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RECOVERY MODE:

Is EPR recyclings savior? 54

Closing the soft skills gap 16

Decorating with lasers 42

Dispensing efficiency

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contents

28

16

COVER PHOTO BY JENNIFER FIELD

APRIL 2013 volume 50 no. 4

ONLINE . . . . . . . . . . . . . . . . . 6

DIALOGUE . . . . . . . . . . . . . . 8

STAFF . . . . . . . . . . . . . . . . . .10

VIEWPOINT . . . . . . . . . . . .11

MARKETPLACE . . . . . . .52

NEWSMAKERS . . . . . . . .53

departments

trendsPACKAGING CONCEPTS. . . . . . . . . . . . . . . . . . . . . . . . . . . .12

SKILL SET To succeed today, packaging professionals must arm themselves with comunication and other non-technical skills . . . . . . .16

VISIONARY: DELL T e computer giant is working to ensure future success by investing in sustainability, and its people.. . . . . . . . .18

SPC SUSTAINABILITY Sustainabilitys ugly stepchildren . . . .20

INDUSTRY INSIGHTS Is EPR recyclings savior? . . . . . . . . . .54

best practicesCOVER STORY Co-packer Aero l harnesses the power of its employees knowledge base to help fuel continuous improvement . . .22

FLEX TIME A new, larger building is facilitating GSC Packagings goal to grow while maintaining high quality standards . . . . . . . . . . . .28

BAGGING BOOST Grain Millers has revitalized its whole-grain packaging operation, boosting e ciency by a reported 40 percent . . .34

UPPER CLASS T e Downton Abbey estate modernizes with a new automated horse-oats packaging line . . . . . . . . . . . . . . . . . . . .36

SPEED RACER Adding a high-speed tablet lling line is helping this pharmaceutical co-packer grow its business and capabilities . . . . .38

SALAD DAYS Installing advanced x-ray inspection is enabling this dressing and condiments company to extend its success. . . . . . . .40

PURCHASING POWER Risk management redux . . . . . . . . . .41

new technologyLASER SHOW With new laser technology, brand owners have access to a whole new realm of decorating possibilities . . . . . . . . . . . .42

NEW PRODUCTS: EQUIPMENT. . . . . . . . . . . . . . . . . . . . .44

NEW PRODUCTS: MATERIALS . . . . . . . . . . . . . . . . . . . . .48

PROMISING PATENTS Closure releases aroma; more. . . . . . .51

22

34

51 42


6 APRIL 2013 www.PackagingDigest.com

online Read these bonus articles at packagingdigest.com

SEEING THESE ARTICLES FOR THE FIRST TIME?

Sign up for Packaging Digests Daily Packaging News e-newsletter to receive

news as it happens. Keep up to date with our quick-scan headlinesthe best source for whats happening in packaging, delivered directly to your email inbox each business day. Go to www.packagingdigest.com/Daily

Natural Products Assn. calls for national standard on GMO labelingSo consumers can make educated decisions about the foods they eat, the nations largest association for natural products joins the growing movement for labeling products with genetically modi ed organisms: People have a right to know whats in their food.www.packagingdigest.com/StdGMOlabeling

PACK EXPO launches packaging automation resourceT e Center for Trends & Technology: Improving Production through Innovation (sponsored by Rockwell Automation and its PartnerNetwork Program) will debut at PACK EXPO Las Vegas 2013. It is designed to be a gathering spot for attendees interested in learning about new technologies.www.packagingdigest.com/PackExpoAutomate

Whole Foods Market commits to full GMO transparencyT e retailer has announced it is requiring all products in its U.S. and Canadian stores to be labeled by 2018 to indicate genetically modi ed organism content. www.packagingdigest.com/WholeFoods

Training explains British Retail Consortium global standard for food packagingUL DQS is o ering two-day training classes on British Retail Consortium; the next will be at the UL University facility in suburban Chicago on May 7-8.www.packagingdigest.com/GlobalStandard

New Belgium Brewing joins ranks of EPR supportersT e Colorado craft brewer has pledged its faith in extended producer responsibility with the help of Recycling Reinvented.www.packagingdigest.com/NewBelgium

Manufacturing report offers good news for packaging industryA market report indicates activity in the manufacturing sector expanded in February for the third consecutive month, and the overall economy grew for the 45th consecutive month.www.packagingdigest.com/GoodNews

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Join the packaging community discussions at Packaging Digests LinkedIn group

at www.linkedin.com, on Twitter at www.twitter.com/packagingdigest or

by commenting on a PD article online at www.packagingdigest.com

dialogue

What a great idea from a consumer and environmental

standpoint. I expect the food industry to be slow on the uptake as getting all of the ketchup out of the bottle will reduce the number of bottles of ketchup sold to consumers.

Ben Wadler, restaurant purchasing director, on LiquiGlide gives foods the slip to reduce waste

Process Expo (@ProcessExpo): T ere are no secrets to success. Its the result of preparation,

hard work & learning from failure -Colin Powell #quote | RT @FoodBevSustain

Love LOVE Love this! Cannot tell you how many bottles of wine had to be tossed because

I didnt nish them in time, and the number of wines I passed on trying just because of this! I really do have just 1 glass if Im having it at home.

Arlene Wynn on Fine wine in a 187-mL glass tube

I agree that protective packaging can play a crucial role during

shipping and consumer delight upon delivery and can result customer loyalty and repeat purchases.

Than Nguyen, Protective Packaging, on Getting in line with online shopping

Barbara Fowler, Smithers Pira (@BarbaraRFowler): #packaging protects far

more resources than it uses #sustpack13

Admirable goal to get the stuff out of the oceans. I do not believe it

can ever be a cost effective approach. You would have to cover too much area to pick up several tons of plastic, I would think. It will be very interesting to see a status report after one year of operation.

Robert Esse, Humidipak/Boveda, on Project reclaims plastic packaging from oceans

PMMI (@PMMIorg): T anks for the RTs and mentions this week! Were really starting

to rev up the social media engines for #PACKEXPO this year, so stay tuned!

LinkedIn poll: Sustainable prioritiesThis months LinkedIn poll indicates that more packaging professionals consider sustainability a priority than an afterthought. Doreen Monteleone, director of EHS and special projects for the Flexographic Technical Assn. and board member of the Sustainable Green Printing Partnership (www.sgppartnership.org) weighed in on prioritization of sustainability: It will vary with the philosphy of the executives within the company and the pressures of the clients. However, I have found that more than 72 percent of exographic printers make reference to their environmental/sustainability initiatives on their websites so it de nitely is important to the industry. The Sustainable Green Printing Partnership was created by the printing industry to offer a mechanism for printers to validate their sustainabilty programs. Green washing is out there!

0 10 20 30 40 50 60 70

It is a top priority in all areas

Important only if clients bring it up

Important only if it also can cut costs

Sustainability is not a priority

66%

Which of the following best describes your packaging

company's sustainability philosophy?

14%

15%

5%

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staffEditorial O ce:1200 Jorie Blvd., Suite 230Oak Brook, IL 60523 630-990-7384 e-mail: [email protected]

Corporate Headquarters:2901 28th St., Suite 100Santa Monica, CA 90405310-445-4200 www.ubmcanon.com

Editorial Advisory Board

Oliver CampbellDirector Procurement, Packaging, Dell

Kim CarswellSenior Manager Packaging, Target

Scott Hemink Senior R&D Manager for International Technical Services, General Mills

Joe HotchkissDirector, Michigan State University, School of Packaging and Center for Packaging Innovation and Sustainability

Joe KellerSection Head Packaging Development Global Packaging Sustainability, T e Procter & Gamble Co.

Denise LefebvreVP, Global Beverage Packaging, PepsiCo

Peter MacauleyDirector, Global Packaging & Sustainability, Abbott Laboratories

Michael OkoroaforVP-Packaging R&D/Innovation, H.J. Heinz

Ron SasineSenior Director of Packaging, Private Brands, Walmart

Art/Production/Marketing

Lead Art Director Marco Aguilera

Production Director Je Tade

Production Manager Brian Wu

Production CoordinatorSaravanan Somasundaram

Marketing Manager Mary Williams

Director of Circulation Sandra Martin

Circulation Manager Xavier Contaoi

Executive Officers

Chief Executive O cer Sally Shankland

Vice-President/Executive Director Stephen Corrick

Sr. Vice President, Events Division Mark Snell

Vice President, Operations Roger Burg

Brand Director-PackagingSteve Everly [email protected]

Technical Editor Rick Lingle 630-990-2364 [email protected]

Senior Editor Jenni Spinner 630-990-7385 [email protected]

Plant Operations Editor Jack Mans 630-990-4208 [email protected]

Associate Art DirectorJennifer Field310-445-4248jenny. [email protected]

Executive EditorLisa McTigue Pierce [email protected]

The Unit Pack name is synonymous with innovative research and improvements in

unit-of-use packaging. Select the perfect size and shape, from 1/2 cc to 90 cc to

hold precisely the amount of product desired. Telephone us toll free 877-930-3200

or e-mail [email protected] today for a brochure and samples.

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viewpoint11 www.PackagingDigest.com APRIL 2013

LISA MCTIGUE PIERCE

Executive [email protected]

A busy month of traveling and conversations at various industry events got me thinking about some opportunities for packaging:

Online shopping will continue to grow. Are your primary packages designed for direct home delivery? Can they survive the sometimes brutal small-parcel environment and still make a positive impression on consumers when they arrive? If they are built solely with the protection-in-numbers pallet-load supply chain in mind, you might be missing an chance to optimize primary and secondary packaging structures together.

I started thinking about that because of this big newsAmazon gears up for private labelfrom the folks at the Private Label Manufacturers Assn. They write: How long will it be before Amazon becomes a factor in private label? Maybe not as long as you think. The giant online retailer has been running classified ads to hire a Director, Global Product Development, Private Brands. You can bet that, once Amazon begins to develop products, its packaging designers will consider the delivery method as they make their material and structural choices. For example

I stopped at Wendys for lunch during a drive from my hometown Chicago to Cincinnati, where I was giving a presentation at the EPS Expo 2013. I love this fast-food chain and was happy to see that they improved the packaging to make the burger easier to eat in the cartheres a paperboard tray now that is easy to hold and collects any droppings.

T e next day, though, as I was making the return trip, I lamented that there was no easy way to eat one of their salads while I was driving.

It doesnt matter that the product itself isnt conducive to eating on the go. For a split second, I was thinking like a consumer and blamed the packaging for not meeting my wants. Portable packaging isnt anything new but theres still room for improvement.

Do you know all the ways consumers are using your products today and where? Is your package functional for all those occasions? You might nd some insight into the need for ber-functional packaging at www.theonehandedworld.blogspot.com.

I brought up the idea of making a product/package easy to open/use with just one hand at a new online community sponsored by DuPontwww.medicalpackaginginnovation.comwith a comment on the 3/18/13 blog post titled Can You Do It in the

Dark? Author Adele Graham-King relays a story about not giving her young daughter her inhaler during the night because she didnt want to turn on the light and possibly end up waking the whole house. She asks, What makes a medical device so intuitive that we can use it anywhere at any time? How many [caregivers] dont medicate correctly due to inconvenience, technical difficulty, situation, or environment?

Can we use your package in the dark or at the park? On a train or in the rain? Here, there or everywhere?

The anywhere, anytime challenge

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packagingconcepts

TRENDS // APRIL 2013 www.PackagingDigest.com

Mintel Market Snapshot

www.mintel.com/gnpd

Studies show that while most women in the U.S. have lotions in their

homes, many dont use it because it takes too long to apply and

absorb, creating a speed bump in their morning routine.

Thats where Vaseline has jumped in with its new Spray & Go

Moisturizer. The product comes in a can with continuous spray

capability, applying and absorbing in seconds. In addition to the

specialized formulation, the product facilitates more convenient use

through two packaging elements:

The external structure consists of a twist-lock actuator that is easy to

press and avoids spills, and a contoured aluminium can that f ts nicely

in the hand.

The internal structure uses bag-on-valve technology for 360-degree

non-aerosol spray delivery, using only compressed air.

The cans deliver a targeted spray (approximately the width of a

users wrist) that spreads easily and evenly, and it absorbs readily with

a few quick rubs.

This breakthrough moisturizer will help more women incorporate

lotion into their morning routines, and will drive category growth in an

area that has not seen innovation in more than f ve years, says Dawn

Hedgepeth, U.S. skin director for brand owner Unilever.

The bag-on-valve mechanism and actuator are supplied by Aptar

Beauty and Home (www.aptar.com), and the aluminium can (which

is printed via dry offset) is manufactured by Envases Del Plata S.A.

(www.envasesdelplata.com). The three varieties (Total Moisture, Aloe

Fresh and Cocoa Radiant, available in 6.5-oz cans) hit retailers across

America in March.

Lotions shows can-do attitude with spray package

Consumer healthcare is dominated by a small

number of pack types: Bottles for liquids, tubes

and sachets for crmes, jars and blister packs for

tablets. In many cases, brands will remain within

these pack types, sticking to generic shapes and

pack designs, to communicate to the consumer

the scientif c and pharmaceutical nature of

the product. However, as consumers become

increasingly comfortable with self-medication, and

brand owners innovate to appeal to new consumers

and f nd new use occasions, packaging that moves

outside of these norms could offer a simple strategy

for differentiation.

One potential target audience is the female

consumer, particularly for supplements. According

to Mintel research, in the U.S. women are more

likely to trust vitamin and dietary supplements and,

as a result, also are more likely to take them. For

example, when offered the statement I believe

that vitamins and other nutrients really make a

difference, 65 percent of female respondents

agreed, compared to only 58 percent of men.

Similarly 51 percent of women asked by Mintel had

taken mineral supplements in the past 12 months,

compared to only 35 percent of men.

Is there an opportunity to create packaging

that reaches out to this consumer group? In

South Africa, one company has done just that

with an innovative design change to the standard

blister pack in a board carton combination. Kenza

Health has created a striking pack for Femolene

Mylife Adult (below left), a pack of 28 hormone

supplement capsules for women. Each of four

blister packs have the blisters arranged in a

circle, disrupting the consumer expectation and

providing an attractive appearance that mimics

a f ower. These blisters are held in a litho-printed

paper booklet such that each page contains the

blister and capsules for one week, with in-depth

product information about that weekly course

of supplements. This simple presentation could

help compliance by making it

immediately clear to the user how

far they are through the supplement

course as each f ower has petals

holding seven tablets, making each

blister appropriate for a single week.

The overall design softens the

image of a product that could come

across as clinical and uncaring.

Another interesting blister

innovation is offered by Nht Nht

in Vietnam (above). In this pack of

Detoxifying Tablets for Women, the

base of the pack (rather than showing the individual

blisters that hold the tablets) is covered over with a

single larger blister to give a simple smooth surface.

This helps to simplify the presentation of the pack

and creates a second billboarding space that could

be used for brand or product information.

Inspiration for healthcare can come from other

categories. For example, in China, Orion Xylitol 3+

gum retail in a 56g tub (at right). To reduce noise

created when the tub is shaken, the base of the tub

can be moved to compress the gum dragees and

stop them from moving about. For those women

who take supplements to work or to the gym,

such a pack could help to

keep their use more discrete.

From the same category,

Wrigleys Eclipse in the US

feature a blister pack where

one blister has been replaced

with a small groove so that the

consumer can pull the blister

from a board sleeve with a nail

(below). This provides ease

of access to the product in a

compact and portable pack.

In 2012, only 5 percent

of global vitamin and dietary

supplement innovation was

targeted at the female

demographic. Therefore, it seems

there is an opportunity for products

that target the health needs of this

group. With many existing packs

simply relying on adding an image

of a healthy woman on the front

of the pack, those brands that can

leverage packaging to better f t into

the lifestyle of this group will clearly

gain a competitive advantage.

Benjamin Punchard, senior

global packaging analyst, Mintel

Blister packs innovate with feminine appeal


1313 www.PackagingDigest.com APRIL 2013 // TRENDS

Makeover of the month

Premium frozen treat brand launches cool new packagingTalenti Gelato & Sorbetto, the company behind the worlds best-selling packaged

gelato, has freshened up the brand with new packaging that

modernizes the look and the feel of the product, and it also has

served up four additions to its stable of f avors.

The companys new logo and typeface are geared to support

the brands simplicity and playfulness. The smiling spoon

logo and happier spoons tagline are aimed to further remind

consumers of the products fun, quality and natural ingredients.

The clear containers, which show off the tantalizing frozen

concoctions inside, are made of PET by Talentis packaging partner; the

screw-on lids are constructed of HDPE.

In addition to the packaging updates, the company has introduced four new

f avors: Alphonso Mango, Argentine Caramel, Southern Butter Pecan and German

Chocolate Cake. All of the companys f avor varieties can be found in freezer cases

at retailers nationwide and through a number of websites.

Whisky bottle takes a shot at heritageTennessee has a long-standing love affair with white

whisky. Short Mountain Distillery hearkens back to

that era by employing a traditional distilling process

using local stone milled grain and Tennessee

spring water to create a sour mash moonshine.

The process, and the packaging, salutes

Short Mountain Moonshines status as the

modern-day heir apparent to white lightning.

The bottle, created by TricorBraun

Design and Engineering (www.

tricorbraundesign.com) has a 1930s feel.

Unique to the design is an indentation

in the bottles shoulder into which a

commemorative, seasonal medallion is

placed. Other embellishments include a

hand-drawn paper label. It uses a T-top wood

and cork closure. The spirit is sold in 750-

mL, individually designed bottles made with

custom-grade f int glass.

The 105-proof moonshine won a Gold

Medal in the 2012 Intl. Review of Spirits

Awards From the Beverage Testing Institute.

Craft beer launches in juicy new cansWinner of a silver medal at the

2011 Great American Beer Festival

competition, Mr. Pineapple (the

brainchild of SanTanBrewing Co.), is

a traditional German wheat ale with a

twist: natural pineapple juice is added

to give it a sweet, refreshing taste. The

libation originally was brewed for the

companys annual Luau celebration

during the summer months in Arizona.

To facilitate consumption at outdoor

venues (which frequently frown upon

breakable bottles) the company has

launched in 12-oz aluminium cans

from Rexam (www.rexam.com).

We are excited to offer our

customers the opportunity to take our

perfect summer seasonal brew with

them on their outdoor adventures,

says Anthony Canecchia, SanTan

Brewing Co. owner and head

brewmaster. By teaming with Rexam,

we are able to meet the growing

demand for our products across

Arizona and beyond in the most

recycled beverage package.

In addition to helping increase the

beers portability, the opaque cans

help preserve the brews f avor by

blocking light, reduce transport weight

compared to glass bottles and help

increase recycling rate.

The seasonal brew launched in

select Arizona retailers at the end of

March 2013.

Flexible pack helps deer-friendly product attract humansAntler Kings Red Zone seed mixes offer hunters and nature enthusiasts a way

to attract deer to their properties by growing a variety of plants that tantalize the

critters. The company, with a newly redesigned package, is hoping to attract more

two-legged creatures (namely, consumers) as well.

The Titanium multilayer f exible packaging structure from partner Flair Flexible

Packaging (www.f airpackaging.com)

is intended to better showcase the seed

mixs properties, and its ability to boost

body weight and rack size of white-tail

deer, on display in farm supply retailers.

The multilayer material blocks

moisture transfer, which protects the

integrity of the seed, and accepts

multi-color reverse rotogravure printing.

In addition to helping decrease order

turnaround time and increasing

billboard, the new bag features a see-

through window that showcases the

product.

The window is important to help

explain what is inside. It really engages

the customer, which is what you want

at a point of purchase, says Antler King

founder Todd Stittleburg.

The product can be purchased at

a variety of farm and hunting supply

stores, and on the companys website

(www.antlerking.com).

before

after


14 TRENDS // APRIL 2013 www.PackagingDigest.com

Unique beverage looks on sunny side with cartonsSunrich Naturals showcased its SoL line of sunf ower-

based shelf-stable beverages at the Natural Products

Industry Expo West in March. The beverages are the

f rst products to pour into Tetra Paks (www.tetrapak.

com) Tetra Brik Aseptic Edge cartons. The containers

are intended to combine product protection, shelf

appeal and sustainability for brand owners.

The Tetra Brik Aseptic Edge features a sloping top,

intended to make it easier for consumers to access,

grasp and open the ridged cap; plus a wider opening

that makes it easier to pour. A new look, improved

functionality, lower cost and better environmental

prof le make the carton suitable for shelf-stable.

The new Tetra Brik Aseptic Edge packaging is ideal for SoL and all of our non-

dairy beverages, says Tina Nelson vp sales and marketing for the company. It

offers superior preservation of the fresh taste and nutritional content of the product

in addition to prolonged shelf life.

Three f avors of the SoL beverage (Original, Unsweetened and Vanilla) are

available.

Lip gloss hits shelves in striking new tubeWith beauty product shelves becoming increasingly crowded, brand

owners are looking to create packages that help their products

stand out and appeal to consumers. The team at OEKAbeauty

(www.oekabeauty.com) has lent a hand to cosmetics giant

Rimmel London by providing a striking new package for its

Apocalips lip gloss.

The new product comes in a package with a black molded

top and a transparent body. The bottle is only partially coated in

the upper region. The f nish ends with a course; the decoration

f ts well with the transparent PET lip gloss packaging because

it combines product visibility (which lets beauty-minded

shoppers see the precise color of the gloss inside) with an

elegant package look.

The new Apocalips gloss is available at department

stores and specialty retailers nationwide.

Bottle shows off natural beautyHelen Herber, a personal care product company based in Europe, recently

launched a range of shower gels that are intended

to deliver clean, beautiful skin without the use of

harsh, harmful chemicals. To create packaging

that communicates the lines natural, beautifying

properties, the company turned to M&H Plastics

(www.mhplastics.com).

Helen Herber consulted with the packaging team and

decided upon the 250-mL Tall Square PET bottle, part

of M&Hs stock container line. They

topped it off with a black gloss pump.

The self-adhesive label uses high-

quality photography that depicts the

main ingredient of the product inside

(varieties include Rose, Melon,

Sweet Plum, Coffee and Cornf ower).

packagingconcepts

Protection offormulations fromenvironmentalexposure

Hermetically sealed glass ampoule

in a butyrate tube

protects from oxygen

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Kate Bertrand Connolly, Contributing Writer

Any packaging engineer who wants to get and keep a job obviously needs good technical skills. But globalization, evolving business models and increased visibility for packaging as a discipline have made communication-based skills like social media, relationship-building and selling almost as important.

Its no longer enough to be versed in traditional packaging. T e industry is changing. Society is changing, as well, says Oliver Campbell, director of procurement for packaging and packaging engineering at Dell.

T e drivers range from global supply chains to demand for greener packaging. Managing global supply chains requires cultural sensitivity, which inherently involves communication, Campbell says. And with more companies producing annual social-responsibility reports, packaging professionals need to be able to communicate what they do to a non-technical audience.

But, Campbell says, Id say the biggest [skills] gap is probably on social media. T e reason I say that is because relatively fewalthough the numbers are growingreally take advantage of it.

Dells packaging team is highly attuned to social media, with the companys Social Media Command Center in Austin, TX, tracking whats being said. If somebody is mentioning Dell

packaging pretty much anywhere in the world, our social media team will alert me to that. I usually know within several hours and can respond if necessary, Campbell says.

He adds that knowing what consumers, bloggers and thought leaders are saying about Dell packaging

does in uence our thinking as we construct our strategic material roadmaps around packaging and what were going to do in the future.

Interpersonal skillsOn the other hand, too much reliance on electronic communication can cause its own problems. Lee Longstreth, director-engineering at TricorBraun, says hes frustrated by the e-heavy communication style he sees in some new hires. In such cases, lack of interpersonal skills may be the underlying weakness.

T e only way you are successful, and you really make an impact for yourself and your company, is to be able to build relationships, Longstreth says. T e problem I see today is that its all so electronic. You cant build a relationship electronically.

With media such as Twitter, texting, instant messaging and even email, its all very short. People dont get a feel for what youre saying or what you really mean, he explains. T eres no in ection to your voice, theres no facial expression to give them an idea of what youre getting at, and its just brutal.

Longstreth advises engineers who are stuck in the e-media rut to meet in person with colleagues and collaboratorsor at least pick up the phonemore frequently. T ese habits serve the double purpose of resolving issues and honing interpersonal skills.

Im talking about being able to walk out of

your o ce [and] down the hall into somebody elses o ce, sit down and resolve a problem, he says. How many times do we have a problem with the person two o ces down and instead of talking to them, we send them an email?

A way with languageMultilingualism, guratively and literally, is another increasingly important communication skill. T e big complaint I hear a lot from leaders of organizations

is that their packaging people are too technical. T ey dont speak the business language, says Brian Wagner, vp, consulting services, Packaging Technology Integrated Solutions (PTIS).

He adds, You have to be multilingual in your own company. T ere are truly di erent languages.

Tackling the soft skills gapNon-technical skills like communication emerge as MUST-HAVES FOR PACKAGING PROFESSIONALS.

If somebody is

mentioning Dell

packaging pretty

much anywhere

in the world, our social

media team will alert me

to that. Oliver Campbell, director of

procurement for packaging and

packaging engineering, Dell

Packaging

people are too

technical. They

dont speak the

business language. Brian Wagner, vp, consulting

services, Packaging Technology

Integrated Solutions (PTIS)

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17 www.PackagingDigest.com APRIL 2013 // TRENDS

Marketing speaks a language that manufacturing doesnt understand and vice versa. In fact, packaging professionals are in a position to learn myriad business languages, including those of design, marketing and nance, because they interact with so many di erent functions within their companies.

Being uent in languages used in di erent regions is becoming more useful, as well. For our Asian-based engineers and designers, basic English skills are needed to help communicate with our international customers. And for our foreign engineers and designers working in Asia, I would suggest learning some Chinese, says Sean Murphy, chief creative o cer at Hong Kong-based YFYJupiter.

He adds, If youre a talented engineer, and you speak English and Chinese or even another language, like German or French, you become more valuable to us because so many of our clients in Asia come from all around the world. T ese language skills will really bump up your resume with us.

Selling itAdaptability is another skill thats becoming more necessary. Like businesspeople in other professions, packaging professionals need to adjust and be more adaptable to this rapidly changing global marketplace, says Pete Macauley, director, global packaging and sustainability, Abbott Laboratories.

Macauley further notes the value of skills like collaboration, persuasion and negotiation, all of which have a strong communications component.

Packaging professionals have always collaborated with others in their own companies, but now they are collaborating much more with other organizations. I sit in more meetings today with my peer competitors than I probably did in my rst 15 or 20 years in the industry. You have to have that collaborative approach, Macauley says.

Also essential is the ability to sell your ideas, he adds. As packaging teams, we always said we want a seat at the tablewe need to be more recognized. Well, you look around industry today, and there are more vp-level packaging people than ever before, so we [have] that recognition. Now weve got to be able

to sell it. Now weve got to deliver on the concepts. In addition, negotiation skills are good to

have. As with selling, negotiation requires careful communication and the ability to craft win-win solutions.

Getting schooledSo wheres a packaging professional to go to develop these skills? T ose on the executive track may decide to earn an MBA degree. Others may go the adult-education route, taking classes in person or online.

Many colleges and universities offer relevant undergraduate and graduate-level classes through their continuing-ed programs. Stanford Universitys Continuing Studies course catalog includes topics like Persuasive Face-to-Face Business Communication, Coaching Skills for Leaders and Managers and Negotiation Mastery: Achieving Outstanding Results and Relationships.

Consultants and industry groups also provide professional-development training. Packaging Technology Integrated Solutions, for example, o ers a workshop called Championing and Selling Packaging.

And companies like Abbott o er in-house training, including cultural-sensitivity classes to prepare packaging professionals for projects in

distant lands or with far- ung team members.Finally, for social media, how-to videos are

readily available online (just Google social media tutorials). But they may not be necessary. T e beauty of something like Twitter is its actually very simple. Most people who get on there and start playing with it will grasp it, says Eben Bayer, CEO of Ecovative. You dont need to be an expert. You just need to show up.

If youre

a talented

engineer, and

you speak

English and Chinese or

even another language,

like German or French,

you become more

valuable to us. Sean Murphy, chief creative

of cer at Hong Kong-based

YFYJupiter

I sit in more

meetings today

with my peer

competitors than

I probably did in my rst 15

or 20 years in the industry.

You have to have that

collaborative approach. Pete Macauley, director, global

packaging and sustainability, Abbott

Laboratories

Ecovative, 518-273-3753

www.mushroompackaging.com

Packaging Technology Integrated Solutions,

800-875-0912, www.ptisglobal.com

TricorBraun, 800-325-7782

www.tricorbraun.com

YFYJupiter, 415-409-2540, www.yfyjupiter.com

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EMPOWERING PACKAGING

ENGINEERS TO MAKE A

DIFFERENCE, combined with

the continued development of

and investment in sustainable

materials, ensures a bright future.

Lisa McTigue Pierce, Executive Editor

Dells revolutionary packaging innovationssuch as bamboo and mushroom packagingmake it easier for customers to be green, enhance the brand experience and promote a healthier supply chain. By building an innovation pipeline, Dell has become a world leader in sustainable packaging, reducing its packaging material use by more than 20 million pounds, saving more than $18 million and contributing to a top- ve placing in Newsweeks U.S. Green Rankings for the past four years.

Oliver Campbell, director of procurement for packaging and packaging engineering at Dell, shares his inspiration and vision for the future.

Q: What is the most pressing problem in packaging today and why?

A: Creativity, and the ability to synthesize

ideas to create innovative advantage. Packaging is currently undergoing rapid transformation in three major areas: One, customers are demanding greener packaging; two, governments worldwide are doing the same through increased regulation; and, three, investment dollars are owing into new technologies. When coupled with a projected 1 billion increase in global populationwhich is like adding another India or Chinain 12 short years, those who succeed will innovate to provide cost-competitive packaging that supports an empowering future that people are demanding.

Q: How do you motivate your team in packaging R&D?

A: I coach my team to think like championsto take the smart risks. Nearly everyone has a special project. Not all projects pan out, but they are all interesting. It works because its more about the team than the individual. We help each other, share the credit and believe in making a di erence. Maybe its corny, but its amazing how powerful this type of culture can be.

Q: Who has in uenced you the most in packaging and how?

A: Hands down, its Bill McDonough and

Michael Braungart who have been my inspiration. Cradle to Cradles contrast of doing good rather than just doing less bad deeply in uenced my thinking when developing bamboo and mushroom packaging. T e book also served as a cultural marker that the world is changing; it said, Its OK to think this way, and this is where the next pro table opportunities lie. I have a signed rst edition copy that I treasure.

Q: What are some of the most exciting packaging projects im which youve been involved?

A: T e projects we work on just seem to get better and better, so stay tuned! T e industry now has more capability and openness to pursue our ideas. But de nitely the best moment was when I told my engineers we were going to make mushroom packaging. T ey looked at me like I was crazy. I told them they would make history, and they did.

Q: Where is the industry headed?A: T e future of packaging looks bright.

Investment capital continues to move into the development of sustainable materials. I think it has to for the reasons outlined above. We know the leaders in this sector, and it has been phenomenal to see their growth.

VISIONARY: DELL

Think like champions

Bold stepsExploring alternative renewable materials

for packaging, such as bamboo and

mushrooms, nets Dell top spots in various

green lists, attention in the press and the

respect of eco-conscious consumers.

2007 Dell introduces the Multipack

server packaging option, which eliminates

up to half of the packaging materials.

Up to four 1U rack height servers or 10

blade servers can be delivered in a single

box with an integrated pallet. Customers

ordering delivery of multiple products at

one time can take advantage of this highly

ef cient delivery option. Collateral materials

can be reduced by up to 75 percent, too:

Only one set of product manuals and CDs is

included in each box, further reducing paper

use and material waste.

2008 Dell launches its three Cs

packaging strategy, which focuses on the

cube (packaging volume), content (what

its made of) and curbside recyclability

of its packaging materials. The goal is to

save more than $8 million and eliminate

approximately 20 million pounds of

packaging material by 2012.

2009 Dell begins shipping its Dell

Inspiron Mini 10 and Mini 10v netbooks

with cushions made from bamboo (below),

a highly renewable material that serves as

an alternative to foams often used

in packaging.

The global green

enterprise IT study

released by Strategic

Oxygen and Cohn & Wolfe

reveals Dell as the No. 1

green technology brand.

2010 At No. 1, Dell tops Newsweeks list

of Americas Greenest Companies.

Dells bamboo packaging is certi ed

compostable in municipal and industrial

aerobic composting facilities, receiving

D-6400 certi cation from the American

Society for Testing and Materials (ASTM).

Since 2008, the company has increased the

amount of recycled content in its packaging

to approximately 32 percent.

2011 After testing cushioning made

from a new rapid renewable material

mushrooms (above, right)Dell says it is

ready to use the EcoCradle mushroom-

based packaging from Ecovative (www.

mushroompackaging.com) commercially in

a pilot with its PowerEdge R710 servers to

help reach its waste reduction goal.

Dells 3Cs strategy earns

the 3R Packaging Merit

Award from Singapores

National Environment

Agency.

Dell ranks No. 8 on

Interbrands 2011 Best

Global Green Brands list.

2012 Dell announces that it has

eliminated more than 20 million pounds of

packaging material since 2008. It exceeds

its goals by reducing the volume of its

packaging more than 12 percent, increasing

the amount of recycled and renewable

content up to 40 percent and ensuring

that up to 75 percent of its packaging is

recyclable or compostable at curbside.

Dell appears again on Interbrands Best

Global Green Brands list, moving up to No. 7.

The Green Supply Chain CHaINA award

by the Global Supply Chain Council, Asias

leading professional organization in supply

chain management, acknowledges Dell

for greening its supply chain with bamboo

packaging.

Thanks to Muller Martini Packaging Technology (see ad on opposite page) for sponsoring this article about Dell, as part of our continuing Visionary series.

Oliver Campbell


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sustainability

You have probably never heard of a package that is advertised for its superior low acidi cation potential. Its similarly doubtful that many corporate sustain-ability goals include a reduction of eutrophication. And its all but certain that a packaging decision has never been made based on an estimate of ionizing radiation. T ese kinds of indicators are what I like to call the ugly stepchildren of sustainabilitywe know that maybe they ought to receive our attention, but they end up not getting much of it.

T e reality is that experts can continue to identify a plethora of important sustainability indicators, but they cant make companies use them. T e choice to use certain indicators lies with the packaging decision makers, who have varying goals and may or may not be the sustainability experts.

One challenge lies in the large and growing number of environmental indicators, and the fact that environmental considerations are only one of several considerations used in decision-making alongside things like cost, availability and marketability. Weighing the merits of several considerations creates the desire for simpli ed information. Cost is often boiled down to one number. Availability can be as

simple as a yes or no. Marketability, however, is a bit

more of an interesting consideration, and perhaps it could serve as a model for determining environmental preferability. To determine marketability, complex information from consumer testing, focus groups, insights and educated guesses may be all distilled into one feeling of whether or not a package will do well in the marketplace. Environmental preferability should follow a similar routea complex set of indicators used to inform one judgment: whether or not the package will be su ciently benign to the environment over its life cycle.

T e trend in determining environmental preferability, though, is to use a sparse set of indicators rather than a complex one. Recyclability seems to be a commonly used indicator (though the idea of recyclability in itself can be rather complex). Its not uncommon for a single metric to be the only contributor used in determining environmental preferability.

As for the ugly stepchildren, they remain on the outside looking in. If a package does happen to be preferable in, say, SOx and NOx emissions, then that information might make its way into marketing materials and be used as justi cation for the superiority of the package. But were a long way from realizing a

supply chain where a uni ed set of numerous indicators are always used in every decision.At the root of the issue lie

the perceptions of consumers on sustainability considerations. T e trickle-up

e ect from consumers is often indirect and convoluted, but any pro t-seeking enterprise has a prime directive to provide a product that is desired by consumers. Unfortunately for our ugly stepchildren, consumers havent heard about the importance of ionizing radiation and eutrophication potential either, and its unlikely that they can all become the next incarnation of concern over global warming.

If consumers concern themselves with the environmental attributes of packaging, its likely that they too will simplify the situation. More often than not, that simpli cation results in a perception of waste generation. To a consumer, less packaging is good, recyclable packaging is betterand thats often the extent of the consideration.

Consumers cannot be expected to understand every aspect of sustainability as it applies to packaging. T e torch must be passed to industry if a holistic set of environmental indicators is ever to be used in supply chain decision-making. If this is to happen, the embracers of the ugly stepchildren must light the way.

Embracing the ugly stepchildren of sustainability

Author Adam Gendell is a project manager at GreenBlues Sustainable Packaging Coalition. For additional

information about the Sustainable Packaging Coalition, visit www.sustainablepackaging.org.

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22 BEST PRACTICES // APRIL 2013 www.PackagingDigest.com

A culture of total employee empowerment

at contract packer Aero l drives continuous

improvement every day.

Jack Mans, Plant Operations Editor

Aero l Technology Inc. (ATI) began its operations in Sullivan, MO, in the fall of 1988 with two small aerosol lines and less than 50,000 sq ft of space. Since then, ATI has greatly expanded and now serves clients around the world. Its capabilities, customer base and facility size have grown exponentially during the past 25 years. Today, ATI is a Lean contract packager with a continuous-improvement culture with approximately 350 full-time employees and 16 production lines in a 400,000-sq-ft facility.

In 2007, ATIs ownership group (privately held) knew that, to remain competitive in todays erce global economy it had to di erentiate itself from its many competitors by being able to create a true value-added culture in which the entire supply chain would bene t. Robert Dunaway, CEO/owner, convinced his partners that ATIs adopting the philosophies and practices of the Toyota Production System (TPS) was vital to the companys long term success and has never looked back. At ATI, the Aero l Business System is no longer just another initiative, but a way of life and the culture of our entire workforce, says Dunaway.

At the outset of its Lean journey, the company immediately dedicated four of its top managers full time to both learn and implement the many learnings and processes of TPS that are now commonplace across the company today. Like anyone about to embark on a journey, they started by creating what is referred to as a Value Stream Map that documented their manufacturing processes and information ow from receipt of raw materials through the shipment of the nished goods to their customers. It was from here that other foundational tools such as 6S, Standard Work, One-Piece Flow and Pull Systems rapidly evolved.

Lean has had an immediate and dramatic impact on the entire workforce and culture since Day 1, says Pat Bergin, president. At the core of the learning, ATI focused on what it considers its most valuable resource. Our most valuable and precious asset is not our equipment, its not how many units we produced in a given dayits our employees, says Bergin. Lean unleashed and empowered the organizations workforce from the CEO on down. It engaged every single employee throughout the entire enterprise, driving continuous improvement on a daily basis, according to Bergin.

In the spring of 2009, ATI subdivided the company into smaller, more manageable business units, also known as Value Streams, with their own individual Pro t & Loss. ATI identi ed that it wasnt doing as well as originally thought in its dry and granular business and decided to exit that category completely. It immediately began looking at the latest high-tech/high-speed liquid bottling line available in the marketplace. T e new line, which started in October 2012, runs 15 di erent bottles with seven di erent closures, including trigger closures. PH

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Lean ef ciency


23 www.PackagingDigest.com APRIL 2013 // BEST PRACTICES

In designing the high speed line, ATI rst established the operational requirements for each piece of equipment on the new line and then used another Lean tool known as 3P (Production, Preparation, Process), which required seven di erent layouts at the outset of the project. Once the equipment was selected, the 3P Team literally placed full-size corrugated cutouts of each piece of equipment on the oor to determine the most suitable line layout.

T is let us get a good idea of how the equipment would t in the room, and how accessible it would be for the operators, says Greg Wilke, who was the project manager for the installation and is now the production leader during start-up for the new line. T e result is an e cient high-speed packaging line that is operated by only three people.

Flexibility is one of our strengths, so the new line needed to be capable of running di erent bottle styles and closures, says Joe Sonderman, svp of operations. Changeover was a paramount

concern, because we have to get in and get out of di erent products in a timely manner.

A major change that was instituted for the new line was that processing and packaging are in the same room, though they are in separately de ned areas. We have always located processing and packaging in separate rooms, but this new arrangement allows close interaction and e ective communication between blending operators and line operators, says Sonderman.

Dedicated line integrationAs the planning for the new line progressed, systems integrator Advanced Packaging Integration became a key contributor. We were initially contacted to bid on the robotic palletizer, says John Vaninger, vp-operations, but as we got more involved in the project, ATI realized that we could do a lot more for them than the robotic palletizer. Advanced Packaging Integration provided the systems integration, supplying all of the conveyors and supplying the controls integration.

ATI had a de nite idea of what they wanted in the new line, says Vaninger. T ey wanted a U-shaped layout with the operators in the center. Because they are a contract packager and have to be able to run a variety of packages, they wanted the line to be as exible as possible and require minimum changeover time.

Among Advanced Packaging Integrations tasks was to integrate the entire packaging line and the development of the controls. We integrated all of the machines into one main processor and common HMI, which monitors the status of each machine and displays the status of each machine, as well as the OEE (Overall Equipment E ectiveness), on the 60-inch overhead LCD scoreboard, says Vaninger. Each machine has its own dedicated controls and HMI, but these are also integrated into the main system.

Advanced Packaging Integration designed and built all of the conveyors along with required line devices that monitor bottle movement throughout the system. All of the bottle conveyors are equipped with quick-change guide rails to reduce changeover time, and all case conveyors are powered by 24-volt DC motors to minimize noise and energy costs.

Multiple vision systems were installed throughout the packaging line to ensure product quality at each stage of the lling and packaging. T ese are included at the exit of the unscrambler to ensure the bottles are oriented properly, at the exit of the labeler to ensure that no labels are missing and that labels are properly oriented, after lling and capping to ensure proper lling level and that caps are in place and are not cocked and after the case packer to ensure that cases are lled. Cognex supplied the cameras, and the controls are Allen-Bradley from Rockwell Automation to provide a common platform.

Running 22-oz Spic and Span bottlesDuring Packaging Digests visit, the line was running a 22-oz Spic and Span bottle with a handle and a trigger closure at a rate of 150 bottles/min. To start this operation, PET bottles are loaded into the oor hopper of a Posimat Posi ex 30-VA bottle unscrambler. T e bottles are lifted to an overhead

Joe Sonderman (left) and Greg Wilke explain features of the Spic and Span bottle.

Monobloc ller/capper includes a 30-head mass ow ller and a 12-head capper. The ller incorporates Coriolis technology that achieves +/-1g ll accuracy.

With the multitude of containers that are run on the new

line and more that will be added, storing and keeping

track of the changeparts for all of the equipment loomed

as a signi cant challenge. Ingeniously, ATI installed a

Shuttle XP500 vertical storage unit with 38 shelves from

Kardex Remstar LLC to store all of its changeparts.

Horizontal shelves are arranged vertically along the

front and back of the unit. When the item on a shelf is

required, the shelf is moved onto a belt system that

transports it down the center of the unit to the opening

at the front, where the item is automatically presented to

the operator.

The Shuttle XP is a fully automated system. When an

item is rst placed into the unit, the operator identi es

the tray number on the control panel and the system

remembers the location. To retrieve an item, the operator

enters the item name, and the system automatically

retrieves it.

The plant uses carts to move the changeparts

between the storage facility and the equipment on the

packaging line.

The Kardex system has worked out very well for

us, says production leader Greg Wilke. It doesnt

take up much oor space for the amount of storage it

provides, and it allows us to easily keep track of all of the

changeparts. Also, it eliminates any damage that might

occur if the parts were sitting out on racks.

Changepart storage protects and delivers

An automated vertical storage unit, with 38 shelves, stores all of the changeparts for the new line. To retrieve an item, the operator enters the item name into the HMI, and the system automatically delivers the appropriate tray to the delivery space.

Continued on page 24



hopper on a cleated conveyor. T e 24-pocket unscrambler has two bowls that rotate in di erent directions to achieve proper bottle orientation. T e bottles leaving the unscrambler are conveyed on a vacuum conveyor to eliminate tipping. A major reason that we selected the Posimat unscrambler is because the changeover from one bottle to another is so quick. Once the new bottle is programmed, it takes a push of the button on the HMI and toolless changeover of the orienter in minutes to perform the changeover, says Sonderman.

T e bottles travel to a Pago Model 520 non-

stop pressure-sensitive labeler that applies both front and back labels as well as wraparound labels. Sonderman says, We label before lling, because there is less product waste if we have to discard a bottle because of a bad label.

T e Model 520 labeler was sold to Aero l by DTM Packaging LLC, but American Fuji Seal Inc. has since purchased Pago. DTM is still the distributor for the labeler in the U.S.

T e labeler features four complete label stations arranged for non-stop con guration to apply the front and back labels. When a roll of

labels runs out, the system automatically switches label stations on the same side of the machine, allowing production to continue uninterrupted during label roll changes. T e operator slides out the label head requiring a new label roll, makes the change and then slides the head back into position, ready to operate.

Sensors detect the bottles entering the machine and adjust the speed automatically. A wheel and chain alignment system separates and aligns the bottles for optimum positioning without the need for changeparts. An upper bottle hold-down belt holds the bottles in place during the labeling process.

T is belt is equipped with an adjustable air bladder that compensates for slight di erences in bottle height. T e main conveyor and hold-down belt are all servo driven and change speeds

synchronously with the label applicators when the line speed is varied or when changing from one bottle to another. T e labeler achieves a label placement accuracy of +/-2mm.

A Cognex camera inspects bottles as they exit to ensure proper label application. If an improperly labeled bottle is detected, it is ejected by an air blast. If three bad bottles in a row are detected, the machine shuts down and triggers an alarm.

Mono-block ller/capperFrom the labeler, the bottles are conveyed to a Pneumatic Scale Angelus (PSA) mono-block ller/capper that includes a 30-head mass ow ller and a 12-head capper. T e ller incorporates Coriolis technology from Micro Motion USA that achieves +/-1g ll accuracy. To meet ATIs explosion-proof requirement, the mono-block system is rated as intrinsically safe.

Product from the blending tanks in the adjacent processing area is pumped to the hold tank installed next to the ller. Level and pressure control in the hold tank maintains a constant level in the tank to maximize ll accuracy. T e product is then pumped to the 30 ll heads, each of which has its own supply tube, enabling each meter to act independently. T e nozzles are designed for laminar ow to minimize splashing and aeration.

Each nozzle is equipped with a diaphragm valve that features soft stop/start capabilities that allow the ow pro le into the bottle to be adjusted to accommodate di cult items, such as foamy or high- or-low viscosity products. T e Micro Motion system automatically tracks product viscosity and temperature and will sound an alarm if they are out of spec. T e system, which includes a no-bottle/no- ll feature, tracks the ll of each

The pressure-sensitive labeler features four complete label stations arranged to apply front and back labels without stopping for label changes.

The versatile case packer ef ciently handles glass, plastic, cans and paperboard in both round and non-round con gurations with containers of various sizes. It also handles a variety of secondary packaging container formats, including RSC cases, trays and display trays Continued on page 26

We label before lling,

because there is less

product waste if we have

to discard a bottle because

of a bad label. Joe Sonderman, ATIs svp of ops


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bottle and will reject the bottle after it leaves the capper if the ll is low.

T e lled bottles travel through a transfer starwheel into the 12-head capper that was chosen by ATI because it can run all types of closures, including trigger and pump caps as well as plug and screw caps. Trigger caps can be a challenge, and a sensor on the capper detects the opening on the bottle and a V-block system helps guide the quills into the bottle. T e capper fully tightens the cap

to a preset torque using magnetic torque control, eliminating the need for a retorquer.

In response to ATIs diverse packaging requirements, PSA also supplied two integrated sorters to supply triggers, pumps, press-on and screw-on closures. Quick SKU changeovers are e ciently accomplished with PSAs Zepf Mark II, No-Tool container handling parts in conjunction with a recipe driven, motorized turret-height adjustment feature.

Here again, exibility was essential, says Sonderman. T is capper allows us to e ciently run every kind of closure we have on the market with minimal changeover requirements. Pneumatic Scale Angeluss solution for not only applying triggers and pumps but also a variety of caps on the same platform was a key reason they were selected.

Integrated controlsT e ller/capper is controlled from a single operator station. T e PLC-based controls architecture is con gured with simple recipe-driven parameters that track and display the weight, temperature and density for each bottle lled.

A user-friendly touchscreen interface allows each lling head to be monitored, sampled and adjusted. And because each mass- ow meter houses its own control package, each meter can be adjusted independently. Product recipes can be created and edited, and rejection parameters for out-of-spec containers can be set as well. Real-time and historical shift data can be viewed on-screen and printed. And the programmable logic control-based technology makes system diagnosis and servicing easier.

T e touchscreen also simpli es capper adjustments. T e touchscreen interface allows operator control of all capper functions and displays diagnostics. Optional recipe height adjustment o ers instant, push-button container height changeover.

A Cognex system at the exit of the capper looks for cocked caps or missing caps or no quills, and rejects those bottles. QC personnel collect samples from all heads once an hour to ensure that there are no undetected problems.

Versatile case packerT e line at ATI is arranged in a U-shape, so bottles leaving the capper make a right turn and then travel along an accumulation conveyor before making another right turn to travel through the downstream equipment.

T ey travel through a PB inkjet printer from Hitachi America Ltd. that applies a lot code on the back side of bottles below the label. Bottles continue through an Enercon Industries Corp.Super Seal induction sealer.

Next the bottles enter a Hartness Intl. Inc. Model 835 case packer. As with all of the equipment, exibility was paramount with quick and simple tool-less changeover. T e Model 835 e ciently handles glass, plastic, cans and paperboard in both round and non-round con gurations with containers of various sizes. It also handles a variety of secondary packaging formats including RSC cases, trays and display trays.

Bottles enter the case packer single le before a swinging gate diverts them into lanes. T e unit was running the Spic and Span bottles in four lanes for 12-pack cases, but it can run up to six lanes, which ATI uses to pack 18-bottle cases. It can also pack multiple cases simultaneously for high-speed requirements.

T e packer features a patented air transfer system that provides low-pressure container handling that o ers gentle conveyance and

se

adodad

The robotic palletizer HMI allows an operator to change over the palletizer in seconds, without changeparts. The custom controls package allows new product patterns to be both added and adjusted via the HMI without the need of a PC.

bottle and will reject the bottle after it leaves the capper if the ll is low

to a preset torque using magnetic torque control, eliminating the need for a retorquer

hropd

a

The wrapper features patented No-Thread powered pre-stretch technology in which the system essentially threads itself without operator intervention, and which stretches the lm to twice or more its stationary length as it is being wound around the pallet to reduce lm usage.


27 www.PackagingDigest.com APRIL 2013 // BEST PRACTICES

packaging of lightweight and unconventionally shaped containers.

ATI installed a Model 330 adhesive case erector/bottom sealer from A-B-C Packaging Machine Corp. to erect the cases for the packer. T e continuous-motion unit features PLC electronics with touchscreen controls for operation, documentation and diagnostics. A Cognex camera

looks down into the nished cases leaving the case packer to ensure that no bottles are missing, after which an A-B-C Packaging Machine top sealer tapes the cases shut.

T e cases travel past a ProSeries printer from Foxjet, an ITW Co., that prints a lot code and other information on the cases, and the cases then travel up a Ryson Intl. Inc. spiral conveyor to an overhead conveyor that transports them to the warehouse.

T ere the cases are palletized with an IRB 660 robot from ABB Inc. that is programmed by Advanced Packaging Integration. T e palletizer HMI allows an operator to change over the palletizer in seconds, requiring no changeparts to

switch to any of ATIs many products. Advanced Packaging Integrations custom controls package allows new product patterns to be both added and adjusted via the HMI without the need of a PC.

T e pallets are conveyed to a Wulftec Intl. Model WCRT175 stretch wrapper, where an arm rotates around the stationary pallet and applies the lm. T e arm starts at the bottom, rises to the top and then goes back down to the bottom of the pallet, so there is a double layer of lm applied.

T e wrapper features Wulftecs patented No-T read powered pre-stretch technology in which the system essentially threads itself without operator intervention. It stretches the lm to twice or more its stationary length as its being wound to reduce lm usage.

T e wrapped pallet is then conveyed past a Model 250 print-and-apply labeler from ID Technology, div. of Pro Mach, that applies a corner-wrap label.

The futureAs ATI looks to its future, Lean is clearly the dominating driving force for the companys culture. It is our way of life, says Bergin. We are steadfast in our convictions that its our employees that are the real experts who guide us in our continuous-improvement processes daily. T ey were involved from the very beginning of the high-speed liquid line from design, to development, to the FAT [factory acceptance test] to the nal implementation and are the true keys to ATIs long-standing success.

ABB Inc., 248-391-9000, www.abb.com

A-B-C Packaging Machine Corp., 727-937-5144,

www.abcpackaging.com

Advanced Packaging Integration, 314-993-3400

www.advancedpack.com

Aerofil Technology Inc., 573-468-1644

www.aerofil.com

Cognex Machine Vision Systems, 508-650-3000

www.cognex.com

DTM Packaging LLC, 781-749-1866

www.dtmpackaging.com

Enercon Industries Corp., 262-255-6070

www.enerconind.com

Foxjet, an ITW Co., 800-369-5384, www.foxjet.com

Hartness Intl. Inc., 800-845-8791, www.hartness.com

Hitachi America Ltd., 704-494-3008

www.hitachi-america.us

ID Technology, div. of Pro Mach, 817-626-7779

www.idtechnology.com

Kardex Remstar LLC, 800-639-5805

www.kardexremstar.com

Micro Motion Inc., 303-530-8400

www2.emersonprocess.com

Pneumatic Scale Corp., 330-923-0491

www.barry-wehmillerco.com

Posimat, 305-477-2029, www.posimat.com

Rockwell Automation, 414-382-2000

www.rockwellautomation.com

Ryson Intl. Inc., 757-898-1530

www.ryson.com

Wulftec Intl., 877-985-3832, www.wulftec.com

Our employees are the

real experts who guide

us in our continuous-

improvement processes. Pat Bergin, president, ATI

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Rick Lingle, Technical Editor

For CEO Bob Shapiro, the recent move of GSC Packaging into a new 100,000-sq-ft facility in Atlanta ful lls a long-held vision: To conduct packaging production the way it should be done from a quality-optimized, material- ow perspective. T e facility features a state-of-the-art layout and design, the latest air-handling technology, lot-code tracking, real-time computerized inventory control, dust control and air-conditioned storage. T e plant has a centrally located quality lab and an on-site maintenance shop. Additionally, there are data ports in the manufacturing areas so that personnel can input production information in real-time online.

But whats at the focal point of Shapiros visionand literally the center of the buildings layoutare 16 parallel packaging suites isolated from each other and from the rest of the plant. Each room is equipped with positive air pressure and subdivided by a cement wall into primary and secondary packaging operations. Personnel enter the front of each suite through a barrier of thick plastic curtains.

While the packaging functions and machinery are segregated, so too are the upstream workers separated from the downstream. Segregation was not feasible in the previous plant, but its something that I always wanted, says Shapiro. Essentially what weve done is removed much of the product contamination risk. Plant personnel are the main source of contamination in any food plant and with this approach weve minimized that risk.

Due to the packaging of nutraceuticals and dietary supplements, the plant adheres to 21CFR111 guidelines that are a higher standard than for food processing for all products. T at drives everything here, Shapiro points out (see Adhering to a higher standard on p.30). In one example, batches approved for packaging are secured within a locked fence in the warehouse.

One of the 16 suites is currently empty, but the others have been earmarked for on-going or short-term projects. We can quickly set up each suite and take them down per-project or we can dedicate rooms inde nitely without interfering with other operations, says Shapiro.

Typically 12 of the suites are actively packaging at any given time over the plants six days weekly, two shifts of operation.

Within the suites, the operations boast 15 packaging production lines comprising seven horizontal form/ ll/seal (FFS) lines, three six-lane

stick pack vertical FFS packaging lines, as well as various semi-automatic, large-format automatic, secondary packaging, shrink wrapping, banding and cartoning, kitting and point-of-purchase display packaging.

Using these systems, GSC Packaging packages dry food-grade powders and particulates for products including nutritional and protein supplements, drink mixes, dry cereals, hot chocolate mix and c

Packaging Digest April 2013

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