Packaging Trends 2010

8/8/2019 Packaging Trends 2010

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PACKAGING INTELLIGENCE BRIEF

Packaging Trends 2010

Brand building, improving efficiency and reducing

costs are driving forces heading into 2010.

NOVEMBER 19, 2009

This report is brought to you with a sponsorshipfrom PMMI Member ProMach Inc.


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Packaging plays a critical role in our global economy and

touches the lives of everyone. For more than 75 years,

PMMI has been the leading global resource for packaging

professionals to learn about industry trends, obtain

training and network.

PMMI is proud to present this Packaging Intelligence Brief.

PMMI Packaging Intelligence Briefs address trends and

topics that are significantly impacting packaging and

outlining how suppliers and manufacturers are responding

to market needs.

www.pmmi.org

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Tel: 703.243.8555

Toll-Free: 1.888.ASK.PMMI

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About the Packaging

Intelligence Brief Series


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P A C K A G I N G T R E N D S 2 0 1 0 1

Packaging Trends 2010

Brand building, improving efficiency and reducing costs are driving forces heading into 2010.

Countering the Recession

As they head into the new year, PACK EXPO attendees are

trying to counter recessionary forces of 2008 and 2009 by

focusing on building brands and improving productivity

with twin goals of increasing sales and cutting costs.

In keeping with these goals, sustainability has evolved into

a mainstream commitment. Sustainable practices encour-

age sales by addressing consumers interest

in greener products, and by reducing

waste and conserving resources, they often

generate cost savings.

Other trends revealed at PACK EXPO Las Vegas

2009 included the increased adoption of digital

printing and safety enhancements.

Brand Building

Attention-grabbing packaging shapes, sizes, features and

materials increase shelf impact and product differentiation,

both of which help convince consumers to buy.

One new way to differentiate product is the Zip Box, a

hybrid carton/zippered pouch package from T.H.E.M.

(Marlton, NJ). The rectangular pack opens and recloses

easily, stacks better than a pouch and fits more

product per pallet than a canister.

Available in a variety of sizes, the Zip Box

fills like a standard carton on a modified car-

toner from Yeaman Machine Technologies, Inc.

The carton base and zipper-pouch top of the hybrid Zip

Box couples easy handling on the packaging line and in

distribution with convenient opening and reclosing for the

consumer.


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Pro Mach, Cincinnati, Ohio, is a leading provider of integrated

packaging products and solutions for food, beverage, household

goods, pharmaceutical, and other diverse consumer and industrial

companies. Through three business units and related divisions,

Pro Mach provides equipment, training, installation, and parts in primarypackaging, end-of-line packaging, and identication and tracking.

For information on ProCustomer, our new customer

service initiative, visit www.ProCustomer.com.

Visit www.ProMachInc.com to learn about Pro Machs

divisions and packaging machinery solutions.

TM

Pro Mach Inc. is proud to sponsor PMMIsreport on Pack Expo Las Vegas 2009


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(Elk Grove Village, Ill.). T.H.E.M. plans to sell printed blanks

as well as offer contract packaging services.

Another attention-grabbing concept, the ElastiTag hang tag

from Bedford Industries, Inc. (Worthington, Minn.) consists

of a single-ply or folded paper body attached to a flat,

stretchy loop. Available in a variety of tag and loop shapes

and sizes, the patented design carries brand, product and

country-of-origin information, point-of-purchase coupons,

inventory management data or a Universal Product Code.

Automating a process that is generally performed manual-

ly, application occurs on a machine from Graphic

Packagings Packaging Machinery Division (Crosby, Minn.).

The patented applicator rolls up to existing conveyors and

applies ElastiTag hang tags at speeds up to 450 per

minute.

Successful brand building also depends on quality control

measures that prevent flawed product from disappointing

the consumer. One way to prevent brand-damaging quali-

ty problems is via machine vision. To simplify integration of

complex inspection systems, CIVision, (Aurora, Ill.), has

launched the Pro Vision Series, a modular, do-it-yourself

system for contract packagers and original equipment

manufacturers.

What was once acceptable, isnt now, warns Tom

McLean, president of CIVision. Crooked, wrinkled labels

are unacceptable today if a brand owner wants to be

viewed as a good vendor. One bad label may prompt

retailers like Wal-Mart to reject the entire shipment.

Capable of inspecting packs moving at up to 600 per

minute, the easily installed and operated system clamps to

the conveyor frame on a universal aluminum mounting

bracket and includes up to four cameras, a touch screen

operator interface, trigger assembly, strobe light, blow-off

reject mechanism, CIVCore vision software and an off-the

shelf, industrially hardened computer. Camera and lighting

height can be fixed or adjustable. Adjustments occur

manually via a hand wheel with a position readout or a slide

release with a guide ruler. They can also be fully

automated with servo drives.

The CIVision Pro Vision Series works with a variety of

cameras monochromatic or color, low, medium or high

resolution. Options include stainless steel mounting brack-

et and NEMA 4X camera and electrical cabinet enclosures.

The system is 100 percent a la carte, so integrators can


The ElastiTag hang tag applicator handles bottles ranging from 12 ounces

to 51 ounces.


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P A C K A G I N G T R E N D S 2 0 1 0

pick and choose features, reports McLean. In fact, he

says, the system is so flexible, customers can supply their

own parts, if desired.

In metal detection, the patent-pending Intellitrack XR signal

processing technology from Thermo Fisher Scientific

(Minneapolis, Minn.) eliminates product effect instead of

compensating for it. Now standard on the companys Apex

metal detectors, the signal processor learns the conductive

and magnetic signatures of the product being inspected

and subtracts those signals from each reading. So, if a

product reads zero, its good. Its especially well-suited for

discrete wet products such as cheese, bread, water and

baby wipes, which change over time and pose a challenge

for traditional phasing methods. Although products with

signals similar to ferrous or nonferrous metal or stainless

steel remain somewhat problematic, detection sensitivity

improves up to 40 percent.

End users also are becoming more familiar with x-ray

inspection technology, which can detect metal contami-

nants as well as a host of other problem materials like

bones and stones.

Theyre no longer asking why x-ray, but when, reports

Rick Cash, marketing technology manager, Process

Instruments for Thermo Fisher Scientific, a supplier of

metal detectors, x-ray inspection systems and check-

weighers. End users are realizing customers will not

tolerate low quality in food.

As a result, Cash predicts, The x-ray market will be equal

or bigger than metal detection in a couple years.

Productivity Improvement

On the productivity continuum, the need to minimize down-

time spurs demand for faster changeover and ease of use.

Tactics to achieve these goals include higher levels of

automation with increased adoption of servos, software

and robotics to speed changeover and reduce faults. The

need to cut downtime also is spurring interest in service

and support, automation of manual processes and hygien-

ic designs that require less time to clean.

Delkor Systems, Inc. (Circle Pines, Minn.) has launched a

more flexible servo version of its Trayfecta carton/tray for-

mer. With servomotor drives controlling three axes of

motion (carton blank picking, carton transfer and forming

head action), each function occurs at its optimal rate. The

Trayfecta S Series not only runs 10 percent to 12 percent

faster, but also occupies less space, changes over without

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P A C K A G I N G I N T E L L I G E N C E B R I E F

Delkors servo-driven Trayfecta S Series carton/tray former features a

lower, more ergonomic blank magazine that is easier to replenish.


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tools in less than 10 minutes and handles a greater variety

of materials and shapes.

Flexibility is readily apparent on the high-speed FSU800

aseptic vertical form-fill-seal machine from Fres-Co

System USA, Inc. (Telford, Pa.). It handles a range of refrig-

erated and shelf-stable products from extended-shelf-life

dairy to high-acid aseptic or can be set up to simply hot fill.

The machine maintains overpressure in the form-fill-seal

area and sterilizes incoming film with ultraviolet light and

peracetic acid to ensure aseptic conditions. With a 22-inch

stroke, potential pouch sizes range from 1.69 ounces to

2.5 gallons with filling speeds from 17 pouches per minute

for the 2.5-gallon size to up to 30 pouches per minute for

the lower volumes. At the 2.5-gallon size, the form-fill-seal

process cuts packaging material costs to $0.25 to $0.30

per pouch versus $0.50 to $0.75 for a bag in box.

Modular construction of the ALS series of printer/applica-

tors from Avery Dennison, Printer Systems Division

(Framingham, Mass.) simplifies service and integration by

offering several mounting, loading and application options.

Built for heavy-duty use with a cast aluminum housing, the

ALS units feature a dynamic rewind and unwind to adjust

speed and torque for precise, repeatable label placement.

The ALS 306 manages labels up to 6 inches wide at

speeds up to 197 feet per minute. The ALS 309 handles

labels up to 9 inches wide at speeds up to 148 feet per

minute. A CompactFlash card slot makes it possible to

save, share and store configuration settings for several

packaging lines. Other standard connectivity options

include serial, Ethernet and USB ports. A ribbon-saver

function conserves material, cuts costs and decreases

downtime by reducing the frequency of ribbon changes.

Already viewed by many as the ultimate in flexibility, robot-

ic equipment is expanding functionality, ease of use and

setup with ultra-hygienic designs, vision capability and

advanced software.

A three-panel printer/applicator from Pro Machs ID

Technology (Fort Worth, Texas) thermal-transfer prints and

applies labels to up to three sides of a pallet, reducing the

number of applicators needed. Built on the same base as

the companys other printer/applicators, the system fea-

tures a pivoting cam with a tamp-jet pad to apply labels to

leading, passing and trailing sides. A jet of air helps release

the label for tamp application on the fly or while the pallet

is stopped. The tamp-blow action helps ensure good con-

tact with the stretch wrap frequently used to unitize pallets.

Changeover takes only seven minutes on the HFP (Highly

Flexible Packer) from Focke & Co. (Whitsett, NC) because


With Fockes two-robot HFP, case packing occupies only 81 square feet

(7.5 square meters) of floor space.


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the only changes involve four indexing pockets, two quick-

release pusher plates and a conveyor guide rail adjust-

ment. When configured to pack at 15 cases per minute,

the dual-robot system orients cases to the product rather

than vice-versa, eliminates expensive product orientation

devices and minimizes product handling, making it partic-

ularly well suited for fragile products like potato chips.

The M-430iA robot from Fanuc Robotics America, Inc.

(Rochester Hills, Mich.) is the first robot certified by the U.S.

Department of Agriculture (USDA) to carry the USDA, AMS

Meat and Poultry Accepted Equipment logo, confirming it

meets or exceeds NSF/ANSI/3-A 14159-1 2002 specifica-

tions. Compatible with floor, ceiling or wall mounting and

designed for washdown conditions, the robot features pos-

itive air pressure inside the housing, a hollow arm to pre-

vent contact with air hoses and electrical cables, dual seals

and windows at strategic locations so if a seal fails, mois-

ture will be visible. Specially designed surfaces and bolts

prevent accumulation of debris. The high-speed robot also

relies on food-grade grease, operates at 120 cycles per

minute with a 2.2-pound payload, 100 cycles per minute

with an 8.8-pound payload and may be equipped with

visual line tracking.

USDA certification is pending for the MPK robot, a similar-

ly equipped, washdown-compatible, IP67-rated unit from

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Delta robots such as the Adept Quattro s640HS feature a hygienic design

for washdown applications like meat and poultry plants.

A growing number of robots,

including the MPK from Motoman,

withstand washdown conditions and

meet USDA standards for handling

raw meat and poultry.


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Motoman (West Carrollton, Ohio). Available in 4.4- and 8.8-

pound payload models, the five-axis robot achieves speeds

in the neighborhood of 100 picks per minute.

Another washdown-compatible robot, designed to handle

raw meat and poultry, is a delta-style (parallel) unit from

Adept Technology Inc. (Pleasanton, Calif.). A new fixed plat-

form on the high-speed Adept Quattro s650HS allows it to

move heavier loads.

Enhanced software and vision capabilities are simplifying

and automating many robotic functions. Prewritten code

shrinks development time and costs by expediting

installation, startup and changeover. For example, with

Layer Tech software, from KUKA Robotics Corp. (Clinton

Township, Mich.) all the operator needs to do is input a few

parameters to set up a layer forming pattern. A similar pro-

gram for bag handling, BagTech, is expected to be avail-

able at the beginning of 2010.

Fanucs iRVision 2D two-dimensional robot guidance tool

and a color camera make it possible for its six-axis M-1iA

delta robot to pick and place products by color without the

use of special sensors or custom fixtures.

Since performance cant be judged good or bad without

measurements, some machinery builders are adding mon-

itoring and reporting capability to their control systems. For

example, the visual management system on No Film Break

stretch wrappers from Lantech.com (Louisville, Ky.) tracks

system performance and even counts down the number of

loads left on a film roll so operators can make a timely

switch. Based on the lean manufacturing concept, the

system provides real-time performance data, such as

availability vs. output, stops due to machine blockage or

starvation, number of loads wrapped per shift, hour, day,

week or month, number of loads per roll of film for last roll

and last 10 rolls, and status messages and alarms.


A three-axis wrist gives the color-vision-equipped M-1iA delta robot a

wider range of motion than standard delta robots.


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Taking the measurement effort a step further, Lantech is

working to establish standards regarding load containment

or holding force and has begun to offer containment

workshops to help end users determine proper machine

settings, improve repeatability and reduce waste and

downtime due to the constant tweaking that occurs on

many packaging lines.

Support

Support has taken on new importance as packagers have

deferred new equipment purchases and/or reduced in-

house technical staff.

Many packaging machinery manufacturers are publicizing

existing programs or expanding service offerings. The six-

month-old Advantage Program at Dorner Manufacturing

Corp. (Hartland, Wisc.) includes a Get Fit introduction, Stay

Fit ongoing maintenance, replacement parts kits, same-

day shipment of parts and a 24-hour service line for mat-

top and belted conveyors.

We also do maintenance and wear training, reports John

Kuhnz, products marketing manager at Dorner.

A similar array of reactive, interactive and proactive support

services, including PMMI Certified Training and an invento-

ry of critical wear parts, is provided under the ProCustomer

initiative recently established at all 11 divisions of Pro

Mach (Cincinnati, Ohio). Its Web site dedicated to service,

ProCustomer.com, recently went live.

After offering its InSite Services program to end users for

several years, Rockwell Automation (Milwaukee, Wisc.) has

extended the program to original equipment manufactur-

ers, who can sell it as part of their service packages.

Available on a subscription basis, the program monitors

equipment, expedites troubleshooting, signals its time for

preventive maintenance tasks, optimizes performance and

downloads updated information to the controller. It also can

maintain a history of the machine and database of support

information as well as organize data in standard or custom

formats to create reports or reveal trends.

At Filamatic (Baltimore, Md.) new one- and two-year serv-

ice agreements can be configured to include a complete

machinery and procedure assessment along with proactive

machine evaluations and tune-ups and operator training in

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The operator interface on Standard-Knapps Tritium Multipacker features

easy-to-understand illustrations and color-coded alerts and moves the

most frequently used buttons below the touch screen to reduce wear and

tear.


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troubleshooting and preventative maintenance. Plans

include a 10 percent discount on hourly service rates as

well as a 10 percent discount on parts purchased within 60

days of a service agreement visit. A newly formed three-

member service team makes on-site visits.

Other firms are simplifying the maintenance process itself.

For example, Walk-By-Maintenance on the new Tritium

Multipacker from Standard-Knapp (Portland, Conn.) makes

every moving part visible. As a result, mechanics spend

less time on diagnosis and assessment. It also makes it

easier to pre-stage parts in preparation for a maintenance

session. Other maintenance-friendly features on the shrink

wrapper include gull-wing guard doors, a slide-out film bed

and self-diagnostic sensors. A smart Operator Interface

relies on easy-to-understand illustrations and color-coded

alerts to present more performance data. In addition, com-

puter-aided fault recovery shortens Mean Time to Recover

and slashes downtime. An energy-efficient heat tunnel

and material-conserving wrapping technology address

sustainability needs.

Sustainability

Sustainable innovations fit well with brand owners lean

initiatives and fall primarily into five categories: utility

conservation, source reduction, recycled content, recycla-

bility and renewable materials.

Converting from the soap and water typically used to

prevent back pressure on bottling lines to Hartness DCL dry

conveyor lube from Hartness International (Greenville, SC)

saves an average of 250,000 gallons of water each year,

and lowers sewer and effluent treatment costs. Removing

water from the conveyor lubrication process also eliminates

wet, slippery floors; water-related damage to equipment

and packaging; the need for drip pans and associated

plumbing; and the time and expense involved with

cleaning regimens needed to discourage the microbial

growth associated with moist conditions. Classified by

USDA as an H1 lubricant (safe for incidental food contact),

the DCL formula consists of a Teflon-based lubricant in a

food-grade mineral oil carrier (medicinal white oil). An

automated pump/manifold distribution system applies 0.1

cubic centimeter of lube per nozzle to the conveyor every

15 minutes.

Like water conservation, saving energy is not only

sustainable, its cost effective. As a result, human/machine

interfaces on packaging machines are beginning to include

screens that show energy usage. Examples include the

Sustainability Measurement Option from Schneider

Packaging Equipment Co., Inc. (Brewerton, NY), which

dashboards parameters including kilowatts, voltage, cur-

rent and overall equipment effectiveness to help quantify

energy costs and carbon footprint.

Machines like the Bel 290 case sealer from Pro Machs

Wexxar Packaging Inc. division, (Delta, BC, Canada) take an

even more proactive approach. To reduce energy con-

sumption, a power save mode allows the system to hiber-

nate until it detects a case approaching. Schneiders Model

HCP-10 case packer has similar capabilities. If no cases



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are arriving, conveyors stop, and the adhesive tank powers

down.

With motors and drives accounting for 68 percent of the

energy consumed in industrial settings, Bosch Rexroth

Corp., (Hoffman Estates, Ill.) takes a multifaceted approach

to energy conservation. Dubbed 4EE, it consists of energy-

efficient components, energy recovery, energy on demand

and energy-efficient design. On packaging machines, dig-

ital servo-amplifiers on motors eliminate the need for air

conditioning cabinets. A regenerative power supply cuts

electricity use up to 20 percent by capturing energy gen-

erated during braking and supplying it to other devices,

storing it in a buffer for the next cycle or feeding it into the

electricity supply grid.

Theres also more attention to optimizing the size of motors

and drives and replacing pneumatic actuation with electric,

according to Rockwell Automations Leo F. Petrokonis,

business development manager packaging industry.

A number of all-electric alternatives to pneumatic

machines have recently arrived on the market including the

Spec.e printer/applicator from Foxjet (St. Charles, Mo.),

and the Platinum E-Series tamp-on labeler from Diagraph

(St. Charles, Mo.) The latter costs about the same as its

pneumatic Platinum Series counterpart.

The most important benefits are accuracy and repeatabil-

ity, says Steve Dods, Diagraphs labeling products man-

ager, about the all-electric unit. Theres no decline in

cycle efficiency or starving for air [when other pneumatic

equipment is working].

In addition, because a fan in the tamp pad holds the label

in place, there arent alignment issues or changeover

involved when switching from one label size to another. An

all-electric swing-arm model will join the Platinum E-Series

tamp-on and wipe-on labelers by the beginning of 2010.

Adhesive guns also are moving from pneumatic to electric.

With smaller packages moving faster and smaller flaps to

seal, higher precision is required, explains Rick Pallante,

marketing development manager, packaging for the

Adhesive Division of Nordson Corp. (Duluth, Ga.).

Another conservation measure, source reduction, light-

weights, downgauges, replaces or eliminates packaging

materials/components. Eliminating liner waste is the goal

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Wexxars Bel 290 case sealer reduces energy consumption by allowing

the system to hibernate until it detects a case approaching.


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behind a pressure-sensitive label printer/applicator from

Arca Automation (Cherry Hill, NJ). The Bi-Fuel Linerless

Printer/Applicator handles linerless polypropylene or paper

labelstock and offers even greater waste reduction poten-

tial when switched to print linerless paper via a direct

thermal process that requires no thermal-transfer ribbon.

Capable of reproducing scannable barcodes, the system

relies on a Sato S8408 printhead customized for linerless

media and a pneumatic applicator, and its slightly higher

cost (about $25,000) is offset by material savings. A sec-

ond generation machine, scheduled to debut in 2010, will

be able to handle both linerless media and traditional liner-

equipped material.

Converting cut-and-stack labelers from open wheel adhesive

pots to closed extrusion systems from Nordson can cut hot

melt consumption 90 percent by eliminating waste and

reducing char. The closed system also cuts energy con-

sumption in half and minimizes downtime related to cleanup,

particularly of the drum, where adhesive tends to collect.

Addressing adhesive buildup another way is the hot-melt-

repellent Dura Motion finish on the Stay Clean Drum from

B&H Labeling (Ceres, Calif.). Available on all new B&H roll-

fed labelers and retrofitable on some older models, the

Stay Clean Drum lengthens the uptime intervals between

stops for cleaning to at least three hours and sometimes as

many as 12 hours.

With standard drums, its not uncommon to stop the line

for cleaning as often as every 40 minutes, notes Bob

Adamson, vice president, Sales & Marketing, B&H.

Eliminating hot melt entirely, the Roll-Adhesleeve roll-fed

labeler from PE Labelers USA (Cincinnati, Ohio), relies on a

label with pressure-sensitive adhesive on the leading and

P A C K A G I NG T R E N D S 2 0 1 0 1 1

Bosch Rexroth Corporations multi-faceted approach to energy conservation, 4EE, covers energy-efficient components and design, energy recovery and

energy on demand.


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trailing edge. The drum cuts and applies shrink or

non-shrink film labels without stretching, enabling use of

monolayer film, usually polypropylene, as thin as 20

microns (0.0008 inch).

When hot melt is used, metallocene chemistries are

replacing ethylene vinyl acetate. Although the price differ-

ential between the two has shrunk, metallocenes remain

more expensive. That might be changing, says Joseph S.

Hetzer, research chemist at H.B. Fuller Co. (Vadnais

Heights, Minn.), the maker of Advantra hot melts

People are starting to look at the total view and not just

the price per pound, explains Hetzer. That big picture

includes a higher yield plus reduced waste since the met-

allocene hot melts contain no oxygen to cause charring.

More importantly to todays sustainability-conscious end-

users: Metallocene hot melts separate more easily in the

recycling process.

Source reduction and recycling benefits are behind the

development of StreamOne extrusion-coated polyester lid-

stock from Rollprint Packaging Products, Inc. (Addison, Ill.).

Intended for use with polyethylene terephthalate (PET) or

polyethylene terephthalate glycol trays, the peelable poly-

ester lidstock replaces the mixed-polymer laminations or

coextruded films typically specified. This means the entire

pack (tray and lidstock) can be recycled in the #1 (PET)

recycling stream. With a thickness of 1 mil (254 microns),

the polyester film also represents a source reduction of

roughly 50 percent compared to commonly used 2- or 2.5-

mil (508- or 635 micron) laminations or coextrusions. Less

material also translates into a cost savings of more than 15

percent. Eventually, we also want to offer PE and

polypropylene lidstocks so we can match any tray materi-

al, says Dwane Hahn, sales manager New Business

Development, Rollprint.

It should be noted that changing to the coated polyester

lidstock may require adjusting seal temperature. In addi-

tion, medical device suppliers will need to follow standard

IQ/OQ procedures to make the change, and Hahn recom-

mends food processors perform drop and puncture tests to

ensure satisfactory performance.

The polyester is probably less puncture resistant and

more abrasion resistant, he explains.

To overcome the variability inherent in recycled content

corrugated, the WF30 case former from Pro Machs

Wexxar features an enhanced Pin & Dome case opening

12



Applications for StreamOne extrusion-coated polyester lidstock includegamma-sterilized medical devices, consumer goods like razors and frozen

foods.


15/17

technology. An electromechanical (rather than pneumatic)

servo system from Festo Corp. (Hauppauge, NY) detects

the amount of resistance in the box score flap and sends

feedback to the controller to compensate for variations and

maintain consistent case forming speed at up to 30 cases

per minute.

Single-ply paper with 100 percent recycled content is con-

verted into cushioning by machines from Sealed Air (Saddle

Brook, NJ). The three-speed FasFil void-fill system shapes

the paper to impart protective properties. Designed to be

positioned over a conveyor, the machine features a shaft-

less cradle unwind, which not only eliminates the need for

core plugs, but also the core itself. When its time for

replenishment, drop-in paper roll loading eliminates the

need to walk around, crawl under or climb over the con-

veyor. To increase throughput, one motor operates both the

knife and clutch.

The PackTiger Hybrid paper system from Sealed Air shapes

single-ply 17-inch by 20-inch sheets into multi-ply pads

for void-fill. Flipping a switch changes density so pads can

serve as cushioning. Designed for pack stations rather than

conveyor applications, the system features a front-loading

paper tray and can connect as many individual sheets as

needed to create the desired length.

Digital Printing

With the advent of more sophisticated digital presses, the

use of digital printing is growing, especially for labels and

shorter runs. Since each impression is generated by the

digital file, digital printers are particularly well-suited for

printing variable data, including unique codes.

For runs under 20,000 the digital press is cheaper than

conventional printing, states John Pitts, sales manager at

CSAT America LLC (Louisville, Colo.). Savings on runs

above 20,000 depend on ink usage and setup time.

Characteristic of todays state-of-the-art digital presses,

CSATs ITS 600 four-color, drop-on-demand inkjet label

printer operates as a standalone unit or integrates with

labelers or converting equipment as well as vision-based

inspection systems. The model shown at PACK EXPO Las

Vegas 2009 featured a 9-inch web width with a 4-inch

print area. A model with a 15.75-inch print area is expect-

ed to debut in 2010.

The ITS 600 digital press prints any web-based material

(film, foil, paper), including die cut and preprinted stock,

destined for use as labels, shrink sleeves, stick packs or

P A C K A G I N G T R E N D S 2 0 1 0 1 3

Three unwind heights allow Sealed Airs FasFil paper void-fill system to

match any conveyor height.


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flow-wrapped packs. An edge guide and sensor ensure

precise positioning. Specially designed printheads are

housed in an enclosure and retract to the back of the

machine for a drip-free, 10-second purge and wipe

cleaning process. Automating cleaning eliminates operator

contact and extends printhead service life. Custom 1-liter

ink cartridges also help maximize uptime.

Four colors are standard, but six are available. A program

in the controller can estimate ink consumption based on a

study of the print file for the job. The software also pre-

pares the file for printing, virtually eliminating setup.

Ultraviolet-light-emitting diodes cure the ink with less heat

than other curing processes and no ozone emissions, so no

blowers are needed to dissipate heat or fumes.

Safety Enhancements

With internal risk assessment initiatives and new safety

standards, especially in Europe, some equipment builders

are adopting Category 3 safety circuits to provide redun-

dancy and fast reaction time.

One company thats standardized on Category 3 safety

components, Columbia Okura LLC, (Vancouver, Wash.) has

built its FL2000 floor-level palletizer with dual-circuit inter-

locks and a discharge light curtain. A sliding tunnel on the

infeed provides additional protection and easy access.

Our customers have asked for Category 3 safety circuits

as an option for several years, reports Ted Yeigh, sales

director, Columbia Okura. This year, we have standardized

on Category 3 circuits across our product line. The compo-

nents are more expensive but offer a greater level of

security. Yeigh estimates Category 3 implementation

probably adds 6 percent to 8 percent to the cost of a

machine.

Bosch Rexroth builds safety functions into its drives and

controllers to reduce monitoring requirements, save on

certification costs, provide a reaction time of less than 2

microseconds and simplify integration. These capabilities

also help U.S. packaging machinery manufacturers build

machines to European requirements.

Safety is receiving more attention in the United States

and outside the country. It plays a key role in the European

Unions CE requirements, and its also part of todays soci-

ety, with its greater levels of litigation and awareness of

injuries, and a higher-value labor force. Further, improved

safety practices tie in with the lean and sustainable initia-

tives that were so prevalent at PACK EXPO Las Vegas

2009. These trends and the others described in this report

will evolve throughout the coming year, and will be on dis-

play next fall at PACK EXPO International 2010.

14


Columbia Okura has standardized on Category 3 safety features for all its

machines including the FL2000 floor-level palletizer, which builds 10-case

patterns at a rate of 20 cases per minute and 15-case patterns at 25

cases per minute.



17/17

About PMMIPMMI is a trade association with more than 550 member companies that manufacture

packaging, processing and related converting machinery, commercially-available pack-

aging machinery components, containers and materials in the United States and

Canada. PMMIs vision is to be the leading global resource for packaging, and its mis-

sion is to improve and promote members abilities to meet the needs of their customers.

PACK EXPOPMMI organizes the PACK EXPO trade shows: PACK EXPO International, PACK EXPO Las

Vegas and EXPO PACK Mxico, connecting packaging and processing equipment and

materials suppliers with their customers around the world.

Coming in 2010: EXPO PACK Mxico in Mexico City, June 2225, and PACK EXPO

International, Oct. 31Nov. 3, at Chicagos McCormick Place. PACK EXPO Las Vegas

returns to the Las Vegas Convention Center Sept. 2628, 2011.

Packexpo.comPackexpo.com is your connection to the packaging and processing supply chain includ-

ing the exhibitors of PACK EXPO. Around the clock, and around the year. Use the site to

find the suppliers you need, any time, and enjoy the benefits of PACK EXPO all year long.

PMT MagazinePMT Magazine is the industrys only publication dedicated to professionals in packaging

operations, purchasing maintenance and training.

Learn more about PMMI and the PACK EXPO trade shows at PMMI.org and Packexpo.com.

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Packaging Trends 2010

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