Packaging Design for Future. Dr. Kurt Stark 2017/02/08

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1 Packaging Design for Future Dr. Kurt Stark 2017/02/08

2 Contents 1. BUERGO.FOL - Company / Applications / Markets - Products 2. Packaging and Packaging materials - History of Packaging - What must Packaging achieve today? - Why are flexible or semi flexible Packaging materials especially sustainable? 3. Kinds of Packaging - Consideration of advantages/disadvantages - "Duo Hard" as a future solution, concerning sustainability and for best profit? - Examples in Practice 4. The best and ideal Packaging for Future - What is the ideal Packaging? - Some thoughts and philosophy

3 1. BUERGO.FOL COMPANY / BRIEF PROFILE CORE COMPETENCY UNIQUE SELLING POINT SPECIALTY SITES 40 years of experience in the co-extrusion of composite films Development of film recipes to suit the application or customer request High-barrier EVOH-based films, printed and unprinted, as well as rigid films Siegenburg, Ingolstadt, Neutraubling EMPLOYEES Around 300 CERTIFICATIONS DIN EN ISO 9001:2008, BRC/IoP Global Standard Version 5, ISO 50001

4 COMPANY / LOCATIONS SIEGENBURG, Bavaria, Germany Headquarters Flexible films INGOLSTADT, Bavaria, Germany Rigid foil factory Pilot Plant for thermoforming NEUTRAUBLING, Bavaria, Germany Centre of excellence Printing and laminating

5 COMPANY TECHNOLOGY / EXTRUSION MACHINES BLOWN-FILM EXTRUSION - Capacity: > 15,000 tons per year 2 x 3 layer 3 x 5 layer 3 x 7 layer 2 x 7 layer shrink-wrap film machines CAST FILM EXTRUSION (APET) Capacity > 25,000 tons per year 3 machines Pilot Plant: Multivac R530 Thermoforming machine

6 APPLICATIONS / MARKETS FOODSTUFFS TECHNICAL APPLICATIONS MEDICAL PRODUCTS PET FOOD CHEMICAL INDUSTRY SPECIAL APPLICATIONS

7 PRODUCTS TUBULAR POUCHES, TOP FILMS AND BAGS BUERGO.FLEX FLOW / TOP, BUERGO.BAG BOTTOM FILMS BUERGO.FLEX BOTTOM TOP FILMS BUERGO.FLEX TOP LAMINATES / RECLOSABLE BUERGO.FLEX SPECIAL / BUERGO.RECLOSE RIGID FILMS / FOAMED RIGID FILMS BUERGO.PET / BUERGO.PET EXPANDED SKIN FILMS BUERGO.SKIN SHRINK FILMS BUERGO.SHRINK SPECIALISED FILMS BFCR BUERGOFOL GmbH Jahnstraße D Siegenburg

8 2. History of Packaging Times are changing. source: scienceblogs.de. und Packaging is changing!

2. History of Packaging source: www.svi-verpackung.

9 2. History of Packaging source: Shopping basket before 1945: metal sheets, carton, paper, glass, wood are common packaging materials. Shopping basket in 1994: material saving packaging materials made from plastics are used.

10 2. What must Packaging achieve today? Protection Barrier, best before date, UV, transport, protection against theft, against forgery, against migration Storage Space saving, convenient Guarantee Undamaged packaging, best before date, consumer protection Transport stowage, manoeuvrability, stackability, tightness, stability Service Information, storage vessel Sales Consumer must be attracted to buy Sustainability Material saving, cheap, bio based, LCA data, Carbon Footprint Advertising Attractivity at POS, brands Consumer friendly Opening characteristics: peel, reclosable, safety peel, perforation Additional functions recycling, disposal of waste, separation Processing thermoforming, sealable, tear resistant, printable, sterilization

2. Why are flexible or semi flexible Packaging materials especially sustainable? Why are flexible or semi flexible Packaging materials more sustainable as rigid containers?

11 2. Why are flexible or semi flexible Packaging materials especially sustainable? Why are flexible or semi flexible Packaging materials more sustainable as rigid containers? - In Europe, more than 50 % of goods are packed with Plastic materials Only 64 % product! - Plastics only have 16 % of the total weight of all Packaging materials used - A huge amount of goods can be packed with a small amount of plastic materials More than 96 % product! Source: BASF - Packaging becomes better and better Between 1997 and 2007 the weight of the total Packaging material decreased by 28 %! This saves 1,8 Mio tons weight per year! - The protective function of modern packaging has the highest contribution for energy saving: On LCA data, the product has the highest share, whereas the packaging material has a negligible share of only a few percents. Source: PlasticsEurope

schützen mit immer weniger Materialeinsatz, 2007 Replacement of plastic packaging

12 2. (Flexible) Packaging Most sustainable! What modern packaging achieves: Source: PlasticsEurope Verpackung - bestens schützen mit immer weniger Materialeinsatz, 2007 Replacement of plastic packaging with alternate materials would mean: Weight 4 times higher, energy consumption factor 1.5 higher, production costs 2 times higher!!

13 3. Kinds of Packaging Overview and percentage of different kinds of Packaging in the market Packaging Systems Name TOP FILM BOTTOM FILM Appr. Percentage a) Soft Packaging Soft, Soft, thermoformed; 20 e.g. PA/PE, 70 µ e.g. PA/PE, 200 µ b) MAP Soft, e.g. OPET/PE = 12/50 µ Hard, semi rigid: e.g. APET or APET/PE = 250/50. Thermoformed. 55 c) Shrink systems Shrink film soft Shrink film soft 15 d) Skin Soft skin film, e.g. 75 µ Hard (semi rigid): e.g. APET or APET/PE = 250/50. Thermoformed. 3-4 e) Flowpack Soft Flowpack film Soft Flowpack film 5 E.g. OPET/PE-EVOH-PE E.g. OPET/PE-EVOH-PE = 12/70 f) DUO HARD Hard (semi rigid), thermoformed Hard (semi rigid), thermoformed 1-2 ( soft = flexible, E-Modulus low; appr. 50 bis 1000 MPa; hard ; semi rigid = stiffer, E-Modulus > 1000 MPa.

14 3. Kinds of Packaging a) Soft Packaging TOP or Lidding Films BOTTOM Films

3. Kinds of Packaging a) Soft Packaging Advantages - (Common) Machines are already installed - Because of flexibility easily thermoformed - Relatively cheap Packaging system - All kinds of goods

15 3. Kinds of Packaging a) Soft Packaging Advantages - (Common) Machines are already installed - Because of flexibility easily thermoformed - Relatively cheap Packaging system - All kinds of goods can be packed - Sterilizable, Pasteurizable Disadvantages - Mechanical stability poor - No rigid system. Not stackable. - Reclosable system hard to realize - Poor manageability, poor convenience

16 3. Kinds of Packaging b) MAP-Packaging (Modified Atmosphere Packaging): Hard (semi rigid) Bottom, soft Lidding Film LIDDING / TOP Films BOTTOM FILMS Thicknesses, e.g. OPET/PE = 12/50 µ OPET/PE RC = 36/50 µ Thicknesses, e.g. APET / PE EP = 250/50 µ APET / PE = 250/50 µ (EP: easy peel RC: Reclose) Foamed APET

- Good price-performance ratio - All kinds of go

17 3. Kinds of Packaging b) MAP-Packaging (Modified Atmosphere Packaging): Semi rigid Bottom, soft Lidding Film Advantages - THE standard system (traditionally) - Machines are already in use / installed - Bottom film is rigid and stable: excellent mechanical stability. Stackable. - Good price-performance ratio - All kinds of goods can be packed, also with reclose (RC). - Convenience and handling are perfect (e.g. opening characteristics) Disadvantages - More material needed in comparison to only soft packaging system. - Higher requirements for Packaging machines: Pre-heating, Cutting, etc.

18 3. Kinds of Packaging c) Shrink systems (highly oriented films which maintain a memory effect) Typical thickness: 70 µ These systems have: Options:

3. Kinds of Packaging c) Shrink systems Advantages - Film directly/tightly touches packed goods - High stability is resulting - Excellent product presentation - All kinds of goods can be packed -

19 3. Kinds of Packaging c) Shrink systems Advantages - Film directly/tightly touches packed goods - High stability is resulting - Excellent product presentation - All kinds of goods can be packed - Film is robust, has ideal barrier properties and is adjusted to the packed good Disadvantages - Not common for small portions below 500 g - Used for higher portions > 2 kg - Reclose hard to realize - Poor handling/convenience

20 3. Kinds of Packaging d) Skin TOP Films BOTTOM Films Typical thickness 90 µ Thicknesses, e.g. APET / PE EP = 250/50 µ APET / PE = 250/50 µ

21 3. Kinds of Packaging d) Skin Advantages - Bottom film is very robust: excellent mechanical stability. Stackable. - Perfect product presentation (like with shrink systems) - Lidding film is directly and tightly touching the packed good. No juices (e.g. from meat) are squeezed out. - All kinds of goods can be packed - Excellent handling and convenience (e.g. Disadvantages opening characteristics) - More material needed compared to y only soft systems (with a soft and flexible bottom film) - Machines are not standard (investments might be needed) - Requimerements for packaging machines are higher: Pre-heating, cutting, skinning process etc.

22 d) Skin 3. Kinds of Packaging

23 3. Kinds of Packaging e) Flow-Pack (FP) Typical thicknesses and structures: OPET/FP = 12/50 µ CPA/FP = 20/50 µ OPA/FP = 15/50 µ

3. Kinds of Packaging e) Flow-Pack Advantages - Machines are trivial and already in use - Because of the softness of the films processing is very easy - Only one film is needed to pack a product -

24 3. Kinds of Packaging e) Flow-Pack Advantages - Machines are trivial and already in use - Because of the softness of the films processing is very easy - Only one film is needed to pack a product - All kinds of goods can be packed - Vertical/horizontal filling with the product Disadvantages - Poor mechanical stability - No solid/rigid system: not stackable - Reclose hard to realize - Poor handling/convenience

3. Kinds of Packaging f) DUO HARD HARD TOP FILM, HARD BOTTOM FILM Thermoformed TOP FILM TOP FILM e.g. APET/PE EP = 200/50 µ (thermoformed; or not thermoformed) BOTTOM FILM e.

25 3. Kinds of Packaging f) DUO HARD HARD TOP FILM, HARD BOTTOM FILM Thermoformed TOP FILM TOP FILM e.g. APET/PE EP = 200/50 µ (thermoformed; or not thermoformed) BOTTOM FILM e.g. APET/PE EP = 250/50 µ (always thermoformed) I N N O V A T I O N

26 3. Kinds of Packaging f) DUO HARD HARD TOP FILM, HARD BOTTOM FILM (both films can also be considered as semi-rigid ) Advantages - Better layer adhesion and bond strength compared to common 2K adhesives - Migration is reduced to a minimum - Both the bottom film and the lidding film are hard and stable: highest mechanical stability. Stackable. Space saving. All is very robust. - Thermoforming: No problem on all common thermoforming machines for lidding and bottom film: Detailled structures can be easily realized. - All kinds of goods can be packed. Established: cheese. Backlog demand: For meat and cold cuts - Tightness (barrier) and a high life period of the packed product are guaranteed, before first opening - Excellent handling and convenience (opening characteristics)

27 3. Kinds of Packaging f) DUO HARD HARD TOP FILM, HARD BOTTOM FILM (both films can also be considered as semi-rigid ) Advantages - Packaging is very appealing and attractive - Elegant Reclose system: The thermoformed lid fits perfectly into the thermoformed bottom film. The lidding film remains connected with the bottom film (kind of hinge) - No smell because of the adhesive: This Reclose system works without adhesives. - A very long best-before date can be maintained. Also, a long shelf-life is given, after first opening of the package. No repacking in boxes etc. is needed. Product remains fresh and tasteful for a very long time. - Converting: Printing in best quality is possible. (Print mostly remains on plain surfaces.) - Summary: Less packed goods rot, almost no product is cast away/littered!

28 3. Kinds of Packaging f) DUO HARD HARD TOP FILM, HARD BOTTOM FILM (both films can also be considered as semi-rigid ) Disadvantages - Higher price, of course, because more material is needed - TOP Film: Film rolls are more difficult to handle, compared to a flexible film. As the lid film is thicker, a reduced roll length is the consequence. - Thermoformed TOP film: Machine settings need to be adjusted. - Printing is less effective, as the TOP film has a higher thickness (compared to thin oriented films like OPET, OPP and OPA).

29 3. Kinds of Packaging Examples in Practice f) DUO HARD HARD TOP FILM, HARD BOTTOM FILM where can you find this? Fresh Box / Fresh Pack Serve Box: Servierbox Böklunder Wurstfabrikation GmbH & Co. KG Bel Deutschland GmbH Sauels frische Wurst GmbH Fleischwaren & Co. KG

30 3. Kinds of Packaging Examples in Practice f) DUO HARD HARD TOP FILM, HARD BOTTOM FILM where can you find this? Fresh Box / Fresh Pack Serve Box: Servierbox H. Kemper GmbH & Co.KG, Nortrup

3. Kinds of Packaging Focus on Reclose Systems Excursion: Reclose Systems Reclose with adhesive layer With opening of a package, an adhesive layer is set free behind the sealing layer.

Booklet Topforming DUO HARD The free adhesive layer which is generated in the opening process can be in the lid or the bottom film. Lid and bottom film are thermoformed and made only by one film.

31 3. Kinds of Packaging Focus on Reclose Systems Excursion: Reclose Systems Reclose with adhesive layer With opening of a package, an adhesive layer is set free behind the sealing layer. Reclose happens with pressing the free adhesive layer in lid or bottom film against the corresponding top or bottom film. Booklet Topforming DUO HARD The free adhesive layer which is generated in the opening process can be in the lid or the bottom film. Lid and bottom film are thermoformed and made only by one film. Lid and bottom film suit well with each other, fit together and do the reclose of the packaging system. Similar to the booklet. A TOP FILM and a BOTTOM FILM are thermoformed and suit well with each other, fit together and do the reclose of the packaging system. For reclose, the TOP or BOTTOM Film are simply and easily pressed together. Reseal-it The TOP Film is perforated (usually Laser perforation) and covered with a label which has a barrier function. First opening leads to an adhesion of the perforated segment onto the label. As the label remains sticky on the areas without the perforated segment, the package can be easily reclosed with the label.

3. Kinds of Packaging Excursion: Reclose Systems Adhesive tape A tight sealed package has an adhesive tape, which is used after the first opening of

Zip Reclose Inside the package are two strips which fit together. Like a zipper, but with polymer strips.

32 3. Kinds of Packaging Excursion: Reclose Systems Adhesive tape A tight sealed package has an adhesive tape, which is used after the first opening of the package to reclose the package. This is often used to pack coffee (coffeebeans). Zip Reclose Inside the package are two strips which fit together. Like a zipper, but with polymer strips. Lap-seal On a packaging machine first the inner side of the packaging film is sealed against the outer side of this film with overlap. A both side adhesive tape is brought in. After the first opening, the reclose is done using the both side adhesive tape.

33 4. The best and ideal Packaging for Future What influences the kind of Packaging? Kind of the packed goods Customer Convenience! Best-before date Order Discounter, Trade (Product Guide) Marketing Producer Production logistics PACKAGING Availability Amount to be packed Storage Machines Tools Print Price (material, Amount, thickness)

34 4. What is the ideal Packaging? Choice of Packaging systems: Price (per square meter) and amount of the packed goods Packaging Systems (unprinted) Name TOP FILM BOTTOM FILM Amount/mass of packed goods a) Soft Packaging 0,4 X 0,8 X 100 g to 10 kg b) MAP normal : 0,5 X Price X Reference! 100 g to 500 g REFERENCE BOTTOM RC: 0,9 X (Bio: 3,5 X) c) Shrink Systems 0,8 X 100 g to 12 kg d) Skin X X 100 g to 2 kg e) Flowpack 0,5 X 100 g to 4 kg f) DUO HARD 1,1 X X 100 g to 500 g ( soft = flexible, E-Modulus low; appr. 50 bis 1000 MPa; hard = stiffer, E-Modulus > 1000 MPa.)

35 4. What is the ideal Packaging? Specialties have a higher price. Example Reclose Systems: Price BOTTOM film, X semi-rigid Price TOP Film, 0,5 X Normal and flexible Price TOP Film, 0,9 X With RECLOSE (RC) Price TOP FILM, 1,1 X Duo Hard, semi-rigid

36 4. Some Thoughts and Philosophy The ideal Packaging? For which application and for which requirements? This presentation first showed the requirements on modern Packaging system. Plastic Packaging is the best. The different kinds of Plastic Packaging systems were shown. The Advantages and the Disadvantages were discussed. As a new Packaging System, DUO HARD was focussed. On the way to the best Packaging systems, different criteria are important. THERE IS NO IDEAL PACKAGING SYSTEM (every system has some disadvantages). BUT: MOST OF THE PACKAGING SYSTEMS ARE ALMOST IDEAL!

37 CONTACT BUERGOFOL GmbH Jahnstraße Siegenburg Germany Fon +49 (0) / Fax +49 (0) / kurt.stark@buergofol.de contact@buergofol.de

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