Modern Packaging & Design - May-June 2011

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3EDITORIAL

Modern Packaging & Design May-June 2011

Packaging, perhaps, is one of the select sectors witnessing tremendous changes (and challenges) in terms of new materials, new production technologies,

new users and thus, new end-products. All these are adding to the growing demand for the right packaging material and technologies, with the right quality and right price. Apart from specialisation and sophistication, eco-consciousness is gaining a wider footprint, especially in packaged foods & medicines.

Quality control, quality assurance and quality improvement, which form the three key pillars of quality management, are not only meant to drive product quality, but also to ensure an effective way for achieving it. In this context, the customersupplier interface should extend beyond the immediate customers and suppliers to unlock the hidden potential.

Biological food safety hazards, though mainly linked to food manufacturing processes and not much to packaging materials, can be included in a hazard analysis. Quality issues, in fact, encompass mould, product leakage, transferable ink, etc. Hence, as a preventive measure, it becomes imperative to test the containers, cartons and other packages with the ingredients and food products to be packed in them and ascertain the possibility of any reactions thereof.

Besides conducting regular process audits by an independent team to make quality built into the products, food manufacturers and

packagers need to follow a hazard-based analysis ecosystem, towards proactively tackling potential food safety issues. It is encouraging to see the implementation of such formalised programmes by packaging suppliers along with their respective manufacturers to identify and avoid potential hazards. Turn to Sector Watch for some of the latest insights into this value-added approach on enhancing packaging quality.

This said, packaging printing can play a differentiating role in the all-important journey of a product to a brand, particularly in the current era of intensifying competition on supermarket shelves. As the application of various high-end printing and graphics technologies grows, the Indian packaging sector seems set to tap the growth opportunities not just in the domestic market but globally too. Take a look at Market Trends for a detailed perspective.

With Interpack 2011 the worlds leading business platform for the packaging domain round the corner, the rising influence of emerging economies on the global map is even more visible. The Curtain Raiser presents a sneak peek into this mega show. Read on

The quest for quality

Manas R [email protected]

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EditorManas R Bastia

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Editorial Advisory BoardP V Narayanan ChairmanCognizance Packaging

M K Banerjee Director - Creativity & Innovations (Global)Essel Propack Ltd

R KrishnamurthyDirector-Marketing & OperationsOrient Press Ltd

S DasManaging DirectorNordson India Pvt Ltd

4CONTENTS


REGUL AR SECTIONSBook Shelf ......................68

Product Update...............68

Product Index..................83

Advertisers List ...............84

Highlights of Next Edition Sector Watch : Packaging SecurityMarket Trends : Innovative Packaging Designs

And much more...

Design Innovation 22 The latest in product designs and innovations

Leaders Speak 24 Mohan Joshi, Country President, Schott Glass India 26 Debdeep Kole, Director, Koley Converting Machinery (P) Ltd

Facility Visit 28 Hindustan National Glass & Industries Pvt Ltd: Driving the sustainability index

Sector Watch 32 Quality standards in packaging: Raising food safety and hygiene value

Market Trends 36 Printing & graphics in packaging: Combining creativity with technology

Packaging Perspectives 40 Food packaging: Convenience, creativity and consistency P V Narayanan, Chairman, Cognizance Packaging

Packaging Printing 44 Colour calibration: Synchronising the shades Bhargav Mistry, Managing Director, Grafica Flextronica

Industry Update 48 Checkweighing: Profit boost with innovative feedback control Gunter Schilpp, Head, Product Management, Mettler Toledo Garvens

Policy Matters 52 Design dynamics in MSMEs: Gaining competitive edge through innovation Jitendra Rajput, Co-ordinator, Design Clinic Scheme, National Institute of Design

Curtain Raiser 55 InterPack 2011 60 In the news

36

Editorial............................3

National News..................6

World News....................12

Tech Updates ..................18

Events Calendar..............62

32

Product Update

Cover Design: Sharad Bharekar

Note: ` stands for Indian rupee, $ stands for US dollar and stands for UK pound, unless mentioned otherwise

Details on page no.62

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6th Anniver

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6NATIONAL NEWS


Health concerns to boost demand of packaged juice segmentThe beverage packaging segment is likely to get a boost, as larger number of Indians choose packaged fruit juices. Rising health consciousness, disposable incomes and urbanisation is driving the growth of the packaged juices in India, according to research firm Datamonitor. The Indian packaged juice segment is expected to display a growth rate

of 7.8 per cent over 2009-14, as per the analysis. In terms of volume sales, the category displayed a healthy 15 per cent Compounded Annual Growth Rate (CAGR) during 200409, reflecting the growing demand among Indian consumers.

Varun Kumar, Senior Analyst, Consumer Markets, Datamonitor, said, Offerings in the Indian juice market have come a long way, from juice prepared by street vendors, via Indias

first popular drink, Frooti, to Tetra Pak fruit juices. A major inhibitor to this category was a cultural aversion to packaged food & beverages, but consumers are slowly progressing towards branded fruit juices, primarily due to growing health consciousness.

Rajoo supplies film line to Polypack flexible packaging Indias Rajoo Engineers has anounced that it is the first Indian company to supply a three-layer blown film line to Polypack, a Lahore-based customised extruder. Polypack is a major flexible packaging supplier in Pakistan, with products like shrink film, milk pouches and lamination-grade film. Sunil Jain, President, Rajoo Engineers, said that the sale provides the company significant entry to the Pakistan market.

The line installed is equipped with 2 x 50 mm and 1 x 60 mm grooved feed barrier extruders. In addition to other film products, the machine is designed to produce 37.5 micron film with 1,500 mm lay-flat width and output of 250 kg per hour. The sale was facilitated by Trade Polymerz, Rajoos agent in Pakistan. Rajoo is aggressively promoting its brand in the South Asian Association for Regional Cooperation Countries, Sri Lanka, Bangladesh and Nepal.

Nichrome collaborates with Spanish technology manufacturer for innovative packaging solutions

Nichrome India Ltd, the pioneer of vertical form-fill-seal machines in India, is all set to cater to the requirements of packaging industry by offering special machinery with re-closability and pourability features for packaged products. The machinery typically known as Horizontal Form-Fill-Seal (HFFS) machines is highly automated and offers a variety of pouch formats like stand up pack (Doypack), zipper

pack, spout (cap) pack. This increases efficiency and ease of operation. Nichrome India has ventured into a technical collaboration with TOTPACK from Spain. In this regard, the company will use the most advanced Spanish technology to manufacture and sell HFFS machines domestically and internationally at an Indian price. Under this technology licensing arrangement, TOTPACK will support Nichrome with its experience and specialty of HFFS technology transfer and upgradation.

The machines will be manufactured in simplex and duplex constructions for products like cosmetics, pharmaceutical powders, juice concentrates, etc. With this technology, the company will be able to offer machines for Doypack style stand-up pouches with spout, zipper and straw attachments. Harish Joshi, Managing Director, Nichrome India Ltd, said, With this collaboration, Nichrome envisages a breakthrough in new market segments like cosmetics, personal care, food, neutraceuticals and Over-The-Counter (OTC) pharma products.

Rajasthan Ventures invests in PR packaging Rajasthan Venture Capital Fund, a state-run venture capital fund based out of Jaipur, has invested `15 crore in the second round of funding of PR Packaging Ltd (PRP), a packaging company located in Faridabad. PR Packaging produces high-quality folding cartons like printed mono cartons, fluted boxes, pouches, brochures, leaflets, etc. Girish Gupta, CEO, Rajasthan Ventures, said, PRP is serving to best-known brands in electronics, pharmaceuticals, cosmetics, automobile industries and food chains. The company is well-positioned in northern India and is planning to foray in flexi tube packaging, as well as seamless and laminated tubes.

The funds will be used to widen its customer base by enhancing its capacity, exploring new packaging opportunities, widening its product portfolio and consolidating its position, and thus become the preferred vendor to all its clients. The Indian packaging industry is expected to grow to `82,500 crore by 2015 from the current `65,000 crore, according to the Indian Institute of Packaging (IIP). At present, India stands at the 11th position in the world packaging industry, which is $550 billion, and with the rising consumer demand and new technologies, it is expected to grow at 18-20 per cent from the current 15 per cent, the industry body added.

(L-R): Vaibhav Modak, Executive Director, & Harish Joshi, MD, Nichrome India (Ltd) with

Joaquim Miro, CEO, TOTPACK Spain

8NATIONAL NEWS


Nutech installs second NovaCut diecutter for further expansion Noida-based Nutech Packaging has installed a Bobst NovaCut, the second die-cutter from the Switzerland-based finishing equipment manufacuturer. Besides the two NovaCut machines, Nutech Packagings plant is equipped with a third Bobst machine, which is a folder-gluer. The 20-year old packaging manufacturer prints paper boards and provides final products for the liquor and cosmetics industry. The company also manufactures corrugated boxes but only for quality concern customers and in house consumption. Jatinder Shroff, Director, Nutech, said, Our business is growing at the rate of 35 per cent annually, and

we expect further growth in the future. The machinery expansion will enable us to meet the growing demand for packaging products.

With the addition of machinery and the need to deliver customer orders in a timely manner, the company is also planning further expansion of the facility. The Nutech plant is equipped with multicolour presses from Planeta and Akiyama and a mono unit from Heidelberg, plates for which are fired by the in-house REE. The plant is also equipped with a German-made rotogravure press. The in-house design team works on sample products, which are produced on the Kongsberg machine. Nutech converts 450 tonne of paper board and kraft paper into producing packaging products and employs 150 persons at its plant.

Paper prices up on buoyant demand Rising costs of raw materials such as coal and furnace oil have resulted in rising costs. Riding on buoyant demand, paper companies such as Bilt, West Coast and JK Paper have increased the prices of writing, printing and packaging paper by about three per cent from April 2011. This is the first increase in the current financial year. In the last financial year, companies had

increased prices thrice. High paper prices are eating into box manufacturers margins. Prices of kraft paper, used for making corrugated boxes for packaging, have risen by 20 per cent from Rs 24 per kg to Rs 29 per kg. Also, the import duty on kraft paper is 10 per cent at present, which adds to the woes of the corrugated box manufacturers. Kirit Modi, President, Indian Corrugated Case Manufactures Association, said, We have appealed to the government to remove the 10 per cent import duty on kraft paper, as the cumulative impact of these increases is 20 per cent. India is one of the fastest growing paper markets, with the government thrust and budgetary allocation to education. The domestic paper industry is estimated to be around 10 million tonne. Of this, the writing paper segment accounts for 3.8 million tonne, packaging grade paper around 4.5 million tonne, while the newsprint industry is about 1.7 million tonne.

Manjushree Technopack awarded Best Supplier Performance Gold AwardBangalore-based packaging major, Manjushree Technopack Ltd, was recently presented with the Best Supplier Performance Gold Award by Hindustan Coca Cola Beverages Ltd (HCCB), the bottling arm of Coca Cola India, at the recently conducted Second Strategic Supplier Summit, in New Delhi. The award was presented to Vimal Kedia, Managing Director, Manjushree Technopack Ltd, by Patrick Yadauga, Senior Vice President - Supply Chain Coca-Cola, India. Also, present were T Krishnakumar, (CEO, Hindustan Coca Cola Beverages Pvt Ltd), Asim Parekh (VP Technical, Coca Cola India) and Atul Singh (President, India and South West Asia Business Unit, The Coca-Cola Company).

Manjushree Technopack is among the leading rigid packaging manufacturers offering total packaging solutions under one roof, right from Concept to Design, R&D, Tooling and Commercialisation of the package. Manjushree has been a preferred supplier for HCCB for over three years.

Convertec installs first Braillemaker One in IndiaSweden-based Convertec has installed its first Braillemaker One digital printing and inspection machine in the Asian subcontinent. The European-headquartered converter installed the regions first Braillemaker One at its label printing plant outside New Delhi. Convertecs local agent Creed Engineers assisted in the installation. The new machine aims to meet the demand for Braille printing of pharmaceutical products exported from India, one of the leading exporters of pharmaceutical products to Europe. The Braillemaker One, equipped with 100 per cent inspection, is designed to print on plain labels, leaflets for cartons, booklets and multi-ply pharmaceutical labels.

(L-R): Vimal Kedia, Managing Director, Manjushree Technopack Ltd, receiving the Best Supplier Performance Gold Award from Patrick Yadauga, Senior Vice President - Supply Chain,

Coca-Cola, India.

10

NATIONAL NEWS


Rasna introduces convenience packs for the powdered drink market

Recognising the needs of a fast-moving metropolitan lifestyle, Rasna has come up with a novel stick pack of its existing product Fruitplus. Saina Nehwal, Indias number one shuttler unveiled the new packaging in New Delhi. Also accompanying Saina was Rasnas Chairman and Managing Director, Piruz Khambatta. He said,

Rasna is proud to be consistently present in the market, and we have been committed to our consumers with the quality and nutritious value of our products. The benefit of these consumers only has yet again formed the basis of our growth. Rasna Fruitplus Singles intends to offer a convenient and hassle-free experience. Children and adults can carry the sticks to their schools, playgrounds and workplaces, respectively.

Rasna Fruitplus Singles has also combined choice with convenience. This product would be available in a mono-carton comprising variedly flavoured stick packs orange, lemon, mango, pineapple and mixed fruit. Unlike some other concentrates, which take time to dissolve in water, Fruitplus Singles gets dissolved within five seconds and offers greater nutritional value of fruits.

Ban to impact packaging sales of Indias film extruders The recent ban on plastics packaging is likely to impact the Indian plastics processors, especially the recently adopted ban on the sale of gutka and other tobacco products. Sunil Jain, President, Rajoo Engineers

Ltd, said, The move would have far reaching repercussions for the plastics packaging industry in India as, by conservative estimates, about 35-40 per cent of the plastics packaging industry serves the gutka industry. It will be interesting to note how the big stakeholders would react this year as they built huge capacities

to cater the gutka industry. Over the years, many processors have added equipment solely to serve the gutka industry.

According to industry experts, the chewing tobacco/pan masala industry is awaiting clarity from the government on the substitute raw material to be used as packaging material.

DCGI makes barcoding mandatory for pharmaceutical packaging The Drug Controller General of India (DCGI) has proposed to make it mandatory for medicines intended for domestic supply to also bear barcodes. This was disclosed by Dr Surinder Singh, Drug Controller General of India (DCGI), Ministry of Health & Family Welfare, Government of India.

The Commerce Ministry unveiled an ambitious scheme to add serial numbers to all exported medicines via the printing of S1-compliant 2D barcodes on primary packaging and 1D or 2D codes on secondary packaging this year. DCGI added that there have been more sweeping proposals for the addition of serial numbers to the unit-pack level on all medicines destined for use in the domestic market.

The Unique Identifier (UID) number will also be printed on the pack in a user-readable format so that it can be sent via text message to a centralised phone number for authentication. He said that the pharmaceutical industry has reservations about the cost-effectiveness of this scheme. NR Munjal, President, Indian Drug Manufactures Association, who was also present at the press conference, said that total cost of the printing of 2D barcodes will add another burden on the industry and the cost of drug will escalate by about 40 per cent, which will certainly be a burden on the consumer.

Bhargav Mistry among five Global Screen Masters

Bhargav Mistry, Managing Director, Grafica Flextronica and DMI was among the five Global Screen Masters who conducted live workshops on various facets of advanced screen printing at the recently concluded FESPA AMERICAS at Orlando, USA. The workshops were held from February

24-26, 2011. All the way from India, Grafica despatched its Nano Premier League (NPL) package to the US for the purpose of conducting live workshop on graphics screen printing jointly with Michel Caza. A set of creative samples produced at DMI were also distributed to all participants and visitors to generate interest in print finishing for value addition in the US.

FESPA AMERICAS was an exhibition cum conference organised by FESPA. This was one of the first of its kind creative live workshop on advanced screen printing organised by FESPA. It was a unique combination of exhibition with live workshop initiated by FESPA on experimental basis. Bhargav Mistry, said, It was a memorable experience to jointly work with other four global screen masters at FESPA AMERICAS.

(LR): Scott Fresener, Ad Verteeg, Bhargav Mistry, Michel Caza, Charlie Taublieb

11

NATIONAL NEWS


HNGIL to invest `5,000 crore in five years to hike production capacityHindusthan National Glass Industries Ltd plans to invest up to Rs 5,000 crore in the next five years to set up new facilities and expand existing capacity. The firm, which had a total production capacity of 9.40 lakh tonne in the last fiscal expects it to go up to 12 lakh tonne in 2011-12. HNGIL currently has plants at Bahadurgarh in Haryana, Nashik in Maharashtra and Neemrana in Rajasthan. It is also setting up a new one at Naidupeta in Andhra Pradesh. R L Khandelia, President, HNGIL, said, We are looking to invest nearly `5,000 crore to set up a greenfield facility and also to augment capacity in the existing plants. We plan to invest Rs 2,500 crore to set up a new facility, for which it its scouting for a location in Rajasthan, Haryana and

Madhya Pradesh. We are looking for about 500 acre of land and are in talks with the governments in these three states and wherever we find the land we will set up the new facility.

He said the new plant will have three manufacturing container glass units and two for float glass. The capacities at the existing facilities are also being enhanced. The company has already spent `160 crore at Bahadurgarh for equipment and machines in the last fiscal. At present, the Bahadurgarh plant produces 2 lakh tonne per annum, which will go up to 3.1 lakh tonne by 2012.

Flex eyes `1,000-crore revenue from non-plastic packagingPackaging major Uflex, which started manufacturing non-plastic-based alternative innovative packaging solutions to plastic pouches, is eyeing a `1,000-crore revenue from this new product by end-this fiscal. The company has already started manufacturing the eco-friendly product and plans to manufacture around 36,000 tonne per annum to cater to the market demand. R K Jain, President (Finance and Accounts), Uflex Group, said, We expect around `1,000-crore revenue from this new product by FY 12 and expect it to increase over the years. We plan to manufacture around 36,000 tonne per annum to garner an around `1,000-crore revenue by end of this fiscal.

The Supreme Courts landmark decision to ban the use of plastic in sachets for storing or selling tobacco, gutka and pan masala came into effect pan-India from March 1, 2011.

12

WORLD NEWS


IPACK-IMA and Expo 2015 plan a global showcase IPACK-IMA 2015 is scheduled to take place in conjunction with the Expo 2015. The change in schedule from the traditional March dates to May 19-23, 2015, is bound to create a perfect synergy between the mainstays of the exhibition, the leader

in packaging, processing & food safety industries, and the Expo. In the process, it will draw worldwide interest towards Milan with Feeding the Planet, Energy for Life.

IPACK-IMA 2015 will extend over the entire South and East areas of the Fiera Milano exhibition centre, adjacent to the entrance of the Expo area and conveniently connected

to the city through the underground network.

Topping off the ensemble into a single, one-of-a-kind global event, Tuttofood the global professional exhibition dedicated to the agro-food industry organised by Fieramilano will also be staged in conjunction with IPACK-IMA. Tuttofood will take up the west area of the exhibition complex.

A&R Carton buys a stake in SP Containers Swedish cartons group A&R Carton has bought another 34 per cent of food and retail packaging supplier SP Containers, thus becoming the majority shareholder of the company.

A&R, which has 14 factories across 8 countries in Europe, now owns 67 per cent of SP Containers. The deal comes two and a half years after A&R first invested in the company. SP Containers specialises in paperboard-based containers and cups for products such as ice cream, dairy, confectionery and pet food. Besides supplying to the UK, the company has export markets in continental Europe, Scandinavia and the Baltic countries. Paul Nixon, Managing Director, SP

Containers, commented, With the assistance of A&R Cartons resources, SP Containers will be able to develop at a much faster rate than previously. We look forward to further cooperation with A&R Carton.

To this, Per Lundeen, Chief Executive, A&R Carton, added, We are pleased to increase our share of SP Containers. SP Containers products complement A&R Cartons product portfolio well.

Robert Willett becomes CEO at Cognex Corporation

Cognex Corporation has announced today that Robert Willett, the companys President and Chief Operating Officer, has been promoted to Chief Executive Officer. Willett will continue to report to Dr Robert J Shillman, Chairman of the Board, who will take on the newly created role of Cognexs Chief Culture Officer.

Since joining Cognex just three years ago, Rob has done excellent job of both managing our business during the 2009 downturn and in laying the groundwork for our companys record-breaking financial performance in 2010, commented Dr Shillman. He continued, His leadership was instrumental in every key area, including choosing strategic markets to pursue growth, thus establishing our product development priorities and, finally, guiding and motivating the talented team of Cognoids around the world to achieve these. Robert is an immensely capable business leader and a true Cognoid who takes his work seriously. He embodies our motto of Work Hard, Play Hard and Move Fast.

Conair aligns products and personnel to assist sheet & film extruders, thermoformersAs part of a continuing effort to support the unique needs of customers in specific market segments, Conair is positioning an expanded range of equipment and services to address the needs of companies producing plastic film & sheet used in thermoformed containers and packaging. Materials involved may be styrene, polyolefins and, increasingly often, Polyethylene Terephthalate (PET) and biopolymers.

During the recent economic downturn, we learned that our customers are most concerned about finding specific solutions that can help them stay competitive and profitable. Listening to their concerns, we have come to understand that

they are interested in equipment and technology, but only insofar as it brings them direct, tangible benefits. We believe that Conair is well positioned to deliver those benefits and help companies in this important market, noted Gene Flockerzi, Vice President, Sales - Packaging, Conair.

To achieve their objectives of increasing productivity, reducing scrap, ensuring quality and cutting costs, film & sheet extruders and thermoformers can draw upon the expertise and service of key Conair people.

Robert Willett

14

WORLD NEWS


Leading packaging machine builders join Rockwell Automation PartnerNetwork programme Douglas Machine Inc., Kliklok-Woodman and Nercon Engineering & Manufacturing have joined the Rockwell Automation Machine Builder programme. The programme gives end-users access to skilled machine builders that have proven their ability to deliver high-quality, innovative machinery. As part of the Rockwell Automation PartnerNetwork framework, the machine builder programme consists of industry-leading Original Equipment Manufacturers (OEMs) who

share Rockwell Automations business values and are committed to delivering solutions to help lower manufacturers total cost of ownership.

To become a part of the PartnerNetwork programme, which includes thousands of specialists in industries, applications, geographies, technologies and services around the world, machine builders must demonstrate both innovation and market leadership in machine design and development that incorporate Rockwell Automation solutions. Members of the programme will benefit from the opportunity to increase market awareness with customers, expand into new market sectors and improve technical & functional excellence.

McDonalds commits to sustainable packaging

Fast food restaurant giant McDonalds has set out a vision to eventually source all its packaging from sustainable sources. The company said that over time its suppliers would provide agricultural raw materials for its food and packaging from land that has been certified as sustainable by an external third-party evaluation process.

McDonalds Sustainable Land Management Commitment (SLMC) will first focus on the five areas that it believes will make the highest impact packaging, beef, poultry, coffee and palm oil.

Jim Skinner, Chief Executive Officer, McDonalds, said, We will continue to focus on developing sustainable sourcing practices and broadening our menu choices. Each year, we set goals that challenge us to put our resources towards strengthening communities and helping maintain a world that can carry all of us well into the future.

To this, Francesca DeBiase, Vice President, Strategic Sourcing, McDonalds, added, We know that our customers care about where their food comes from.

SIG Combibloc produces new carton format for Sunraysia

SIG Combibloc has claimed that Sunraysia will be the first in the UK to use the combifitMidi carton format, 750 ml. Sunraysia has p r e v i o u s l y packaged its long-life juices in Polyethylene

Terephthalate (PET), glass and competitor carton formats. But, the firm claimed that the new carton pack

will not only differentiate the brand on supermarket shelves, but will also provide clear benefits including efficient and long-life storage and easy pouring.

Gavin Cox, Commercial Director, Sunraysia, said, Our aim has always been to provide premium quality and natural healthy juices to our discerning consumer. The new combifitMidi carton pack will ensure that our juices are protected from light & air, and the quality and nutrition are conserved at all times. Sunraysias tomato, prune, beetroot, carrot, mango and pear juices packaged in the 750-ml combifitMidi carton will be available from UK supermarket giants including Tesco, Sainsburys, ASDA, Waitrose and Ocado.

Nano-bricks to improve food packaging Scientists have recently announced that a new material containing an ingredient used to make bricks shows promise as a transparent coating for improving the strength and performance of plastic food packaging. Termed as nano-bricks, this film appears as bricks and mortar when observed under a microscope. This coating could help food products and beverages stay fresh and flavourful

for longer and may replace some foil packaging currently in use.

Scientists have said that ordinary plastic soda bottles tend to lose their fizz after just a few months of storage on grocery store shelves. Manufacturers can apply the new coating to these bottles, to slow down the loss of CO2 gas and help sodas stay bubbly for several more months, or even years.

The coating could also extend the shelf-life of portable food packages

known as Meal, Ready to Eat (MREs) that sustain soldiers in the field, with the added benefit of being microwavable.

15

WORLD NEWS


Cardia and Wesco announce exclusive distributorshipCardia Bioplastics Limited (Cardia) has recently announced appointment of Chinas leading plastics distribution company Wesco China (Wesco) as exclusive distributor for China. Wesco is a joint venture with Sasol Limited, a leading South African petrochemical company. Wesco will distribute Cardias portfolio of Biohybrid resins derived from sustainable resources throughout China. The exclusive distribution agreement enables Wesco to offer customers the comprehensive range of Cardia Bioplastics sustainable resins to Chinese packaging and plastic products industries.

China has recently emerged as the world leader in sustainable energy production through investments in various areas such as hydropower, solar, geothermal and biofuels. Following this success, China is establishing its environmental credentials further in an important area of sustainable plastics. Chinas demand for environment-friendly bioplastics, which are plastics that are biodegradable or derived from renewable resources, is rapidly developing.

Danone Canada adopts green packaging technology

Danone Canada has announced two major innovations in packaging: a new ecological manufacturing process for its individual serving products, called expansion, and the use of an ecological high-density polyethylene for its drinkable yoghurt packaging.

These innovations have come in direct response to Danones corporate objective of reducing

the companys carbon footprint by 30 per cent by 2012.

These bold environmental initiatives, which are in line with our mission and objectives for reducing our carbon footprint, have made us completely rethink our product packaging in the interest of the environment and well-being of our consumers, said Anne-Julie Maltais, Manager - External Communications, Danone, Canada.

The expansion process involves adding an inert agent to the polystyrene plastic. This agent forms a thin layer of foam in the polystyrene, thereby reducing the overall density of the plastic from approximately 18 per cent. Thus, the weight of individual serving packages of Activia, Stonyfield, Silhouette and Creamy brands is reduced by the same percentage.

Inert packaging material keeps food safe and taste intact

Recall of a product that has been tainted by its packaging can result in considerable monetory losses and harm the reputation of a company. Although the instance of a chemical migrating from the packaging to the food is less common, the retail supply chain needs to have the knowledge of the chemicals present in the

packaging to ensure that there is no health risk and the food reaches the consumer in good condition.

The main legislative driver, the European directive, ensures that food does not get tainted by its packaging. It outlines that chemicals from packaging should not endanger human health or change the composition, or cause decomposition of the packed food. It also stipulates a maximum migration limit of no more than 60 mg of the chemical for every kilogram of food substance.

It is a measure of inertness of the packaging rather than safety considerations, said Chris Howick, Manager, Product Stewardship, Ineos ChlorVinyls. He added, If a manufacturer uses a material at the maximum migration limit, then it must show that the limit is obeyed. New packaging range by Johnsen &

JorgensenP a c k a g i n g specialist Johnsen & Jorgensen has introduced a new range of bottle filling, capping and cleaning machinery, thus strengthening its reputation as a one-stop shop for packaging solutions.

The new filling equipment includes a single-head, low-vacuum operated machine that can fill approximately 350 bottles per hour and, for larger plants, a four-head in-line version with a capacity to fill over 600 bottles per hour.

We believe that this new range of equipment will not only benefit our existing customers but strengthen our one-stop-shop appeal to new prospective packaging clients, said Mike Bogod, Specialist Sales Manager, Johnsen & Jorgensen.

Bottles and dispensers make up the main segment in the cosmetics industry, while jars are offered in a variety of materials. According to the company, it is responding to growing customer demand for advice and recommendations on filling equipment as well as its core products of containers and caps, and hence offering a dedicated range of nine machines.

16

WORLD NEWS


Suppliers get bioplastics deal for London 2012 Olympics

In a landmark agreement between organisers and bioplastics producers, it has been agreed that the packaging destined for the London 2012 Olympic Park will have to be made from compostable bioplastics if it cannot be recycled in existing waste streams.

LOCOG, the Games organising committee, has signed an agreement with the National Non-Food Crops Centre (NNFCC), the trade body that represents biopolymers producers, for NNFCC to oversee suppliers of non-recyclable packaging to the Games. Under the agreement, all non-reusable and non-recyclable packaging eg, crisp packets, fast-food trays or liquid cartons must be independently certified under the EN 13432 standard for compostability.

The compostable packaging should be made from starch or cellulose-based plastics. Plastic Polyethylene Terephthalate (PET) bottles made from standard oil-based polymers will not be included in the agreement, as these can be recycled in existing waste streams.

New glow-in-the-dark bottle from Heineken

Heineken has developed a news aluminium can that combines the ice-cold feel of a metal can with the classic shape of a glass bottle. It is designed to entertain party goers.

According to Heineken, the glow-in-the dark bottle was launched

in Milan at the design trade show Salone del Mobile. On the heels of the bottle redesign, Heineken announced plans for another new design initiative called Open Design Explorations. The project aims to create new concepts for bars, clubs and social spaces, one of which will be a pop-up club at the citys 2012 furniture fair.

The design brief for this concept club asks designers to become part of a multidisciplinary team that will study social interaction in clubs around the world. This exploration will provide authentic insights that will help create the pop-up club.

Crown, Clemson partner for packaging education programme

Crown Holdings Inc., the world leader in metal packaging technology, has become the first corporate Partner in Packaging, a new initiative of the packaging science programme at Clemson University. As part of the partnership, Crown will donate a gift of cash for use as unrestricted programme funds, and gifts-in-kind of metal packaging fabrication equipment, faculty travel and regular participation of company personnel in the educational mission of this programme.

The value of Crowns gift is estimated at $400,000 over the five years. A commitment to help students learn about metal packaging is at the heart of the partnership. The laboratory equipment provided by Crown will give students hands-on experience in can manufacturing, testing and production of physical prototypes for research purposes. To further support knowledge transfer, Crown will send key personnel to Clemson every semester to lecture and mentor students on metal packaging innovations. Crown will also support faculty to attend Interpack, the leading international packaging trade show, to be held in Germany in May 2011 and 2014.

China becomes export destination for Hindustan Tin Works Hindustan Tin Works Ltd (HTW) continues its success story in exports, with a fresh order from China, potentially making India another export hub for metal can industry in Asia. Exports from HTW the leading can manufacturer of India have grown by 341 per cent in the last five years. It now exports to 22 countries across the world including the US, Australia, Europe, Africa, the Middle East and South East Asia, with its latest customer, China.

HTW attributes its export growth to Indias low-cost manufacturing base, consistent and strict quality regimes which it has strictly enforced. HTW has been certified by Transpacific Certifications Limited (TCL) for ISO 9001:2008 and Hazard Analysis and Critical Control Points (HACCP) and is an approved supplier to the major multinationals.

So, China may be exporting millions of cans to entire world, but there is one Indian company HTW that exports metal can components to China.

18

TECH UPDATES


Quadpack to unveil innovations in make-up and foam pumpQuadpack will launch innovations in foam pumps as well as new airless and make-up packaging development at the next MakeUp in Paris show, to be held from June 23-24, 2011.

The company will launch a new foamer manufactured by Apollo, designed for make-up removal. According to Quadpack, Apollo foam pumps use patented technology to achieve outstanding foam quality. The new foamers avoid metal parts in the product path, thereby greatly reducing product compatibility issues.

Quadpack will also showcase at MakeUp in Paris the latest in airless make-up containers that protect products from external contamination and preserve their integrity. These containers will include Dual 2-in-1 packs that blend foundation and concealer in a single tube or bottle, the glass-effect crystal range and an airless spot pen with brush applicator, offering clog-free precision dosage and targeted

application of foundation. Quadpack is a leading provider

of packaging solutions for prestige, masstige and mass market beauty and skincare brands. It sources and develops customised packs through a strategic network of manufacturing partners.

Mushroom-based packaging from Dell Computers

Ecovative Design has created mushroom-based packaging. Dell is the first technology company to start pilot shipments of this packaging, and will be testing these on its PowerEdge R710 servers. This new packaging reduces solid waste and fossil fuel consumption. This is achieved as the packaging

is made of compostable material, and requires one-tenth of the energy to produce in comparison to Styrofoam.

Packaging is a large contributor to waste and fossil fuel usage, and hence a huge concern for companies in addressing sustainability issues. Thus, this new mushroom packaging is a noteworthy innovation, as it is a sustainable form of packaging using agricultural waste that can then be composted.

Most companies today are seeking ways to improve the sustainability of their operations across their entire value chain, from energy usage, water usage and waste, to name a few. Companies choosing to purchase Dell servers or other Dell products using this sustainable mushroom-based packaging are improving their operational effects on the environment, and thus their image. Not only will they be contributing less to land-fill waste, but also they will be indirectly supporting the reduction of fossil fuel usage.

Worlds thinnest phone by Sony Ericsson Current smartphone manufacturers are in the race to make the worlds thinnest phone, but XPERIA Arc has managed to achieve this feat a slender, tactile device. Measuring 125 x 63 x 8.7 mm and weighing 117 g, the chassis is plastic rather than metal and not soft-touch plastic but it bows nicely in the middle, making the device that feels thinner than what the spec sheet might suggest.

Sony Ericssons use of shiny chrome-effect plastic is an acquired taste, but it is limited to buttons and edges at the left edge, a microUSB socket on the right edge above a small volume rocker, with a camera shortcut further down the side and a power/lock button on the top adjacent to a micro HDMI port covered with a small dust-flap. The plastic battery cover finished with a two-tone paint job opens to reveal both microSD and SIM slots that are blocked by the battery.

Arcs crowning glory is a 4.2-inch 854 x 480 capacitive touchscreen from Sony Ericsson. It is 0.2-inch bigger than XPERIA X10. A regular LCD TFT presents excellent visuals, although viewing angles are on the narrow side.

Aged to perfectionThe iPhone is now being retired after three years because its touchscreen no longer functions efficiently. In contrast, the point-and-shoot camera works like new even after seven years of use, but is being retired because it is not digital. After more than three years of use, abrasion of the hard-anodised surface of the iPhone reveals the raw aluminium underneath. In contrast, the cameras shell wears in a similar way but its emulated metallic finish is only surface deep and its wear shows awkward artifacts of the injection moulding process used to create it.

Consumer products today stay new for only a brief period after being removed from their package, and then they function as used products. Most people welcome and find this wear and ageing of products as aesthetically pleasing. A Japanese term for this is wabi-sabi, which describes the aesthetically pleasing wear of an object as it decays over time. It celebrates the purity of the imperfect. Thus, ageing with dignity is a criteria that designers should recognise in their efforts.

19

TECH UPDATES


Wines now supplied in plastic containers Major distributor of alcomalts, beers and fine wines, Societe de Vin Internationale LTEE has used plastic packaging for the first time to supply wines to its airline customer, Air Transat charter airline. The 1 L PET barrier bottle was delivered by Amcor Rigid Plastics.

The Polyethylene Terephthalate (PET) stock container weighs only 54 g, while its glass predecessor weighs 430 g. The bottle is made with KHS Plasmaxs special barrier coating technology. It also has an aluminium screw cap.

The KHS Plasmax Silicon Oxide barrier coating safeguards the contents from oxidation by sealing the container from the inside. Plasmax is a Food and Drug Administration (FDA)-approved passive barrier for products that are sensitive to oxygen. This transparent material, with a thickness of less than 100 nm, is resistant to delamination, abrasion and cracking. During recycling, the barrier coating can be removed easily and does not pollute the recycling stream.

Some of its advantages include reducing fuel consumption in the airline industry, cutting down logistics expenditure and allowing producers to decrease their impact on the environment by decreasing the quantity of packaging and, in turn, reducing the waste sent to landfill.

A clever little bag from PumaKnowing that shoe boxes contribute millions of tonnes of waste each year, an essential step in Pumas long-term sustainability programme was to

create a packaging system that would reduce the brands footprint, from its energy and water use to its waste and CO2 emissions.

For this, Puma turned to Yves Bhar and his team at fuseproject. My thoughts were immediately about reinventing the way shoes are shipped and how they are experienced by the consumers, said Bhar, Founder, fuseproject. He added, But the logistics and material research was really challenging.

Bhar and his team spent 21 months conducting extensive research and development. After nearly 40 prototypes and 2,000 sketches, Bhar developed the clever little bag. This unique packaging system eliminates the shoebox entirely. Instead, it consists of a die-cut sheet of ink-free, thin-gauge recycled paperboard that tapers to form four walls, which are held in place by a 20 per cent, non-woven polypropylene bag.

Gold-plated window electrodes for organic solar cellsResearchers at the University of Warwick have developed a gold-plated window as the transparent electrode for organic solar cells. These electrodes have the potential to be relatively inexpensive since the thickness of gold used is only 8 billionth of a metre. This ultra-low thickness means that even at the current high gold price, the cost of the gold needed to fabricate one square metre of this electrode is only around 4.5. It can be readily recouped from the organic solar cell at the end of its life. This method can be scaled up for large area applications like solar cells.

Organic solar cells have long relied on Indium Tin Oxide (ITO)-coated glass as the transparent electrode, although this is largely due to the absence of a suitable alternative.

An ultra-thin film of air-stable metal like gold would offer a viable alternative to ITO; however, it has not yet proved possible to deposit a film thin enough to be transparent without being too fragile and electrically resistive to be useful.

Monobloc configuration to run labelling processess The DecoBloc labeller from Krones AG will make it possible to create a monobloc configuration synchronising a modularised labeller. This will feature a Sleevematic carousel, a Shrinkmat tunnel and a Linadry unit for predrying the containers. Users can then use this monobloc to run all common labelling processes, with enhanced flexibility. Whether it is cold-glue, pressure-sensitive, hotmelt or shrink and stretch sleeves.

The docking stations feature motorised height adjustment, so that irrespective of the floor level involved, the labelling stations can be swiftly prepared for a product change-over at the touch of a button. Different machine sizes offer outputs of up to 72,000 containers an hour. Servomotors are used to ensure maximally accurate dress positioning. For sleeving applications, there is a choice between shrink-sleeve labels with a downstream Shrinkmat tunnel or stretch-sleeve labelling. There is also an option for camera-based alignment of the containers on an embossed marking.

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TECH UPDATES


Champagne house can pack 8,500 bottles of famous fizz an hour with new Cermex line

Cermex has created a line that, at full pelt, can pack nearly 8,500 bottles of Veuve Clicquot every hour. Three elements of the

line were major advances from its predecessor the heavy integration of robotics; automation of format changeovers, which has cut the time taken from more than two hours to less than 20 minutes; and an improvement in the protection of bottles and their secondary packaging.

The line can handle 16 different formats of packing to accommodate producing corrugated cases of 6 or 12 bottles in a top-to-toe arrangement. These may or may not be packed in Design Boxes; and may be in different bottles, including standard 75cl yellow-label, lightweight and special options or the premium Grande Dame shape.

Equipment in the installation includes an AN110 gantry packer, two Fanuc M710 50-kg robots that have automatic gripping head changeover, an F272.40 tray erector, a WB45.80 wrap around case packer and a P4 palletiser.

A movie-inspired design show by Disney and DuPont Corian

Light Tape company contributes to the TRON designs CORIAN exhibition, providing their unique, high-tech and proprietary electroluminescent film technology, which will be used to

create fascinating lighting effects inspired by the film TRON: Legacy.

Light Tape by Electro-LuminX Lighting Corporation (USA) is an advanced technology, thin-film light bulb. It has no glass, gas or mercury, stays cool to touch, creates zero light pollution and is highly flexible. Being extremely robust, Light Tape has a long lifespan and ultra-low carbon footprint.

With a wide choice of colours, widths and custom shapes, Light Tape can be used both indoors and outdoors with stunning effects. Using less than 100 watt of power for every 100 m length, Light Tape is contributing to CO2 emission reduction on a global scale.

Toothbrush recycling to reduce carbon footprint Preserve is no stranger to sustainability the company has been turning recycled plastic, including post-consumer polypropylene food packaging, into toothbrushes since 1997. It has also added tableware and kitchen products made from 100 per cent recycled plastic to its lineup.

To help keep its used toothbrushes out of landfills, the company created a mail-back pack, which functions as a postage-paid return mailer for consumers wishing to recycle their toothbrushes. Preserve grinds the toothbrushes and uses the polypropylene to make products such as plastic lumber. Made from a Biaxially Oriented Polypropylene/Polyethylene (BOPP/PE) laminate, the pouch is 80 per cent lighter than the previously used package. The lighter materials reduce the packages carbon footprint and decrease packaging material costs.

Proco Machinery upgrades its Multipak Palletizer Packaging System The Multipak Palletizer Packaging System from Proco Machinery Inc., a leading supplier of automation systems for the plastics container industry, has introduced several enhancements for greater performance and flexibility for bottle manufacturers.

The new features include an automatic pallet feed magazine, which stores and feeds the pallets onto a pallet conveyor that efficiently moves pallets in and out of the system. Other enhancements are an automatic slip sheet magazine, which stores slips sheets and places them between each pallet layer and an automatic top frame magazine that stores top frames and places them on top of the pallet.

The Multipak Palletizer boasts a modular construction and operates as a semi-automatic system or in fully automatic mode at line speeds up to 150 bottles/min. It is fitted with heavy-duty castor wheels that allow the unit to be easily moved from one line to another. Its rectangular shape enables it to fit in most blow moulding lines without occupying much machine space. The unit can handle half-cube or full-cube pallet sizes up to 105 inches. It can also be configured for tray and box packaging.

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DESIGN INNOVAT ION


In a sea of look-alikes, the challenge is to bring to the market new and improved product concepts where the packaging does more than simply contain and protect the contents. Packaging innovation is crucial to the future of packaged goods, with user convenience being a key driver. As smart packaging concepts are predicted to be commonplace features in the future, this column is a tribute to the latest innovations in packaging designs.

Home compostable packaging Marijuana just got greener. OrganiCanns sustainably grown organic, medical cannabis is now available in environmentally friendly packaging.

OrganiCanns new packaging is made from certified-compostable film printed with water-based inks. The compostable film is made from sustainably produced wood. OrganiCanns packaging safely biodegrades in home or commercial compost. It will even biodegrade in a wastewater environment. Unlike many compostable packages that require the high heat and pressure of commercial compost facilities, OrganiCanns packaging will safely biodegrade in home compost. Patients can place the packages in home compost piles where they typically biodegrade in just a few weeks.

OrganiCann offers home compostable packaging for a range of products from dry cannabis and joints to concentrates and even cannabis-infused teas.

Manufacturer: OrganiCann

Re-sealable snack-pack for crispy nachosDoritos tortilla chips have been in the market since 1964. However, adding a fresh appeal to its brand is Peter Parlovs geometric packaging with surface triangulations. The principle advantage of this design is that its folds and dimensions allow easy opening & closing of the pack, without a clip. This is suitable as a quick snack option for consumers constantly on the move, without compromising on the quality of the chips, even after opening it. The package is made of cardboard, which serves the dual functions of environmental sustainability, while at the same time imitating the shape and natural texture of the triangular chips, also called nachos. The inspiration for this design comes from ancient Mexican history. The final form of the packaging resembles the classic totem poles of Aztec architecture. The design is also a visual standout on supermarket shelves, since its flat and angular surfaces offer ergonomic value, and create a perfect canvas for expressive & attractive illustrations.

Manufacturer: Doritos

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DESIGN INNOVAT ION


Sneaker Model No.1The team at Depot WPF design house took up the challenge to differentiate the MLK packaging on the store shelf and to distinguish it from the products by the big dairy producers, and emerged successful. The milk cartons from MLK may not look any different at first sight, but a closer look reveals its distinctive characteristics. The graphics on the package utilise natural farming patterns a family farm, where the products are manufactured in a traditional way. Illustrations are hand-made (with a pencil), which enables to stress the hand-made production process. In addition, a pencil technique makes the image soft.

The brand visual identity consists of black and white graphic patterns, which were taken from the real environment of the small milk farm. The patterns of the real farm were used in order to reflect the naturalness of the dairy production and the products. Interestingly, MLK won the Epica Awards 2010.

Manufacturer: Society27

A multi-purpose bottle to clean homeOne can now Flip, Mix, Clean, with the innovative household cleaner from Replenish. It features a PET spray bottle with a built-in measuring cup, along with a four-ounce pod of concentrate that is attached to the bottom. So, to use, flip the product upside down, squeeze the pod until the measurement cup is full, and add water. Each pod has enough fluid for four full bottles. As the product is designed for reuse, and the system is based on a concentrate, Replenish uses 90 per cent less plastic, oil and CO2 emissions than pre-mixed household cleaners.

Manufacturer: Replenish

Instant innovation through instant food Nestles highly popular culinary unit, Maggi, has recently launched a new range of microwaveable ready-to-meals under its Topfinito brand. The range comprises four exciting flavours. The high-barrier plastic containers for this packaging has been developed by design-firm Rexam through its unique Rotary ThermoForming (RTF) technology. These containers have superior retort and barrier performance and zero in-built stress as they are moulded in the melt-phase. They are filled on a modified high-speed can-filling machine at Nestl factory in Conow, Hamburg. The cups are then sealed with a double-seamed easy-open aluminium foil and an injection-moulded lid . It is decorated with insulating-shrink labels to preserve Maggis brand identity on super-market shelves. This modern and convenient single-portion pack is designed for a delicious and nutritious meal catering to people on the go. The 380 gm meals can be heated in a 600 W microwave oven for only three minutes and can be readily consumed. The packs have a minimum shelf-life of a year without the need for refrigeration or freezing, so the meals can be stored and used anywhere.

Manufacturer: Nestle

Current market potential of pharmaceuticalsIndia is on its way to become one of the largest pharmaceutical markets worldwide. As shown by a new study published by the auditing and consulting company Pricewaterhouse Coopers (PwC), sales of pharma products in India may rise from $19 billion in 2009 to around $50 billion in 2020. This growth will be driven and supported by domestic demand in Indias prosperous middle class as well as the booming exports of high-quality generics and biosimilars. Packaging is an integral operation of high-end pharmaceuticals and a double-digit growth is expected from the packaging division as well.

Growth drivers of Indias pharmaceutical packaging market The increase in lifestyle diseases such as diabetes and hypertension has contributed to an increased demand for injectables a trend that is expected to continue further. In addition, patients admitted in hospitals expect quick recovery and return to home as soon as possible. Here, injectables play a vital role to fulfil the expectations of patients admitted in hospitals. Further, increasing numbers of insurance companies are

entering the health sector. From our point of view, this will result in not only an increasing demand for pharmaceutical products, but also a rising need for high-quality pharmaceutical packaging. A reliable supply of glass tubing is, therefore, important for both packaging manufacturers and pharmaceutical companies.

The pharmaceutical industry has grown from reverse engineering technology to a highly technical and innovative business. India has taken giant strides in making world-class drugs and also in the field of biotechnology, and Schott is proud to be associated with this value chain.

Penetration of global innovations in Indian marketIndian pharmaceutical companies are investing heavily in their injectables business in order to create world-class facilities. Compared to other countries in the world, India has the highest number of US Food and Drug Administration (USFDA) approvals. The expertise gained over the years has given an edge to companies here for producing quality products. Multinational companies, therefore, often look towards India and plan to make it their manufacturing hub.

We want to participate in the growth of the injectables market asserts Mohan Joshi, Country President, Schott Glass India. Having been associated with Schott and its pharmaceutical glass packaging operations for over a decade, he underlines the traditional importance of glass and recent innovations making a headway in the industry, in an exclusive interview with Annabel Dsouza

LEADERS SPEAK

24 Modern Packaging & Design May-June 2011

25Modern Packaging & Design May-June 2011

LEADERS SPEAK

Important innovations here are medicines manufactured through biotechnological methods or those based on proteins. These biopharmaceuticals treat or protect against increasingly frequent severe illnesses such as cancer and rheumatic diseases. Among other things, these medicines are characterised by extremely high specificity, selectivity and completely new mechanisms of action. These drugs affect disease-causing molecules in a targeted manner. Because two people having the same illness do not necessarily require the same medication, a customised treatment in the form of biopharmaceuticals is assuming a greater importance today. The product group biopharmaceuticals also place special demands on packaging and raise the question as to how sensitive active substances can be packaged and stored properly. The use of high-quality vials, syringes, cartridges and ampoules is essential for achieving the industrys goal of high productivity with modern production and filling systems. For this, the demand is constantly growing for high-quality pharmaceutical packaging that can be processed easily.

Also, a worldwide trend being observed is the shift from vials to prefilled syringes for special drug applications based on the demand for a precise dosage and the need for increased user-friendliness. This trend will also be seen in India in the near future.

Unique role of glass in the pharma packaging spaceThere is a consistently high demand for glass packaging and we are confident that this will continue based on the advantages that glass offers for the protection of drugs. Our Fiolax glass tubing, first introduced to the market 100 years ago in 1911, is a borosilicate glass that has been optimised for use in pharmaceutical packaging and is known for its high resistance to chemicals. It can be easily sterilised and features excellent barrier characteristics for medications. Because of its low alkali content and optional Ultraviolet (UV) protection, it offers long-term stability as required for ensuring effectiveness of medicines. The precisely shaped glass tubing with low geometric

tolerances also resists breakage and scratches, an important feature for machine processing during mass production of such containers.

Delivering quality solutions to Indian marketSchott recognised early the underlying potential of the pharmaceutical packaging market, and therefore started manufacturing pharmaceutical tubing in India in Jambusar, near Baroda, in 1998. Today, Schott Glass India manufactures and supplies Type 1 pharmaceutical glass tubing to our customers. They then use it for manufacturing vials, ampoules, cartridges and other types of primary pharmaceutical packaging as per requirements of the pharma industry. With the growth of pharma market in India, Schott Glass India has increased its production capacity by almost three times. Besides local products such as Neutral Glass Clear (NGC) and Neutral Glass Amber (NGA), it will produce Fiolax, which is a popular premium glass tubing for manufacturing pharmaceutical containers.

International quality is the key for pharmaceutical companies and Schott Glass India has, therefore, taken several initiatives for improving the quality of its products as per international standards, following its vision of always being a step ahead in terms of performance and quality. For example, we were the first glass manufacturer in India to publish our Technical Terms of Supply (TLB SGI) for NGC and NGA and also to receive ISO 9002 certification by Rhineland/Berlin-Brandenburg Inspectorate (TV). We have also developed an information and tracking system for Fiolax glass tubing that offers customers precise information and important manufacturing, material and quality parameters for a given match.

Thus, it is possible to track all details of a production process for a period of 10 years from the date of manufacturing all the way to the final glass tubing. This can be done by what is called Traceability as per requirements of the pharmaceutical industry. At the same time, we have ensured

maintaining cost-competitiveness to meet the omnipresent price pressures that will continue to increase in the future.

Preparing for overcoming challenges aheadThe Made in India label is probably the biggest challenge for the industry. Companies in the developed world have a rigid and longstanding system of documentation and system procedure. Therefore, it is never enough just to create and run a world-class facility. One always has to keep in mind the fields of pre- and post-manufacturing, logistics, compliance issues, documentation requirements as well as consistency in the quality of products and services. Thanks to our uniform worldwide quality standards in manufacturing, Schott is always in a position to provide its customers with products of the same high quality from various sites. The company simultaneously maintains a close presence with customers, which has been possible with various manufacturing sites for pharmaceutical tubing in India, Germany, Spain and Brazil. Together, these facilities produce approximately one million kilometres of pharmaceutical tubing each year.

Future beckonsAs a pharmaceutical glass tubing provider, we want to participate in the growth taking place in the injectables market. We have invested heavily on capacity expansion and are fully capable to cater to international quality for our domestic market. Moreover, we have implemented a consistent quality and tighter dimensional control of Outside Diameter (OD) and Inside Diameter (ID) for ensuring that pharmaceutical companies gain optimum yield on their high-speed machines. We have also been able to further eliminate cosmetic defects thanks to the latest manufacturing technology.

Schott has invested in its human resources, technology and processes to support the ambitious growth plan of its associated Indian pharmaceutical companies and will be able to serve the challenges for sustainable quality and services in the coming years.

Current trends in the Indian

packaging industry

The packaging industry in India has

witnessed immense growth in the past

few years and is continuing its upward

trend due to the buoyancy in the

sector. Although recently, there have

been changes in the use of some

packaging processes and materials,

the sector has hardly experienced any

overall setback.

Factors driving growth in the

packaging sector

Today, a growing proportion of

consumers are looking for good quality

and high-level packaged products. We

are witnessing an increase in consumer

expectations regarding high-quality

packaging not only to sustain the

contents of the products inside, but

also to enhance their aesthetic appeal.

Also, quality packaging boosts the

value of products, which is beneficial

for manufacturers of Fast Moving

Consumer Goods (FMCG) and other

related goods.

Challenges faced by the industry

A few products, such as gutkha and

khaini, have made some massive

changes in their packaging following

court orders that caused stoppage in

the production of these products and,

in turn, the processing machinery. This

production halt resulted in the industry

being stagnant for a few months.

After the court order was relaxed,

the market gradually has returned

to progress. Also, through the years,

government norms have increasingly

been tightening on packaging, as the

display of important information is

now mandatory for companies.

Expansion plans for the future

A number of innovations are emerging

today; hence, it becomes essential that

we adapt and innovate in order

to stand against the growing

competition in the market. In order

to do so, we have decided to bring

latest technology machinery from

overseas to process our items

for ensuring higher accuracy and

Globalisation has increased awareness about the high quality of Indian products....believes Debdeep Kole, Director, Koley Converting

Machinery (P) Ltd. He believes that with the entry of

multinational players in the Indian packaging industry,

the country is witnessing a gradual shift towards flexible

forms, as is the global norm. Kole highlights the need for

maintaining high quality and spreading awareness for the

same, in conversation with Anwesh Koley

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26 Modern Packaging & Design May-June 2011

27Modern Packaging & Design May-June 2011

LEADERS SPEAK

productivity. These machines will function along with our

existing equipment that are domestically sourced, and

hence give us an edge in manufacturing that couples the

best of both worlds.

Latest innovations in technology

In the current scenario, where pollution has become a

major factor in our countrys welfare, we have witnessed

a huge increase in foil and paper packaging. This

prompted us to design specialty machinery for paper and

aluminium foil, which are currently growing in demand.

Adopting green manufacturing techniques is another

area gaining strength, and we would like to contribute

to this for ensuring that our products cause minimal

damage to the environment. Sustainable production

will attract a lot more attention in the near future as

global norms will become more stringent with regard to

environmental concerns.

Future of flexible packaging in India

The growth in flexible packaging has shown great variety

and depth. The best gains are expected in the worlds

emerging markets, including Eastern Asia, Eastern

Europe, Africa and the Middle East. India, specifically,

will witness enormous growth due to various reasons.

The most important of these is growth of the middle

class with a population of more than 400 million, and a

large disposable income. Also, the change in production

techniques from the more traditional rigid packaging to

flexible forms of today will have a positive impact on

the industry. With globalisation bringing more and more

multinational companies to India, awareness regarding

quality has increased and will continue to do so until

there is no information gap among industry players. It

will also ensure the availability of modern plants and

equipment for the flexible packaging industry.

Threats from Chinese machinery entering India

The current buyers of machinery in the Indian market

are more educated in comparison with the scenario a

few years ago. Also, they now understand that reliability

and service support of inexpensive Chinese machinery

do not match those from India and overseas, which

are comparatively expensive. The global customer is

fast understanding the importance of quality and

is showing tremendous enthusiasm towards Indian

products, which score much higher on this aspect over

Chinese products.


Driving the sustainability indexHindustan National Glass & Industries Ltd

With a pan-India manufacturing presence, Hindustan National Glass Industries Ltd (HNGIL) has emerged as the undisputed leader in the container glass industry and forayed into float glass segment also. The packaging industry is witnessing a resurgence in demand for glass bottles, especially in the Southern & Western regions. Annabel Dsouza explores the companys efforts to meet this surging market while also mapping its future strategies.

As Indias demographic structure changes to suit a surging economy and rapid urbanisation, the countrys

packaging industry is witnessing growing demands in terms of volume as well as innovations. This holds true especially for the container glass segment, which scores significantly high on the sustainability index. Glass packaging accounts for almost 7-8 per cent of Indias total packaging consumption and the industry is currently worth over $ 16 billion. As container glass manufacturing in India soars to greater heights, it is both intriguing and important to understand the meticulous functioning of the market leader in this sector Hindustan National Glass Industries Ltd (HNGIL). Started in the early 1950s, with a focus on the container glass, HNGIL holds more than 55 per cent of this marketshare in India and has today emerged as a household brand in the glass bottles domain.

Building the foundation Along with an established presence in the float glass segment, packaging remains HNGILs key strength and the company invests great efforts to maintain this leadership status. With its headquaters in Kolkata, HNGIL

has a pan-Indian presence. This is another advantage of HNGIL, with seven manufacturing plants across the nation, from Rishikesh (Uttaranchal) to Puducherry (Tamil Nadu) and from Halol (Gujarat) to Rishra (West Bengal). The company also has a strategic manufacturing presence at Bahadurgarh (Delhi) and Neemrana (Haryana). The Sinnar container glass facility, located 30 km away from Nashik city, was acquired by HNGIL in 2005 from Larsen & Toubro Ltd (L&T), and there has been no looking back ever since.

A noteworthy achievement of this HGNIL facility has been its drastic capacity enhancement. This is a typical advantage of HNGIL, as it seeks to convert loss-making ventures into profitable enterprises. Elaborating on the sturdy and steady growth curve of this facility, CSK Mehta, Vice President, HNGIL, says, Glass is the most eco-friendly solution available to the global packaging industry, and we try to make the entire manufacturing process as sustainable and efficient as possible. After our take over, we have increased the capacity of this plant from 320 tonne per day to 400 tonne, with energy savings of about 15 crore per year.

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Photo: Joshua Navalkar

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This operational efficiency coupled with state-of-the-art technology enables HNGIL not only to seize domestic demand but also cater to an evolving exports market in over 20 countries all over the world.

Impressive infrastructureSpread over an expansive area of 70.27 acres, this facility currently runs four individual section lines, with a daily output of about 15 lakh bottles per day. The plant caters to the glass bottling demands of all major brands of liquor, Fast Moving Consumer Goods (FMCG) and pharmaceutical products in the region. The facility is well-equipped with a convertible furnace having a melting capacity of 390 tonne per day and four Independent Section (IS) manufacturing lines. Mould is a critical aspect of glass bottle design and manufacture; hence, the in-house mould workshop enables HNGIL to exercise better control over precision and delivery of the final product. Considering the high-speed IS machines at the plant, the moulds are specifically designed for increased accuracy along with efficient cooling mechanisms.

As glass is a 100 per cent recyclable resource, cullet or broken glass constitutes about 30-40 per cent of the batch mixture that is fed into the furnace. However, the glass industry is facing a challenge in recovering used containers from the market. The other raw materials for glass manufacture include natural minerals such as silica sand, quartz

sand, soda ash, dolomite, feldspar and coke. These materials are stored in large silos having a capacity of nearly 400 metric tonne. Here, the contents are automatically weighed, homogenised and conveyed to the furnace. At 1,500C, the furnace from HORN Glass Industries AG is among the latest in glass melting technology.

Efficiency meets qualityIn keeping with HNGILs commitment towards efficiency, Mehta states, As compared to its past power consumption of 300 kW per day, we have upgraded the plant in order to reduce its consumption to about 175 kW per day. Even furnace oil consumption has been reduced from 115 litre per tonne of glass to 95 litre per tonne. Also, in terms of Liquefied Petroleum Gas (LPG) usage, we have brought down the consumption from 27 kg of gas per tonne glass to less than 9 kg per tonne. We are currently planning to switch all operations from LPG to Liquefied Natural Gas (LNG), so as to reduce costs and enhance sustainability.

Even at the glass conditioning front, the forehearth from SORG GmbH is maintained at 1,200C, from where the viscous glass is transferred to the IS machines. Here, the glass is moulded into the required shape and size using the blow & blow process for narrow-neck bottles, press & blow process for wide-mouth bottles and the Narrow Neck Press & Blow (NNPB) process for higher output of lightweight

& tough bottles. The IS machines from Emhart are optimised from double to triple gobs to enhance production cycles and reduce downtime. At the annealing lehr, the glass forms are gradually cooled to release stress and ensure longevity of the bottles. The bottles then proceed towards quality assurance stages, where each bottle is assessed by auto inspection machines from SGCC as well as visual checks by experienced professionals. The automatic quality inspection lines ensure immediate feedback and zero error into the system. This is followed by random sampling of hourly batches, where the respective sample is subjected to polariscope analysis

Glass is the most eco-friendly solution available to the global packaging industry, and we try to make the entire manufacturing process as sustainable and efficient as possible.

CSK MehtaVice President, HNGIL

Narrow-neck moulds for beverage bottles Improvisation in quality and quantity High-speed production


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for adequate stress control and other customer specifications. Besides, this plant is equipped with an on-site ceramic printing facility with three decorating lines.

After moving through all manufacturing and processing stages, the glass bottles are stored in a 12,000 sq ft warehouse, having a capacity of 10,000 metric tonne. With intelligent planning and management, the total breakage loss at this storage facility has been reduced from 10 per cent to nearly 1 per cent. This warehouse infrastructure is being improved further to store up to 35,000 metric tonne of containers.

On an expansion driveWith a strength of more than 600 employees, HNGIL emphasises considerably on employee health and welfare. Being a loud noise zone, all workers are provided with the appropriate gear that includes ear plugs, aprons, shoes, helmets, etc, as prescribed by industry regulations. Also, the company ensures that all workers at hazardous locations of the plant undergo regular heath check-ups and other medical facilites.

After optimising its resources to achieve a capacity of 400 metric tonne, the company has ambitious plans to further expand this facility by adding the worlds largest end fire furnace and six additional IS lines. This will be a 150 per cent capacity enhancement, which aims to deliver an output of about 650 metric tonne. Being a market leader, HNGIL is expected to meet the demands of the regions ever-growing alco-bev segment as well.

Mehta avers, Today, glass has a sustainable Compounded Annual Growth Rate (CAGR) of about 10-11 per cent. This translates into production of 300-400 metric tonne of glass or the need for one more furnace every year. HNGIL has been striving to meet this demand by putting up greenfield facilities and building

on its key strengths to emerge with dependable solutions. Similarly, we have upgraded another furnace at our facility in Neemrana, Haryana. He further explains, Another key strength of HNGIL is its ability to integrate world-class technologies from various suppliers. We have leveraged our presence as the market leader to complement the machinery obtained from some of the leading brands in the business like Sorg, Horn, Emhart, SGCC, etc. Through this significant expansion, we hope to target the export potential as well.

Creating milestones In 2009, HNGIL was rated as the best Indian company in the glass & ceramic category by Dun & Bradstreet a leading credit rating agency. Apart from this, the Sinnar facility has received several accreditations for its best-in-class manufacturing practices. As the company gears itself to further establish its presence in the container glass segment of Western India, this facility will play a pivotal role in achieving this goal. Today, the Sinnar facility prides itself on having some of the most honoured names in the industry as customers. These include Nestle, Unilever, Dabur, Cipla, Pfizer, among others.

With enhanced production capacity, the solutions provided by HNGIL will not only improve in volumes but also facilitate world-class innovations in India. On this note, Mehta concludes, Apart from current plans, this plant will also witness addition of two more lines to its capacity in the near future. With significant investments, we are looking forward to a total of 12 production lines to fully utilise this plants capacity. However, the challenge before us is to maintain cleanroom specifications similar to those in developed countries. Achieving these standards will bring us on par with global standards of manufacturing, thereby giving HNGIL a complete edge in the industry. Precision moulds designed for high speed

Complete automation in packaging


SECTOR WATCH


We live in a rapidly changing world where yesterdays status quo is no longer good enough. Requirements to improve food product quality & safety, enhance and stabilise food composition & nutrition, extend shelf-life & product stability, build customer confidence, provide information, etc on food packages are fast becoming market demands. Beverley Lewis tracks the increasing demand for high-quality packaging in the food and beverages sector.

Raising food safety and hygiene valueQuality standards in packaging

Quality food packaging plays a vital role in ensuring the purity, safety, preservation and protection of food products. Right packaging of fresh and processed foods is also important during bulk transportation, unit

packaging for distribution and prevention of wastage. With proper and quality packaging, food products can be protected against severe and varied climatic conditions. Quality standards can be divided into process standards and product standards. Most of the product standards in India are governed by the Bureau of Indian

Standards (BIS) and process standards are as per the International Organization for Standard

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Modern Packaging & Design - May-June 2011

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