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An innovative manufacturing process for flexible packaging industry 12-13 Aug 2015: meeting at AWRE in Melbourne, Australia
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Page 1: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

An innovative manufacturing process

for flexible packaging industry

12-13 Aug 2015: meeting at AWRE in Melbourne, Australia

Page 2: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Polimer sas di Federici Renato e C. – is an Italy-based company specialized in the

production of garbage bags with and without drawtape.

Polimer’s production cycle is based on a brand-new and highly advanced technology that

allows a radical filtration of recycled materials to obtain the highest quality output.

Since foundation 45 years ago, Polimer has been developing efficient, highly-effective and

economic product solutions that can match the highest international standards according to

the requirements of every single local market.

Annual production capacity is 130 million bags, to cater Italian domestic market, export to

European Union markets, and production under private label.

Mr. Renato Federici, founder and Managing Director of Polimer sas, developed an

innovative production process and filed patent application in Italy,

Executive Summary

The industrial application of the patented process allows to directly extrude the

granules obtained from the waste destined for incineration by eliminating the step of

re-granulation, a critical step in the standard process currently applied in the

industry

Page 3: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

1

The competitive advantages derived by the application

of the patented process include:

Executive Summary

raw material from waste = less cost

eliminating the step of re-granulation = greater energy savings

final scrap being regenerated and transformed into secondary

raw material

excellent quality of the finished product

finished product is 100% environmentally sustainable =

100% green product

2

4

5

3

Page 4: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

The Polimer Advantage

Page 5: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Business goals The project has been conceived and developed by Mr. Renato

Federici, owner of Italy-based Polimer sas, based on his

consolidated multi-year experience in the manufacturing and

production of environmentally sustainable garbage bags

Mr. Renato Federici has filed patent application in Italy for an

industrial process that generates a 100% environmentally

sustainable “green” product by using raw materials from waste

destined to incineration

Depending to the type of raw materials being used, this patent

allows to modify the traditional production process by

eliminating the step of re-granulation of the polymer itself. This

allows substantial savings in terms of time, manpower, energy

consumption and CO2 emissions.

1

2

3

In order to start the industrialization phase, Mr. Renato

Federici is considering a potential business/financial partner

interested in investing in this innovative production process

Product launch and

marketing of a completely

environmentally

sustainable product

Efficiency of the urban

waste collection cycle

Industrialization of the

production process

Market penetration in the

target segment of dark

sustainable garbage bags

Project overview

Page 6: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Purchase of raw materials in the form of granules resulting from

garbage bound to incinerators

Extrusion of raw materials which are

heated and transformed into

plastic film

Welding and packaging: the film is

cut and heat-sealed to create the bag

Retail sale

Waste

Garbage Granulation

By starting from purchasing

the granules obtained from

waste processing, the patented

process allows to process the

granules that would otherwise

destined for incenerators.

The purchased

granules, although

featuring an

inferior quality

compared to virgin

polymer, can only

be extruded by

applying the

patented process

as otherwise being

of difficult working,

thus obtaining a

film reel of

excellent quality.

The reel

obtained from

the extrusion is

machined in

the welding

step in the

traditional

method

The finished product has the same

quallitative features of the products

obtained from the processing of

virgin polymers, and to date the

patented process leads to products

in dark shades

After being used, the product is

either destined to incinerators or is

being granulated again and resued

as raw material

Within the “patented” lifecycle,

waste is being granulated so

that it re-enters the production

process as raw material.

Within the “traditional”

lifecyle, post consumer

waste is usually bound

to incinerators.

6

5

4

3

2

1

The idea behind the Polimer advantage: Lifecycle of waste as used in the patented production process

Page 7: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Mr. Renato Federici, boasting over 40 years of experience in the field

of flexible packaging industry, today introduces a wide range of large

and small bags for the collection of waste, garbage and trash, with

and without handle, made of polyethylene from 100% recycled

material, and suitable for every waste colection solution.

Mr. Renato Federici is Founder and Managing Director of Polimer sas

(www.polimeritalia.com) , a company based nearby the city of

Cremona, in Northern Italy, that manufactures and produces the

following range of products:

refuse sacks, trash bags, and garbage bags made of polyethylene

derived entirely from recycled material

biodegradable and compostable bags, for which he has recently

obtained the European certification “Vincotte”, applicable for example

for the separate collection of organic waste in both home and

business environments

film sheets made of polyethylene and suitable for covering areas,

indoor and outdoor tables, and for a wide range of other applications

The professional competence and know-how developed by Mr.

Renato Federici allowed him to conceive, develop, and patent a

new industrial process that allows the processing of very low

quality raw material, by skipping a step in the production

process when using raw material derived from recycled waste.

Mr. Renato Federici: business profile The patent

Mr. Renato Federici: the entrepreneur behind this innovative idea

Mr. Renato Federici filed patent application in Italy on 16 Oct 2014

(#B02014A000564)

Patent is expected to be approved by October 2015 with a 20-year

validity until 16 Oct 2034

Page 8: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Polimer is located in Northern Italy, in the town of Sospiro, 10 kms/6.5

miles from the city of Cremona, and 107 kms/67 miles from Milan.

Federici Andrea 99,9%

Federici Renato 0,1%

Polimer is founded by Mr. Renato Federici 1994

Polimer begian targeting the private label sector 2010

Polimer began the process of technological

innovation for processing the granules derived from

recycled waste

2012-

2014

Polimer filed patent application 2014

Polimer s.a.s. at a snapshot Polimer s.a.s.: company timeline

Polimer s.a.s.: company shareholders

Polimer s.a.s. at a snapshot

# plant locations: 1 (2,000 square meters)

# employees: 12

# of film lines: 3

# of bagging machines: 2 (Hudson & Sharp 1300 and Coemter 1200)

Production capability, per year: 130 million bags

Production capability, per year, for bags using the patented innovative

process:

25 million bags produced on Coemter bagging machine

(for a drawtape bag, size cm. 70x110/45, thickness 10µ, 10 bags

per roll, roll weight 700 gr. = 2.5 million rolls x 10 bags/roll)

37.5 million bags produced on Hudson & Shart bagging machine

(for a drawtape bag, size cm. 55x65/30, thickness 15µ, 15 bags per

roll, roll weight 357 gr. = 2.5 million rolls x 15 bags/roll)

Page 9: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Polimer: the range of products

CATEGORY PRODUCTS FEATURES

TRASH BAGS FOR

SEPARATE RECYCLE

HYGIENIC BAGS FOR

PETS

POLYETHYLENE

COVERS FOR

GREENHOUSES AND

AGRICULTURE,

POLYETHYLENE

MULCHING FILMS

TRANSPARENT FILMS

FOR COVERING

LAUNDRY

POLYETHYLENE TABLE

COVERS, MULTI-

PURPOSE

Bags with or without handles in an array of neutral, purple, yellow and blue

colors, all on a transparent basis

Suitable for recycling of paper, plastic, aluminum and glass

Available in different sizes, with practical handles, reinforced thikness, and liquid

tight

Protective covers made of transparent polyethylene, UV rays resistant, with a

thickness of 48 microns

Suitable for agriculture

Made of black polyetylene, low density and high thickness, size of 1.5x5 meters

(4 feet 11 1/16 inches x 16 feet 4 27/32 inches)

Suitable for agriculture

Transparent films for covering laundry, with a thickness of 60 microns

Fully waterproof and environmentally friendly

Multi-purpose film in transparent polyetylene, with thickness ranging from 25 to

35 microns, and different sizes

Trekking films with thickness of 50 microns, highly resistant, walkable, fully

waterproof and environmentally friendly

Table cover films, in white polyetylene, waterproof, 25 microns of thickness

suitable for protecting tables from dust, scratches, water, leaves and weathering

Page 10: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Polimer: the range of products

CATEGORY PRODUCTS FEATURES

CERTIFIED

BIODEGRADABLE, AND

COMPOSTABLE BAGS

GARBAGE BAGS WITH

HANDLES

GARBAGE BAGS WITH

HANDLES, IN DISPLAY

SET

GARBAGE BAGS WITH

HANDLES WITHOUT

BAND

BLACK GARBAGE

BAGS WITHOUT

HANDLES

Wide range in different sizes and customizable to suit any demand or request

Suitable for supermarkets, municipalities, restaurants, hospitality, medical and

hospitals, areas of well-being

Vincotte certified

Represents the widest range of products on the market (great variety of sizes,

thickness, and different colors)

Suitable for home and office

Easy to close, easy to move

Range of vibrant colors, fragrance, and selection of thickness make this product

unique

A Polimer exclusive product

Suitable for home and office

Wide range in black color, for general waste, with practical and robust yellow

handles scrolling

Suitable for home and office

Full availability of a moltitude of combinations of sizes and thickness

Suitable for home and office

Side reinforced welds, high grip and total impermeability against leakage

Page 11: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

The patent the patent developed by Mr. Renato Federici has 2 areas of application

1

2

Large and small trash bags with or without handles

The Patent, applied to the extruder for the production of

large and small bags, with handles or traditional,

introduces an effective innovation in the production

process stages:

it allows to directly extrude the granules obtained

from the waste destined for incineration, by

eliminating the step of re-granulation, a critical

step in the standard process currently applied in

the industry

COMPETITIVE ADVANTAGES

① raw material from waste = less cost

② eliminating the step of re-granulation = greater

energy savings

③ final scrap being regenerated and transformed

into secondary raw material

④ excellent quality of the finished product

⑤ finished product is 100% environmentally

sustainable = 100% green product

Biodegradable and compostable trash bags

The Patent, applied to the extruder for the production of

large and small biodegradable and compostable bags,

introduces a strategic advantage at the level of the raw

material being used:

COMPETITIVE ADVANTAGES

① substitute raw material = less cost

② lower emission of CO2

③ excellent quality of the finished product

④ finished product is 100% environmentally

sustainable = 100% green product

it allows to replace the use of virgin raw material

with substitute raw material

Page 12: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Bags with or without handles Raw Materials

CLASSIFICATION OF RAW MATERIALS USED FOR THE PRODUCTION OF BAGS

Raw Material

Cost per

kg in EUR.

Double

check

Cost of

double

check per

kg in EUR

Total cost*

A VIRGIN (first choice) 1,30 No - 1,30

B VIRGIN (second choice) 1,20 No - 1,20

C REGENERATED FROM REEL 1,15 No - 1,15

D RIGENERATED FROM BAGS, REELS, PRINTED 0,56 Yes 0,4 0,96

E1 SCRAPS, WASHED (first choice) 0,85 No - 0,85

E2 SCRAPS, WASHED (second choice) 0,70 Yes 0,4 1,10

F WASTE DESTINED FOR INCINERATION 0,55 Yes 0,4 0,95

CO

LOR

D

AR

K

F GARBAGE WASTE DESTINED FOR INCINERATION 0,55 No - 0,55

[*]: total cost of raw material prior to the extrusion step

• Generally speaking the scraps, washed (first choice) do not require the phase of re-granulation, but in most cases by omitting

this step some processing problems may emerge that would generate extra costs

• Differentiated and refined garbage waste (destined for incineration) represents the raw material of more low quality and more

difficult to process, and for this reason often the second phase, or re-granulation, is not sufficient and it becomes necessary

to pass to the mixing step (blending with virgin polymers), generating a further increase in the cost of the raw material

• The patented process is able to directly extrude the raw material without havng to perform any prior step, and the

products so obtained are available for the segment of dark bags, with significant competitive economic and

environmental advantages

SCOPE

Page 13: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Bags with or without handles Production Process

GARBAGE WASTE

DESTINED FOR

INCINERATION

1. re-

granulation

Granules

2. Extrusion

Reels

3. Cutting and

Welding

Large and

small bags

2. Extrusion

Reels

3. Cutting and

Welding

Large and

small bags

GARBAGE WASTE

DESTINED FOR

INCINERATION

INNOVATIVE PRODUCTION PROCESS

STANDARD PRODUCTION PROCESS

Thanks to a forty years experience in the flexible packaging industry, and a deep understanding of the technical problems

associated with the use of recycled materials for the production of 100% environmentally friendly products, Mr. Renato Federici

has patented an innovative technological solution concerning the extursion step, a solution which allows the use of raw

matierials of lesser quality, and already pavailable in the market (garbage waste destined for incineration) thus eliminating the

step of re-granulation.

Page 14: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Bags with or without handles Patent Overview

0,55

Cost of

Raw Material *

0,55

0,25

Cost of

Extrusion

0,25

Granulation Machinery

+

Standard Extruder

Extruder Patented by

Mr Renato Federici

Cost of

Reel

1,20

0,80

0,40

Cost of

Re-granulation

-

Economic

advantage

= - 34%

of cost of

production Notes: prices in EUR per kg

[*] reported cost per kg for the purchase of granules from garbage waste destined for incineration

STANDARD

SOLUTION

PATENTED

SOLUTION

applied to the extruder for the production of bags with or without handles

exclusive extrusion of granules obtained from refined garbage waste destined for incineration

① with the patented extrusion machinery, Mr. Renato Federici is able to directly extrude the

granules obtained from garbage waste that cannot be processed by standard extruders

currentlyused in the industry, and which should therefore be subject to a phase prior to re-

processing in order to be extruded

② the patent allows the elimination of the phase of re-granulation, providing a huge energy saving

which is then reflected on a lower final production cost of the reel

③ the final product is of exceptional high quality and 100% made from raw materials resulting from

waste, and with the least possible consumption of energy

COMPETITIVE ADVANTAGES

PATENT

PROCESS

Page 15: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Biodegradable and Compostable Bags Production Process

INNOVATIVE PRODUCTION PROCESS (with different mix of raw materials)

The patented innovative solution developed by Mr. Renato Federici is also applicable to the productiion process of

biodegradable and compostable bags. Also in this case the technologically innovative solution concerns the extrusion phase that

allows the use of a virgin raw material replacement while minimizing the use of virgin material and thus achieving significant

competitive advantages.

STANDARD PRODUCTION PROCESS

VIRGIN POLYMER

2. Extrusion 3. Cutting &

Welding

Large and

small bags Reels

VIRGIN POLYMER

SUBSTITUTE RAW

MATERIAL

3. Cutting &

Welding

Large and

small bags

2. Extrusion

Reels

Page 16: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Biodegradable and Compostable Bags Patent Overview

3.25 *

Cost of

Raw Material *

2.01 **

3.50

Cost of

Reel

2.26

Standard Extruder

Extruder Patented by

Mr Renato Federici

0.25

Cost of

Extrusion

0.25

Economic

advantage

= - 35%

of cost of

production Notes: prices in EUR per kg

[*] reported cost per kg for the purchase of virgin polymer

[**]: reported cost per kg resulting from the mix of virgin polymers and raw materials

STANDARD

SOLUTION

PATENTED

SOLUTION

applied to the extruder for the production of biodegradable and compostable bags

extrusion of a mixture composed of lesser percentage of virgin polymers and greater percentage of

alternative raw materials (eg. Calcium carbonate or talc)

① the patented innovative process developed by Mr. Renato Federici, applied to the extruder for

the production of biodegradable and compostable bags, allows incurring in lower costs for

procurement of raw material as it reduces the use of the virgin polymer and to replace it with

alternative raw material

② It also allows a more easy processing of raw materials

COMPETITIVE ADVANTAGES

PATENT

PROCESS

Page 17: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

Trash Bags Market Driver

TREND IN WASTE

PRODUCTION

The amount of waste produced by the world’s

increasing population drives the need for

trash bags for waste collection

Price flactuation caused due to trends in the

cost increase of raw materials of virgin type

(eg. Hdpe, lldpe, and ldpe).

SPREADING OF RECYCLED

WASTE COLLECTION

For the same level of total waste volume,

recycling is creating a growing need for

multiple trash bags for the collection of

different types of waste

REGULATORY CHANGES The ban on sale of non-biodegradable bags

requires the purchase of dedicated products

Sharp increase in recent years

expected further growth in the

coming years

Flactuating price trend

The patented solution developed by Mr. Renato Federici is not

subject to this price flactuation condition as it reduces to little or no

percentage the use of virgin polymer by substituting it with raw

materials resulting from garbage waste destined to incineration.

PERFORMANCE OF

DISTRIBUTION CHANNELS

Supermarkets chains as main distribution

channel

VOLUME

PRICE COST OF RAW MATERIALS

Page 18: An innovative manufacturing process for flexible packaging ......of flexible packaging industry, today introduces a wide range of large and small bags for the collection of waste,

MTW Group

Marketing that Works Pte Ltd

30 Cecil Street

#19-08 Prudential Tower

Singapore 049712

www.marketingthatworks.us

[email protected]

For more info, and

to schedule a meeting at AWRE 2015 in Melbourne, Australia,

please send an email to: [email protected]


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