Design Conversion. International Packaging Conclave Pack Plus print-packaging.com

Transcription

1 Design Conversion International Packaging Conclave 2013 Pack Plus October 05, Greater Noida by print-packaging.com Package Design and Conversion Opportunities through Consumer Focused Integrated Approach by group.com Folie 1

2 What the Consumers s Want Package should be tamper proof/ evident - assurance of no Pilferage or Adulteration Packaged material delivered in Original condition Ability to SEE the packaged materials Ease of handling Appropriate Portioning/ package size for different needs Attractive package with Clearly printed messages/ instruction for use, best before date etc. Possibility to Consume Easily Microwavable, Retort, Reclosable etc. Low price Folie 2

3 What the Marketers Want Good Protection of packaged material Good shelf life Visibility of the packaged material Aesthetically superior package with Outstanding Graphics Identical packages Designed to promote Brand Image/ inspire confidence Flexibility in terms of Package Designs i.e. shapes and sizes Easy handling of package Package suitable for Ease of Use Microwavable, Retort, t Re-closable etc. Difficult to Counterfeit, Tamper proof/ evident Folie 3

4 What do the Manufacturers Want Adequate packaging (Shelf life, portioning, quality and quantity retention) Repeatability High efficiency of filling and packaging machines Faithful reproduction of graphics and branding elements Compliance with regulations on environment and relevant agencies/ statutory bodies Low carbon footprint Tamper proof/ evident Anti counterfeiting Low Price Adaptable to Supply chain Folie 4

5 Advantages of Flexible Packaging Favourable Weight to Volume ratio Light weight, low volume for Transportation Logistics friendly Low Carbon Footprint Extremely versatile Creates Less Waste, Easy Recyclability Low cost of production Wide possibilities for packaging material changes Folie 5

6 Advantages of Flexible Packaging Easy Designing for variety of portions Lends easily to Innovation in package designs Possibility of outstanding Graphics Easy to use Re-closable, Retortable, Microwavable etc. Tamper proof/ evident Multifunctional, intelligent films etc Folie 6

7 Advantages of Flexible Packaging Economy Resource conservation Weight reduction: Low Density below 1 Aluminimum-2.7 i 27 Steel 7.8 Glass 3.14 Paper Polyolefin - ~0.93 Low Energy requirement for processing Weight to strength ratio PP tapes as strong as steel by weight Folie 7

8 Flexible Packaging g Touching Your Lives Every day - Retail - Snack Foods Medical & Pharma Personal Hygiene & Home Products Windmöller & Hölscher Your Reliable Partner for Flexible Packaging g Folie 8

9 Flexible Packaging Touching Your Lives Every day Retail Multiple Use Carry Bags Industrial Polymers, Chemicals and others Food products Meat, Confectionery Windmöller & Hölscher Your Reliable Partner for Flexible Packaging Folie 9

10 Flexible Packaging Pharma Blister and Foil Folie 10

11 Challenges Before Flexible Packaging Industry Pressure on prices Big consumers wish to cut margins of suppliers Pressure on costs rising prices of raw materials, electricity and other inputs Increasing costs of marketing and management Technological upgradation in small and medium scale sectors Technological needs for better barrier properties due to low- fat foods, highly aromatic fresheners, drugs and medicines Integration of features such as colour tagging, RFID, tamper evidence, anti counterfeiting etc. Technological solutions for CAP/ MAP, retort, irradiation, microwave etc Folie 11

12 Technological Changes New Polymers targeted to specific end uses Designing g Films to facilitate design of packaging g High quality, high speed Printing Increasing use of Flexographic printing New Generation Gravure printing machines High level of Integration of systems and Automation Anti Counterfeiting systems/ designs Intelligent t Films, Biodegradable d materials Use of RFID and other tracking technologies Downgauging Energy optimisation Lowering carbon Footprint Higher safety standards Folie 12

13 Approaches to Deliver Better Packaging g System Approach to R&D: Machine Builders Raw Materials Suppliers Additives and Master Batch Suppliers Ink and Adhesive Suppliers Processors/ Converters End Users Logistics Integrated Approach to Design and Manufacturing: Knowledge of processes from start to finish e.g. extrusion, printing, converting Integrating technologies for reduced operator dependence Technologies to reduce carbon footprint and increased safety Futuristic orientation Flexibility to enable better designing of more efficient package including FFS Folie 13

14 Flexible Packaging Widest Choice of Materials and Package Design Folie 14

15 Organised Retail - Shopper s Paradise Convenience for the Modern Woman Folie 15

16 Convenience as Driver for Consumer Product Development Change in society: Meteoric rise in the number Nuclear families Increasing number of one-person households Both partners are working full time Less time available for cooking Solution: Simple preparation of the meal Easy opening and reclosable package Fast and complete meal Variety of small portions Easily understandable benefit Folie 16 (source: Dr. Wirts,Südpack)

17 Consumer Applications => Deep Freeze e Film Applications: Vegetables Fish Meat Convenience foods Requirements: Closed cold chain Network of supermarkets Food industry Film design PE 3-layer Mainly blown film Folie 17

18 Consumer Applications => Meat and Cheese Applications: Fish Meat Cheese Sausage Convenience: Long-term freshness Small portions Film design 5- to 9-layer barrier film Blown and cast film Folie 18

19 Consumer Applications => Convenience Packaging g Barrier film based package for convenience foods Convenience: Pressure cooker function in the microwave oven Oven function in the microwave oven (source: Dr. Wirts,Südpack) Example Eco Vent and Eco Steam patented by Südpack (Germany) Folie 19

20 Consumer Applications => Label and Sleeve Film Replacing paper labels Properties: Very low gel level Excellent transparency High gloss No wrinkles allowed Advantages: Excellent optical properties of the package More flexible in packaging design Resistant against humidity Folie 20

21 Consumer Applications => Collation o Shrink Requirements Excellent holding forces Homogeneous shrinking Very high requirements in terms of transparency and gloss High quality print Production Usually blown film Downgauging Resin recipes available (source: SunChemical) Folie 21

22 Consumer Applications => Pouches Replacing tin and glass Advantages: Effective to fill Saving of weight Wide range of design Reverse printing possible Reclosability possible Film Design/ Combination Mainly PE/PET laminates Folie 22

23 Consumer Applications => Reclosable Packaging Long-term freshness Convenient handling Popular solutions: Zipper systems Sticky tape Easy peel additives Hotmelt for reclosability Booklet packaging (source: Wipak) Folie 23

24 Milk Packaging Three Layer Film Pouches replace Glass bottles for Milk, Chach, Lassi etc. 1 litre of milk in a pouch weighing about 5g Glass bottle: 400g Carton: 80g PET bottle: 30g Folie 24

25 Food Packaging - Barrier Films Folie 25

26 Barrier Films protect against Exchange of moisture - Protection against drying up (e.g., bakery products) - Protection of hygroscopic products (e.g., milk powder) Oxygen permeation - microbiologic spoilage (oxidation of greases, flavors, etc e.g., bakery products, nut products, ready-to-serve meals) Emerging of CO2 - change of protective gas type - undesired vacuum effect (e.g., with bakery products, meat products) Exchange of aroma - loss of aroma from the product packaged - assuming a different smell (e.g., coffee, spices, washing agents) Folie 26

27 Toothpaste Tubes without Aluminium Foil Folie 27

28 EXTRUSION PRINTING CONVERTING Coffee Co ee Film Folie 28

29 FILMEX: PA - EVOH Film, Tray and Lid Applications Folie 29

30 AQUAREX New Opportunities in Film Production The Latest Downward Extrusion Water Quenched Film Lines 1. High Transparency and Gloss 2. High Seal Strength 3. High Tearing strength 4. Soft Touch 5. No leakers 6. High output 7. Barrier and non-barrier films 8. High Speed on FFS Machines Folie 30

31 Film Tested Through the Complete Supply Cycle Integrated Approach Tests carried out in a Joint Project by the machine builder, the film manufacturer, the end user and transportation t ti across India Material packaged: Edible Oil Supplier: One of India s leading brands Results: Nil Leakers Nil damaged pouches Travel through the toughest terrains and longest distances in trucks No print loss Highest performance FFS machines run at 40 pouches / min their highest speeds Film has potential to run faster could not be tried due to above Folie 31

32 Proven Example - Oil Film Current Structures Oil pouch Hydrogenated oil no barrier required Edible oil barrier required 3-layer PE film PE 1 / PE 2 / PE 3 Symmetrical barrier film PE 1 / TIE / PA / HV / PE 3 Asymmetrical barrier film PA / TIE / PE 1 / PE 2 / PE 3 PA /TIE/PE / 1 /TIE/PA / /TIE/PE / 2 Laminated PE-Film BOPA /TIE/PE / 1 / PE 2 / PE Folie 32

33 Outlook White Elephant? Replacement of 3-layer oil/ghee pouches? Folie 33 [Big Bazaar, N.A.]

34 Outlook White Elephant? Replacement of 3-layer oil/ghee pouches? Substitution of laminates? Folie 34 [Future Agrovet LTD.]

35 Outlook White Elephant? Replacement of 3-layer oil/ghee pouches? Substitution of laminates? Transparent toothpaste film? Folie 35 [Colgate Palmolive]

36 Outlook White Elephant? Replacement of 3-layer oil/ghee pouches? Substitution of laminates? Transparent toothpaste film? Film for rice packaging? Folie 36 [Best Select, Sresta Natural Bioproducts PVT. LTD.]

37 Outlook White Elephant? Replacement of 3-layer oil/ghee pouches? Substitution of laminates? Transparent toothpaste film? Film for rice packaging? Film for sugar packaging? Folie 37 [Mawana Sugar]

38 Outlook White Elephant? Replacement of 3-layer oil/ghee pouches? Substitution of laminates? Transparent toothpaste film? Film for rice packaging? Film for sugar packaging? Film for atta/ flour packaging? Folie 38 [C.A. Pillsbury and Company]

39 Outlook White Elephant? Replacement of 3-layer oil/ghee pouches? Substitution of laminates? Transparent toothpaste film? Film for rice packaging? Film for sugar packaging? Film for atta/flour packaging? Film for dry-fruits and legumes? Folie 39 [Future Agrovet LTD.]

40 Outlook White Elephant? Replacement of 3-layer oil/ghee pouches? Substitution of laminates? Transparent toothpaste film? Film for rice packaging? Film for sugar packaging? Film for atta/ flour packaging? Film for dry-fruits and legumes? Film for spice packaging Folie 40 [Future Agrovet LTD.]

41 Outlook White Elephant? Replacement of 3-layer oil/ghee pouches? Substitution of laminates? Transparent toothpaste film? Film for rice packaging? Film for sugar packaging? Film for atta/ flour packaging? Film for dry-fruits and legumes? Film for spice packaging Substitution of PVC? [Hanes, N.A.] Folie 41

42 Outlook White Elephant? Replacement of 3-layer oil/ghee pouches? Substitution of laminates? Transparent toothpaste film? Film for rice packaging? Film for sugar packaging? Film for atta/ flour packaging? Film for dry-fruits and legumes? Film for spice packaging Substitution of PVC? Thick thermoforming films Folie 42

43 Outlook White Elephant? Replacement of 3-layer oil/ ghee pouches? Substitution of laminates? Transparent toothpaste film? Film for rice packaging? Film for sugar packaging? Film for atta/ flour packaging? Film for dry-fruits and legumes? Film for spice packaging Substitution of PVC? Thick thermoforming films Other 3,5,7 or 9-layer films? Folie 43

44 Consumer Applications => Biodegradable Film Raw material capacity in 2011: approx t, expected to touch 780, t by 2016 Volume for packaging ~ t/a Market growth >30% per year Only ~17% of Bioplastics produced are Biodegradable Products: T-shirt bags Shopping bags Vegetable and fruit packaging Production: Blown and cast A lot of small resin suppliers (source: Novamont, Innovia) Folie 44

45 Industrial Applications => FFS Film (Heavy Duty) Replacement of woven sacks in the petrochemical industry Effective filling with special machines Discovering new markets like pet food, sugar, For free flowing products Folie 45

46 Industrial Applications => Surface Protection o Applications: Building industry Electronic devices Steel processing industry Film design LDPE - mono -> coated PE 3 layer sticky Blown or cast film Folie 46 (source: Novacell)

47 Shrink Wrap Folie 47

48 Easy Family - W&H Impression and Register Setting Systems Make-ready Proofing V static dynamic Production Stop t Production Start EASY SET-S Material change Sleeve change EASY REG-S Ink change Deck pre-setting EASY SET-D Quality check Color matching EASY REG-D Deck fine setting Folie 48

49 DATA TRANSFER EASY-COL The EASY - Tool for: Significant reductions of left-over ink quantities Efficient, measurement based color matching on the machine Quality assurance through digital color and recipe data transfer Folie 49

50 EASY-COL: Workflow with Interface to the Ink Room (Option) Print sample ok? IFS Ink Room Basic recipes Target colors Job recipes Ink weights EASY-COL Color Matching PC References Recipes Assortments Anilox data Serve r (24 h) Computer guided mixing of correction recipes using base inks with feedback loop! Folie 50

51 EASY-SET D Operating Principle True Dynamic measurement under real production conditions Incl: adapter-,,see sleeve-, e, tape-,,pae, plate-, design- and speed related ed tolerances! Live impression setting EASY-SET D Topography Impression waste: 20 m per color (depending on print repeat) Folie 51

52 Easy Set HD -Dynamic Impression setting System Folie 52

53 Automatic Impression Setting System Line Camera Full Image Folie 53

54 Folie 54

55 Folie 55

56 Improvements for Operators: Detection of High/ Low spot areas under real time productions conditions Ensuring waste reduction Folie 56

57 Thank You Folie 57