140227 Packaging-Trends eBook-En V3.3

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The white paper is instigated

by the GEPPIA

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trends

White paper carried out by for the GEPPIA

http://www.nexteo-interactive.com/http://www.nexteo-interactive.com/


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summar y 5

trends

Foreword

The Geppia’s Packaging Trends white paper:

a nugget of collective thinking ............................................12

Contributors

Opinion column .....................................................................8

Our partners .......................................................................10

Environment

Protecting the environment and the consumers .................16

Now is the time for the virtuous circle of recycling ..............18

Tomorrow’s packaging: more environmental-friendly

packaging with enhanced functionalities ............................22

Food Safety - a zero tolerance approach

to food safety hazards .........................................................26

Towards full control using vision inspection .........................30


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– www.packaging-trends.com –6

summar y 7

Packaging and consuming

Packaging reduces waste ...................................................38

There is still much to invent in processingand machine design ............................................................40

Packaging and manufacturing processes

are continuously evolving ....................................................44

Packaging innovation: “The problem is not to nd ideas…

but rather to nd what the problem is” ....................................48

Aseptic milk packaging: new trends ....................................52

Ergonomics is a priority for our customers ..........................56

Bio

...........................................................................................120

Thanks

..........................................................................................130

Editorial focus

An American’s stance on global packaging trends ............ 112

Asia: The fastest growing packaging market

in the world ........................................................................ 116

The future lies in virtuous packaging .................................118

Distribution networks

Adapting to all the distribution channels .............................84

Committing to smart packaging ...........................................86

Traceability, a key development focus .................................90

Packaging, a key vector of innovation .................................94

Innovative solutions based on

ultra-specialized sleeving ...................................................98

Cost efciency

How automation reduces costs ..........................................62

A new cycle,

reinvented systems..............................................................64

Offering complete lines with

overall performance warranties ...........................................68

Flexibility, a key priority for the industry .............................72

New challenges for tomorrow’s packaging machines .........76

Robots integrate perfectly into any automated process

that favours exibility ...........................................................78

Industry focus

Innovation is the key to increasingindustrial competitiveness .................................................106

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Fabrice Peltier

Diadeis

Pat Reynolds

Packaging World

Richard Mallett

HACCP Europe

Roland Nicolas

Serac

Nathalie Pereira

Cermex

Eric Drapé

Ipsen group

Florence Bertaux

Fanuc

Pierre-Yves Berthe

Mecapack

Vincent Ferry

Danone research

Andrea Barbolini

Schneider Electric

Bruno Guillemat

Pernod Ricard

Annette

Freidinger-Legay

Pascal de Guglielmo

Synerlink

Pierre-Etienne Hannecart

Nestlé

Eric Fresnel

Sleever International

Arnaud Rolland

Coca-Cola Entreprise

Philippe Thuvien

L’Oréal

Christophe Venaille

Luceo

Wong Tsz Hin

Asia Pacifc Food Industry

Bruno Garnier

Carrefour

Daniel Magnin

Nestlé

Henri Saporta

Emballages Magazine

trends

opinion column

Jean-Camille Uring

Symop


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par tners

Contributors

Institutional partners

Sponsors

Packaging & Processing machinery-The French Trade Association

http://www.geppia.com/geppia/easysite/geppia-int/en-ushttp://www.geppia.com/geppia/easysite/geppia-int/en-ushttp://www.weidmuller.com/http://www.thimonnier.com/en/index.phphttp://www.thimon.com/index_uk.phphttp://www.tecnimodern.com/index-cat-tecnimodern-famille-139768-lng-ANGLAIS.htmlhttp://www.tecma-pack.fr/index-gb.phphttp://www.schmersal.com/http://www.rockwellautomation.com/http://www.boschrexroth.com/http://www.preciamolen.com/en/http://www.pkb.fr/http://www.pdceurope.com/http://www.packr.com/http://www.paccor.com/http://www.omron.com/http://www.mg-tech.fr/http://www.markem-imaje.com/http://liftvrac-convoyeur.fr/doc-%E0%AD%B4%E9%AC%A9charger/home/http://www.karlville.com/http://www.machinesdubuit.com/index_en.htmlhttp://www.arcil.net/index_gb.htmhttp://www.synerlink-engineering.com/http://www.sleever.com/http://www.serac-group.com/http://www.schneider-electric.com/http://www.mecapack.com/http://www.luceo-inspection.com/http://www.fanucrobotics.com/http://www.cermex.com/http://www.ubifrance.com/http://www.sleever.com/frhttp://adepta.com/index.php/enhttp://www.serac-group.com/fr/http://www.symop.com/uk/index.asphttp://www.mecapack.fr/http://www.geppia.com/geppia/easysite/geppia-int/en-us


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13 fore word

trends

Jean-Marc DoréGEPPIA President and Founder

The Geppia’s PackagingTrends white paper: a nuggetof collective thinking

In order to get a better hold on tomorrow’s tech-nological challenges, the GEPPIA (Packagingand Process Machinery Manufacturers tradeassociation*) initiated, in collaboration with itsmembers, an industry white paper teaming withexclusive content.

The GEPPIA has brought together experts from a variety of back-grounds and countries to express their view on the future constraintsthat may be either a common denominator or an opportunity togrow.

Unveiling the packaging and manufacturing trends and shedding

light on future opportunities will help market players anticipate thechallenges and remain on the cutting edge in terms of innovation.

This white paper results from the expertise of our trade associa-tion’s members, who have supported the publication since the be-ginning. It lays the grounds for an ongoing trend watch, with otherpackaging professionals and users joining in.

We hope the paper’s content will spur your interest and provideguidelines for your business outlook.

We look forward to receiving your feedback and contributions.

* The GEPPIA represents today over 80 manufacturers and 4000 profes-sionals, mainly based in France. Their cumulated sales turnover in thesectors of processing and packaging machinery exceeds 1 billion Euros.


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Chapter

Now is the time for the virtuous

circle of recycling

Arnaud Rolland


Introduction

Henri Saporta

Emballages Magazine

Tomorrow’s packaging: more functionalities,

more sustainable

Bruno Guillemat

Pernod-Ricard

Food Safety - a zero tolerance approach

to food safety hazards

Richard Mallett

HACCP International

Towards full control using vision inspection

Christophe Venaille

Luceo


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– www.packaging-trends.com –

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Protecting our environment goes hand in hand with publichealth. Packaging has become inherently suspicious; scien-tists, manufacturers and legislators are constantly on the loo-kout for traces, whether parts per million or per billion (PPM orPPB) of undesirable substances.

The incident brought about by the bisphenol A (BPA)– a chemi-cal substance that we suspect of endocrine disruption–showshow difcult it is today to compromise between being precau-tionary, assessing public health risks and manufacturing ef-ciently.

Virtuous and healthy: those are the attributes of tomor -row’s packaging.

Reducing the impact of packaging: in the last twentyyears the trend has gained momentum in the developedcountries, mainly Europe and North America. Packagesare designed based on sustainability considerations,weights are reduced, materials are replaced, source re-duction is introduced, waste is sorted and recycled.

Nowadays you often nd packaging containing a high percen-tage of recycled material, such as polyethylene terephthalate(PET) and high density polyethylene (PEhd); we even tend toforget that glass, steel, aluminium, paper and cardboard havea high recycled material content. In the elds of energy andmaterials, most of the industry players have shifted from fossilresources to renewable ones. Green chemistry and recycling,or the combination of both, could lead the way to innitely reu-sable packaging materials.

However the gap is tremendous compared to developingcountries. When the package’s end of life is not controlled, it

generates unbearable pollution. Packaging no longer bringseconomic development and public health safety, on thecontrary. Plastic wastelands degrade the image of an industrythat supplies high performance materials. This is where thesupporters of oxo biodegradable material have their word tosay: better use a material that is biodegradable than one thatis recyclable but isn’t for want of infrastructure. In the futureany new packaging plant should integrate the end of life of theproduct.

Protecting the environment and

the consumersHenri Saporta

Chief Editor

Emballages Magazine

introduction

– Protecting the environment and the consumers –

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Now is the time for thevirtuous circle of recycling

Arnaud RollandSustainable Development Manager


We are entering a new era where the price ofraw materials is increasing as they are beco-

ming less available. Manufacturers are getting more in-volved in optimizing the materials used in their packages,in reducing their purchasing volume and recycling ratherthan buying new raw materials. The objective is both envi-ronmental and nancial. It is a real long-term trend.

Recycled materials clearly are tomorrow’s materials. Their po-tential is endless. Progress must be made in the supply chain

and in public awareness.This is what is called the circular economy, also known as«cradle to cradle». In the light of the shortage in resources, it ismore necessary than ever to re-use those we have and investin the search for new materials, that will allow us to do withoutnon-renewable resources - like second generation bio-basedplastic, a promising solution in the eld of packaging.

Reducing the carbon footprint of packaging

At Coca-Cola, our objective is to reduce by one-third the car-bon footprint of our beverages at the European level by 2020.We are working on the whole life cycle of our goods at sixstages: ingredients, packaging, production in our plants, trans-portation of our products, refrigeration, and end of life.The packaging production stage represents 47% of our overallcarbon footprint alone !

In order to reach our overall objective, the rst step consistsin working on reducing raw materials. Packaging production isstrongly linked to the extraction and processing of raw materials.

We therefore target to use 25% less non-recyclable materialsin our packaging to produce the same quantity by 2020.

Partnering with our suppliers and distributors

Recently we decided to remove a carton undercoat when

supplying our goods and found a new system which does notimpair the product’s integrity. We conducted tests over severalmonths and, in certain cases, adapted our production lines.We are also working on the reduction of plastic lms aroundour packs and on the thickness of our labels.

With our main can supplier, Ball Packaging, we are testingthe can of the future, the lightest on the market. Our industrialteams are working hand in hand to nd, within two to threeyears, the thinnest possible aluminum sheet.

The aim is to involve the whole supply chain to continuously in-

vent new machines and new technologies in order to respondto the strategic challenges, make sure that we are gaining inproductivity, efciency and safety. All this without impairing thepackage’s quality.

Maximizing renewable resources to produce tomorrow’sbottle

Second line of action: reducing the carbon footprint, in parti-cular of plastic bottles, and using renewable resources to pro-duce packages. The PlantBottle™ is the rst alternative solu-tion to fossil-based PET. This technology has existed since

2009 in the United States and since 2011 in Western Europe.In 2010, the worldwide production of 2.5 billion Plantbottle™packages made it possible to save the equivalent of 60,000barrels of oil used in the manufacturing of PET plastic bottles.

We launched it in France at the end of 2011 on our 50 cl bottles,which contain up to 22.5% of plant-origin plastic. In the manu-facturing process, in order to obtain the PET plastic molecule,we use bioethanol derived from sugar cane.

– Now is the time for the virtuous circle of recycling –

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The pre-form of our 50 cl bottles is comprised of recycled plas-tic (up to 25%), plant plastic (22.5%) and virgin plastic; i.e.three difference sources of plastic molecules which come fromthree different manufacturing processes to make a single pre-form which will give only one bottle!

Last important goal: make the public aware that waste sortingis important. This is what we do in music festivals for examplefor young people. This is what we will do with our project ofan educational centre within our joint-venture in Beaune. Wemust all be part of this collective challenge. This is why Coca-Cola is committed at the world level to reducing the environ-mental impact of its packaging. This strategy takes local formsin each country with objectives and investments adapted tonational markets.

But our ultimate goal is to nd, within 5 to 10 years, a techno-logical and industrial solution that makes it possible to produceplastic bottles with 100% of plant residue. In the United States,together with other large companies, such as Ford, Procter& Gamble and Heinz, Coca-Cola Company has developedtomorrow’s bottle.

Three partnerships have also been signed with leading start-up companies specialised in the development of second-ge-neration plastic. The ultimate objective is to disconnect pro-duction of plastic from fossil resources.

Using more recycled materials

The third eld of research lies in the use of recycled mate-rials. Coca-Cola Entreprise is the rst food company to in-vest directly in the recycling industry as well as participatein research and development: we have invested 6.5 millionEuros in a joint-venture with APPE, the recycled PET leader

in France, in order to increase the share of recycled plasticbottles in France.

Coca-Cola Entreprise has conducted the same type of projectin the UK with the creation of Continuum Recycling, a jointventure with Eco Plastics, the English leader of recycled PETplastic for food products. This investment will increase by 70%the capacity of the Sainte-Marie-la-Blanche plant. The projectis also aimed at improving plastic recycling technologies inFrance.

Most of the PET is recycled for textile, construction and auto-

motive (e.g. dashboards) applications. In the food industry itis authorized only since 2007 in France. This is an advancedtechnology for food products and still a young industry. Inves-ting in this sector makes it possible to develop it, consolidateit, and innovate with new machinery.

Although the use of recycled PET has no inuence on the pro-duction chains of our bottling plants, it alters the pre-forms’manufacturing process.

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For Pernod Ricard, packaging innovation is directly linkedto an environmentally-friendly approach. The trend to-wards packaging ‘premiumization’ in the wine and spiritssector goes hand in hand with the sustainable develop-ment approach. However, packaging must also becomemore functional and more interactive. The developmentof new technologies is also involved in ghting counter -feiting and enhancing consumer experience; two topicswhich are particularly dear to Pernod Ricard.

In the wine and spirits sector, packaging development liesin the ‘premiumization’ of packs, with luxury packaging mo-ving upmarket - while taking into account the environmentalrequirements (recyclability, choice of materials, reducing car-bon footprint…). Sustainable development represents both aconstraint and new innovation opportunities. Pernod Ricardhas therefore started thinking abouthow to combine luxury andsustainable development; a true challenge and a source ofinspiration for tomorrow’s packaging innovation.

‘Premiumizing’ glass in an environmentally friendly manner

On our markets, glass remains the material of reference. Itconveys quality, preservation and purity. Studies are regularlyconducted to reduce the weight of bottles. Process develop-ment makes it easier to address distribution of materials, tomonitor thickness proles, and to work on design in order to‘premiumize’ glass.We may however use alternatives to glass for new marketsand new products, like Malibu portable pouches, with exiblepackaging.

In secondary packaging, the environmentally-friendly ap-proach is more important yet. We innovate in order to increasethe product visibility in the store displays while addressingthe environmental aspects. Work is done in particular on giftboxes and limited editions. The issue is to avoid combiningincompatible materials and excessively complex packaging to

favor recyclability.

Innovating for enhanced consumer experience

Packaging must also follow the change in consumer habitsand be user-friendly It is therefore more than a mere bottle:further functions and services have to be included in it so that itbecomes part of the consumer experience, i.e. help the brandconnectand interact with consumers. Facilitating handling andpouring may lead to changing the cap or customizing theproduct depending on the consumer’s tastes. Innovating alsoconsists in offering new ways of consuming and preparing our

products.

The Pernod Ricard Research Center is working in that direc-tion. It carries out many additional tasks: monitoring and sha-ring ideas to identify technological opportunities and innova-tive packaging solutions; providing our subsidiaries technicalsupport to speed up the innovation process; and setting uptransversal project teams to acquire new knowledge and de-vote it to product innovation. These three tasks allow us toidentify opportunities. It should be pointed out that packagingis part of the product. Packaging innovation can only be achie-ved in combination with product innovation.

Adapting packaging lines

These innovations and constraints have an impact on produc-tion chains. Our suppliers’ material has to be developed, oreven integrated in new equipment used in other areas of appli-cation. As premium bottles have more fragile and sophistica-ted gift packs, further precautions must be taken on the lines. Alternatives to glass also require specic packaging lines.

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Bruno Guillemat

Head of Packaging Departmentin the Pernod Ricard Research Center

– Tomorrow’s packaging: more functionalities, more sustainable –

Tomorrow’s packaging: morefunctionalities, more sustainable

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The complex new capping solutions result in modifying thetools used to position these new caps. Although traditional caps are crimped, we are moving towardsmore premium caps with more complex and appealing forms,which require other capping techniques.

Faced with the increased complexity of packaging, tomorrow’smachines will have to be more exible. Glass containers havea very specic design, forms that are no longer cylindrical,variable formats and caps that may differ depending on thecountry (in particular to address counterfeiting).

Fighting counterfeits

Our brands have to be protected, above all on sensitive mar-kets. Pernod Ricard has therefore set up a specic structure toght against counterfeits, in which the Research Center takespart at the technical level. In particular we are working on a

tamper-evident capping system that ensures consumers thatthe packaging is tamper-free.

We use new technologies to better secure capping. Our capsare therefore difcult to copy and non-reusable. They act as alock. We are also working on all packaging items in our bottlesby including identication and authentication technologies.

Codes and marking are incorporated in the cap, the label andthe bottle. QR Codes may be of interest in facilitating the inte-raction with consumers and involving them in the checking ourproducts. Lastly, vision and robotics take part in quality control

and the assembly of complex parts for premium packaging.Developing increasingly functional packaging

Lastly, innovative packaging should be able to better commu-nicate, adapt to its environment and protect it, give informationand interact with consumers. Printed electronics and miniatu-rized energy might bring new functions - or new services - topackaging which are ideal to enhance consumer experienceand interactivity with the brand.

For example, we could offer new functions incorporated intothe packaging: help consumers better use our products (byproviding advice on preservation and consumption), facilita-ting their use, suggesting recipes or giving more informationon the brand. This could help go further in the brand expe-rience through mobile and digital applications, QR Codes, or

new technologies.

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During the latter part of the twentieth centuryand the early part of the twenty rst century,food safety has been a major concern and this

has been reected in the evolution of food safety legislationworldwide. Food distributors and their suppliers must nowprove their credentials to satisfy the requirements not only offood safety regulatory bodies but also of food retailers, whoseek to mitigate risk arising from uncontrolled food-bornehazards. Food safety issues regularly make the headlines worldwide.

However what does that expression really mean? Food safety isdened as taking all possible control measures to ensure that foodis safe. This means that the risk of food contamination should beeliminated or at least reduced to the lowest possible level so thatfood served or sold to customers is eaten without incurring anyrisk to their health. A universal issue

Food safety concerns everyone. Companies have become awarethat the topic is of critical importance. The most senior directorsnow seek to incorporate it as part of their overall strategy to protect

their brand. They are increasingly sensitive to food safety issuesincluding contaminated raw materials, hazards introduced duringprocessing and packaging, and hazards induced by food contactwith materials.

Manufacturers have good reason to be sensitive. Across the globethere are laws to prevent contamination from any source. In theeld of food processing and packaging it is required that foodbe protected from chemical products that may migrate from thecontainer or the equipment and get to the food product itself.

Awareness is important both at the distributors’ and suppliers’ level. The retail industry across Europe and indeed across the worldhave set up best practices, administered for the most part throughthe Global Food Safety Initiative, and in the form of Global FoodSafety Standards to be adopted by food manufacturers. Thesestandards require assessment and control of food safety from all

potential sources, including raw materials, processing, packagingand labeling.

Labeling is a critical issue. A signicant number of product recallsare a result of incorrect labeling, with incorrect allergy advicebeing one of the greatest causes. European regulations regar-ding labeling are constantly evolving. They lay out very clearlythe requirements concerning clear labeling. However control oflabeling, to ensure that food enters the distribution chain with thecorrect information is down to the food manufacturer.

Suppliers and equipment manufacturers are also concerned

The need to assess and control food safety hazards is extendingrapidly now to non-food suppliers. The food processing industryrecognizes the risk from this source and demands evidence ofcompliance that processing and packaging equipment can beused without risk to the HACCP (Hazard Analysis And CriticalControl Points) based food safety management system.

Already an increasing number of suppliers within the food chain,right up to and including supermarkets, is searching for equipmentmanufacturers that can prove that their equipment or materialswill not lead to health hazards through contamination or migration.

Food processing and packaging equipment manufacturers are notforgotten when it comes to the Global Food Safety Standards,benchmarked by the Global Food Safety Initiative and used bysupermarkets to approve their food suppliers.

As just one example, the BRC (british retail Consortium) GlobalFood Safety Standard requires control of food safety in mate-rials, processing and packaging, and also equipment and envi-ronment. More and more food processing companies are lookingfor a guarantee from their food and non-food suppliers that using

Food Safety - a zero toleranceapproach to food safety hazards

Richard MalletManaging Director

HACCP Europe

– Food Safety – a zero tolerance approach to food safety hazards –

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their materials will not undermine their HACCP based controls.Equipment and material manufacturers supplying the food indus-try are beginning to see this as an opportunity to show that thedesign of their machines supports the principles of food hygienecontrol based on HACCP. It is becoming something of a compe-titive advantage for those equipment and material manufacturers

that achieve a food safety based certication such as that provi -ded by the HACCP International Certication body.

The HACCP mission

For over 50 years, The World Health Organisation has promotedfood safety control through HACCP worldwide and its Codex Ali-mentarius publication. The principles require an assessment offood safety and security from all the sources, not only for ingre-dients and food production line operators.

Legislation across the world now requires that food manufactu-

rers implement and maintain a documented HACCP system. TheEuropean Food Hygiene Regulations is one example of how thisrequirement is mandated across a whole continent! The majorsupermarkets also demand that their suppliers implement andmaintain an HACCP system. For example the BRC (British RetailConsortium) Global Food Safety Standard used by retailers to ap-prove suppliers within the food chain, require a food manufacturerto maintain, validate, verify and review an HACCP Plan. The mission of HACCP, managing food safety, is also applicable tonon-food, including packaging and processing equipment. Indeedthe principle of HACCP is used by my own organisation, HACCP

International, a certication body for equipment and materials,ranging from processing equipment, packaging equipment, che-micals and materials of fabrication such as hygienic wall and oormaterials.

Equipment and materials are assessed, following Codex Alimen-tarius HACCP Principles, for any potential risk to food arisingfrom unhygienic design, design characteristics that may lead toincreased risk of food contamination, consequence of error in useor misuse, poor quality user manuals or service manuals, or un-

substantiated food safety based claims. The equipment or mate-rial supplier can then present the HACCP International Certicateto the food processor to demonstrate that the article or materialis safe for use in a food environment. This in turn supports theHACCP plan implemented by the food processor or manufacturer.

Towards unlimited control

Generally efcient and full control is the only way of reducing therisk of food safety in the food industry. Automation will remove anyelements associated with human error, but this does not mean thatautomated systems can be relied on without correct commissio-ning and verication - an operator must necessarily check that thequality of automatic control is constantly optimized and effective.

Integrity of packaging and labeling is also the last line of defense:if a food product is contaminated, improperly packaged or labeled,

the probability that this food product ends up at supermarkets in-creases – the product will have entered the food distribution chainalready.

A temporary competitive advantage

In the zero-risk race, the developed world, with a history of robustand mature HACCP based controls, may still keep a small win-dow of opportunity and a competitive advantage in with regardto food safety. But for how long? Emerging countries learn anddevelop very quickly. Some have already tightened their rulesregarding food safety, often using European Union Food Hygiene

Regulations as a template for the improvements that they make totheir own food safety legislation. Within ve years, the differencesbetween the two worlds will have disappeared.

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Food packaging is strongly growing world-wide due to emerging consumer trends suchas individual portions and ready-to-eat pro-

ducts. Health safety is more than ever critical: while pac-kaging must preserve and protect the foodstuff it containsuntil it is eaten, it must also provide useful and reliableinformation for its risk-free consumption.Manufacturers need to set up a control system as partof their food safety risk analysis. Vision inspection hasmany advantages in comparison to manual and statisticalsystems.

The press and the media regularly report incidents occur-ring in the food and beverage supply chain. Consumers havebecome increasingly wary of processed products and keep awatchful eye on the quality of what they eat; they are obviouslylooking for tasty products but will not compromise on health orsafety. The pressure is passed onto the supply chain and themanufacturers in the food industry.

Distributors are thus seeking to avoid bacteriological and aller-gen risks which may occur if the product is packaged in aninappropriate container, if it is mislabeled or misprinted, or if

the packaging is poorly sealed. This issue is even more sen-sitive for products sold under the distributors’ own brand : if adefect is reported, the whole brand will be impacted.

Manufacturers are to solve the productivity/protability, qualityand food safety equation. Beyond the protection of their brand,they also eliminate the impact of a packaging defect on theproduct life cycle: waste of production time, consumables andenergy consumption.

Towards full controlusing vision inspection

Christophe VenailleFood and Beverage Business Unit Manager

Luceo

Advantages of vision inspection

Setting up a control system is therefore critical in order to opti-mize product packaging as it meets the food safety, producti-vity, protability and quality requirements.

Articial vision integrates cameras that operate like a humaneye: they check rst the markings (printed characters, sell-bydate, stickers, codes...), second the perfect tightness of va-cuum and modied atmosphere packs. They can even detectcontaminants in the sealing areas of sealed or heat-sealedpackaging.

Controlling sealing is part of the CCP (Critical Control Points)for sterilized product manufacturers. The advantage of a 100%inspection is that it ensures full control on this issue. Conti-nuous control allows the immediate detection and withdrawalof the defective packaging. The manufacturer does not need

to go back and control the batch from the beginning, whichoccurs in standard product control. Another advantage is thatthe volume of rejects tends to decrease and in some instancesdisappear.

The control equipment at the end of the packaging line isits eye and memory. All the packaged products are ‘photo-graphed’, which is a real asset if there is a doubt on a pro-duction series. Manufacturers can refer to the saved data tovalidate later ndings.

This automatic, reliable, non-destructive technology takes part

in the continuous improvement of the production cycle thanks tothe immediate correction of packaging discrepancies. It offersgood traceability by making it possible to save and archive data.

Preventing all contamination and guaranteeingfull traceability

The Tiama group has been the world leader in the glass contai-ner inspection sector for 40 years and entered the food andbeverage industry in 2006 under the Luceo brand.

– Towards full control using vision inspection –

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It has signicantly grown since this date with more than 200machines in operation.

The Intermarché retailer - 2,000 stores in Europe - has equip-ped its own facilities with Luceo solutions. It has invested inseal checking systems in order to avoid product loss during

the pasteurization phase.

The Campofrio group, the European leader in the processedmeat sector, has also opted for vision inspection in order toincrease its productivity while guaranteeing awless packa-ging quality.

Fratelli Tanzi, a cured meat producer, has invested in a visionsystem, upon the request of its English distributor, Marks &Spencer, which imposes on its foodstuff suppliers to meetthree obligations: error-free labeling, full traceability of all pro-ducts, and data archiving.

The US company Hausbeck Pickle Co has also equipped itsplant with Luceo systems for the detection of leaks on its picklepackaging lines.

Today these same technologies are used on many applica-tions : sliced cheese, fresh meat, pizza, deli maintained in coolor ambient temperatures, baby food....

Future development

Luceo’s goal is to address all types of packages and be more

and more efcient in the type of defects found. In short, thepoint is to push further the limits of detection and to cover thewhole supply chain: from the arrival of bulk raw materials at theprocessing plant to packaged nished products. In the eld ofvision inspection we are denitely heading towards full control.

Having graduated from a telecom engineering school, Chris-tophe Venaille joins Thalès in 1985 and manages medicalimagery and robotics projects.

– Towards full control using vision inspection –

en vironmen t

He later moves to the food industry, and more specically MSC(a Danone subsidiary specialized in glass control machinery)as Diversication Project Manager in 1995. MSC becomespart of the Tiama group in 2003. In 2007 Christophe Venailleis promoted MSC Engineering Manager and in 2009 he be-comes the Tiama Group R&D Manager.

Since 2012 he manages the Agro Luceo business unit.



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Céline Leduc

In a tough economic and environmental context, weoffer customized lling and capping machines thatmeet increasing levels of requirements in terms of

lling accuracy, hygiene, reduction of downtimes, securitystandards.

PACK’R strength lies in its technological innovations that si-gnicantly reduce format changeover times, cleaning timesand efuents generation.

PACK’R

Eric Maussion

We must address our customers’ ecological and eco-nomical requirements.

We work on developing new technologies to decrease the

use of virgin polymers (by reducing density and recycling plastic «waste» coming from customers) while reducing thenal cost to offset the increase in raw materials.

PACCOR

Derek Vandevoorde

The major step is to take an active pro-environmentapproach. In order to satisfy this need, as well ascustomers’ standard requirements - productivity, cost

and service - PDC Europe, prize-winner of the «Best Ener-

gy Efciency Award, Inno-Bev 2013», offers a customizedrange of equipment.

A non-heat high elasticity PE sleeve applicator, a super-compact linear high-speed shrink sleeve applicator (up to600 cpm), and a low-energy recyclable hot-air shrink tunnelshowcase PDC’s “eco-friendly” product line.

PDC Europe

Céline Francina

R&D department of Karlville Development considerEnvironment as a major concern.That’s why we develop shrink solutions that generate

energy savings, like for example with our Tornado (uniqueair recycling system).

We also enable our clients to make our machines run athigh speed with less thickness of lm.

Making our machines easier to maintain is also a target weare achieving with servo motorization developments andEthernet support.

KARLVILLE DEVELOPMENT

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en vironmen t

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pack ag ing&consum ing

Chapter

There is still much to invent in processing

and machine design

Annette Freidinger-Legay

Expert International en Emballage et Conditionnement

Introduction

Henri Saporta

Emballages Magazine

Packaging and manufacturing processes

are continuously evolving

Daniel Magnin & Pierre-Etienne Hannecart

Nestlé

Packaging innovation: “The problem is not to nd

ideas… but rather to nd what the problem is”

Vincent Ferry

Danone research

Aseptic milk packaging: new trendsRoland Nicolas

Serac

Ergonomics is a priority for our customers

Nathalie Pereira

Cermex


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Waste or save ? It may sound like a strange question,and yet…the Save Food initiative, led by the FAO (UnitedNations Organization for Food and Agriculture) and theInterpack tradeshow held in Düsseldorf, revealed thaton average one third of the food produced each year iswasted.

If you look at the gures in more detail you discover that thewaste ranges from 20 to 75% depending on the food productand amounts to 1.2 billion tons. In the developed countries300 kilograms (661 lbs) are wasted per year per individual,most of it occurring at the consumer level. As the world popu-lation is expected to increase by 50% and reach 9 billion in2050 and famine remains a critical issue, food waste is both acurse and a global scandal.

Consumers in developed countries are over-cautious as a resultof relying on highly sophisticated technology. Crucial informa-tion, such as use-by date or optimal shelf life are misunderstood

by consumers, who end up throwing out by mistake productsthat are still t for consumption. In order to limit the waste, theEuropean Union along with other countries are considering areform of the use-by dates.

In developing countries, lagging infrastructures and technolo-gies are generating waste at the crop level. In those instancesprocess and packaging, when properly applied, are a solution,not the source of the problem.

Packaging reduces waste

Henri SaportaChief Editor

Emballages Magazine

introduction As with aseptic lling, modied atmosphere or vacuum-packa-ging, modern packaging methods deliver healthy and naturalproducts and long shelf life. Time-tested solutions like canningstabilize food products for a long time without requiring sophis-ticated infrastructure.

As far as high value-added consumer goods, such as electro-nics, are concerned, secondary packaging and cushion pro-tections ensure that the product is shipped and arrives in per-fect condition. Beyond the obvious insurance issues, reducingproduct damage also contributes to preserving value.

Efcient and useful: those are the attributes of tomor -row’s packaging.

– Packaging reduces waste –




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Let’s be honest: today’s society is rathergloomy. Economically speaking, we are not overcomewith euphoria! And this affects the behavior of consumerswho claim for smart shopping and increasingly favorsnack food. This may lead to increasing innovation andinventing new ways of processing materials - while stilllooking for new sustainable materials. It is now essentialto ‘give added value to packages at a lower cost’.

In order to treat themselves despite this air of gloominess,French people want to make their everyday life different andpurchase product with an emotional value that makes themhappy. Limited editions take off, both in the high volume consu-mer goods and the luxury industry with Champagne. Because people have less and less time, snack foods aremore and more popular… with signicant consequences onpackaging. Packaging must preserve the food from extremeexternal temperature variations, include different ingredients,be easy to open, be heatable in the oven, microwave oven andin a water bath, while preventing burns! Brands, whatever thesector, have to innovate and meet both environmental require-ments and the snack food trend. How can we ght both against food waste and for packa-ging reduction? Fighting against food waste has also emerged for somemonths. However, it might go against the ght for packagingreduction that has been on since 1992. For environmental pro-tection purposes, we have worked on the reduction in weight

and thickness of packaging materials, and on a weight ratiofavorable to the product rather than the packaging. This tendsto favor large containers.This brings up a critical issue : what should be favored: ghtingagainst food waste by offering small quantities and individualdoses, or protecting the planet by generating less packaging

waste using large containers? The solution might lie in ‘portion-sized’ or re-sealable packa-ging that would allow deferred consumption or in active andclever packaging that would allow a longer preservation of theproduct, including once it is opened (through food substancesthat ght against oxidation like Vitamin C), or that would avoidthe development of micro-organisms on the packaging wall.Laboratories rely heavily on the properties of essential oils inthis area. They undeniably are a great future for tomorrow’spackaging.

Today’s… and tomorrow’s most used materials According to the last market survey carried out by Pira Inter-national, the world packaging production ($670 billion in 2010)should reach $820 billion in 2016 (Source: The Future of Glo-bal Packaging - Smithers Pira - January 2012), with an ave-rage annual growth rate above 3%.The growth is mainly driven by urbanization, the developmentof the health sector, and the development of emerging andtransitional economies, like China, India and Brazil, but alsosome eastern European countries, where purchasing poweris on the rise.

Overall the classication of the world’s most used materialsshould remain the same in the next years: cardboard (corruga-ted and at) should remain the leader (30.49% of the market,$250 billion in 2016), followed by rigid plastics (24.39% of themarket, $200 billion in 2016) that are boosted by the drinksmarket, cosmetics, personal care products and detergents,and by exible plastics (19.88% of the market, $163 billion in2016), used in fresh and processed food products as well asdrugs.

There is still much to invent inprocessing and machine design

Annette Freidinger-Legay International Packaging Expert

– There is still much to invent in processing and machine design –




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Number Four in the market, metal packaging (14% of the mar-ket) should decrease by 2016 in favor of rigid plastics. Lastly,number ve on the market, glass should still increase but at aslower rate (6.46% of the market, $53 billion in 2016). Countries with strong environmental sensitivity favor cellulosicbers, i.e. paper-board. Japan, which has a strong culture of

convenience fresh and individual food portions, favors com-plex exible materials which ensure that those products areprotected. By contrast, for developing countries, we note thatrigid plastic materials rapidly take a strong market share sincethe processing industry for those materials requires signi-cantly less capital than the glass, paper or metal industry. Acloser look at the PET penetration rate for water and drinkbottles worldwide speaks for itself. New materials have adjusted their strategy New materials have slowed to a standstill. 5 years ago, consi-

derable publicity was made around biopolymers. But now weare realizing that using corn or wheat to make packaging ma-terials was perhaps not the wisest thing to do knowing that onebillion human beings have no food! Bio-based PET is still usedbut it comes from sub-products such as sugar cane residues.Some are looking for starch sources that could be availablewithout using corn, such as potato wash water. Another rea-son for the standstill undergone by new materials derives fromthe regulations that have precisely dened what is meant bybiodegradable and compostable materials. The future technological developments should lead to a grea-ter consumption of better dened biopolymers. The worldwideproduction of biopolymers should thus reach 5.8 million tonsin 2016, according to the association European Bioplastics.Bio-based PET production would thus be 4.6 million tons, i.e.80% of the worldwide offer in front of PLA (298,000 tons), PE(250,000 tons) and PHA (142,000 tons) (Source: Salon del’Emballage, France, 2012). The focus is also on incorporating recycled materials in pac-kaging. As regards corrugated board, a traditional cardboard

box often contains up to 80% of recycled bers. A wine bottlemay be manufactured with 100% recycled glass. Aluminum,whose transformation requires a high amount of energy, isworth recycling. Progress is being made not only on recyclingprocesses which, for example, allow to put recycled PET incontact with food according to drastic European regulations,

but also on automated sorting systems that in the future willallow consumers to put all their packaging wastes in a uniquedustbin. There is no longer reference to waste but to secon-dary materials. From my point of view, the future belongs to active materialswhose permeability will be perfectly mastered in relation to gasand steam and which will be able to regulate the atmosphere,thus preventing the development of micro-organisms insidethe packaging, and extending the life duration of food productsonce the packaging is opened. Nano-particles have interes-ting physical properties in this context… but for the future…

and provided that regulations allow it. However, it is certainlyan avenue worth exploring to ght against waste.

– There is still much to invent in processing and machine design –




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Packaging has evolved from its basic protection functionand has acquired enhanced features. It must be conve-nient, interact with the consumer, convey emotion andprotect the environment.Designing packaging is increasingly complex and requiresboth brands and equipment manufacturers to change the

way they work.

Metal boxes were originally designed to merely offer consu-mers a awless product. Packaging design then evolved, in -troducing the concept of functionality.

For example, making sure that consumers do not hurt them-selves when opening a tin can, and that they do not need to-ols. Today we provide further convenience with easy-to-openlids and seals, and the ability to re-seal the packages for laterconsumption.

Packaging must thus not only preserve the product it containsbut also ensure handling the product is an enjoyable expe-rience, blending in interaction and emotion. The environmen-tal impact must be as small as possible.

Packaging needs to serve the consumers’ current lifestyles.They want to eat on-the-go, fast, in portions, and expect theproduct to be customized.

Packaging and manufacturingprocesses are continuously

evolving

Daniel Magnin

Global Head of Packaging Equipment & OperationsNestlé

Pierre-Etienne Hannecart

Head of Consumer Centric Packaging Nestlé

Continuously innovating

This drives Nestlé to continuously innovate. Our products –and their packaging – must be designed so that they can easi-ly adapt to all the distribution channels: discount retailers (dis-playing products on pallets), supermarkets (with high visual

appeal), gas stations, e-commerce (including home deliveryand drive-through)…

Packaging is constantly integrating new materials and tech-niques. Sustainability is the number one priority, for the pro-duct itself and for the environmental impact of its packaging.Everyone is working to this end, focusing on two goals : redu-cing the quantity of packaging required and developing envi-ronmental-friendly material.

Inclusive Design, a major challenge

Consumer prole and habits are continuously changing anddeveloping. Our challenge today consists in offering packagesthat are optimized throughout the supply chain and designedto be used by the largest number of consumers, regardless oftheir age and abilities. We must take into account the ageingof the population, longer life expectancy and the growing num-ber of senior citizens living alone and independently.

We must offer solutions meeting all these demographicchanges. Inclusive design is an approach that does not ex-clude anyone when using packaging. If it is designed for anolder market segment, surely it is suitable for a vast majorityof the population.

Nestlé rolls out the Inclusive Design approach

Nestlé has been developing this methodology for four years inpartnership with universities and based on functional analysiscriteria and simulations tools. They allow us to dene the ergo-nomic performance of our existing and new products.Since designers know and integrate consumer expectationsand the interactions with packaging throughout its life cycle,

– Packaging and manufacturing processes are continuously evolving –


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they design products that can easily be used by a large portionof the targeted consumer base.

NESCAFÉ® Gold is now packaged in a more ergonomiccontainer featuring a better grip, a new seal and an easy-to-open tab. In the bottled water sector, the Hépar® bottle cap

has just recently been fully redesigned. It ensures a better gripand is easier to open and close. Our aim is clearly to placeconsumers at the heart of our packaging development and tomeet their expectations and requirements with simple, intui-tive, easy to use and cost-effective solutions.

Redesigning machines and processes

Our machinery must meet the new production requirements,in particular with higher productivity and exibility. One of ourpriorities is to implement the principles of Lean Manufacturing,that have proven their efciency in the automotive industry.

This consists in dening the needs from the early stages ofthe project, as well as extensive equipment specications thatintegrate all the aspects of productivity:- safety at work in order to eliminate any risk of accidentcaused by our equipment- hygiene (product quality and machinery maintenance);- line waste reduction (less material loss, less waste);- decrease in efciency loss due to scheduled or unschedu-led production interruptions;- and exibility (it consists rstly in being able to make rapidand precise changeovers ; secondly in adapting to productand consumer changes, as well as new material technologies.New materials are generally more demanding, which requiresstricter monitoring of the machine parameters while maintai-ning production speed.)

We rst came up with a method to assist project managers indesigning the new production lines. The methodology drawsout which tasks they should carry out at each developmentstage.Step two: set up models to dene and validate the equipment,manage the project process, control performance and check

that the project outcome is in line with the initial specications.It is necessary to make sure that there is no loss of informationand that the needs identied at an early stage have been per -fectly met between the initial specications and the machineproduction launch .Step three: dene standards on certain types of equipment

and operating methods.We are also working on communication between machines,in particular between the production lines and our centralizeddata management system. Nestlé is pioneer in this eld ; oneof our engineers is a member of the Board of Directors ofOMAC (Organization for Machine Automation and Control).This is paramount in decreasing efciency losses.

New technologies obviously result in developing lines and ma-chinery; like mechanization and automation, which are aimedat reducing the risks related to manual operations. An emer-

ging technology, digital printing is also a strong asset for thefuture. Digital or on-line printing of packages allows to custo-mize them, to be more exible on lines, to produce labels ondemand and to reduce stocking up on materials. Although thetechnique is already in use, it is clear that it gets more andmore industrialized.

– Packaging and manufacturing processes are continuously evolving –




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Successful innovation is a subtle mix of boldness and sim-plicity. “Why didn’t we think of it before?” - this remarkabout innovation precisely demonstrates that it is suc-cessful. In order to nd a good idea, however, the right pro-blem should be found rst. Simplicity and meaning are infact the two fundamentals necessary to design tomorrow’spackaging.

Innovation is above all a matter of nding the “true” problem tobe solved; the one with potential. At Danone, our new yogurt pot,KISS, is a major example. Firstly, its name shows the search forsimplicity: “Keep It Simple and Safe”. It was undertaken becausethe packaging of Danone Fresh Products had to be simplied.Thus, this brings consistency in the range and message andresults in true differentiation on the retailer’s shelf thanks to itslook and ergonomics. It has improved our operational exibili-ty through standardization. Lastly, Danone has thus initiated areturn to basics by drawing on its roots and DNA: displaying itsproducts in an original and friendly manner.

As a result, both packaging differentiation and ergonomics havebeen achieved with the KISS pot. Reinventing the yogurt pot The concept struck me during the Danone Convention in Februa-ry 2009 : the special series of yogurt pots made for our 90 yearanniversary aroused in me a creative ash. I told myself that theDanone pot had to be reinvented. Although the idea was simple,yet it had to be achieved with a modern technology adapted to

Packaging innovation:“The problem is not to nd

ideas… but rather to ndwhat the problem is”

Vincent Ferry Packaging Manager

Danone Research

the contemporary world. And above all we had to convince thegroup’s senior executives to adopt it. The design work consisted in analyzing and meeting the consu-mers’ needs while considering the numerous constraints (econo-mic, industrial, logistic, environmental, legal …), in order to shake

them up and enhance them in the end. In total, the developmentlasted two years in which we carried out an industrial pilot with ARCIL, our machine supplier, as well as consumer tests. The group then decided to make a rst “life size” launch in Spainin July 2010 on 5 of our brands. Since Spain owns ERCA machi-nery, this conguration made it possible to include the constraintsof our two main suppliers by dening a standard tting for thesingle pot concept, whatever the machine used. Concurrently with the new packaging, we also improved ourrecipes and made our store displays more appealing. Velouté

was the rst brand to benet from the repackaging in September2012 and recorded a 20% growth in volume. Integrating new machines and transforming the existingones This in-depth transformation obviously mobilized many resourceswithin the company. It required that the company invest in newmachinery. In particular, we changed the molds, the cutting de-vices, sealing pieces, and adapted conveyors and the wrappingsystem. In the end, this work greatly exceeded the purely technical peri-meter. KISS is more than a product: it is a unifying concept.We had to organize the support of our personnel through, in par-ticular, training, and redesigned our plants (moved walls, chan-ged ceilings, gutters and tiles, reorganized our stock…), withoutstopping production. A true challenge! Today, we have upgradedhalf of the machinery with, overall, performance exceeding theset objectives.

– Packaging innovation: “The problem is not to fnd ideas… ” –


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Rethinking packaging The objective of Danone Produits Frais France is to reduce orremove packaging, when possible, in order to improve its car-bon footprint while retaining satisfactory protection, display andconsumer information levels. April 2010 was a signicant step

with the removal of the secondary packaging on the Activia andTaillene brands – 1,600 tons of cardboard saved, i.e. the equiva-lent of 2,500 tons of CO².Then, in April 2011, four brands reduced secondary packaging ontheir large formats – i.e. 1,000 tons of cardboard saved or 1,800tons of CO² equivalent. In the wake of Activia and Taillene, Velouté is starting its meta-morphosis. Until now, we could not remove secondary packagingbecause the former pot had no individual decoration. Thanks toKISS, it is now possible.

We must bear in mind that packaging plays a major role in the lifeand identity of the products. They contribute to their protection,make them easy to nd on the shelves and display consumerinformation. The difculty lies mainly in graphic design. Basical-ly the same brand visibility and amount of information must beconveyed over a smaller printing surface. A true challenge forgraphic design agencies! What is at stake is worth the effort: froman environmental point of view, cardboard represents a total ofapproximately 20% of the packaging carbon footprint! Choosing the right materials The choice of materials is another research area. To minimizethe environmental impact, eight levers have been identied: redu-cing packaging quantity, increasing transportation density, recy-cling industrial waste, using recycled and plant-based materials,integrating the existing collecting, sorting and recycling channels,favoring 100% consumption without waste and giving materials asecond life. In the years 2006-2007, we used expanded polystyrène on ouryogurt pots, which resulted in reducing the quantity of packaging

and decreasing the weight of the pot by 20%. Regarding the KISSpot, we wish in the future to reintroduce expanded polystyrène.The rst tests have just started. Constantly reinventing ourselves

And we are not going to stop there in terms of innovation. Wemust reinvent ourselves every day ! I recommend relying on com-mon sense and respecting the rule “let’s keep on simplifying”. Successful packaging connects consumers to their product. Let’snot forget that packaging is the rst media that is in contact withthem. They have it in hand when purchasing and consuming. Itmust therefore enhance the outlet shelves and convey a strongmessage. Successful packaging also connects the manufacturerto its partners and suppliers. What KISS does within the companycan also be seen outside. KISS is the showcase for Danone’sexpertise and its ambassador. Successful innovation is like hitting

a strike at bowling: when the ball is launched in the right directionwith the right energy, striking is systematic. To achieve this, tech-nique, experience and a lot of common sense are needed!

– Packaging innovation: “The problem is not to fnd ideas… ” –


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Aseptic milk packaging:new trends

Roland NicolasDairy & Aseptic Business Development Director

Serac

France has been a pioneer in the eld of asep-tic milk bottle lling in Europe. The French

may even be the world’s greatest plastic bottled UHT milkconsumers! Serac’s objective in this eld is to meet themanufacturers’ constantly evolving demand and to adaptits range of aseptic machines in order to address newtrends.

Milk shelf life in France is traditionally high, in response to theretailers’ requirements and the inconsistent quality of the col-lected milk, which forced manufacturers to use extensive heattreatment. The quality has improved signicantly for a numberof years. Now 95% of milk in France is UHT. Yet there is avariety of milk processing methods throughout Europe.

Belgium, Spain and Portugal follow the same pattern asFrance. By contrast, Northern Europe favors pasteurized milk. As for Germany and Italy, they offer both fresh milk and UHTmilk. The European drinking milk market is therefore not ho-mogeneous.Bottled UHT milk has just started to develop in Russia, wherethe rst aseptic line has just been set up.

The main advantage of milk aseptic lling is that it can be usedto extend the milk shelf life with a lesser deterioration of orga-noleptic properties of the product compared with sterilized milkfor example.

The reason is that milk, which is highly nutritious , is one of themost sensitive products from a microbiologic and organolepticpoint of view.

Complex decontamination solutions

Today, as far as Serac’s aseptic lines are concerned, thereare several solutions to decontaminate plastic bottles for UHTmilk. First of all, an aseptic blowing machine can be used toproduce a sterile co-extruded and blow-molded HDPE bottle

that consists either of six layers (light and oxygen barrier) orthree layers (light barrier only). No chemical treatment is thusrequired inside the bottle.The bottle is then trimmed just before being lled in a sterileatmosphere.

Second, for open-neck bottles, including PET bottles, “wetprocessing” with a peracetic-acid based liquid solution (PAA)or “dry processing” with a hydrogen peroxide-based gas solu-tion (H2O2) can be used.Unlike PAA processing, H2O2 processing has the advantageof not requiring sterile water rinsing after processing. It there-

fore reduces overall water consumption.Innovating to add value

Although milk remains a staple product, its manufacturing re-quires complex processing: UHT sterilization of milk, asepticlling, barrier materials, and therefore a high production cost.

In order to attract new market players, technical innovation istherefore important. As a pioneer in the design of aseptic llingmachines, Serac is continually investing in R&D in this eld.One of the major elds of research in packaging decontamina-tion is the electron beam or “E-Beam”.With this process, it is possible to avoid using chemical pro-ducts. Nowadays, there is growing interest in «chemical-free»processes. E-beam is therefore one of tomorrow’s solutions.

Towards smaller and more exible machines

Demand is also evolving in terms of machines. High outputvolumes enable the large dairy companies to write off theirproduction units.

– Aseptic milk packaging: new trends –


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Dominique Ribet

Our customers for the packaging sector are mainlysystem integrators, looking for reliable and availablesolutions, allowing them to reduce considerably the

“time to market” of their equipment.

We provide them, on the basis of our unique and progres-sive hardware, all the opportunities for integrating a wei-ghing function in their process.

PRECIA MOLEN

Arnaud Laugier

Marking is the ultimate link between a manufacturerand its customers. It is therefore a key player for twomajor trends in packaging : safety and customization.

It will become increasingly complex as it will have to be ableto reassure and communicate with consumers. We aim at providing solutions that address this growing complexity,while adapting our marking and coding systems as well asour CoLOS traceability software to more demanding requi-rements in terms of productivity and cost reduction.

MARKEM-IMAJE

Marcel Boursier

In order to remain competitive, food processing companies need to work toward reducing both direct andindirect costs. This is what we are offering with the

Liftvrac range, a new generation of lifting conveyors for bulk products, by signicatively reducing losses of raw materialsin production as well as the footprint of manufacturing lines.

We also respect a quality level that meets consumers’expectations as our conveying system gently handles themost fragile products.

LIFTVRAC

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Newcomers on the other hand look for smaller machines withslower outputs, especially on the new markets. They also tendto favor bottles versus cartons because they stand out on theretailer shelf.

Greater exibility is another emerging trend

In order to make investments protable, food manufacturersalso wish to ll different products on the same line, such as fruit juices (products with acid pH) or fermented milk (non-sterilechilled products). We are therefore starting to have requestsfor exible multi-product lines in order to produce extendedshelf life and cold chain products on a same line. Flexibilityin packaging materials is also required, with lines that can llboth polyethylene and PET bottles.

Lastly exibility is required in terms of packaging sizes, withlines lling both quarter of a liter and one liter containers. We

have therefore developed neck transfer systems which areused to rapidly change the format without requiring machinesterilization.

To sum it all up, production lines must be more exible in termsof products, materials and formats, while retaining their pri-mary objectives: product sterility and integrity, as well as per-formance of the lling line.

Column written further to Roland Nicolas’ interview


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Our customers are increasingly demandingfor ergonomics, both in relation to operators’ musculos-keletal disorders and productivity and maintenance. Thistrend towards ergonomics grows stronger every year andencourages us to adapt our machinery. We are thereforeworking on improving format changeover, on better inte-grating robotics and new technologies, quite simply be-cause ergonomics is one of our major concerns.

In order to constantly enhance the ergonomics of our packa-ging solutions, we are mainly working on ve developmentfocuses. First reducing the weight of tooling which must bemodied when changing format in order to allow a better andquicker manipulation and a less restrictive storage in terms ofrequired areas. For example, as regards our packing equip-ment, we offer ProSelex®, a product-collating solution forvarious formats and various primary packaging formats. WithProSelex®, we have signicantly reduced:- format changeover time as it is easy to remove the ‘comb’and ‘counter-comb’ designed to pre-collate the products andform the batch;- the weight of the interchangeable parts (very compact simple

combs versus screws that are bulkier and heavier);- Required tooling storage space.

We have also reduced by more than half the weight of cer-tain parts in our top loading gripping, including on multi-arti-culated robots. This reduction results in a decrease in energyconsumption necessary to operate the modules and functionsconcerned.

Ergonomics is a priorityfor our customers

Nathalie PereiraHead of Strategic Marketing & Packing

and Overwrapping Product Manager Cermex

Second development focus: facilitating parameter setting andadjustments during format changeovers by integrating indica-tors and guiding systems. Generalizing settings is a trend thatallows operators to avoid tooling interchangeability at everynew format.

Third development focus: having universal operating prin-ciples, i.e. fully automated and motorized format changeovers,and also more exible solutions. Ergonomics during machineoperation is enhanced. It is sufcient to select the new formaton a HMI for it to change automatically. For example, on ourshrink-wrappers, our SFR (Regulated Flow Selection) systemallows automatic adjustment to the product format. We havealso developed an automatic changeover device for consu-mables. Also on this range of equipment, lm reel changeo-ver is automatic through a patented device called DIS, withoutstopping the machine.The operator no longer needs to change a reel while the ma-

chine is still running with the previous lm, which is ideal forvery high speed lines.

Robotics ‘for the benet of operators’

Fourth development focus: integrating robotics in our machi-nery. This trend has been generalized for a number of yearsfor palletizing and more recently for case packing. Roboticsoffer high exibility thanks to the possible automatic part chan-geover function and also a possible adjustment of paramaters.

Cermex also stood out last year as the only one on the marketto integrate operator interaction in its robotic packaging ma-chines. We offer a compact robotic palletizing solution (newgeneration PR) with collaborative functionality. The combina-tion of robotics with new technologies - including laser scan-ners - increases interactivity between the operator and therobot, line productivity, and machinery ergonomics. When anoperator gets close to the palletizing cell, it starts reducing itsspeed. It stops only if the operator enters the unit. This colla-borative aspect combined with robotics thus results in redu-cing production downtimes while increasing safety.

– Ergonomics is a priority for our customers –


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Sylvie Guinard

With the rapid expansion of selling and supply of products

in exible bags, packaging machine manufacturers must provide new solutions combining exibility, versatility and

performances.

Thimonnier’s offer ranges from mechano-pneumatic machines tomechatronics machines. We develop machines driven by PLCand Servomotors. The electronic evolution facilitates controls ofmachine parameters and machine adjustment accuracy.

With these new technologies we optimize the efciency, qualityand exibility of our machines.

THIMONNIER

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The other advantages are the extremely simplied use of ma-chines and a machine footprint reduced by 10% as a result ofoptimized required safety distances.

Enhancing the human machine interface

Last development focus: operator interface or machine intel-ligence. We are developing screens that are as ergonomicas possible, intuitive user-friendly menus, and warning mes-sages.We are constantly seeking to further integrate in the packagingmachines new technologies visible in consumer products.

Increased access to the main functions

The height of the work surface must also be optimal for ope-rators. The reason is to avoid handling that is too sudden orresults in unnecessary muscle tension. For example, on our

VersaFilm® shrink wrappers, we have set platforms for a faci-litated access to the work surface. And our lm feeding tablesare mounted on guide rails and can be removed by the ope-rator, a major advantage also appreciated for maintenance.Lastly, on our case packing machines, we have also loweredthe feeding height of cardboard consumable modules.

Moreover, maintenance is made easier with ground-levelaccess for all machines manufactured by Cermex. We canalso choose components that no longer need to be lubricated,or self-lubricating ones. Ergonomics, productivity and main-tenance costs are thus improved for the operator with lessdowntime and human interventions.

Considering the Total Cost of Ownership and maximizingservices

For those customers who are far ahead in terms of ergono-mics, the Total Cost of Ownership is critical. In other words:the total cost of ownership of a material over its whole lifecycle. It is not the immediate price of the machine that theyare interested in, but its price over its whole lifetime.

Lastly we must keep on developing our services: always en-hancing customer proximity, delivering readily-available spareparts, providing after-sale technicians 24 hours a day, offeringbreakdown assistance via remote maintenance (Internet ortelephone) and many other services.

For Cermex, it is essential to provide a comprehensive pac-kage over the whole life cycle of our products: equipment andrelated services. This is our company’s philosophy.

– Ergonomics is a priority for our customers –


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cos t e f cienc y

Chapter

“We are dealing with a new cycle,

with reinvented systems”

Fabrice Peltier

Diadeis

Introduction

Henri Saporta

Emballages Magazine

Offering complete lines with overallperformance warranties

Pascal de Guglielmo

Arcil Group

Flexibility, a key priority for the industry

Pierre-Yves Berthe

Proplast Group

New challenges for tomorrow’s

packaging machinesAndrea Barbolini

Schneider Electric Automation Gmbh

Robotics automation: towards more exibility

and added value

Florence Bertaux

Fanuc France

t f i ncy


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Whether it be primary, secondary or tertiary, packagingis the only way to market a product in good conditions.Its cost cannot be dissociated from the product’s overallcost.

Depending on the packaging’s requirements, whether it beergonomics, safety, shelf life, traceability, protection againstcounterfeiting or branding, or all of the above, its share in theproduct’s sales price varies.

During an economic downturn, priority is given to reducingcosts; suppliers of materials, packaging and machinery aretrapped in critical situations. Raw material prices uctuate,there are frequent shortages due to increasing demand fromthe developing countries, taxes increase, competition is toughand demand waxes and wanes. The margins of manufactu-rers are thinning.

Adapting continuously to consumer cycles is the key to suc-cess. High volume standard products are behind us and havebeen replaced by short life cycle products. Today they are hy-

per-segmented, customized, seasonal, or attached to a shortterm promotion. Brands want to weave tight relations with theirconsumers and respond to their least requirement.

Social media and mobile technology have enabled informa-tion sharing. The consumer can comment on a brand to makeit evolve, or decide to abandon it.

How automation reduces costs

Henri SaportaChief Editor Emballages Magazine

introduction

cos t e f cienc y

As batches are smaller, the production equipment, end-of-lineprocedures and logistics must adapt fast.

Brands want ever more reactivity and exibility, which calls forintegrating servo-controlled motors, automation, fast formatchangeover, short cleaning cycles, rationalizing workstation

operations and throughputs, digital printing and delaying iden-tication.

Investing in sophisticated machinery must be done in line withcost control. Product segmentation is often revenue-based.Differences in living standards and the long term effects ofeconomic downturns push the brands to address all consu-mers from all backgrounds and from both developed and de-veloping countries.

Economical and high performance: those are the attri-butes of tomorrow’s packaging.

– How automation reduces costs –

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“We are dealing with a new cycle,with reinvented systems”

Fabrice Peltier Packaging design Expert

Diadeis

Given the current economic slowdown, thepackaging market is doing rather well; espe-

cially since it focuses on responding as closely as pos-sible to the evolution of our patterns of consumption.Although today the sustainable design logic is an inte-gral part of the manufacturing processes, innovation ison-going. With the continuous improvement of the mate-rials’ preservation qualities and the renewed interest forcardboard, packaging is permanently reinventing itself.

Sustainable packaging is now well-established in our society.In this area, we are no longer at a crossroads but in movementand action insofar as brands are actually working on sustai-nable design and even on recycling design. Every customermeeting mentions these issues and the same goes for trades-hows where these environmental concerns give rise to inno-vation. Sustainability is no longer an abstract concept, it is anintegral part of the companies’ strategies.

Brands are therefore directly affected since it can either bevery costly or lucrative. Sustainable design is an integral partof the process.

Packaging Manufacturers are facing major changes

These new trends obviously affect packaging machinery sup-pliers. Some of them are already ahead on these issues. Theyhave not waited for markets to impose their requirements.Packaging is evolving for good. In the beginning it was desi-gned to solve an industrial problem: preserve its content andtransport it to retail stores. However, nowadays, the retail in-dustry model is facing major changes.

Another issue is to reduce materials consumption. Packa-ging’s impact must be moderate on the environment and onthe volume of materials required. The developed countries’goal is to reach a 75% recycling rate. We therefore have twoobligations: improve the environmental impact of packs andabove all make them recyclable.

As a result, packaging and material manufacturers can’t affordto work separately. Partnerships are essential. We are movingtowards joint solutions.Yesterday’s material manufacturer will in the future have totake an interest in the machines and the end product – and thesame goes for machine and end-product manufacturers. Weare dealing with a new cycle, with reinvented systems.Brands and machine manufacturers are challenging them-selves in order to adapt their system in the long run. Thisrevolution is both defensive and prospective. It is not rela-ted to packaging itself, but to the evolution of our society,our consumption and purchasing patterns, the supply chain,manufacturing, globalization, as well as local sourcing. No-wadays, we need to see the whole picture, not just isolatedevents.

Machines are evolving in sync with the end products. Theyneed to be more exible and communicate with one another.

Intelligent packaging and the return of cardboard

New materials, compacting and associating materials areparticularly promising. After having been left aside for a longtime, cardboard is back. It is considered the material of thefuture! Cardboard is becoming less rigid, it can be compactedwith plastic lm. These developments are directly linked to theprice of resources and their image. With inexpensive oil, it wassimple to produce plastic packaging.

This is no longer the case today; paper and cardboard havebecome competitive again, all the more so as thin plastic andpolymer lms can be added.

– “We are dealing with a new cycle, with reinvented systems” –

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There is also much talk about smart packaging. However, theattribute applies if it is used to preserve the food product. It isinherently smart ! Add to that nano-materials and a numberof technologies used to extend the food products’ shelf life.Packaging materials’ shelf life itself is continuously improving.Like this astonis

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