TAIEX Workshop on Packaging and package materialsmodern trends in food industry : 5. Oktober 2010 1
Index Generality ARCIL Group in a glance ARCIL FFS principle Cups production principles Plastic materials Costs Jacques HANNOTEAUX Senior Sales director - Sustainability 2
ARCIL Group Presentation Full packaging line 3
GROUP partner ENGINEERING Complete line engineering, turnkey project management PROCESS PACKAGING Filling Microwave heating Form-Fill-Seal Robotic packaging Case packing
ARCIL Group Key figures 10 million of Arcil cups are filled per hour Villejuif plant (Paris S) Corbeil Essonne plant (Paris S) Puiseux-Pontoise plant (Paris N-W) 80 TO 2010: >70m 300 persons 5000 m 2 workshop 60 40 20 0 87 90 93 96 99 02 05 08 More than 300 machines are running in 50 countries ARCIL range from 4000 to 100 000 cups/h (10ml to 1l) 5
ARCIL Group Partial references 6
Cups production principles FS and FFS FS technology Supply of preformed cups (printed or with banderol) Supply of pre-cutted embossed aluminium lid (Sleeving) Decontamination of empty cups Filling Decontamination of lid Lid sealing Single cup output ARCIL FFS technology Supply of plastic reel 2 to 8h production Supply of label reel 8h production Supply of lid reel 4h production Plastic heating Forming Filling Decontamination of lid foil Lid sealing Multipack trimming 7
ARCIL FFS principle Technical description Plastic introduction Heating boxes (130 to 160 C) Forming with in mould labelling UV Lid thermosealing Trimming Exit conveyor Laminar flow Plastic reel Ultraclean Filling chains 8
ARCIL FFS principle Plastic thermoforming The new surface of the cup is made of the bottom ( 50 mm diameter) and the sidewall. Example : 50 mm Elongation factor: 5 to 7 0,75 mm 50 mm 60 mm thickness of side wall 0,10 to 0,15mm (before adding label and depending on cup shape) Thermoforming with punch End of forming by blowing 9
ARCIL FFS principle cups example 10
ARCIL FFS principle Cups materials Cup includes 2 or 3 raw materials: Lid for cup sealing All around Label for marketing communication and top load resistance Body of cups made in thermoformed plastic 11
ARCIL FFS principle Cups material Choice of materials depends on several factors: Product Kind of product (Fat and sugar rates, ph, Bacteria sensibility...) Shelf life Filling temperature Post heating treatment Barrier resistance (contamination, moisture, gas, Oxygen, light, UV...) Organoleptic preservation (colour, smell, texture, taste...) Marketing Shape of cups and dimensions Marketing appearance (transparent, translucent, colour...) Packaging cost Peeling facilities Logisitic Ended product storage conditions (cold, light...) Transport Technology Thermoforming ability Cutting ability and scoring capability for multipack Customer specific requirement... 12
Label material Advantages of label Advantages of label reel bringing stronger top load resistance enabling to decrease of plastic thickness No extra-cost Marketing communication surface Printing quality in HELIOGRAVURE up to 8 colours Labelling differentiation: multiflavor / multipack 1 reel 700mm = 8 hours production (1 reel in operation / 1 in stand-by / automatic changeover, synchronized according to preset recipe) 13
Label material Type of material OPS Gravure printing PS (75µm) hotmelt (8 gr/m2 - melting temperature in mould: 45 C) Paper Gravure printing Paper (97gr/m2 ) hotmelt (+ 8 to 13gr/m2 - melting at 45 C or 75 C) 14
Lid material Advantages of lid Advantages of lid reel Gas, water and impact resistance (transport in supermarket) Easy peeling Hygienic thermo-sealing Marketing communication surface + dating + traceability Printing quality in HELIOGRAVURE up to 8 colours Labelling differentiation: multiflavor / multipack 1 reel 300mm = 4 hours production (1 reel in operation / 1 in stand-by / automatic changeover, synchronized according to preset recipe) Choice according to following factors: Product Shelf life Used plastic material Barrier resistance 15
Lid material Type of lid Mixpap (Paper + PET) Gravure printing Coated paper (45gr/m2) Adhesive Polyester (12µm) Heat seal laque PET Gravure printing PET (23 or 36µm) Heat seal laque PET + ALU (i.e. hot product) Gravure printing Aluminium (15 or 30µm) Adhesive Polyester (12µm) Heat seal laque (220 C) 16
Plastic material Advantages Advantages of plastic reel Cost Mechanical properties Packaging capabilities (various mono colour, multi-colour, multi pack...) Extreme versatility at low temperature resistance impact gas, water, acid, fat barrier Easy handling, 80 000 cups with standard reel 1200mm (Jumbo reel 2000mm = 130 000 cups), Hygiene (manufacturing of web in food grade condition + ultra-clean ARCIL line + minimum dust and moisture vs carton), Low density (vs metal or glass), Plastic choices: No kind of plastic is universal! Mono or multi-layer complex Colour Application (product, marketing, shelf life, resistance...) 17
Plastic material Barrier properties Sealing chord tightness UV Micro-organisms Oxygen Gas (CO 2, N 2 ) Aroma Moisture Smell 18
Plastic material Applications GPPS (General Purpose Polystyrene) Not used in FFS Amorphous, transparent, and brittle. This one is often used for CD boxes. His mechanical characteristics do not allow reeling in (because of breakability) HIPS (High Impact Polystyrene) - used at 90% in FFS Polymerization of styrene + polybutadiene (Pbu) = HIPS Better resistance to impact than GPPS. Pbu contributes to limit cracking and give plasticity. High % Pbu PS becomes easier to process (to thermoform) Low % Pbu better top load resistance, pre-cut difficult to control. Balanced % Pbu quality of pre-cut, breakability (60% shock /40% crystal or 50/50) Additives Plasticizers : used to facilitate processing the material, mainly lubricants (oil). Antioxidants : protect polymer from oxigen. Others : Citric acid for foam PS, foodgrade pigments for colouring, UV absorber, flameretardants, 19
Plastic material Applications PE barrier H 2 O barrier for long life product and resistant to fat and acid Difficult to thermoform / higher cost than PS / PE lid mandatory PET PS/PE PS/PE/PS more flexible by the possibility of using paper lid EVOH barrier O 2 barrier (depending on moisture rate) to avoid migration in pot (oxidation risk). Easy thermoforming / higher cost than PS PS/EVOH/PE PS/EVOH/PS more flexible by the possibility of using paper lid PP/EVOH/PP used when heat treatment is needed PP Low cost Less top load resistance Fat, acid, O 2, H 2 O barrier and heat resistant No multipack possible (Non scored cup) difficult to thermoform (lower pace, more losses while restart) 20
Plastic material Complex materials Examples: PS/PE 8% 8% of PE (non porous to steam) Adhesive 92% of PS PS/EVOH/ PE 11% 8% of PE (non porous to steam) Adhesive 3% of EVOH (non porous to gazes) Adhesive 89% of PS Example: PS/EVOH/PE is well used when long shelf life is needed (Filling temperatures up to 95 C) 21
Cost Sustainability 22
THANK YOU! Visit our website: www.arcil.fr Cyril AVARE Mail: ca@arcil.fr +33 6 26 59 02 00
Plastic material Polymers Polyethylene tereftalate High Density Polyethylene Polyvinyl Chloride (PVC) Low Density Polyethylene PETE HDPE V LDPE Properties: Clarity, strength/toughness, barrier to gas and moisture, resistance to heat. Difficulty with Thermoforming. Applications : PETE is commonly used in carbonated beverage containers because of its excellent ability to keep the fizz in the beverage. PETE is also used in some food containers because it is clear (so the contents can be seen) Properties: Stiffness, strength/toughness, resistance to chemicals and moisture, permeability to gas. Applications : large 4-litre containers, such as bottles for milk, juice and water. It is also used for packaging ice cream because it can withstand cold temperatures without becoming brittle. In addition, HPDE bottles are chemically resilient, making them suitable for laundry products, such as detergent and bleach. Properties : Versatility, strength/toughness, resistance to grease/oil, transparency, resistance to chemicals. Applications : Vinyl is used to make transparent bottles that have handles because the material has good flow characteristics and the handle can be molded easily right into the bottle. Not well used for food because of Chlorine. Properties : Ease of processing, barrier to moisture, strength/toughness, flexibility, ease of sealing. Applications : Carry-out sacks, bread bags, frozen food bags, and dry-cleaning bags, moisture barrier in multi-layer sheets. 24
Plastic material Polymers Polypropylene Polystyrene Ethylene Vinyl Alcohol (EVOH) For example PP PS OTHER Properties : Strength/toughness, resistance to chemicals, resistance to heat, barrier to moisture, versatility, resistance to grease/oil. Applications : containers for hot fill liquids/food, compatible with microwave oven, sterilization, yoghurt and margarine tubs. Properties : Brittle, stiff, and transparent when GPPS. Good thermoforming qualities, versatility, insulation, clarity, easily foamed when HIPS. Low barrier to gas. Applications : Yogurt containers, cups, plates. Polystyrene does not absorb excess fluids (thus its use in meat trays) and is also a good insulator (making sure your coffee or soup stays hot) Properties : translucent, flexible Applications : mainly O 2 barrier in multi layer sheets 25