Flexible Packaging April 2011

PACKAGING THAT POPS Flexible substrates and stunning quality wins new business

In today’s competitive market, great presentation builds great brands. And the first tangible asset any brand has is packaging. As once-unique features become commonplace, the need for short-run flexible packaging is on the rise. Produced by digital packaging converters, flexible packaging is easier to ship and distribute, and it can protect and extend product shelf life.

Digital opens doors The digital label and packaging market is expected to grow from $1.95 billion in 2009 to $4.05 billion in 2014, according to InfoTrends’ March 2010 report, “Digital Color Printing in Packaging: The Ecosystem.” And flexible packaging can position digital converters to stake their claim. “We see the ability to offer high-quality flexible packaging as a major advancement for the CPC market,” says Kathy Popovich, director of marketing for Innovative Labeling Solutions (ILS). ILS uses an HP Indigo digital press in combination with the AB Graphic Digilam to provide turnkey flexible packaging solutions for virtually every segment. Brand owners rely heavily on consumer trial to build awareness around new formulations and SKUs, so being able to deploy a robust program is a must. With HP Indigo digital technology, digital converters can deliver high-quality packaging that can meet these needs better than conventional printing methods.

Investing in HP Indigo Packaging converters can add flexible packaging to their offerings, and win new business, using one of HP’s end-to-end digital printing solutions, including the HP Indigo WS6000 Digital Press. Already in use at facilities around the world, HP Indigo digital presses can print on a wide variety of flexible packaging films and other substrates.

Delivering packaging that pops on store shelves, HP Indigo digital presses replicate PANTONE® Colors and special brandspecific hues. Eric Knop, director of business development for ILS, explains, “HP Indigo technology provides us with the print quality of gravure, without the minimum order quantities, lead time or setup waste and costs.” And the HP Indigo WS6000 prints at speeds up to 98 feet per minute in 4-color mode, getting packaged products to market faster than traditional processes. HP SmartStream workflow solutions offer a special Labels and Packaging module for increased productivity from start to finish.

Winning business By offering more—stand-up pouches, three-side seal bags and mock-ups—packaging converters can really grow business. Knop says that so far, ILS’ new flexible packaging services have been incredibly well-received, both by current and potential customers. “Impact at shelf is paramount for today’s brands, whether they are private label or a worldwide brand,” adds Popovich. “The versatility that HP Indigo digital presses offer in terms of graphic flexibility, print quality and speed-to-market is critical to success in this new consumer landscape. We’re excited to be one of the first to deliver it.”

Learn more at www.hp.com/go/packaging

© Copyright 2011 Hewlett·Packard Development Company, LP. The information contained herein is subject to change without notice.

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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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18 COVER FEATURE Quantifying Your Sustainable Practices One company’s sustainable changes are pushing it into a more efficient business position.

25 FEATURES 10 FPA UPDATE

36 SPECIAL REPORT ON FLEXO

Association Activities Update Corporate Sustainability Metrics...2011 Board of Directors Announced...Students Design Innovative Flexible Packages...and more.

Flexible Materials Manufacturer Named First American HD Flexo Certified Printer The process and use of HD digital flexographic technology provides high-resolution laser optics and advanced screening technologies to deliver extended color gamut, higher contrast, increased tonal range and smoother vignettes.

25 PRINTING: WORKFLOW &

29

ENTERPRISE MANAGEMENT Efficiently Connecting Software, Workflow and Production With an MIS software solution in place, system maintenance overhead costs can be kept to a minimum, while return is maximized.

DEPARTMENTS

27 TECHNOLOGY:

8 EDITOR’S FORUM

PLASTICS ADDITIVES Nucleation of PE Cuts Cycle Times and Boosts Performance By utilizing nucleated PE, film converters can reduce cycle times and take advantage of downgauging opportunities to lower system costs.

16 CONVERTER NEWS Retort Flexible Packaging Program Expanded… and The End Result. 31 SUPPLIER NEWS Distribution Agreement Signed...and Flexographic Press Purchased.

29 INDUSTRY Q&A:

36

COLOR MANAGEMENT Ensuring Optimal Color Management As a founding employee of Color Logic, Mark Geeves, director of sales and marketing, understands the color management market’s demands.

33 INDUSTRY INSIGHT 34 HOT PRODUCTS 38 CLASSIFIEDS

30 ROUNDTABLE ON SURFACE TREATMENT (SPECIAL ADVERTISING SECTION)

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42 CALENDAR OF EVENTS & AD INDEX

www.flexpackmag.com | FLEXIBLEPACKAGING

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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

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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APRIL 2011

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Editor’s Forum

THE INDISPENSABL E TOOL F OR CONVERTERS & PRINTERS OF F LEXIBLE PACKAGING

®

GO GREEN AND STILL PROSPER he more you think about the direction of business these days, the more you realize the arrow points to sustainability. Even though the economy had slowed, sustainability has grown in business. Consumers want sustainable solutions, whether in products, services or even packaging. Not to mention, the benefits sustainable changes offer to the environment. That is why it is so important to immerse your business in making a green impact. Many companies are hesitant to alter workflow and production practices to more earth-friendly ones, but I say if you can make a few tweaks here or there, and it doesn’t impact the business, that makes good business sense. Flexible Packaging’s cover story highlights a few companies’ green initiatives that have brought impressive returns on investment. One company’s sustainability policy is, “Adopting strategies and activities that allow a company and its stakeholders to realize their profit goals in ways that protect, sustain and restore the Earth’s life support system.” Find out how your company might be able to make similar green changes on page 18.

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Return on investment is still the name of the game. The April issue’s focus is keen, lean or green. Choosing to do business more keenly, more leanly, or more greenly will ensure success, no matter the choice. Printers will appreciate the information presented on page 25. This article highlights software that can improve workflow and enterprise management, as well as production. There’s also a great explanation of Plastics Additives on page 27. Page 29 offers information on Color Management and why it’s so integral to the printing process. Even our Special Advertisers Section includes the Roundtable on Surface Treatment and how to troubleshoot accordingly. As always, our Converter News and Supplier News sections will keep you in the know on industry goings-on (pages 16 and 31, respectively). This month’s issue is sure to give you knowledge on how to create a more effective, seamless workflow. Green initiatives seem to be here to stay. So take a seat and read how to update your company’s practices and processes. You might be pleasantly surprised to read how much companies are getting back for their investments. After all, return on investment is still the ultimate name of the game. Go green and still prosper. FP Sincerely, ERIN J. WOLFORD (847) 405-4042 [email protected]

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Packaging Group Publisher Mike Barr, [email protected] 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] Marketing Coordinator Elisabeth Cuneo, [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] 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 3

APRIL 2011

THE NEW STANDARD IN FLEXO STACK

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CONTACT RETROFLEX

phone: (920) 532-4850 • fax: (920) 532-4854 [email protected] • www.retroflex.com

F LE X I B L E PAC K AG I N G A S S OCIATI ON | UPDATE

CORPORATE SUSTAINABILITY METRICS FOR FLEXIBLE PACKAGING MANUFACTURERS FPA Releases Corporate Sustainability Metrics & Guidance Document emands on businesses to provide proof of sustainable business practices continue to escalate across the value chain. In response to requests from stakeholders for transparent flexible packaging manufacturing information, the Flexible Packaging Association commissioned Packaging and Technology Integrated Solutions to conduct research and identify corporate sustainability metrics, including definitions and reporting methods for what should be measured, and how it should be measured. The results of that study are available in the FPA Corporate Sustainability Metrics for Flexible Packaging Manufacturers Report. The Report provides guidance on responding to stakeholders’ requests and is intended to provide a

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consistent reporting method for the most frequently requested information on greenhouse gas emissions, energy and water use, and waste management. The Report also includes a list of sustainability goals and expectations from key brand owners, retailers, and investment firms; and, publicly available supplier questionnaires from Walmart, P&G, SAM (DJSI World), Carbon Disclosure Project, CDP Water Disclosure, and Bloomberg. For more information on The Corporate Sustainability Metrics for Flexible Packaging Manufacturers Report, contact the association at (410) 694-0800. The Report is a benefit of FPA membership. FP

FLEXIBLE PACKAGING ASSOCIATION ASSOCIATION ANNOUNCES 2011 BOARD OF DIRECTORS The Flexible Packaging Association is pleased to announce its 2011 Board of Directors. Directors are elected by FPA voting members through mail ballot. Directors are elected for a term of one year and assume their directorship at the FPA Annual Meeting. For more information, contact FPA at (410) 694-0800. FP

OFFICERS & EXECUTIVE COMMITTEE

DIRECTORS:

Chairman of the Board: William Burke, Nordenia USA Immediate Past Chairman: John Baumann, Ampac Packaging LLC Executive Vice Chairman (chairman-elect): Jim Mize, Sealed Air Corporation Treasurer: Michael Impastato, Flint Group President (non-voting member): Marla Donahue, Flexible Packaging Association

Fred Crowe, Master Packaging Michael D’Angelo, Bobst Group North America Jeff Dowd, Belmark, Incorporated Paul Griffith, ExxonMobil Chemical Company Terry Harper, Printpack Incorporated Ernest Holley, Oracle Packaging John Hotz, NOVA Chemicals, Incorporated Jack Knott, Exopack, LLC Jeffery Lammers, Bemis Company, Incorporated Larry L. Lanham, Polymer Packaging Incorporated

EXECUTIVE COMMITTEE MEMBERS AT LARGE:

Tom Cochran, Amcor Flexibles Pedro Fernandez, DuPont Company Ken Swanson, Berry Plastics Corporation Rob Tiede, Sonoco Flexible Packaging Battle Wall, St. Johns Packaging Ltd.

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Joseph Marinacci, Graphic Packaging International, Incorporated Jon McClure, ISO Poly Films, Incorporated Charles Murray, Sun Chemical Company Paul Nietvelt, The Dow Chemical Company Michael Nowak, cei Irv Robinson, Robbie Madeleine Robinson, LPS Industries, LLC James Ross, Siegwerk USA Co. Jeffery Taylor, Westlake Chemical Corporation

APRIL 2011

STUDENTS DESIGN INNOVATIVE FLEXIBLE PACKAGES Creative Concepts for Windshield Wiper Fluid, Cupcake Mix Receive Top Honors in 2011 Student Flexible Packaging Design Challenge Forty-six creative flexible packaging concepts were submitted into the Flexible Packaging Association’s 7th annual Student Flexible Packaging Design Challenge. Entries included a wide range of flexible packaging ideas for food, beverages, cleaning, health, and beauty items. Of those, two concepts were selected to receive top honors in the 2011 Student Design Challenge. First place honors were presented to Mohawk College students Michelle O'Connell and Tasha Aird for their development of the Windshield Washer Fluid Package. “This package includes a unique innovation that also acts as a funnel for filling automobile fluids. Attached to the end of the hose is a semi-rigid threaded cap closure,” explained O’Connell. Their proposed design would replace the one gallon semi-rigid container, which is currently used in the market. The new package would offer many benefits

including a reinforced handle for easy carrying and a unique pull-off hose incorporated into the side of the stand-up pouch, which eliminates the use of a separate tool for filling the fluid reservoir. Michelle and Tasha also received second place honors for their Topper’s Cupcake Package. “This package represents a creative flexible design for individually portioned and premixed cupcake batter. It is a polymer-based pouch with a convenient pouring feature. All ingredients are in dry form – the customer only needs to add water, pour, and bake!” said Aird. The new design would contain enough mix to create a dozen cupcakes and would be available in several different flavors including vanilla, double chocolate and cha cha cherry. The unique shape of the pouch combined with vibrant graphics SDC continues on page 12 >>

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F LE X I B L E PAC K AG I N G A S S OCIATI ON | UPDATE << SDC continued from page 11

make the package stand out on store shelves. For their development of the first and second place winning entries, the students will receive a team prize of $1,500 and commemorative plaques. The 2011 Student Design Challenge included entries from 50 students enrolled in packaging and printing programs at San Jose State University, University of Wisconsin – Stout, Washington State University, Western Michigan University, Mohawk College, and the Indian Institute of Packaging (India). More than 380 unique flexible packaging ideas have been submitted into the Student Design Challenge since the competition was established by FPA in 2004. The entries have addressed important packaging issues, advanced the use of flexible packaging, improved an existing flexible package, and packaged products not currently available in flexible packaging. Special thanks are given to the judges of the 2011 Student Flexible Packaging Design Challenge: 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.

WATSON STANDARD JOINS FPA

The Flexible Packaging Association is pleased to announce that Watson Standard has joined the association. As an associate member, the company specializes in application based, customer specific conventional and energy curable coatings, adhesives and related products for the flexible packaging industry. The company’s FPA official representative is Julie Watson, marketing director; and, the FPA alternate representative is Patrick Maloney, vice president of Sales and Technology. For more information, visit www.watsonstandard.com.

For more information about FPA’s Student Flexible Packaging Design Challenge, please contact the association at (410) 694-0800 or visit www.flexpack.org. FP

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APRIL 2011

The Robinette Company Choosing the Greener Path

The Robinette Company, based in Bristol, ol, TN, made a commitment to use environmentally responsible esponsible processes for production. This goal brought them down a greener path and to leading-edge capabilities. Today,, the company is one of the few that prints wateraterbased inks on film and uses solvent-freee adhesives for lamination. “High performance equipment is a must for these applications. At Robinette, we’ve worked for years with W&H machinery and knew we could expect not only the best equipment performance, but also exceptional customer service,” said President, George Thomas. The Robinette Company operates one MIRAFLEX and two NOVOFLEX presses. At W&H, we are proud to be partnered with the Robinette Company.

Ow wner Joe Rob binette (l) with Prresident George Thomas (r)

Robinette’s 52” MIRAFLEX CM 8

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Converter News

BEMIS EXPANDS RETORT FLEXIBLE PACKAGING PROGRAM everaging recent acquisitions with significant investments and material science innovations, Bemis Flexible Packaging has strengthened its retort packaging offering to create a powerhouse global resource for brand packagers. As processors continue a steady transition to shelfstable flexible and rigid packaging for a variety of foods, Bemis has furthered its position as a global leader with expanded retort packaging capabilities. Examples of Bemis’ next-level retort materials include breakthrough new self-venting technologies for microwave packaging; high-efficiency film with ultrasonic-compatible sealants; clear films that allow consumers to see the package contents; and easy-peel lidding structures with high-burst strength. “Slowly but surely, retort flexible and rigid packaging is finding its place on North America’s grocery shelves,” says

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the END RESULT

SUNCHIPS QUIETS DOWN fter surviving a viral media firestorm over the noise level of its previous, compostable SunChips bags and temporarily pulling some versions of that bag off the market, Frito-Lay is now relaunching the bags with a new, quieter packaging structure. The Plano, Texas-based company will replace the adhesive between the outer and inner layers with a rubber-like sealant that buffers the noise and could make it comparable to the decibel level of other snack bags. The bags use polylactic acid (PLA), a material that offers compostability advantages and a renewable resource from corn byproducts. Brad Rodgers, manager of sustainable packaging for PepsiCo Advanced Research, will address Frito-Lay’s noise-reducing initiative and the efforts to reconstruct the bags during a presentation at the 2011 Food Packaging Technologies Summit, to be held April 5-7 in St. Louis. Rodgers also will discuss the new bags in the March 31 issue of Packaging Strategies Newsletter. FP

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Bemis has strengthened its retort packaging capabilities to offer unmatched expertise and the industry’s broadest portfolio of flexible and rigid retort solutions.

Dan Bornemann, market manager at Bemis Flexible Packaging – Milprint Division. “Today you’ll see foods including entrees, side dishes, baby foods and even soup in shelf-stable flexible packaging. And because we expect more and more markets and applications to make the transition, we continue to invest in capabilities and technologies to support the growth.” Bemis retort packaging structures are engineered from a market-leading array of self-manufactured sealants with ultra-high thermal stability, burst strength and barrier. Materials include foil laminations and unsupported foil from 0.275 to 2.8 mils. Retort – a process that uses super-heated water to cook foods in the original shelf-stable package – is gaining traction due to many environmental and cost advantages. Retort pouches are a sustainable alternative to metal cans, offering significant space savings throughout the supply chain. They pack off tighter than cans when filled, so more packages fit in the same truck, saving fuel use and transport cost. In addition, they generate less waste after use, saving landfill space and disposal fees. Sustainability is only one of retort’s many advantages. Retort pouches sterilize in less time than cans, which improves food quality, texture, color and aroma. The pouches also offer an alternative for food processors concerned about the possible toxic effects of Bisphenol-A (BPA), which is present in cans’ epoxy-coated lining. Consumer benefits include extended shelf life combined with space-efficient storage; ease of opening and dispensing and on-the-go convenience. FP Bemis (920) 527-2300; www.bemis.com

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APRIL 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”

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Cover Feature: Green Plants, Processes and Products

Quantifying your

$USTAINABLE practices

By Erin J. Wolford, Editor-in-Chief

ONE COMPANY’S SUSTAINABLE CHANGES ARE PUSHING IT INTO A MORE EFFICIENT BUSINESS POSITION. ustainability is morally right, but in business, sustainability has to make business sense, too. For Prairie State Group’s (PSG) executives and managers, sustainability is a major goal, when it does not interfere with product or service quality. And being able to quantify how these practices make an impact, both environmentally and monetarily, is important. Executives and management at PSG made tough decisions in production to reduce waste and cost. Dan Doherty, PSG’s executive vice president/principal, has encouraged all of his employees to submit ideas that could make the company more sustainable. “We encourage process improvement through our plant-wide idea program, GIFT – Great Ideas for Today. Recently, a GIFT incentive

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program resulted in 93 new ideas from our employees; many of these ideas reÆected our organization’s commitment to sustainability,” says Doherty.

Drum Recycling PSG’s green initiatives continue to Æow through the rest of the company. Recognizing that cleaned empty solvent drums were being thrown away into the compactor, the company decided to come up with an answer to alleviate that. “Since partnering with a local drum recycling company, we have recycled 224 drums in 2009 and 384 drums in 2010. This means less waste in our local landÅlls as well as less use of natural resources to manufacture new drums. We have seen 100 percent improvement in the overall waste reduction program here at PSG as a direct result of this waste not being in our compactor,” Doherty says.

Raw Material Waste Reclamation “At more than 250 Åve- to eight-color orders a month, we generate plenty of make-ready and waste rolls. Approximately 90 percent of these Æexible packaging rolls were being loaded into the compactor. We found and partnered with a company that regrinds waste

| www.flexpackmag.com

rolls to be used in other manufacturing processes,” explains Doherty. PSG’s quantiÅable numbers for landÅll waste include 2,068,300 pounds of waste in 2008; 1,361,260 pounds in 2009; and now 1,108,460 pounds in 2010. Implementation of this initiative has reduced landÅll waste by 47 percent since 2008. “As a result, the frequency with which we have waste hauled away from our facility has diminished, going from 3 pick ups a week to less than one. And still, our sales have increased while our waste has decreased signiÅcantly. Of course, this also saves us

[money in] hauling and dumping fees,” Doherty explains. “We saw a savings of nearly $45,000 in 2010 over what we spent for waste removal in 2008-2009. We would highly recommend this initiative to our colleagues, as it has an easy implementation once a holding area is designated to gather the material to be recycled.”

Press Wash Recycling PSG sought to lower its press wash solvent waste as well. In 2008, PSG contributed to 136 drums of spent solvent press wash. PSG decided that something needed to change. “The Årst step in the reduction was to implement a program that allowed us to reuse the dirty press wash two to three times, reducing our disposal by 103 drums in 2009. The waste stream was reviewed again in June 2010 and we removed contaminates, which allowed us to reduce our number again, this time to 86 drums,” Doherty explains. “During the last six months of 2010, only 33 drums of solvent press wash waste were generated. We installed a solvent recycling system in-house in December 2010. Currently we send out less than one drum per week and expect to see continued reduction to fewer than 40 drums total in 2011,” says Doherty. “Using an electronically controlled distillation process, the ECOpure separates co contaminates from the used solvent, re resulting in a 95 percent recovery rate a a 90 percent reduction of disposal of and to waste,” comments PPCTS president toxic R Richard McDonald, manufacturer of the so solvent recycling machine. These improvements have helped P PSG decrease its waste hauling, as well as lo lower its need to purchase large amounts o press wash solvent. Environmental of im impacts include saved fuel associated w hauling old solvent and delivering with n solvent, the elimination of properly new d disposing of spent solvent, as well as sa saving the production of new solvent. “In addition, we save approximately $ $100 per drum that we do not send out. P Prairie State Group’s executive vice president/ principal Daniel Doherty and PPCTS’ president p Richard McDonald partnered to bring PSG R true ROI with actual sustainable claims to boot. tr APRIL 2011 A

The 2010 reduction saved us close to $6,000 over the 2008 numbers. We have not purchased any new unused solvent since early December. Additionally, we are using fewer buckets, as we no longer utilize used press wash solvent more than one time. This saves not only money, but also storage cost and Æoor space,” says Doherty. PSG’s new press wash solvent recycling program may also put them in better graces with the Environmental Protection Agency (EPA). “Because we've continued down this earth-friendly path, we are applying for Small Quantity Generator status, moving away from our Large Quantity Generator status with the local and federal regulatory bodies. This will decrease our reporting functions as well as show a working minimization program,” Doherty explains.

Plate Wash Solvent Recycling Doherty and his team also looked into

improving the company’s plate wash solvent use. “After just one use, we were replacing solvent with a recycled product and sending out dirty solvent. This created biweekly out-of-state shipments of dirty solvent as well as the occasional need to purchase new virgin solvent.” The PSG team determined a way around that problem. “By creating our own recycling solution, we were able to decrease our dirty solvent shipments from 27 drums in 2008 to 16 drums in 2009 and 10 drums in 2010. Less regulated waste being shipped out means a decreased shipping impact, too. Less fuel consumption, truck emissions and road wear are just a few of the overall environmental beneÅts,” Doherty explains.

Energy Consumption Initiatives As with many production plants, companies are required to track and record natural gas usage. Doherty explains that the company was able

ENVIRONMENTALLY-FRIENDLY ROLL PROTECTION OFFERED Environmentally friendly recycling services from Badger Plug reduce the flow of packaging components to landfills, and provide roll packaging products at a reduced cost. Endboards, sleeve plugs, pallets and H/U channels from Badger Plug are all recyclable through the company’s recycling services. “We found a local company that will recycle our end boards and plugs and give us a credit for the returns. The end boards are used as-is, requiring fewer natural resources and less energy to break them down to be used in a different application as well as reducing the need to produce new end boards,” says Doherty. Badger Plug partners with a variety of industries to collect larger volumess of unwanted roll packaging components. These recycling services reduce landfill waste and help adger Plug’s save the environment. Badger recycling services also help ng the bottom line by offering ed customers quality recycled roll packaging products at a reduced cost. Badger Plug badgerplug.com (920) 757-7300; www.badgerplug.com

FLEXIBLEPACKAGING

| www.flexpackmag.com

19

Cover Feature: Green Plants, Processes and Products

to adjust usage to lower operational costs while being more earth friendly. “We utilize a pollution control device for solvent emission destruction. In compliance testing in 2007, the Illinois EPA approved a high temperature setting for this device that required a large amount of natural gas to achieve. With increased proÅciency, we sought to reduce the temperature setting in order to decrease our natural gas usage.” “In September 2010, we retested and earned the approval for this lower temperature. We are reducing the impact on our environment by decreasing our consumption of natural gas, a resource that is regulated by the Illinois EPA; as a greenhouse gas, further regulations regarding this resource may be pending,” continues Doherty. “As a result of our decreased consumption, we have seen a 23 percent reduction in our gas bill in the forth quarter of 2010 versus the same quarter in 2009.

The cost per therm is running near $0.40 and we anticipate a yearly savings of approximately $12,000. While we had to pay for the retesting of this pollution control device, we expect the return on investment to be around 18 months,” Doherty explains. PSG has also started recycling all waste paper, plastic and aluminum cans that the ofÅce generates at a local recycling center. Doherty also mentions that the company will be changing out all of the lights throughout the ofÅces, plant and warehouse. “We are going to change out all of the lights – we’ll get a 2 year payback with a $30,000 investment. All of the lights will be changed out and installed in the plants and ofÅces with automatic turnon/-off motion sensors to save electricity and environmental impact.” Being able to quantify your sustainable practices into true return on investment (ROI) numbers might be more attainable than you think. Prairie State Group’s motto is, “Shorter

Executives and management at PSG, custom printer and laminator of flexible packaging and custom printed pressure sensitive labeling, made tough decisions in production to reduce waste and cost.

runs, quicker turnarounds, high-end graphics.” Sustainable practices could easily be added to that motto, too. FP

SMART CORONA at your Àngertips!

Toll Free: 888-PILLAR6 Web: www.pillartech.com E-mail: [email protected]

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FLEXIBLEPACKAGING

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APRIL 2011

We make the converter foil that you use to make flexible packaging.

Innovation in flexible packaging

oraclepackaging.com (336) 777-5000 Phone (336) 777-5440 Fax [email protected] 220 Polo Road Winston-Salem, NC 27105 USA Member

Cover Feature: Green Plants, Processes and Products

GREEN INITIATIVES SPREAD ACROSS THE INDUSTRY nother company that’s focusing its efforts on sustainable solutions is Davis-Standard. Davis-Standard is focusing on several growing markets using new technology for applications in electronics, green technology,

A

Davis-Standard is adapting to serve customers and the environment better and offering solutions, like this direct drive extruder, to its customers.

Go Green with Roll Protection Now you can protect the planet and your roll products.

Let’s re reduce roll packaging that ends up in landfills. Badger Plug will recycle and pay for bulk quantities of roll protection products that can be re-sold as used packaging. It’s just one way to ensure that our quality products can also contribute to a better environment. Call us for details.

Sleeve Plugs End Boards

Green is a better idea in roll protection!

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24

FLEXIBLEPACKAGING

engineered films and packaging using biax products or derivatives. The variety and quantity of equipment installed around the world reflects the company’s ability to address a variety of processes. Work in green markets includes technology for EVA encapsulation, coreless rolls, recycling and down gauging of film products, biodegradable resins and lithium ion batteries. Equipment that supports energy efficiency and cost reduction is a focus of Davis-Standard, such as highly efficient motors, newly designed barrel heaters, proven gearless extruder technology, energy-saving primer dryer designs, scrapless winders, highly efficient air rings for blown film and much more. Davis-Standard’s Converting Systems group also introduced a new series of Black Clawson Converting Machinery underwater, water ring and air ring pelletizers for micro pellets, normal pellets and macro pellets in laboratory sizes to high-capacity virgin resin plant sizes. This technology was developed to support new markets, such as bio resins as well as de-bottlenecking projects and improved scrap recovery at all levels. Davis-Standard’s Extrusion Systems group recently completed a series of tests that showed its direct drive extruders consistently provided quieter (as much as 70 percent at 100 rpm), more energyefficient operation (as much as 25 percent) when compared to its AC- or DC-drive counterparts. These extruders are capable of processing a variety of resins for all extrusion applications. FP

| www.flexpackmag.com

(860) 599-1010; www.davis-standard.com

APRIL 2011

Printing: Workflow & Enterprise Management

EFFICIENTLY CONNECTING SOFTWARE, WORKFLOW AND PRODUCTION What is MIS?

Many MIS software programs are specifically organized for printing or packaging, according to Jan De Roeck of EskoArtwork.

By Jan De Roeck, Contributing writer number of printers and converters we know have conventional Æexo and more than one digital press. For the volume of business these converters receive, there is certainly sufÅcient printing press capacity. But what is often lost is that press or Ånishing equipment capacity is not the key determinant for overall production capacity. With production runs getting smaller, more orders have to be processed throughout the plant. This puts more pressure and strain on prepress and order administration. So, even with sufÅcient printing capacity, the true bottleneck of a converter is typically its capacity to manage the jobs. With this in mind, MIS, all of a sudden, becomes very relevant for every packaging and label converter, but especially for a converter using digital presses. The next logical step would be integrating MIS and prepress, which can create a supercharged automation system, sharing workÆow data, automatically driving prepress and ultimately delivering pre-production capacity on par with printing and Ånishing capacity.

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APRIL 2011

An MIS is any software system that enables a business to operate with more information. The intelligence that comes with more available data can help businesses run more effectively, making well-informed business decisions. The data collection and reporting areas are varied, covering all facets of a business, including Ånancial reporting, quoting, sales order processing, sales management, scheduling, production Æoor management, purchasing and inventory – to name a few. If conceived well and prepared properly, a printer does not need a large staff of developers on-hand to maintain the system. System maintenance overhead costs can be kept to a minimum, while return is maximized. Nor does one have to start with a complete system. Some companies begin by focusing on one area of their business, and expanding as they gain conÅdence and expertise. A business can grow into a full, dedicated system. It is

all in the preparation. MIS software can come in many sizes and Æavors. They can exist as prepackaged, off-the-shelf software. Many of these systems are available speciÅcally organized for printing or packaging. Some can be a bit more complex to implement, but less intrusive to a business, allowing a printer to customize the system to Åt their speciÅc way of doing business.

Integration and Information Sharing The rationale for integrating an MIS and prepress system is simple. In Æexible packaging, the entire manufacturing process is extremely tight, under strict deadlines. We all bemoan the fact that it takes months to develop the product concept, weeks for design and approval, but only days to get it all done. It is critical that the process is managed efÅciently. It’s about data transfer, and the power of information Æow throughout the production cycle.

With an MIS software system, maintenance overhead costs can be kept to a minimum, while return is maximized.

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25

Printing: Workflow & Enterprise Management

Integration of MIS and the production workÆow also reduces the risk of operator error. For example, if a barcode is needed and it is available from the business system, it can be forwarded to the production workÆow, i.e. the workÆow operator does not have to en-

ter the value, where there is a signiÅcant problem if entered incorrectly. Information typically Æows in both directions. For starters, the MIS offers a transfer of job speciÅcations. Information that is usually sent to the workÆow include job order details, due date, involved product,

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plate layout speciÅcations including gang printing, and output speciÅcations – colors, materials, etc. With this information, prepress actions are launched, including all of the workÆow tasks and the plate layout, typically created automatically. In return, the production workÆow offers status feedback. Product Åles are delivered, including links to PDF and .jpg image Åles, along with reports. The brand owner can receive updated status reports, along with requests for internal approval milestones. Has the proof been delivered and approved? Are the plates ready? All this information is fed into the MIS so that anyone with access to the system can receive feedback when the job is in process. Combining the two systems makes it easy to see the beneÅt to the converter, particularly when the workÆow can draw data from an external database. Production workÆows can actually pull information from a business database, and that content can be automatically placed into the design. From a business proposition, converters can develop tighter relationships with brand owners, and the integration of these systems forge tight interaction between them. For the printer and brand owner, the MIS system is at the heart of the information Æow. The MIS is fed the status of the project on a regular, real-time basis and the brand owner can receive regular updates. By tying in business systems with production workÆows, other opportunities open up where a converter or trade shop can provide additional value-add services, like developing copy translations, overseeing ingredient copy for brand extensions, and the management to get text placed and approved correctly. Once the integration between systems is in place, the prospects are endless. FP

About the Author Jan De Roeck is the director of product marketing software for EskoArtwork.

©2011 EFI. All rights reserved.

EskoArtwork (800) 743-7131; www.esko.com

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APRIL 2011

Technology: Plastics Additives

NUCLEATION OF PE CUTS CYCLE TIMES AND BOOSTS PERFORMANCE By Wim Van de Velde, Contributing writer olyoleÅns, including polypropylene (PP) and polyethylene (PE), are the most widely used plastics in the world, and are essential to the packaging industry. Many trends, from consumers’ desire for improved aesthetics to manufacturers’ drive to cut costs, have led to improvements in the appearance, performance and processing efÅciency of polyoleÅns. SpeciÅcally, PP has been successfully modiÅed through nucleation and clariÅcation to improve aesthetics, physical properties, warpage control and processing speed. In contrast, although nucleation of PE has been studied for some time, a number of technical issues prevented success. Recently, however, a new nucleation technology was developed, offering the Æexible packaging

P

industry signiÅcant improvements in barrier performance coupled with enhanced productivity and aesthetics. By utilizing nucleated PE, Ålm converters can reduce cycle times and take advantage of down-gauging opportunities (through barrier improvements) to lower system costs, while packaging manufacturers can achieve better barrier performance for extended product shelf life, improve optical quality and gain new freedom to create novel designs. Another important advantage of nucleation is environmental responsibility. By improving the value and costeffectiveness of PE, nucleation has the potential to expand the use of this easily recycled material and replace other plastics that may not be as sustainable.

BARRIER IMPROVEMENT FOR HYPERFORM HPN-20E 3.5

80 HDPE

HDPE +HPN-20E

70

3

2.5

50 2 40 1.5 30

WVTR (g/m2/day)

OTR (cc/m2/day)

60

1

20

0.5

10 0

0 OTR (cc/m2/day)

WVTR(g/m2/day)

This chart displays the superior barrier performance of PE nucleated with Milliken Hyperform HPN-20E agent in high-density polyethylene. Permeation of water vapor and oxygen is reduced significantly vs. non-nucleated HDPE. HPN-20E improves gas barrier between 20 percent and 40 percent, resulting in down gauging opportunities of 20 percent or more.

APRIL 2011

New nucleation technology promises to make a major impact on the future of flexible packaging, according to Van de Valde.

Nucleation Benefits Nucleation is the process that occurs in the initial formation of a crystal. During cooling of molten PE, the molecules become arranged in a crystalline pattern. Without a nucleating agent, this pattern tends to be random and the crystals tend to be larger, reÆecting more light and producing a lower level of clarity. But a new nucleating agent on the market positively impacts the crystallization process in several ways: It decreases the size of the PE crystals for improved optical performance in butane gas-phase linear low-density polyethylene (LLDPE) blown Ålm. It promotes a controlled and uniform crystal orientation that increases barrier performance, and it raises the peak crystallization temperature and signiÅcantly increases the rate of crystallization (half time is decreased) to shorten cycle times. The optical improvement of LLDPE blown Ålm (particularly C4 gas phase), creates opportunities for Ålm converters to reduce the amount of low-density PE (LDPE) – in cases where low-density polyethylene (LDPE) is used for optical

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Technology: Plastics Additives quality and not melt strength – used in typical LLDPE-rich blends, resulting in the potential for cost savings. Due to the speciÅc crystalline orientation that the new nucleating agent imparts, called Hyperform HPN-20E, a passive barrier mechanism is created, signiÅcantly reducing permeation for a wide range of permeants, including water, oxygen, solvents, hydrocarbons and grease. Better barrier performance translates into cost and quality beneÅts. Thanks to the 20 percent to 40 percent improvement in barrier properties in high-density PE (HDPE) blown Ålm applications that is achievable with nucleation, companies have the choice of two desirable results: increasing the shelf life of products with a Ålm of existing thickness, or using a thinner-gauge Ålm (down-gauging by as much as 20 percent) to maintain current shelf life. For converters, nucleation technology cuts cycle times to lower system costs. A higher peak crystallization temperature results in an earlier onset of crystallization,

thus decreasing the frost line height, which can be then be offset by increasing output in blown Ålm.

Nucleated PE for Film Packaging Nucleation of PE is particularly appropriate for blown Ålm, among other applications. For blown Ålm, there are signiÅcant effects in a wide range of PE types (LLDPE, mLLDPE, HDPE), as well as enhancements in physical and barrier performance. This additive offers improved clarity and gloss, particularly in C4 gas phase LLDPE. It also allows for a broader processing window for LLDPE and LLDPE/ LDPE blended Ålms, leading to higher output rates. In LLDPE/LDPE blends, LDPE amounts

Automatic high speed pouch making machines.

Automatic machines for vacuum thermoshrinking sacks.

Automatic machines for bags on roll.

can be reduced when used for optics. The advent of new nucleation technology has removed a longstanding roadblock to broader use of PE in the packaging industry. Nucleation of PE provides beneÅts to converters – cost savings through reduced cycle times and down-gauging. However, it also has wider implications, particularly for the environment. Down-gauging provides the opportunity to reduce overall packaging volume to conserve resources, and the expanded use of easily recycled PE helps to relieve the burden on landÅlls. This technology promises to make a major impact on the future of Æexible packaging. FP Milliken Chemical (864) 503-2200; www.millikenchemical.com

About the Author Wim Van de Velde is the global product line manager for Milliken & Company. Milliken Chemical, a division of Milliken & Company, specializes in developing and producing additives and colorants for the global plastics and household care industries. Milliken Chemical has application and development centers around the world dedicated to customer support.

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 needs to always offer a tailor made solution. Since 1964 Elba installed all over the world more than 2000 machines. To Elba group belong Fiborsin who manufactures extruder plants for plastic nets.

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FLEXIBLEPACKAGING

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APRIL 2011

Industry Q&A: Color Management

ENSURING OPTIMAL COLOR MANAGEMENT As a founding employee of Color Logic, Mark Geeves, director of sales and marketing, understands the color management market’s demands. Mark Geeves Color Logic

By Erin J. Wolford, Editor-in-chief

Q:

Knowing color is an integral part of branding as well as an important marketing tool; what are other obvious and not-soobvious results of color?

A:

While color is indeed an important part of branding and marketing, the overall appearance of the product packaging is equally important. Many design factors can determine how a product stands out on the shelf – and color is only one of them. In fact, as color management becomes more standard, other factors become even more important, particularly as a way of distinguishing between varieties of the same product.

Q: A:

What are important points to ensure optimal color management?

The subject is best understood in terms of the three Cs of color management: Calibration, Characterization (ICC ProÅling), and Control of the Process. The most important of these is Control of the Process. If the system is not under control, Calibration and Characterization become inconsequential.

Q:

What additional technologies might converters consider using for best color management?

A:

Color management should be adapted speciÅcally to the type of image or printing being done. Because Bec the Color-Logic Process Metallic Me Color System involves either silver silv inks or metallic Ålm, printers and an converters should use polarization tio with their densitometers, which is more sensitive to ink Ålm and specialized sp substrates – a critical issue i with silver inks or metallic l objects. We recommend use of a spectrophotometer, which Silver inks or metallic films, like those on this wine bottle label, should use polarization with the converter's/ printer's densitometer because it's more sensitive to ink film and specialized substrates.

APRIL 2011

The Color-Logic software – a simple plug-in to any conventional graphic design program – produces the necessary files for many printing situations.

permits using a polarization Ålter when metallic inks are being run or when a clear Ålm is being applied to a metallic object. Using polarization ensures that metallic printing is consistent or that the metallic look of the object being covered is consistent. The spectrophotometer should be switched back to Status T or E responses when measuring process colors.

Q:

What new and exciting news does Color-Logic have to share with the flexible packaging industry?

A:

Color-Logic has developed a graphic design and color communication system that enables converters and printers to print a broad range of metallic colors as solids, within images, or as gradations, with a mere Åve inks. Understanding the Color-Logic process essentially involves wiping away all conventional wisdom about metallic printing, or printing Ålm which will be applied on metallic objects. Basically, the Color-Logic process involves conventional CMYK printing plus a silver Åfth color, or conventional CMYK printing plus a white Åfth color, which is used to mask either a silver substrate or a metallic object being wrapped. The Color-Logic software – a simple plug-in to any conventional graphic design program – produces the Åve necessary Åles for either situation. FP Color-Logic Inc. (513) 258-0047; www.color-logic.com

FLEXIBLEPACKAGING

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29

Roundtable: Special Advertising Section

ROUNDTABLE ON SURFACE TREATMENT Robert B. Hablewitz

Tom Gilbertson

Business Unit Manager Pillar Technologies, an ITW Company

VP Application Engineering Enercon Industries Corporation

7 years with the company/ 3 years in this position

27 years with the company

(262) 912-7200 www.pillartech.com

(262) 255-6070 www.enerconind.com/treating

stainless steel) electrode that may be of a Åxed width or in many cases may be adjustable (segmented electrode) to the web width being processed.

By Erin J. Wolford, Editor-in-Chief

Q:

Surface treatments vary throughout the industry; what are some common surface treatment technologies and for which application(s) are they appropriate? Hablewitz: Common surface treatment technologies include: • Bare roll treatment, which is normally required for conductive substrates, like metalized Ålms. Bare roll treatment commonly utilizes a ceramic electrode and conductive (bare) treater ground roll to insure that the conductive substrate is electrically grounded at the point of the corona discharge. • Covered roll treatment can be used for most all treatment applications when conductive substrates will not be processed. Covered roll treatment usually utilizes a metal (normally

Gilbertson: When evaluating corona

discharge and atmospheric plasma technologies, it is important to recognize that corona systems are generally less expensive. The general rule is to use corona if it can meet the application’s requirements. Atmospheric plasma should be used if materials are unresponsive to corona treatment or if the application requirements dictate. For example, atmospheric plasma is capable of providing higher and longer lasting treatment results. Longer lasting treatment adds signiÅcant value if it translates into improvements in productivity, inventory and distribution channels. Differences in types of roll coverings and proper web handling techniques are critical and can impact the success of the application as well.

Q:

Poor surface treatment leads to inferior products. What kinds of problems might be the result of poor surface treatment?

A high definition corona system for treating conductive and non-conductive substrates for printing, coating and laminating applications.

30

FLEXIBLEPACKAGING

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Hablewitz: One of the trends that we

have seen in recent years is that customers are processing thinner and thinner Ålms. Thinner Ålms normally mean lighter web tension, which can cause web handling problems in the corona treatment process. Lighter tensions make the Ålm much more susceptible to wrinkling and other issues that can cause uneven and/or backside treatment. With thicker webs and higher web tensions, it is common to supply treaters with the intension to drive the treater rolls with the web. It is becoming much more common to supply surface treatment equipment with nip rolls and roll drive packages to help prevent this phenomenon of backside treatment. Gilbertson: It might be better to say low and inconsistent surface energy leads to inferior products. You can see this on the store shelf in pinholes in the printing of snack food bags, de-lamination of multiple layer packages or failed adhesion bonds on folding cartons. But where you really see the effects of poor substrate surface energy is on the converter’s bottom line and waste receptacles. Most of the time, quality control checks will prevent inferior product from ever leaving the converting plant. So how can converting operations better manage their substrate surface energy? By taking control of their process, understanding technology and eliminating surface energy as a variable. FP APRIL 2011

Supplier News

ANDERSON & VREELAND TO DISTRIBUTE ROLAND PRINTER/CUTTERS oland, an innovative leader in the manufacture of inkjet printer/cutters, has appointed Anderson & Vreeland, Inc. as its distributor in the United States, effective immediately. As the world’s first UV inkjet printer/cutters, Roland’s DPI award-winning VersaUV LEC series is changing the packaging prototype and short-run label industries. For the first time, professionals can print CMYK plus white and clear inks on virtually any substrate and then crease, contour cut or perf-cut designs, all on one device through one seamless workflow. VersaUV uses safe, low-heat LED lamps to print on materials ranging from metallic and synthetic papers and foils to BOPP, PE and PET film. Prototypes and comps are so realistic they are virtually indistinguishable from finished products. Two models are designed for a host of short-run production, packaging prototyping and proofing applications. The LEC-330 UV inkjet printer/cutter has a maximum printing width of 29 inches and the LEC-540 can print and cut up to 53 inches. Darin Lyon, vice president and general manager of

R

APRIL 2011

Anderson & Vreeland will be distributing Roland Printers and Cutters, including the LEC-330 printer/cutter.

A&V, notes, “With Roland, we now have the world’s most advanced, high-quality printer/cutters to offer our customers. These products complement our extensive line of products to create the broadest, most advanced selection of flexo proofing and plate processing equipment.” Anderson & Vreeland will sell Roland’s VersaUV LEC printer/cutters and provide technical support using a nationwide staff of technical sales representatives. FP Anderson & Vreeland, Inc. (866) 282-7697; www.andersonvreeland.com Roland (800) 542-2307; www.rolanddga.com

FLEXIBLEPACKAGING

| www.flexpackmag.com APRIL 2011

31

Supplier News

CAPRI PACKAGING ORDERS FLEXOGRAPHIC PRESS FROM WINDMOELLER & HOELSCHER Capri Packaging, a division of Schreiber Foods, has added a 10-color Miraflex CM flexographic press from Windmoeller & Hoelscher. The press is located in Capri’s newly expanded 120,000 sq. ft. facility in Clinton, Mo. Schreiber Foods, the world's largest customer-brand dairy company, initially opened Capri Packaging in 1994 to produce flexible packaging that would meet the unique needs of its customers in the private label market. In addition to supplying Schreiber customers, Capri also supplies external customers with packaging solutions. The new press and plant expansion were pivotal in supporting Capri's overall growth in these areas, “With the new press and our ability to turn around multiple shortruns and a variety of SKUs, we are well equipped and ready to take on more outside packaging jobs. The press has also helped make our printing operation more efficient by reducing waste and energy consumption,” says Myron Geiser, Director of Packaging. Plant Manager Rick Heck adds, “The Miraflex began production in December 2010 and the start-up went very well. Production speeds are up. Changeover times

32

FLEXIBLEPACKAGING

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Capri Packaging, a division of Schreiber Foods, has added a 10-color Miraflex CM flexographic press from Windmoeller & Hoelscher.

are down. That combination is important for meeting our customers' needs and for driving future growth.” The line at Capri is capable of printing speeds up to 1,650 ft/min. It is equipped with Easy-set for automatic impression setting, Easy-Reg for registration, Turboclean automatic ink. FP Windmoeller & Hoelscher (800) 854-8702; www.whcorp.com Capri Packaging (660) 885-9221; www.schreiberfoods.com

APRIL 2011

Industry Insight

FLEXO INDUSTRY MEETS LATEST CHALLENGES IN PACKAGING SEGMENTS By Dennis Curtin, Contributing columnist ombining a struggling economy with rising ink material costs, global demand for supplies and competition from other print methods – it’s a challenging scene for flexo printers to juggle as we move well into 2011. Looking at the aspects of the particular challenges is helpful in predicting where we are headed. Building the industry picture begins with costs. As an ink supplier, we have to stay close to the primary ingredients in terms of ready supplies and costs involved. In the last year or so, a “perfect storm” of tight supply, increasing raw materials costs and printer-customers who are dealing with the overall weak economy has placed us in a difficult position.

C

Rising Materials Costs Looking at key ink ingredients shows the current suppliers’ tightrope walk. These include all pigments, especially Carbazole violet, Phthalo blue, titanium dioxide, acrylic monomers, waxes, plus all packaging and shipping used across the ink industry. Titanium dioxide, used in the manufacturing of opaque white, gives printed jobs great opacity so patterns pop off the surface, and is in a period of high demand and tight supply. According to Industrial Minerals, “Supply is barely keeping pace with demand,” with the result being “supply shock.” Visits to ink suppliers by their suppliers are focused on their explanations of price increases. In the case of acrylic monomers used

APRIL 2011

Dennis Curtin believes that the current supply chain issues the industry is experiencing can be staved off through more aggressive shopping of the market, checking out new sources and helping flexo printers to be more efficient.

in water-based inks, feed stocks were allocated and prices went up dramatically in 2010 and continue to increase in 2011.

Considering on-site mixing of inks or alternative pigment choices could be a cost-saving measure.

Strategies to Combat Rising Prices While there is no magic bullet to handle all these disruptive supply chain issues, smart companies are more aggressively shopping the market, checking out new sources and helping flexo printers to be more efficient. If costs can be minimized in other areas, the increases can be offset to some extent. Extensive use of less-expensive supplies is one area for exploration. For example, there are usually circumstances where we have all tended to use the “more economical” supplies, such as in less-demanding print jobs. A careful review of every instance allows

printers to save. Customers may be dialed-in to the benefits and potential changes. With flexo advances being made constantly, the result does not have to be reduced quality. The latest presses are already running at higher quality levels, at higher speeds, using less ink with faster startups. Educating the customer about potential trade-offs, or re-design of jobs, can also be a win-win. For example, evaluating custom colors and offering alternative pigment choices may allow for a printed piece to be re-designed and now open to a wider range of ink supply and cost solutions. Closely allied to the print jobs review approach is a commitment to do more ink blending on site. This results in significant savings in cost and reduced waste. In addition, running trials of ink alternatives opens up new options. Comparing inks and substrates in relation to each other initiates another potential way of working smarter for efficiency and savings. Ink suppliers and flexo packaging printers can compare notes on changes. As long as the flexo industry continues to make efficiency and quality strides and despite current supply challenges, flexo still remains the star of the printing world. FP

About the Columnist: Dennis Curtin is the senior vice president of Press Color Inc. Press Color Inc. (920) 687-1313; www.presscolorinks.com/

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Hot Products

Rubber-based Pressure-sensitive Adhesives on Hand Offering customers an alternative to film labeling materials based on acrylic adhesives, MACtac Printing Products offers a variety of prime films featuring highquality, rubber-based pressure-sensitive adhesives designed for use on a wide range of flexible packaging applications. These prime film solutions are suitable for cold, damp labeling applications and can be used in general purpose or highly conformable label applications, including food and beverage, cosmetics, household or pharmaceutical. MACtac prime film solutions feature a permanent, rubber-based adhesive with excellent tack and ultimate adhesion to a variety of surfaces, including polystyrene, polypropylene and polyethylene. MACtac (800) 255-9733; www.MACtac.com/rolllabel

HIGH SPEED, HIGH RESOLUTION EQUIPMENT TO SENSE REGISTRATION MARKS Tri-Tronics Company, Inc., has introduced a high speed, high resolution sensor designed to accurately detect printed registration marks on continuous web machinery. The Mark-Eye Pro uses the broadband characteristics of a white LED light that provides the high resolution needed for detecting a wider range of color combinations on any color background. This sensor offers a onetouch autoset setup and detects color combinations on any background. It offers high immunity to ambient light, 5-LED contrast indicator and a selection of lens and fiberoptic light guides Tri-Tronics Company, Inc. (800) 237-0946; www.ttco.com

We Treat You Right.

Surface Treatment Innovators www.enerconind.com/treating 262 255 6070 [email protected]

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UNIQUE WEB MEASUREMENT SYSTEM FEATURING TERAHERTZ TECHNOLOGY UNVEILED Advanced Photonix, Inc. (API), has introduced the first online industrial time domain terahertz system for superior scanning web measurement. Its Picometrix T-Ray 4000 is the first web measurement system for the converting/package printing marketplace to feature pulsed terahertz technology. While improving product quality and reducing waste, this solution is the non-nucleonic, non-ionizing, non-contact measurement solution that combines basis weight, percent moisture, caliper thickness and multilayer thickness measurements into one ultra-fast multifunction sensor. Advanced Photonix, Inc. (734) 864-5600; www.advancedphotonix.com

Extremely Tight Tolerance Coating Rolls Available Coating rolls used to apply the thinnest of coatings must be constructed to extremely tight tolerances. Today’s super thin web coatings require extremely tight tolerances from coating rollers. Roller tolerance (or concentricity) is measured as TIR – Total Indicated Runout. The tighter the tolerance, the smaller the TIR dimension. Since rolls are ground and polished with roll bearings in place, Webex uses special bearings with certified tolerances. Most coating rolls are also Webex ThermEx heat transfer rolls often specified with a chrome-plated finish. To ensure such exacting tolerances on coating rolls, the company uses an electronic gauge to measure roll TIR. Webex (920) 729-6666; www.webexinc.com

APRIL 2011

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Special Report: Flexo

FLEXIBLE MATERIALS MANUFACTURER NAMED FIRST AMERICAN HD FLEXO CERTIFIED PRINTER mpac earned the distinction of being named the first HD Flexo certified printer through the implementation of EskoArtwork’s HD Flexo High Definition Flexographic technology in the printing of flexible film. The process and use of HD digital flexographic technology provides high-resolution laser optics and advanced screening technologies to deliver extended color gamut, higher contrast, increased tonal range and smoother vignettes. HD Flexo printing uses these technologies to deliver 150-line screening at 4000 dpi with a smaller dot size and imaging quality that rivals offset. For Ampac’s Seattle facility, the upgrade to HD flexo was not a hard decision to make, as they had already found success with their existing print capabilities, continuing a thriving partnership with EskoArtwork. One of Ampac Seattle’s strong-points is the ability to provide industry leading art support and development to its customers. The ability to provide HD flexo brings this competency to a new level.

A

The process and use of HD digital flexographic technology provides high-resolution laser optics and advanced screening technologies to deliver extended color gamut, higher contrast, increased tonal range and smoother vignettes.

Several noticeable benefits in Ampac’s use of HD flexo technology has been the reduced time in pre-press setup, as well as reduced customer turnaround time and cost savings. Jobs once using gravure print can now move to HD flexo, which can reduce costs associated with gravure prepress. Customers with smaller print runs, whether for surface or reverse print laminations, can now have finely detailed graphics without the higher pre-press costs associated with gravure print.

Smaller print runs can now have finely detailed graphics without the higher pre-press costs. Ampac notes that the success of the implementation of EskoArtwork’s HD flexo technology is due to the Seattle facility’s personnel. Ampac art director, Joe Lydic says, “EskoArtwork gave us the tools, but it took the whole company to pull it off. We have the talented people to pull the plates and run the press. Our staff, in combination with the HD Flexo software and hardware upgrade, has allowed us to live up to our name and mission: Ampac - innovation in action.” According to EskoArtwork, “[Ampac is] constantly innovating to offer the very best in flexo quality.” The HD Flexo Certified seal is only offered to those companies that have passed EskoArtwork’s strenuous HD flexo certification program. FP Ampac (513) 671-1777; www.ampaconline.com EskoArtwork (800) 743-7131; www.esko.com

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[email protected] s www.uteco.com [email protected] s www.uteco.com

H I G H

S P E E D

F L E X O

P R I N T I N G

Leading edge innovation in flexographic printing

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sP2P® : dynamic adjustment system controls printing pressures sPCT® : Press Control during Transition sPTC ® : Predictable Torque Control sSprintWash® : new automatic washup system sFlexoSmartPackHP® : Uteco engineering platform for improved performance and GENETIC INNOVATION profitability in flexographic printing sShopWare ® Production Management, Control & Monitoring: easy machine-operator 54%#/./24(!-%2)#! interface to manage productivity 4/7.0/).4$2)6%s35)4% ® +%..%3!7 '!s0(  s&!8   sLogiPack : automatic handling [email protected]swww.uteco.com of reels and cores

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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] MATERIALS WANTED

CAREER OPPORTUNITY

LOOKING FOR MANUFACTURER DIRECT REPS/ BROKERS

flexpackmag.com PET / BON / PLA FILM

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

RECRUITMENT

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) Please direct your inquiries and resume to: [email protected] 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? Positions to fill? Advertise in the

Classified Network Call Diana Rotman

847-405-4116

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

AIB CERTIFIED EXCELLENCE THROUGH DILIGENCE

[email protected] 38

FLEXIBLEPACKAGING

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APRIL 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

Impex International Group LP 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

PAPERS PP Based Synthetic Direct / Transfer Metalized Holographic Metalized Wet Strength (Beer Labels) 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

AND

WORLDWIDE SALES REPS -----

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

WANTED TO BUY

WE BUY LAMINATE SCRAP • FOIL SCRAP • FILM SCRAP • PAPER SCRAP

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

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

ÁH[SDFNPDJFRP APRIL 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

ROLLERS

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

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

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

After

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

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

We take Visa 847-487-8877

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

PLASTIC CORE PLUGS

GRAPHICS

SCREEN GRAPHICS

40

Screen-printed and Thermal Die Cut Decals, Bumper Stickers, Corrugated Signs

Advertise in the Flexible Packaging

800-848-4462 www.inovarscreen.com

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

FLEXIBLEPACKAGING

| www.flexpackmag.com

Classified Network !!

APRIL 2011

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

Roll-Fed SOLUTIONS

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.

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.

Cincinnati Convertors, Inc.

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

••• Don J. Kemps LLC ••• SUPPLIES

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]

flexpackmag.com APRIL 2011

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Calendar of Events

Apr 5, 2011 2011 TAPPI PLACE Flexible Packaging Symposium Orlando, Fla. www.tappi.org/11place

May 12, 2011 to May 18, 2011 interpack 2011: Processes and Packaging Dusseldorf, Germany www.mdna.com

Apr 6, 2011 to Apr 8, 2011 ICE USA 2011 - International Converting Exhibition Orlando, Fla. www.ice-x-usa.com

Jun 7, 2011 to Jun 9, 2011 Global Pouch Forum Hosted by BNP Media Fort Lauderdale, Fla. http://www.globalpouchforum.com/

Apr 19, 2011 to Apr 21, 2011 Food Safety Summit Washington, D.C. www.foodsafetysummit.com/

Jun 7, 2011 to Jun 9, 2011 EastPack New York, N.Y. http://www.eastpackshow.com

Ad Index COMPANY EFI Radius NAME

PAGE

WEB SITE

American Profol, Inc.

32

www.americanprofol.com

Anderson & Vreeland Inc.

12

www.AndersonVreeland.com

B&B- MAF

36

www.bub-maf.com

Badger Plug

24

www.badgerplug.com

COMPANY NAME

PAGE

WEB SITE

Jemmco, Inc.

7

www.jemmco.com

KHS AG

31

www.khs.com/service

Macro Engineering & Technology

35

www.macroeng.com

Oracle Packaging

21

www.oraclepackaging.com

Danafilms, Inc.

11

www.danafilms.com

Pearl Technologies

22, 23

Davis-Standard Converting Systems

BC

www.bc-egan.com

Pillar Technologies

20

www.pillartech.com

EFI Radius

26

www.efi.com/radius

PPC Techonologies & Solutions

5

www.ppcts.com

Elba USA

28

www.elbausa.com

Retroflex, Inc.

9

www.retroflex.com

34

www.enerconind.com/treating

Tesa Tape

3

www.tesatape.com

The Dow Chemical Company

43

www.dow.com

Uteco North America

37

www.uteco.com

Windmoeller & Hoelscher

13

www.whcorp.com

Enercon Industries Flexible Packaging Association

14, 15

www.flexpack.org

Hewlett-Packard

2

www.hp.com/go/packaging

Hosakawa Alpine America

17

www.halpine.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 Chris Wilson E-mail: [email protected] Call: (248) 244-8264 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

www.pearltechinc.com

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]

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Better Together THE DOW CHEMICAL COMPANY & THE NORDMECCANICA GROUP WILL DEMONSTRATE

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1PVDIFT Come see the latest packaging technologies run on today’s best equipment. Learn how Dow’s enabling materials are essential for the packaging solutions of tomorrow – adhesives, resins and Älms that work together. See how Nordmeccanica’s Super Simplex™ Laminator addresses the range of functionalities demanded for multi-layer food packaging.

Invitation Only Event Wednesday, May 11, 2011 Nordmeccanica’s Technical Center 250 H Executive Drive Edgewood, NY 11717 COME LEARN

How Dow’s: + MOR-FREE™ Solventless Laminating Adhesives + SARANEX™ Barrier Films + SEALUTION™ Peel Polymers work together for easy-open packaging and improved barrier lamination Älms. TO REQUEST AN INVITATION, CONTACT:

Nancy Smith, The Dow Chemical Company E: [email protected]
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