WHY FLEXIBLES PACKAGING? PRESERVE PROTECT PROMOTE

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Milo Hector Adams
5 years ago
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1 POUCH PRESENTATION

2 WHY FLEXIBLES PACKAGING? PRESERVE PROTECT PROMOTE

3 POUCHES - CONCEPTS 2-side-seal pouches 3-side-seal pouches Stand-up pouches (SUP) Center seal pouches Side-gusset pouches Flat bottom pouches Pillow pouches Bag-in-Box Pre-made Partially pre-made Vertical Form-Fill-Seal Horizontal Form-Fill-Seal Fitment / Closure / Zipper / Slider

4 Pouch pictures have been taken from web POUCH DEFINITION 2-SIDE-SEAL POUCH Done starting from 1 web folded in two halves It has just a side-seal, no bottom seal is needed. F-F-S or pre-made

5 Pouch pictures have been taken from web POUCH DEFINITION 3-SIDE-SEAL POUCH Done starting from 1 web folded in two halves (F-F-S and pre-made) Done starting from 2 webs, with or without web printing synchronization (pre-made) It has a side-seal, and a bottom seal. Fitments if needed

6 POUCH DEFINITION STAND-UP POUCH Done starting from 1 web folded in two halves and gusset plied from the bottom (F-F-S and pre-made) Done starting from 1 web, slit in two halves in-line and gusset from a separate reel (pre-made) Done starting from 3 webs, with and without printing synchronization, gusset from a separate reel (pre-made) It has a side-seal, and a bottom seal (K-seal or Doyen rounded) seal Fitments if needed

7 Pouch pictures have been taken from web POUCH DEFINITION STAND-UP POUCH Doyen / Parabolic / Rounded K-seal Flat or plow or corner bottom Double side-gussets Double top & bottom gussets Others

8 POUCH DEFINITION STAND-UP POUCH DOYEN Cleanest look Excellent stability (eg. Liquids) Shipping integrity Inserted gusset Full range of sizes, shapes, features, fitments, hang holes, etc.

9 POUCH DEFINITION STAND-UP POUCH K-SEAL Lifted or flat bottom Clean look Good stability (eg. Dense products) Shipping integrity Inserted or formed gusset Wide range of sizes, shapes, features, etc. Usually lower cost associated to sealing dies manufacturing

10 POUCH DEFINITION STAND-UP POUCH FLAT / PLOW / CORNER SEAL Easiest to make on FFS Flat bottom Roughest look Stability depends on product and design Shipping integrity not as good as others Formed gusset No sealing dies

11 Pouch pictures have been taken from web POUCH DEFINITION STAND-UP POUCH TOP AND BOTTOM GUSSETS Pre-made or HFFS Excellent «billboard» Gussets an be different films Excellent stability Challenging shipping integrity Formed or inserted gussets Not as popular

12 POUCH DEFINITION STAND-UP POUCH OTHERS Pouch pictures have been taken from web

Pouch pictures have been taken from web POUCH DEFINITION CENTER SEAL POUCH Done starting from 1 web folded in two halves and sealed in the middle back side to make a tubular film,

13 Pouch pictures have been taken from web POUCH DEFINITION CENTER SEAL POUCH Done starting from 1 web folded in two halves and sealed in the middle back side to make a tubular film, last a bottom seal (F-F-S and pre-made) In case of material sealable inside and outside, middle back seal is flat In case of material sealable only inside, middle back seal is «pin» style

14 POUCH DEFINITION SIDE-GUSSET POUCH Done starting from 1 web folded, sealed, side-gussets folded, sealed on one side and on the bottom (F-F-S and pre-made) Done starting from 2 webs, front + one side gusset & back + one side gusset (with and without printing synchronization), side seal on all edges (corners), bottom seal (pre-made) Done starting from 4 independent webs, one for front side, one for back side, one for left gusset and one for right gusset (with and without printing synchronization), side seal on all 4 edges (corners), bottom seal (pre-made) Fitments if needed

15 Pouch pictures have been taken from web POUCH DEFINITION SIDE-GUSSET POUCH Can be made on VFFS Square face Gussets can be edge-sealed Stability depends on product and weight Excellent shipping integrity Formed or inserted gussets No sealing dies

16 POUCH DEFINITION SIDE-GUSSET POUCH OTHERS Pouch pictures have been taken from web

17 POUCH DEFINITION FLAT-BOTTOM POUCH Done starting from 1 web slit in 2 halves for front and back panel, bottom gusset can be folded from front panel, or inserted from separate reel, side-gussets are from an independent web and inserted before front and bacl are coming together (pre-made) Done starting from 2 webs (with and without printing synchronization) for front and back panel, bottom gusset can be folded from front panel, or inserted from separate reel, side-gussets are from an independent web and inserted before front and back are coming together (pre-made) Fitments if needed

18 POUCH DEFINITION FLAT-BOTTOM POUCH Pouch pictures have been taken from web

19 Pouch pictures have been taken from web POUCH DEFINITION PILLOW POUCH Starting from a tubular film, no gussets

20 POUCH DEFINITION BAG-IN-BOX POUCH Knows as BIB It can be pillow style, 3-side-seal style, side-gusset style, stand-up pouch style (pre-made) Fitments are always needed Needed specialized filling equipment (most of the time liquid or semi-liquid products)

21 POUCH FEATURES

22 POUCH FEATURES FUNCTIONALITY.how it will be used? FILMS.print, opaque, clear, barrier, stiffness, etc. FITMENTS.zipper, closure, cap, valve etc. FORMING.pouch making FILLING.product to be filled and processing FREIGHT.maintaining package integrity through transportation and end use

23 POUCH FEATURES - FUNCTIONALITY How will the consumer interact with the package? How will it be displayed for sale? Do you want the end-user to see the product? How much shelf life? Will it e opened and reclosed? Will it be sold via e-commerce When do you want to launch?

24 POUCH FEATURES - FUNCTIONALITY FLEXIBLE REPLACEMENTS Filling line developments Expanding co-packing network Food processing options Barrier films, especially clear Growing recycling options Competitive costing Plastic tubes Squeeze bottles Food service (cans and jugs) Paint Health care Construction use

25 POUCH FEATURES - FUNCTIONALITY RETAIL SUP LARGE FORMATS New products Many new designs Wide range of sizes Fitments Lightweight Standing or hanging Club stores, Walmart, Amazon Ease of use, built-in handles Lightweight, high barrier Powders, pieces, liquids New fitments and reclose features Fill speeds (kg/hour liters/hour) Hot-fill / retort / aseptic / HPP

26 POUCH FEATURES - FILMS How stiff or soft should be the pouch be? How much shelf life? How much durability will it need? What graphic effect do you want? Photographic quality or line art? Matte or glossy finish? Clear window or gusset? Is carbon footprint important?

27 POUCH FEATURES FILMS PROCESSES EXTRUSION.cast vs. blown, single ply, coextrusion, extrusion coating LAMINATION.adhesive vs. extrusion vs. thermal PRINTING.flexo, rotogravure, digital, litho COATING.how, when, why? SLITTING.why is it so critical? LASER SCORING.how, why and where?

28 POUCH FEATURES FILMS RESINS AND OTHER MATERIALS RESINS.which grades are used and why, key providers FILMS which types and why, key attributes SUPPLIERS.why are there so few suppliers for some films? LAMINATION what are the benefits? Solvent-based or solvent-less? INKS.why are there so many types, which are appropriate? COATING.gloss and matte, barrier, printing, UV and EB

29 POUCH FEATURES FILMS RESINS LDPE LLDPE HDPE.both film and adhesive PP.always as a film BOPP, CPP PET always as a film BOPET PA.always as a film COEX, BON/BOPA EVOH.always as a coex film PLA.always as a film

30 POUCH FEATURES - FITMENTS How will the consumer open the package? Is the package single or multi-use? Is press-to-seal adequate or is a more substantial seal needed? Will a cap be necessary? How large an opening? Will the product pour out? Will the consumer insert their hand? Will the pouch connect to a dispenser?

31 POUCH FEATURES - FITMENTS Pictures have been taken from web

32 POUCH FEATURES - FORMING What type of films will be used? How much product volume is needed? How critical is pouch formation and quality? Will the pouch be shaped in some way? Will the pouch have fitments? Handles? Pegholes? Valves? Labels? What type of gusset features are desired? Will the pouch have a clear gusset? Existing filling equipment or co-packers?

33 POUCH FEATURES - FILLING What size and shape is the pouch? Do you have existing filling equipment? Are there existing copackers? How will the product be delivered to the filler? Will the product be further processed HFH, retort, HPP, MAP? Can there be product in the seals? Do you need nitrogen dosing, vacuum, or other post-fill options? What speeds do you expect/need?

34 POUCH FEATURES - FREIGHT What are the distribution channels? Have you decided on secondary / tertiary packaging? Will the secondary / tertiary packaging be used as a display? What are the shipping distances? What methods are used to ship (truck, rail, ocean, air)? Will there be fulfillment needs? Could the pouches be shipped individually?

35 POUCH FEATURES - FREIGHT Secondary packaging is critical Design the shipper and flexible package as a system If possible, use the product to support Shipping, other than truck E-commerce air and hand deliveries Rail, sea container

36 POUCHES PREMADE VS FORM-FILL-SEAL

37 POUCHES EQUIPMENT STYLES Vertical Form-Fill-Seal (VFFS) Horizontal Form-Fill-Seal (HFFS) Pre-made fillers Partially with or without fitment Fully with pre-sealed fitment

38 POUCHES EQUIPMENT STYLES VFFS VFFS technology is very well established globally, with everything from lettuce to cheese to candy packed in this manner Pack types can include fin or lap side seal, as well as numerous end seal techniques for SUPs and square bottoms Many of the modern machines can include two-stage filling, allowing for multiple items or types of items to be filled simultaneously There are more than 30 significant companies that supply VFFS equipment for flexible packaging

39 POUCHES EQUIPMENT STYLES VFFS

40 POUCHES EQUIPMENT STYLES VFFS PACKAGING PROCESS OVERVIEW - CONSIDERATIONS Fin and lap seals Not used for partially pre-made pouches Easy to incorporate multi-component filling

41 POUCHES EQUIPMENT STYLES VFFS TYPICAL POUCH STRUCTURES DRY FOOD PRODUCTS Lap seals: PE/Ink/Adh/PE BOPP/Ink/PEx/BOPP BOPP/Ink/PEx/Met BOPP Fin seals: BOPP/Ink/Adh/PE PET/Ink/Adh/PE LIQUID FOOD PRODUCTS Fin seals: BOPP/Ink/Adh/PE PET/Ink/Adh/Coex PA BON/Ink/Adh/PE PET/Ink/Adh/PET/Adh/PE

42 POUCHES EQUIPMENT STYLES HFFS HFFS technology continues to improve in both speed and efficiency. Volpak, Bossar, Mespack, Effytec and others are gaining traction in the market This process is expected to grow worldwide, driven largely by perceived supply chain and cost advantages. Several contract manufacturers have installed new equipment in the past months. This process also allows the end user to decouple film, zipper/fitment and filler.

43 POUCHES EQUIPMENT STYLES HFFS

44 POUCHES EQUIPMENT STYLES HFFS PACKAGING PROCESS OVERVIEW - CONSIDERATIONS Horizontal vs. Vertical Why? Vertical. Higher output and pillow style (usually) Larger pieces and formats Horizontal. More style options Zippers & Fitments Fewer equipment suppliers Can also usually fill pre-mades

45 POUCHES EQUIPMENT STYLES HFFS TYPICAL POUCH STRUCTURES DRY FOOD PRODUCTS Ink/Paper/Adh/PE Ink/Paper/PEx/Foil/Pex PET/Ink/PEx/Foil/PEx/PE PET/Ink/Adh/Paper/Adh/PE LIQUID FOOD PRODUCTS PET/Ink/Adh/Coex PE PET/Ink/Adh/Coex PA PET/Ink/Adh/Foil/Adh/PE PET/Ink/Adh/BON/Adh/PE PET/Ink/Adh/PET/Adh/PE

46 POUCHES EQUIPMENT STYLES PRE-MADE Currently the most common manufacturing strategy globally for liquids in pouches is the installation of a pouch filler that run pre-made pouches with fitments loaded into the filler from a rail. This format, and the strategy above, were driven largely by Indag for pouches without fitments and Gualapack (Italy) for fitmented pouches. Other equipment companies include Karlville, Toyo Jidoki, PSG Lee and others Alternative option is maganized, re-made, open-top pouches, to be filled through the top with a fitment assembly sealed into the top, post-fill.

47 POUCHES EQUIPMENT STYLES PRE-MADE

48 POUCHES EQUIPMENT STYLES PRE-MADE PACKAGING PROCESS OVERVIEW - CONSIDERATIONS Film supply Must be very flat COF is important in and out Compatibility with fitments Pouch supply Understand fillers Understadn end use parameters In both case it is very important to test!

49 POUCHES EQUIPMENT STYLES PRE-MADE TYPICAL POUCH STRUCTURES DRY FOOD PRODUCTS PET/Ink/Adh/Coex PE PET/Ink/Adh/Foil/Adh/PE AlOx PET/Ink/Adh/PET/Adh/PE LIQUID FOOD PRODUCTS PET/Ink/Adh/Coex PE PET/Ink/Adh/Coex PA PET/Ink/Adh/Foil/Adh/PE AlOx PET/Ink/Adh/BON/Adh/PE AlOx PET/Ink/Adh/PET/Adh/PE

50 POUCHES FOOD PROCESSING TECHNIQUES Hot fill and hold - HFH Retort Ultraclean and aseptic High pressure pasteurization HPP Modified atmosphere packaging - MAP

51 POUCHES FOOD PROCESSING TECHNIQUES HFH HOT FILL AND HOLD Just like it sounds Old fashioned technique Very common Low cost Hard on the product

52 POUCHES FOOD PROCESSING TECHNIQUES RETORT Very common for cans Fill, then cook product in the package Extremely effective Very hard on the product Tortures the package Cost effective at high volumes

POUCHES FOOD PROCESSING TECHNIQUES ULTRA

Gentler processing than retort No special

53 POUCHES FOOD PROCESSING TECHNIQUES ULTRA CLEAN AND ACEPTIC Often used for dairy and low-acid foods Clean product, clean package, filled clean Excellent product quality Gentler processing than retort No special package requirements Becoming cost effective at high volumes

POUCHES FOOD PROCESSING TECHNIQUES HPP HIGH

refrigerated products «not heat pasteurized» claims

54 POUCHES FOOD PROCESSING TECHNIQUES HPP HIGH PRESSURE PASTEURIZATION Relatively new processing technique Fill, then expose package to extraordinaty pressures Extends shelf-life or refrigerated products «not heat pasteurized» claims can be made No special package requirements Often processed at contract locations

55 POUCHES FOOD PROCESSING TECHNIQUES HPP HIGH PRESSURE PASTEURIZATION Relatively new processing technique Fill, then expose package to extraordinary pressures Extends shelf-life or refrigerated products «not heat pasteurized» claims can be made No special package requirements Often processed at contract locations

56 POUCHES FOOD PROCESSING TECHNIQUES COMPARISONS

57 POUCHES TESTING Which tests are appropriate for each application? Importance of temperature on testing How does food processing effect properties When to test in each step of the process?

58 POUCHES FILM TESTING Stiffness Toughness Seal initiation temp (SIT) Hot tack COF Dimensional stability Barriers MVTR, OTR Curl Deadfold Contamination seal Heat resistance Chemical resistance

59 POUCHES TESTING MADE AND/OR FILLED Typical tests include: Side seal strength seal integrity Film interlaminate bond strength film integrity COF (coefficient of friction) insures proper loading and transport Drop tests how well the pouches will transport through to retails Vacuum test overall package integrity (gross leaks) Compression test seal strength over time (micro leaks)

60 POUCHES WHERE IS THIS GOING? Recyclable, compostable, combustible, edible film Barrier pouches with laminations of similar materials Functional coatings Ultrasonic sealing How important is printing? Crossing the line between rigid and flexible packaging

61 POUCHES WHERE IS THIS GOING? Recyclable, compostable, combustible, edible film Recyclable (PET,PP,PE) Compostable (PLA,PHA,PCL, cellophane) Edible (Whey protein, sodium isolate, gelatin-based Degradable (Starch-modified PE,PP))

62 POUCHES WHERE IS THIS GOING? Barrier pouches with laminations of similar materials PET/AlOx PET/APET Coated PE/Coex PE Nanocomposite PE/Coex PE Coated BOPP/Met BOPP/Coated BOPP Coated BOPP/CPP

63 POUCHES WHERE IS THIS GOING? Functional coatings Technology is rapidly advancing Gloss, matte, sealability, machinability Barrier coatings oxygen, UV, moisture, aroma Oxygen scavengers COF both inside and outside the pouch Metallized (widely used as foil replacement Aluminum oxide (clear, high barrier for noretort) Silica oxide (clearer, high barrier for retort) Antimicrobials (direct and headspace absorption) Receptors (enhance in-package cooking) Tactile effects (changes the feel of the package)

64 POUCHES WHERE IS THIS GOING? Potential to completely change pouches Seal through product in seals Eliminates reliance on PE or PP sealants Reduces seal widths Offer entirely new pouch designs Ultrasonic sealing

65 POUCHES WHERE IS THIS GOING? How important is printing? More e-commerce = fewer printed pouches More e-commerce = digital, print ondemand Shorter runs More SKUs Coded, functional and clear inks

66 POUCHES WHERE IS THIS GOING? Films used to provide stiffness Flexible films used with molded frames Thin films with rigid, deep draw fitments Crossing the line between rigid and flexible packaging

67 POUCHES THE FUTURE Many more shapes More clear pouches Seamless pouches Higher manufacturing and filling speeds Combination flexible and rigid packaging Dispensing pouches without fitments

68 WHO WINS AT POUCH LAUNCH?

MARTIN PEROUTKA Trinecka 674 273 43 Bustehrad Czech Republic

69 MARTIN PEROUTKA Trinecka Bustehrad Czech Republic Telephone Fax

Technology and Innovations in Flexible Packaging

Technology and Innovations in Flexible Packaging September 25, 2012 Millie Nuño Market Manager Food mnuno@ampaconline.com About Ampac About Ampac Vision and Purpose VISION We are the world s leader in