doing that without sacriÅcing the performance of the w package p is a bit of a challenge.

A:

Q:

Drilling down into adhesives for flexible films: What’s the reason that solventless adhesives are growing in popularity?

An operator operat rator or takes takkes a close cl close lose look loo look at a film lamination. Most new laminating equipment use solventless adhesives, which offer operational benefits. PHOTO COURTESY OF HENKEL CORP.

A:

Basically, it’s due to the faster line speeds, the fact that there can be potential cost savings from not having to use solvents, and Ånally from the reduction in emissions. The technology was quickly accepted in Europe, but has been seeing more acceptance over the years in North America. Today, most of the new laminating equipment is solventless.

Q:

What can you say about the packaging films that are laminated using your adhesives?

A:

The most-used materials remain polyethylene and polypropylene, the latter fairly inexpensive and appropriate for applications including snacks and confections. Polyester is particularly appropriate for higher-heat applications, though pricing pressures the last several months have created almost a shortage-like situation. A major trend relates to sustainability and the use of recyclable materials to replace traditional PE Ålms; for example, Ålms made of polylactic acid (PLA) Ålms

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Are you seeing much in the way of simplified and downgauged film structures?

A:

What are the effects of the cost pressures you mention?

There has been consolidation of raw w material supplies and capacity constraints caused by lack of investments when the he industry wasn’t proÅtable. It’s almost been likee a “perfect storm” set of circumstances.

Guenther Hering Henkel Corp.

Q:

What role do you see for electron beam (e-beam) technology in curing?

A:

We have been working in e-beam for about 10 years now and offer a full range of products for those applications. There has been only limited use of the technology due to a fairly high investment cost in the equipment along with a higher cost of chemicals compared to traditional materials. However, I see opportunities for this technology, especially in the area of source reduction, to replace some laminations with coatings on monolayer materials.

Q:

Where do you see the market headed?

A:

I foresee more opportunities for Æexible packaging going forward to replace traditional containers. Examples include eliminating cereal boxes and replacing aluminum cans with retortable pouches. All of these are driven by costs, the energy footprint, and other environmental advantages and with more convenience for consumers such as for closure mechanisms. FP Henkel Corp. (919) 319-1933; www.henkelna.com

JANUARY / FEBRUARY 2011

PR

ODUCTIVIT

Y

SPEED

SAFETY

HENKEL AND NORDMECCANICA TO HOST

Joint Workshop On Scrap Prevention The one-day interactive session on scrap prevention will include:

s )NDUSTRYEXPERTPRESENTATIONWITH1! s &ULL SCALELAMINATINGRUN s (ANDS ONEXHIBITDEMONSTRATIONS

FEBRUARY 16TH, 2011 at Nordmeccanica’s Technical Center 250 H Executive Drive Edgewood, NY 11717

Learn about the latest in Liofol® adhesive and Nordmeccanica machine technology. To register, visit: Henkel Corporation 10 Finderne Avenue Bridgewater, NJ 08807 1.908.685.7000

www.henkeladhesivesna.com/nyworkshopfp or call: 1.908.685.5028 Images courtesy of Henkel Corporation – Düsseldorf, Germany Except as otherwise noted, all marks used are trademarks and/or registered trademarks of Henkel and/or its affiliates in the U.S. and elsewhere. ® = registered in the U.S. Patent and Trademark Office. © Henkel Corporation, 2010. All rights reserved. 6981 (11/10)