Packaging World January/February 2024 by PMMIMediaGroup

Fit-to-size packaging automation – learn more at www.westrock.com/ automation MODEX Booth #B-9435

2024

JAN/FEB packworld.com

Coke Bottler’s Fiber-based Multipacks Extend Trend 62

Chobani’s ‘Living and Breathing’ Packaging 66

Bacardi & Diageo Test Reusable Program 84

MRFs to CPGs: Design Your Packaging for Recyclability 98

114

Machinery & Sustainability Innovations from PACK EXPO Las Vegas

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Data Mastery Unlocks Connected Packaging

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Liberty Coca-Cola Beverages says it will replace 200,000 lb of plastic per year by implementing paperbased mulitpacks. The bottler most recently partnered with WestRock to replace plastic rings with fiber-based can and bottle handles. Last year, Liberty tapped Graphic Packaging for a similar application.

FEATURES 66 Diageo & Bacardi’s Circular Spirits Format Emerges by Land, Sea, & Casino The big spirits brands and their channel partners seek to eliminate tons of single-use packaging waste in bars, casinos, and even cruise ships with the disruptive ecoTOTE and SmartPour reusable packaging format.

76 Automating Snack Bag Line Cuts Labor Costs by 40% Two continuous-motion baggers feed into a single case packing operation that has made it possible for Darlington Snacks to double production while cutting labor costs.

84 Collaboration is Vital to Driving Recycling Success Stakeholders spanning the full recycling value chain gather at the inaugural Packaging Recycling Summit to share solutions for more effective, profitable, and sustainable recycling of packaging materials in the U.S.

98 Is Smart Packaging Hitting its Stride? 98

The stars are aligning on multiple relevant fronts: consumer behavior, legislation, technology, and data management and capacity. This confluence of advancements is slowly but surely unlocking the potential of active and intelligent packaging.

110 AUTOMATION Intelligent Automation Means Productivity, Precision Supply chain delays pushed Balpack to investigate new servo-electric VFDs, PLCs, and HMI components. Integrator HPE suggested Mitsubishi Electric.

114 PACK EXPO Las Vegas 2023 Innovations Report PMMI Media Group editors scoured the exhibits at PACK EXPO Las Vegas 2023 to find the latest in packaging machinery and sustainable materials.

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ACOPOStrak Fast. Flexible. Productive. ACOPOStrak is a revolution in adaptive manufacturing. This highly flexible transport system extends the economy of mass production down to batches of one. Parts and products are transported quickly and flexibly from processing station to processing station on independently controlled shuttles. • Increase overall equipment effectiveness (OEE) • Boost the return on investment in your machines (ROI) • Shorten your time to market (TTM)

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DEPARTMENTS 26

COLUMNS

7 Lead Off 50 The Legal Side 52 The Big Picture 54 Professional Perspective 56 Sustainable Packaging 62 Design Impact 168 The Insider NEWS/EVENTS

8 News 32 Quotables/By the Numbers 164 Industry Watch INTERVIEWS

38 First Person: Jacob Duer, The Alliance to End Plastic Waste 46 First Person: Tanu Grewal, AlEn USA ADVERTISING

166 Advertiser Index

EDITORIAL ADVISORY BOARD Aladin Alkhawam Supply Chain Security Director, Endo International plc Jan Brücklmeier Technical Application Group Packaging Technology Expert, Nestlé M. Shawn French Director – Innovation & Packaging Engineering (Beverage), Danone North America Patrick Keenan R&D Packaging Engineer, General Mills/Annie’s Organic Snacks

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Packaging Recycling Summit Video Library pwgo.to/8221

VIDEO

Bacardi & Diageo’s Reusable Packaging System pwgo.to/8210

VIDEO

Darlington Snacks’ Automated Packaging Line pwgo.to/8212

VIDEO

Refillable Skincare Packaging Design pwgo.to/8177

Mike Marcinkowski Global R&D Officer, GPA Global & Hub Folding Box Co. David Smith, PhD Principal, David S. Smith & Associates Brian Stepowany Packaging R&D, Senior Manager, B&G Foods, Inc.

VIDEO

Jasmine Sutherland President, Texas Food Solutions; Vice President, Perfect Fit Meals

Balpack’s New Controls Platform

YOUR EAST COAST CONNECTION

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Packaging World® (ISSN # 1073-7367) is a registered trademark of PMMI, The Association for Packaging and Processing Technologies. Packaging World® is published monthly by PMMI with its publishing office, PMMI Media Group, located at 401 N. Michigan Avenue, Suite 1700, Chicago, IL 60611; 312.222.1010; Fax: 312.222.1310. Periodicals postage paid at Chicago, IL, and additional mailing offices. Copyright 2024 by PMMI. All rights reserved. Materials in this publication must not be reproduced in any form without written permission of the publisher. Applications for a free subscription may be made online at www.packworld.com/subscribe. Paid subscription rates per year are $254 in the U.S., $363 Canada and Mexico by surface mail; $605 Europe and South America; $907 Far East, Australia, and other countries by air mail. Single copy price in U.S. is $20. To subscribe or manage your subscription to Packaging World, visit Packworld.com/subscribe. Free digital edition available to qualified individuals outside the United States. POSTMASTER; Send address changes to Packaging World®, 401 N. Michigan Avenue, Suite 1700, Chicago, IL 60611. PRINTED IN USA by Quad. The opinions expressed in articles are those of the authors and not necessarily those of PMMI. Comments, questions and letters to the editor are welcome and can be sent to: editors@packworld.com. Mailing List: We make a portion of our mailing list available to reputable firms. If you would prefer that we don’t include your name, please write us at the Chicago, IL address.

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CONTENT Matt Reynolds Chief Editor Anne Marie Mohan Senior Editor Sean Riley Senior News Director Pat Reynolds, Sterling Anthony, Eric F. Greenberg, Ben Miyares Contributing Editors David Bacho Creative Director

ADVERTISING John Schrei Vice President, Sales jschrei@pmmimediagroup.com Lara Krieger Senior Manager, Print Operations lkrieger@pmmimediagroup.com Janet Fabiano Financial Services Manager jfabiano@pmmimediagroup.com

PMMI MEDIA GROUP David Newcorn President Elizabeth Kachoris Vice President, Digital Kelly Greeby Senior Director, Media Operations Jen Krepelka Director, Digital Media Trey Smith Senior Director, Events Sharon Taylor Director, Marketing Joseph Angel Founding Partner and Executive Vice President, Industry Outreach, PMMI Questions about your subscription or wish to renew? Contact circulation@pmmimediagroup.com.

PMMI Media Group 401 N. Michigan Ave., Suite 1700, Chicago, IL 60611 Phone: 312/222-1010 • Fax: 312/222-1310 E-Mail: info@packworld.com • Web: www.packworld.com PMMI The Association for Packaging and Processing Technologies 12930 Worldgate Dr., Suite 200, Herndon VA, 20170 Phone: 571/612-3200 • Fax: 703/243-8556 • Web: www.pmmi.org

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LEAD OFF

Where Did Demand for rPET Go? Consumer-sourced feedstock for rPET is heavily seasonal since cold beverages are more likely to be consumed during hot summers, and PET bottles are well-suited for on-the-go summer travels. Peak rPET supply occurs at the end of summer, depressing its prices. In winter, the script is flipped. Consumers tend to travel less and buy/recycle fewer cold beverages in PET bottles. This natural rhythm sets up an annual supply and demand showdown in Q1 when feedstock streams slow to a trickle, but converter need for rPET begins to ramp back up to satisfy demand for preforms for the looming summer PET boom months. According to Emily Friedman, plastics expert and senior editor at ICIS, a chemicals and energy intelligence provider, February and March are “preform season.” Demand is increasing while supply is at its tightest, so that’s when rPET prices should be highest. “That’s a known, traditional pattern in the rPET space,” Friedman says. “But this year is interesting. We’re coming off very weak demand in 2023—many analysts venture that rPET demand was down as much as 15% in 2023—and we saw depressed prices throughout the whole year, not just at that late summer period.” Why was that? One factor was destocking efforts to counteract COVID-era oversupply. During the pandemic, when supply chains were uncertain and demand for single-use PET was very high, reprocessors, converters, and brands all overpurchased rPET raw materials or preforms. Stakeholders needed to work through that oversupply slack to get back nearer to just in time (JIT) inventory management patterns, temporarily depressing demand. Also, as global economies started to flip from hot to cold last year, consumer spending has gotten tighter and weaker. Friedman says that while the destocking efforts of 2023 have largely subsided, consumer softness remains. “When that bottom-line pressure begins, it becomes a real question if consumer brand companies are willing to stick to those voluntary sustainability goals when PCR material is going to be more expensive than what they can find on the virgin market,” Friedman says. “It became a two-fold issue in recycled plastics where not only is raw demand going down, but [CPG and FMCG] companies might be scaling back or pushing off programs intending to use recycled content.” When asked whether this was a harbinger of a larger potential trend—brands and CPGs seeing profitability and sustainability as at odds, and naturally choosing profitability—Friedman is careful to point out that brands and CPGs are by no means a monolith, and can’t be easily lumped together. “I really hesitate to say that brand companies are generally backing off [sustainability commitments] right now, but I know some of my market contacts have customers who have withdrawn or lowered orders of rPET. We also see some of them going to imported volumes of rPET rather than domestic volumes, and that significantly impacts the local rPET market.” When freight is reliable and inexpensive, importing less expensive foreign rPET can be a way to keep costs down and still hit recycled content goals—though it could be argued that shipping that content from Asia or Latin America is purpose defeating. But recent global freight instability in Panama and Middle East passages have import prices rising, perhaps buoying local rPET. Still, as we pivot into 2024’s edition of preform season, we’d expect to see some of the supply bale tightening, which Friedman confirms we have seen, and some upward price pressure because of that. “But we still are seeing very weak demand downstream, which has filtered into currently stagnated bale prices,” Friedman says. “And it’s very shocking to see, across both east and west coasts since they’re different markets for PET and rPET. But we’re seeing flat to soft market demand in this pricing, a lot lower than what we would typically see at this time. It’s very much counter to trend… rPET markets being unexpectedly weak shows that not all brands are increasing their PCR content, and sustainability is not a harmonious effort across all consumer brands companies. If that were true, we’d see higher prices and maxed out demand.” A silver lining might be that all this softness is evidence of a larger soft landing—ICIS economists have concluded that the recession predicted has been largely avoided, and cheerier economic climes await in Q2 of 2024. But a sobering takeaway might be that circularity in the plastics markets is a luxury for fat and happy brand owners, and when belts must be tightened it becomes more of a nice-to-have than a gotta-have. PW

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NEWS

Paper-Based Carriers Help Coca-Cola Bottler Replace Plastic Multipacks Liberty Coca-Cola Beverages, a local Coca-Cola bottler serving Philadelphia, New Jersey, and New York City, and WestRock, a supplier of sustainable paper and packaging solutions, are collaborating to implement a paperboard carrier that replaces plastic rings for its multipack bottled beverages. The move by the bottler is yet another example in an ongoing trend of large beverage brands and their packaging partners/bottlers making the switch from plastic-based to paper-based multipacks in a variety of applications. Most recently, Coca-Cola bottler HBC in Austria made the switch to paper-based multipacks. PepsiCo announced a similar move in Canada in August 2023. And Liberty itself switched to paperboard for its mini-can lines. Packaging World covered this mini-can paper-based multipack application when it rolled out in 2022. The bottler worked with Graphic Packaging International (GPI) and its Keel-Clip pack format on that project. In this set of Liberty applications, WestRock’s PETCollar Shield Plus paper-based packaging will be used at Liberty’s Philadelphia production facility to package Coca-Cola’s top brands in multipacks. The 12-oz (355mL) and 16.9-oz (500-mL) products packaged with durable, easy-to-hold carriers will be distributed throughout Liberty’s multi-state territory. Liberty will be the first bottler in the world to implement the PETCollar Shield Plus bottle clip solution, the company says. “We’ve made it our mission to invest in technology that produces recyclable beverage containers that can return to our system while significantly reducing the need for secondary plastic packaging,” says Fran McGorry, co-owner of Liberty Coca-Cola Beverages. “We know the most valuable change to reduce plastic waste occurs when bottlers and packaging producers work together. We are proud to partner with WestRock to make this change.”

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Liberty expects to have the new paperboard carrier packaging system installed and operating by summer 2024. Once installed, the packaging system will add to the local bottler’s paperboard packaging for mini-cans, implemented in 2022 as earlier mentioned. Both packaging systems combined are expected to replace 200,000 pounds of plastic a year from Liberty’s footprint. PETCollar Shield Plus is a paperboard multipack carrier and part of WestRock’s PETCollar product family, which includes multipack clip solutions in a variety of sizes, designs and configurations for bundled bottles. “Our partners at Liberty Coca-Cola continue to push the boundaries by promoting secondary packaging alternatives to plastic throughout their operations while meeting the diverse needs of their consumer base,” says Sam Shoemaker, president, consumer packaging, WestRock. “We share their commitment to innovation and look forward to supporting their ambitious sustainability goals.” Committing to implement the PETCollar Shield Plus packaging is the latest move Liberty is making to advance its sustainability efforts. Along with being the first bottler in the U.S. to replace plastic rings for mini-cans, Liberty was among the first Coca-Cola bottlers to produce and distribute bottles made from 100% recycled plastic (excluding cap and label) in the U.S. It has also installed a sustainable compacter that significantly reduces the bottler’s carbon footprint and processes large volumes of full plastic and aluminum containers for recycling. “We are passionate about making investments in the communities we serve,” adds Paul Mulligan, co-owner of Liberty Coca-Cola Beverages. “We truly care about the environment, and we will continue to invest in systems that raise the bar for the entire industry. We want to lead by example and do the right thing.” —Matt Reynolds

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Refillable Skincare Package Driven by Consumer Preferences a reusable and durable acrylonitrile styrene (AS) jar and refill pods made from polypropylene. The real “twist” though is a lock/ unlock mechanism made up of a movable ring around the top of the jar that, when matched with raised guides on the refill, is used to secure the pod in the package. According to Jiang, Junoco tested more than 50 lock/unlock prototypes and materials before selecting the final design, which was subsequently tested 1,000 times for durability. The mechanism involves what Jiang describes as a simple twist-and-release action. “Users can securely lock the pod in place by twisting it into the container, ensuring a tight seal to maintain hygiene,” he explains. “To refill, users smoothly twist the mechanism in the opposite direction, allowing for effortless removal and replacement.” Jiang says Junoco used AS for the jar due to the material’s long-lasting nature as well as for its aesthetic properties, which allowed the team to create a sophisticated look for the product, renamed Jade 10 Cleansing Balm. “The surface texture was carefully crafted to emulate the look and feel of smooth and polished jade, enhancing both the visual and tactile aspects of the product,” he explains. “Additionally, subtle marbling patterns were introduced to evoke the natural variations and transparency found in jade, capturing the essence of jade that aligns with our mission of providing transparency in the products we are creating. The clear elements we created on our refillable jar allow glimpses of the jade-inspired hues, resulting in a captivating and elegant visual experience while creating a harmonious fusion.” In the case of the refill pod, PP was chosen due to its According to Jiang, the impetus for the packaging came in sustainability and functionality. This includes its ability to 2021 with a stream of 200+ emails and Instagram comments be recycled, which aligns with Junoco’s sustainability goals; from customers requesting a refill option for one of the company’s its durability, which makes it suitable for packaging that bestselling products, Clean 10 Cleansing Balm. “Once we requires resistance to wear, tear, and impact; its light weight, established that refills were in high demand, we took into which contributes to a reduction in transportation costs and consideration user convenience and experience, and conducted emissions; and its heat-sealability, which Jiang says is “crucial several questionnaires and polls with consumers on their for maintaining product freshness and preventing experiences using our competitors’ refills,” he says. contamination.” “After we finalized a list of what consumers wanted and Junoco is using the refillable/reusable packaging did not want, we began our design of the interchangeable for its Jade 10 Cleansing Balm, as well as its 0 Mark refill pod system.” Body Butter and Buffing Butter. Each refill comes with Jiang notes that the project required multiple Watch a video a product sticker that can be adhered to the reusable manufacturers working to address what were identified of Junoco’s jar to identify the product within. Says Jiang, it’s the as crucial obstacles to reusable packaging: hygiene, refillable interchangeability of the system that allows for greater durability, and user experience. “Our founding team packaging at sustainability versus other refillable packaging systems worked together with our in-house designers to come pwgo.to/8177 using designated packaging for each product, which up with the concept of this packaging,” he says. “We “only moderately lessens the issue of packaging waste,” explored samples globally, from Europe to Asia, seeking a he notes. cutting-edge design.” Junoco’s new packaging was launched on Nov. 1, 2023, Many of the designs the team explored relied on with much online excitement from consumers both before existing molds and lacked innovation. Recognizing the and after the introduction. The products, along with the preferences of the new generation of consumers, Junoco rest of Junoco’s skincare offerings, are sold D2C on its aimed to create a distinctive system to drive repeat website, www.junoco.com. The cleansing balm in 2.87-oz reusable purchases. “Our goal was not just a single, intriguing refillable packaging is available for $23, with refills priced at $14.99; 3-oz pod, but a groundbreaking approach by creating a system enabling 0 Mark Body Butter in reusable packaging is $18, while refills are interchangeable pods within the same container,” says Jiang. $10.99 apiece; and 3-oz Buffing Butter is available for $16, with The resulting packaging system, manufactured by a refills retailing for $8. —Anne Marie Mohan proprietary packaging supplier in Shanghai, China, consists of Founded by CEO Kyle Jiang in 2018 with a commitment to keep sustainability at the core of every skincare product it creates, the Junoco brand embodies the “skinmalism” trend of “less is more,” identified several years ago in the beauty products industry. Junoco’s products contain minimal, clean ingredients and promote a simple skincare routine. This approach extends to the company’s packaging as well, particularly its recently released refillable/reusable packaging system, which features easy-to-use, interchangeable refill pods that allow the consumer to reuse a single jar for different products.

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Wind Turbine Part Packaging is Anything but a Breeze Mondi Grünburg in Austria partnered with NKE, a manufacturer of bearings for wind, railway, and industrial applications, to create a new packaging solution for wind power components. With the rising demand for renewable energy sources, the wind power sector is growing. The challenging operating conditions of wind turbines necessitate components that deliver exceptional efficiency and reliability. With premium-class rolling bearings sold in over 80 countries, including the booming wind farm market here the U.S., NKE faced mounting complaints due to bearing damage in transit. Each hybrid bearing is worth thousands of dollars and weighs more than 20 kg (44 lb), featuring inner and outer rings made of high-quality steel and ceramic balls. Part damage is costly. Even costlier, it often goes unnoticed until during or after installation, resulting in delays in wind energy production. Recognizing the urgency, Mondi’s in-house team of packaging consultants and product development specialists quickly designed what it says is a cutting-edge packaging solution to ensure optimal protection for NKE’s bearings during transport. The innovative design incorporates one-way shock sensors, providing real-time feedback on the bearing’s condition upon arrival. “This collaboration means not only an improvement in the bearing itself but also in its protection during transport and, most importantly, until its installation in the wind turbine tower. The packaging also incorporates several technological advances. It not only perfectly fulfils our

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stringent requirements for unparalleled protection and efficiency but also demonstrates a steadfast commitment to sustainability,” says Victor Zaera, head of operation & quality at NKE. What sets this application apart is that it was completed in a mere three weeks, as Mondi Grünburg, traditionally known for delivering packaging solutions for the FMCG and food and beverage industries, successfully ventured into the heavy-duty sector. Leveraging its expertise in creating visually appealing, intelligent packaging that stands out on shelves, Mondi Grünburg integrated its printing excellence into the design. The result is an offset-printed box with an additional flexo print on the inside, providing clear usage instructions and simplifying handling as accompanying documents are no longer necessary. The result is a premium package for industrial goods, offering optimal protection to its contents as transport damage of the bearings can now be prevented. The design has already undergone rigorous testing and certification at Mondi’s lab, a performance laboratory certified by The International Safe Transit Association (ISTA) to ensure that the customers’ packaging is suitable for the product and protects it in their specific supply chain. The design’s performance earned it recognition from external experts, receiving an award in the so-called ‘wellpappe konstruktiv’ (corrugated) category during the Forum Wellpappe Awards ceremony in Vienna in October, 2023. This qualified the application for the international WorldStar competition by the World Packaging Organisation. —Matt Reynolds

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Mono-material PP Cheese Pack Launch Coincides with Recycling Center Opening In yet another data point on the trend line toward monomaterial substrates designed to be more easily recyclable, Swedish sustainable dairy co-op Skånemejerier rolled out a mono-material polypropylene (PP) pack for leading Swedish supermarket ICA’s own brand of Hushållsost cheese. The new pack comprises a mono-material base web and lidding film, all of which is produced and printed by supplier Mondi before being converted for 1-kg and 2-kg blocks of cheese by Skånemejerier. The mono-material solution provides high barriers against oxygen and water vapor, keeping the product fresh on the supermarket shelf. It also protects the cheese with high puncture resistance. And great printability allows the brand and recycling messages to be communicated well on-pack, the company says. “Our collaboration with Mondi has been a thorough process. We started our first test and trials in 2019 and are delighted to be bringing this fully recyclable packaging to market before the end of 2023,” says Ingemar Jönsson, packaging manager at Skånemejerier. “The great working relationship we had, meant that we were able to adapt materials and machinery efficiently, resulting in a successful, fit for purpose solution. We have strong, effective and good-looking packaging that keeps materials in the

loop and responds to consumer demands for more sustainable solutions.” This new pack format is being launched in conjunction with the opening of Swedish Plastic Recycling’s Site Zero, which purports to be world’s largest sorting facility for used plastic packaging. This state-the-of-art facility went live in November 2023, and now processes used plastic waste from both Sweden and Finland. Thanks to the new Skånemejerier pack’s monomaterial design, the facility will be able to effectively sort it for recycling, contributing to a circular economy. “We are very positive about the new packaging that Mondi has developed together with Skånemejerier for ICA,” adds Rickard Jansson, Development Engineer at Swedish Plastic Recycling. “By using mono-material film instead of laminate consisting of different types of plastic, we can sort out and recycle the packaging that is left in the system, thus avoiding incineration. With Site Zero’s new technology, this PP film-based packaging will be able to become new products, which has not been possible in any facility in Sweden before. It provides circular plastic flows that reduce the need for fossil raw materials and combustion.” The mono-material cheese packaging on ICA’s shelves won 2023’s PackNorth Award in the food category and was also recognized at the Empack fair in October in Stockholm, Sweden. —Matt Reynolds

Cup Noodles’ Historic Switch to Paper Nissin Foods USA has recently unveiled what—for the company—is a groundbreaking change to its iconic Cup Noodles ramen noodle soup packaging, announcing the replacement of the long-standing polystyrene cup with a new, paper cup set to debut in early 2024. This shift marks a significant departure from tradition, as the brand has utilized the PS cup since its introduction in the U.S. back in 1973. “Since its invention more than 50 years ago, Cup Noodles has become a cultural mainstay and a staple in households around the world,” says Michael Price, president and chief executive officer of Nissin Foods USA. “And while Cup Noodles will continue to have that same satisfying taste and iconic look, we continue to find ways to evolve the brand to support the current needs of our consumers, the environment, and the world. This updated packaging and the new paper cup marks an important milestone for Cup Noodles and a key step in our environmental commitment.” The transition to the new packaging was done in partnership with Graphic Packaging International and involves its proprietary retail double-wall fiber-based cup. Noted GPI President and Chief Executive Officer Michael Doss in the company’s Third Quarter 2023 Earnings Call in October, “Historically, the noodle cups have been made of foam. The fiber-based solution we developed serves as a

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more sustainable packaging alternative and is effective in shelf-stable retail environments. Notably, our retail cup solution for Nissin provides added convenience for the consumer as it is safe for microwave use, eliminating an extra step required meal preparation when using foam.” The new packaging will be rolled out across all flavors of Cup Noodles in the 16-oz size. Additionally, the cup will be made with 40% recycled fiber, no longer require a plastic wrap, and feature a sleeve made with 100% recycled paper. The new packaging is PS-free, removing the use of this plastic from the entire company portfolio. As noted by Doss, for the first time ever, Cup Noodles will be microwavable, no longer requiring boiling water, thus significantly reducing cooking time, which Nissin says will allow consumers an even more convenient way to enjoy and cook their favorite instant ramen. Easily heated in two minutes and 15 seconds, the new packaging delivers a reliable, hassle-free meal option. Says the company, its transition to a paper cup signifies a deep-seated commitment to sustainability, aligning with the company’s Earth Food Challenge 2030. Through this global initiative, Nissin aims to minimize CO2 emissions by 30% by 2030 and reach carbon neutrality by 2050. —Anne Marie Mohan

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Industrial Robots Collaborative Robots Integrated Bagging Lines

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PACK EXPO East Returns The East Coast’s largest and most comprehensive packaging and processing show, PACK EXPO East 2024 (March 18-20, Pennsylvania Convention Center, Philadelphia) is dedicated to the latest solutions and innovations for more than 40 vertical markets. Presented by PMMI, the association for packaging and processing technologies, PACK EXPO East 2024 will help attendees identify new technologies, meet key partners, and see innovation in action. PACK EXPO East will bring together 7,000 industry professionals and more than 400 exhibitors spread out over 100,000 net sq ft of space making it the largest show to date.

“PACK EXPO East brings unparalleled value to manufacturers in this region and beyond. This show provides attendees an up-close view of the latest packaging and processing solutions, an opportunity to make new connections, and personalized help for their biggest manufacturing needs,” says Jim Pittas, president and CEO, PMMI. “PACK EXPO East’s convenient location makes it a mustattend event for packaging and processing professionals in the region seeking to improve and grow their operations.” The show floor will feature hundreds of solutions that address the trends and challenges driving vertical markets including food and beverage, life sciences, pharmaceutical, and medical device, cosmetics and personal care, industrial and household chemical, and many others. Previous PACK EXPO East attendees attest to the comprehensive solutions, educational opportunities, and networking found on the show floor. “PACK EXPO East makes it so much easier to connect in person and see the machinery that you are interested in investing in. There is such a wide range of exhibitors here serving almost all industries I can think of that you are bound to find the solution you are looking for. The educational opportunities available are an amazing bonus to an already irreplaceable show,” says Jesse Gracey, production equipment manager, at Allen Distribution, a third-party logistics company. “PACK EXPO East has a lot to offer. I wanted to find flow wrap and bagging machines for my business but there was so much more that I discovered that I didn’t realize I could potentially use in my facility. This has definitely been an invaluable networking experience,” says Patricia Verderame, owner, Maven Foods, a baked goods brand specializing in biscotti. Businesses of all sizes and backgrounds have found the show useful. “As a new business owner, I needed innovations that can help streamline my production. It was hard to see machinery and connect with professionals online, so I decided to come to PACK EXPO East. Initially, I came to find automated shrink wrap equipment but what I found was so much

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more,” says Karen Armstrong, owner and president at LCI Paper Co, an ecommerce specialty paper company. The show also will feature the Reusable Packaging Pavilion, sponsored by the Reusable Packaging Association (RPA), presenting sustainable packaging solutions to help reduce waste, cut costs, and gain supply chain efficiency. The Association Partner Pavilion will house leading associations dedicated to advancing the packaging and processing industry and offering significant resources, insights, and expertise in one central location. Participating associations include the RPA, Institute of Packaging Professionals, Contract Packaging Association, Flexible Packaging Association, OMAC – Organization for Machine Automation and Control, and the Foundation for Supply Chain Solutions (F4SS) with more being added. Free educational opportunities are abundant at this year’s show, including new and popular show features. New to PACK EXPO East is Industry Speaks (Booth 1653), where experts from the PACK EXPO Partner Program, covering multiple industry verticals, will address hot topics and industry trends. In the center of the action, the Innovation Stage (Booth 1153) offers opportunities for professional enrichment where exhibitors present free, 30-minute seminars throughout the day. Attendees can learn about breakthrough technologies, innovative applications, and proven approaches from the experts themselves. Registered attendees can look forward to many networking opportunities after the show floor closes for the day. The PACK EXPO East “A Taste of Philly” opening reception on Monday, March 18, kicks things off with some of the best small bites and beverages the city has to offer. The Packaging & Processing Women’s Leadership Network (PPWLN) networking reception will take place on Tuesday, March 19. Emerging professionals in packaging and processing can unwind with their peers at the Young Professionals Network’s (YPN) free networking reception. Learn more about the industry and how to get involved with YPN on Monday, March 18, at SPIN Philadelphia. Attendees can plan their visit before the show by using the My Show Planner feature to identify and map out exhibitors to visit, search for educational sessions, and more. The PACK EXPO East show app is available now and can be downloaded from the Apple App or Google Play Store to help navigate the show floor and easily locate exhibitors while at the show. Just a drive or train trip away for most of the East Coast, no other regional event will offer such a wide range of state-of-the-art packaging and processing solutions as PACK EXPO East. For more information and to register, visit packexpoeast.com. —Sean Riley

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Kraft Heinz 360CRISP Delivers Crispy, Microwavable Sandwich Kraft Heinz believes it has cracked the code on delivering a frozen, grilled cheese sandwich that when microwaved, has a golden brown, pan-like crust outside and melty cheese inside, making the days of a burnt exterior and frozen interior history. The technology enabling this is the company’s new proprietary 360CRISP platform, and the product is its Lunchables Grilled Cheesies—the first frozen food offering under the company’s Lunchables kids’ snack brand. According to Alan Kleinerman, vice president of disruption for Kraft Heinz, 360CRISP is an example of the company’s mission to lead the future of food. “The things we are doing today would not have been possible at Kraft Heinz even a couple of years ago,” he says, “and we are constantly exploring how we can bring consumers more convenient options to meet their evolving needs. “As part of our new approach to innovation, we created One Innovation Engine, which reimagines product development and leverages breakthrough technologies to create a portfolio that delivers value for our customers and consumers—not only based on where they are today, but where they will be in the future. We’re building consumer-first innovations that sit at the intersection between food and technology to revolutionize the meal table, and the 360CRISP platform is just the beginning.”

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360CRISP was developed in just under a year—from prototype to innovation platform—through what Kleinerman refers to as an “agile pod” at Kraft Heinz. The microwavable product consists of multiple, differentiated, focused susceptors with strategic venting and varied heat points to ensure proper cooking throughout the food. The sandwich sits inside a tray, with a another susceptor on top of the product. All three are packaged in a film overwrap. Preparation instructions are as follows: 1.) Remove the plastic wrapper, but keep the lid on; 2.) Microwave the box on a paper towel for 60 sec on high (for 1100-watt microwaves); and 3.) Cool down for 60 sec and enjoy. The simple instructions allow kids to easily prepare the sandwich on their own. Says Kleinerman, “As current frozen kid-friendly sandwich options fall short in texture and preparation, we wanted to offer a nostalgic family favorite that many kids ask for after school, on the weekends and beyond—providing a convenient snack option that empowers kids to independently prepare it in the microwave, no pans or stove necessary.” The Lunchables Grilled Cheesies product is available in two varieties, Original and Pepperoni Pizza, both featuring Kraft Singles American cheese. The snack debuted in September 2023 priced at $4.99 for a two-count box. —Anne Marie Mohan

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Chilau Foods Adopts Accessible Lidding Accessibility is a big topic in packaging these days, and underserved or altogether untapped population segments, and their dollar shares, await CPGs and brands that can better accommodate them. That’s at least partially why Chilau Foods, a line of southern-inspired stew bases and spices, adopted the EEASY Lid by Consumer Convenience Technologies (CCT) for all of its products in a move it says will provide consumers with a new level of accessibility. “While our stew bases were created to make cooking simple and delicious, opening our jars should be just as easy,” says Michael Anderson, founder of Chilau Foods. “We’ve always been a company that makes cooking easy for consumers. As we expand, the EEASY Lid allows us to provide our customers with an unbeatable cooking experience, starting with accessible packaging.” IPAC, Inc. of Winter Springs, Fla.—Chilau Foods’ copacker—recently converted its manufacturing line to accommodate the EEASY Lid, which is designed to help brands provide an unprecedented level of accessibility to

their jarred food products. The EEASY Lid allows consumers to vent a vacuum-sealed jar by simply pressing a button on the lid, reducing the amount of torque needed to twist off the lid. Traditional jarred products on a store shelf require more than 40 in-lb of torque to open, with some requiring more than 50 in-lb of torque. With the EEASY Lid, it only takes an average of 9 in-lb of torque to open a jar. Chilau’s products are currently available in nearly 350 stores across the U.S., including Winn-Dixie, Market Street, Albertsons, United Supermarkets, Harveys Supermarkets, and Plum Market. The new lid will be on all of its jars and in all of its market locations by early 2024. —Matt Reynolds

Compostable Biodolomer Cups Debut at the Abu Dhabi Grand Prix We’ve been keeping an eye on how captive audiences at major sporting events and concerts can serve as laboratories for new sustainable packaging systems and materials—generally these tend to be foodservice packaging systems. That’s why it piqued our interest when we heard that a F1 race in November had marked the first time a major global sports event used compostable bioplastic beer cups. That’s according to Gaia Biomaterials, who created the substrate, and Happy Dolphin, a converter of “plasticfree” bags, utensils, and packaging who made the cups. At the Formula 1 Etihad Airways Abu Dhabi Grand Prix, 150,000 beer cups made of emerging compostable substrate biodolomer were used in place of traditional beer cups in order to keep waste, microplastics, and CO2 to a minimum. “It’s a fantastic sign of recognition to have been chosen by such a prestigious event,” says David Hughes of UK-based Happy Dolphin. “The cups are very durable and stable and are suitable for printing. They can be collected along with food waste and put straight in an industrial compost. The result will be soil that is very high in minerals.” Industrially compostable materials are uniquely intriguing for these sorts of closed-system events, usually in ballparks or other venues where collection efforts can be concentrated to a single location, without much spillover into the communities outside the gates. These sorts of locations can be incubators of ideas like industrial compost before the wider, municipality-based infrastructure is in place to make them practical. Industrially

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compostable packaging could contaminate mechanical recycling streams if an uneducated public were to try to recycle them, and wouldn’t degrade in your flower garden the way backyard compostable materials would. Biodolomer, devised by Swedish material tech company Gaia Biomaterials, is a bioplastic primarily made from natural minerals and vegetable oils. It comes in granules and can be used in most plastic production methods. It has the same characteristics as plastic—but is compostable, very durable, and is said not to leave any micro plastic or plastic pollution. Biodolomer is used for everything from grocery bags to cover film for agriculture. It is 100% compostable, CO2 neutral, and does not result in any microplastics, the company says. “This a fantastic opportunity for us to show the world what our material can do, And that it is possible to totally eliminate plastic waste”, says Peter Stenström, CEO of Gaia Biomaterials. The beer cups used in Abu Dhabi were developed by Happy Dolphin to be suitable for major events. They are sturdy, which reduces foaming from beer taps, and can be printed on all sides. Two different fill-level measurement indicators are embossed into the walls of the cups. “They are extremely robust”, Hughes adds. “We’ve stepped on them, hit them with cricket bats, sat on them and they just wrinkle and can be put back in shape—ready for a refill. The only thing that broke them was when we ran them over with a car.” —Matt Reynolds

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Clemson Announces Fall 2023 Packaging Science Award Winners Clemson University announced that Sarah Lynskey was named the Robert Testin Outstanding Packaging Science Senior Award winner, and Leah Severance was the Packaging World Outstanding Packaging Science Senior nominee.

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While at Clemson, Sarah Lynskey has been active in the Packaging Science Club, holding various executive board positions. She is currently in her third semester as Club vice president, using the role to connect with peers and industry professionals. Academically, she engaged in creative projects like packaging life cycle analysis studies, integrating postconsumer recycled content into blown films, planning zero-waste events, and Sarah Lynskey volunteering for the Gameday Recycling Challenge. She also interned for the past three semesters in the Prototyping Lab at The Sonoco Institute of Packaging Design and Graphics on campus. She also was a student co-director for the 2023 Packaging Jamboree and assisted in planning the 2023 Sonoco Fresh Summit reception. In 2022, she completed a co-op as an e-commerce and environmental impact intern at Pregis. She spent summer 2023 at Newell Brands as a packaging engineer intern. Following graduation, she plans to return to the Newell Brands packaging team.

Packaging World Outstanding Packaging Science Senior winner for Fall 2023 Leah Severance graduated from Clemson in December 2023 with a major in Packaging Science and a minor in Sustainability. While on campus, she took advantage of a host of field-related opportunities, from the Sonoco Fresh Summit to PACK EXPO. In Fall 2021, she completed a co-op with Colgate-Palmolive, working in a manufacturing facility. In Spring 2023, she completed a second co-op with Hill’s Pet Nutrition on its R&D team. Severance notably Leah Severance participated in a special topics class studying compostable packaging, and plans to work on sustainable materials in the future. —Matt Reynolds

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D’Arrigo and Superfresh Growers Pick PCR for Produce D’Arrigo California, a grower, packer, and shipper of fresh produce that ships under the Andy Boy label, tapped Emerald Packaging to further develop a post-consumer resin (PCR) bag in low-density polyethylene (LDPE) for its premiere romaine hearts products. The bag will be available in all grocers that carry Andy Boy romaine hearts across North America. “We’ve made substantial investments in solar power and recycling and have implemented packaging solutions that substantially decrease our use of plastic and its environmental impact. The incorporation of post-consumer recycled materials in our packaging exemplifies our unwavering commitment to sustainability,” says John D’Arrigo, president and chief executive officer, D’Arrigo California. The new romaine hearts bag will be made up of 30% PCR plastic, reducing the need for virgin plastic production thus working toward a more circular economy. The use of PCR reduces plastic pollution by diverting waste material from landfill, which could also end up in the oceans. D’Arrigo had used 5% PCR in millions of its three-count romaine heart bags since the beginning of 2023, stepping up PCR content over the last several months. In December, D’Arrigo California transitioned its two- and three-count romaine heart bags to 30% PCR, the current sweet spot for the resin in flexible packaging meant for grocery stores. D’Arrigo has a track record of integrating environmental initiatives into its daily operations, with a focus on making farming, as well as its packaging, more sustainable. Over the last few years, it has cut the amount of plastic used in their romaine packaging by 25% and has also eliminated the zipper, reducing plastic by another 5%. Plastic reduction is one of the company’s sustainability efforts alongside commitments to recycling, solar power, and water conservation. The material used in the new bags was produced by Circulus Holdings, a Houston-based company producing PCR from mechanically recycled LDPE. Emerald has partnered with Circulus’s Modesto, Calif. facility for over a year, working to manufacture packaging using Circulus PCR, which has a U.S. FDA letter of no objection (LONO), making it fit for food packaging. Emerald uses high-speed wide-web flexographic presses from Windmoeller & Hoelscher to print the bags in four colors. They are then converted into premade bags that are packed in the fields where the produce grows. Elsewhere on the PCR produce front, Washington-based fruit producer Superfresh Growers also announced that it has introduced its first apple and pear bags made from an undisclosed percentage of PCR plastic. The recycled polyethylene (PE) is derived from items people recycle daily, such as plastic bottles and other bags through store drop off-based PCR or post-industrial (PIR) sources, like back-of-house shrink film. Superfresh’s new PCR packaging is sourced from U.S. recycling centers via an undisclosed supplier, can be continuously recycled, is SGS Global Services certified, and also has an FDA LONO. The move to a PCR bag helps Superfresh Growers to reduce its footprint and conserve resources. The company says the cost of the bags is comparable to a bag made from 100% virgin plastic. The Superfresh Growers PCR bag can be recycled through current plastic bag and film recycling streams, such as in-store drop-off. As this design is added to its packaging lineup, Superfresh Growers says it’s excited about continued growth in packaging sustainability and carbon footprint reduction. —Matt Reynolds

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NEWS

Kraft Heinz Introduces First Fully Recyclable Ketchup Cap Kraft Heinz Company’s first fully recyclable cap for its squeezable ketchup bottle demonstrates a collaborative achievement, using Berry Global’s design and manufacturing capabilities to support retail brands moving towards more sustainable packaging solutions, the companies say. “We know our consumers care about their impact on the environment and so do we, which is why we’re delighted to see our innovative, more sustainable caps on Heinz Tomato Ketchup bottles across the UK. Although a small change, this makes it easy for the millions of Heinz lovers across the country to recycle their whole squeezy bottle at once—a small action with big potential for impact,” says Jojo de Noronha, president, Kraft Heinz Northern Europe. Historically, Heinz sauce bottles used a flexible silicone valve to deliver a consistent portion of sauce per squeeze, but this was often challenging to recycle. Together with Berry Global, Heinz has now switched to a mono-material cap, manufactured in PP. This means it meets requirements for recyclability. The project has been eight years, 45 prototypes, and more than 185,000 hours in development, to ensure the optimum balance between functionality and sustainability. Berry was involved through the design and production process, from concept to the creation of the series tools in Berry’s in-house tool shop, as well as the development of the assembly equipment for industrial production. Heinz followed a rigorous testing procedure to make sure the cap met the highest quality standards. An extended consumer survey confirmed that the new concept would be well received by the public, as it dispenses the same perfect amount of sauce every time without affecting the squeezability. In fact, the study found that the new cap design helps consumers squeeze more ketchup out of the bottle when it is nearly empty. The company says this is a testament to Berry’s ability to look holistically at the overall solution to improve the cap’s performance alongside its recyclability. Matthias Hammersen, sales director, food market at Berry Global, comments: “Heinz set us the kind of challenge that suits us and our development departments best: to reconstruct the design of the cap to make it fully recyclable, without affecting the performance that millions of consumers know and love. We’re delighted that the finished result exceeds our initial expectations and actually improves the consumer experience.” The concept won Rigid Pack of the Year for Kraft Heinz at the 2023 UK Packaging Awards in October. The caps are being rolled out UK-wide on 400-mL and bigger top-down bottles of Heinz Tomato Ketchup, including 50% Less Sugar and Salt varieties. In the future, the cap will also be rolled out across more of the Heinz sauces range in the UK and Europe. Heinz claims the move to the recyclable cap will save a potential 300 million plastic lids from being sent to landfill every year globally. —Matt Reynolds

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New Paper Carton with Venting Keeps Fried Chicken Crispy Time-strapped consumers have come to depend on the convenience and homemade quality of freshly prepared meal options served up in the deli departments of their local supermarkets. One item continuing to grow in popularity is fried chicken. According to a recent report from AyrKing Corp., “The Fried Chicken Factor: A Meal on the Rise,” fried chicken has begun to stake its claim as a go-to meal, not just in restaurants, but in retail settings. Among consumer preferences for retail-purchased fried chicken are convenience, flavor quality, freshness, minimal processing, and flavor consistency. successful in maintaining the chicken’s crunchy, crispy texture.” In late spring 2023, grocery retailer Kroger and its fried chicken providThe new paperboard gable box with handle is designed with ventilaer, Home Chef, realized their fried chicken product was failing to deliver tion holes in the side panels that allow steam to escape and help mainon these consumer requirements, necessitating some significant product tain the crunchy texture of the chicken. To preserve the box’s structure, an and packaging changes. According to Home Chef, after surveying and aqueous coating is used on the outside of the carton. In addition, a piece testing revealed its Fried Chicken & Tenders sold in Kroger Family Stores of wax paper is placed inside the box before the chicken is added to aid in nationwide were not the crispiest or most flavorful when compared with grease resistance. The box also features a window with an anti-fog coating top-rated retail/QSR chicken, its culinary team embarked on a six-month that lets consumers see the product inside. redevelopment project along with (unnamed) packaging innovators to Aesthetics were also important to the redesign, shares Broadrick. For improve the offering. branding purposes, the previous packaging used a printed paperboard Recipe changes included double breading each piece of chicken sleeve culminating with a handle on the top of the clamshell. “Our teams by hand, using ingredients such as tapioca starch and potato starch to knew the new packaging should not only enhance the Home Chef Fried maximize breading hold and crunch, and incorporating 10 spices in the Chicken product, but also be easily portable for a seamless shopping exbreading to season each bite. To ensure the improvements to the recipe perience,” says Broadrick. “We also considered the color of the packaging. resulted in a crispier, crunchier Fried Chicken texture, however, Kroger Not only does the bright blue stand out against the golden brown chicken, and Home Chef also needed to make changes in the packaging. which can be seen through the transparent window in the box, but cusAs Jason Broadrick, category manager at Kroger, explains, Home Chef’s tomers will recognize the color from the products’ previous packaging, so existing clamshell packaging was made entirely of plastic and had no they can easily find the updated chicken items on shelves.” venting holes, which meant condensation from the warm chicken would Home Chef’s revamped Fried Chicken, including eight-piece meals, a become trapped inside the package, and the chicken would lose its crispy la carte pieces, and tenders, debuted in the new packaging in deli departtexture. Therefore, package ventilation was key. ment warmers nationwide at participating Kroger stores, among them “During R&D, we tested a variety of packaging types, including a packKroger, Dillons, Smith’s, Fry’s, Ralphs, QFC, and others, in November 2023. age that was similar to the previous plastic clamshell with added ventilation,” says Broadrick. “Ultimately, a paper-based package was the most —Anne Marie Mohan ERIEZ_ XtremelyReliable_ThirdPg_PW_11_23.qxp_Layout 1 10/27/23 4:03 PM Page 1

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Sustainability ‘Baked in’ to New Paper Packaging for Frozen Bread paper from UPM Specialty Papers integrated as an inner liner in corrugated boxes manufactured by Adara. According to Salokannel, one of the challenges of the project was finding the correct paper weight for the application. “At the beginning, it was too thin to be used as the inside liner for the corrugated box structure,” she says. “UPM produced a heavier, 110 g/m2 paper that is still quite thin, but corrugated producer Adara was skilled enough to make board out of the material. The process is still challenging though, as the board gets curved easily if the paper liners and fluting are not in balance.” She adds that, although relatively thin, the material does provide the necessary barriers to protect the bread from grease and moisture. While UPM has not disclosed the specific details of the mineral barrier coating used on the paper, Salokannel confirms that no plastics are used in the material. In addition to eliminating plastic from its frozen bread packaging, the transition to the new packaging has also resulted in another benefit for Lantmännen Unibake: a streamlined packaging process. “Now we can skip the part in the packaging line that puts the bags inside the box,” Salokannel explains. Lantmännen Unibake began using the new packaging in October 2023 in the Finnish market, and Salokannel shares that it has been well-received by customers. “They were eagerly waiting for it as it also helps them in achieving their own sustainability targets,” she says. As the project is still in its early stages, the company does not yet have data on the impact of the switch, but nevertheless, the initiative represents a significant step by Lantmännen Unibake toward reducing the use of plastics in its supply chain. —Anne Marie Mohan

In the realm of frozen bakery goods, the challenge of maintaining product freshness while reaching sustainability goals has led companies to explore alternative packaging solutions. Denmarkbased Lantmännen Unibake, one of Europe’s largest bakery groups specializing in fresh and frozen bakery products for retail and foodservice markets, has recently made strides in this area by adopting new paper-based packaging for its pre- and fully-baked loaves of frozen bread, replacing traditional plastic bags. Reflecting on the impetus for the change, Riikka Salokannel, packaging development manager for Lantmännen Unibake Finland, shares that the company is committed to the United Nations Science Based Targets (SBTi) initiative, with its main goal to reach net zero greenhouse gas emissions across the value chain by 2050. Salokannel’s expertise in packaging design and development led her to be a driving force behind the initiative. “I was following the development of packaging papers for bread bags and noticed that there are some new plasticfree materials with barriers available,” she says. “During my long packaging design and development career, I have always tried to find more sustainable packaging solutions—that is my main personal motivation for innovative thinking. I have also worked as a structural designer of corrugated packages, so I know the philosophy of corrugated material, and thus I began to wonder if we could replace the inner liner [of the corrugated case] with this new barrier paper.” The previous packaging method involved wrapping from seven to 13 frozen loaves in a large low-density polyethylene bag comprising 33 g of plastic. The bag was then placed in an outer corrugated case. The new approach uses Asendo barrier

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$8.8M

The amount of a loan Nestlé is providing U.K.-based Impact Recycling for its new flexible packaging recycling site. When open, the facility will be able to recycle 28,000 tons of plastic—more than the amount of flexible plastic packaging Nestlé UK and Ireland place into the market

The number of single-use plastic bottles and caps that could be eliminated with a 10% increase in reusable beverage packaging by 2030, according to a new report from ocean advocacy group Oceana

100%

The percentage of delivery bags, envelopes, and boxes used by Amazon across Europe that are recyclable, including for those items sold by Amazon as well as third-party selling partners

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QUOTABLES

“We’ve spent too much time chasing circular fantasies while huge amounts of plastic continue to flood into our oceans. We’ve estimated that a stack of the single-use plastic packaging used by the beverage sector in 2022 alone could reach all the way to the sun and back. Adding recycled content to bottles and cups won’t topple this single-use plastic tower. The way to really make a difference is to replace single-use plastic with reusable packaging. We need companies and governments to stop betting on the wrong horse with recycling and to prioritize the expansion and re-establishment of reusable packaging systems instead.” –Matt Littlejohn, senior vice president for Strategic Initiatives at Oceana, in a press release from the organization, “Report: Switching to Reusable Packaging Could Eliminate 1 Trillion Single-Use Plastic Bottles and Cups”

“As AI is introduced on the manufacturing floor, it won’t necessarily change what robotics have been doing a million times over for years. Determining precision welding feed rates and plotting robot paths are classically defined problems with very little room for techniques like machine learning to improve upon. Rather, LLM [large language models] and similar methods will make the entire system easier for the operator to use and more adaptable to the needs of the manufacturer.” –Holger Kenn, director of business strategy for AI and Emerging Technologies at Microsoft, in an article from A3 – The Association for Advancing Automation, “How AI is Transforming Industrial Human-machine Interfaces”

“The compost industry has taken a firm stance in California to say yes, we need to get 75% of organics out of landfills. Yes, we need to figure out a way to support the state’s goals of all packaging being reusable, recyclable or compostable. But today, the lack of clarity around this means that something as small as redesigning the common contaminant of a product sticker to be compostable—which we now have BPI-certified produce stickers—would disallow that compost from organic agriculture.” –Rhodes Yepsen, executive director of the Biodegradable Products Institute (BPI), in an article from Waste Dive, “BPI seeks to change USDA’s ‘out-of-date’ definition for compost”

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FIRST PERSON

Alliance Works to End Plastic Waste President and CEO of the Alliance to End Plastic Waste Jacob Duer shares details on the many projects supported by the organization to transform the global plastics ecosystem, as well as perspectives on single-use plastics and the Global Plastics Treaty. Packaging World:

Can you talk a bit about your background and what led you to your leadership position at the Alliance to End Plastic Waste?

Jacob Duer: My career has been dedicated mainly to policy work, specifically around the environment and sustainable development, both of which are directly related to the Alliance’s goal to transform the global plastics ecosystem. For the past 20 years, I was with the United Nations (UN) in a variety of roles, most notably, leading the Chemicals and Health Branch of the UN Environment Programme, the secretariat of the Strategic Approach to International Chemicals Management (SAICM), and the intergovernmental negotiating process that led to the adoption and entry into force of the Minamata Convention on Mercury, which is a globally legally binding instrument to eliminate mercury pollution. The UN aims to address endemic challenges around the world, from child literacy to food scarcity. It also serves as proof that intergovernmental and industry collaboration is the cornerstone of problem-solving. This is why I joined the Alliance. I believe that only by working directly with the plastic value chain and building on the experience, know-how, and perspective of industries, governments, financial institutions, communities, and civil society will we be able to make a real and measurable

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impact in addressing the plastic waste challenge. Together, we can develop ground-breaking solutions that are not just better for the environment, but also socially responsible and economically viable.

How did the Alliance come about? How has it grown since it was established? The Alliance is a global non-profit started in 2019 by engaged business leaders with a mission to help end plastic waste entering the environment. Today, we convene more than 70 companies across the plastic value chain, including producers and users of plastic, as well as converters, packaging companies, recyclers, and waste management companies. To advance our mission, we work with governments, industry, civil society, academia, development institutions, financial institutions, and others to design solutions, recycle, and introduce more circular models such as refill and reuse, and combine those solutions with infrastructure development and investment in technology and innovation. In the Global South, billions of people still bury, dump, or openly burn their waste because they have no or limited access to waste management infrastructure and services. Within Southeast Asia, the Alliance directly diverts plastic waste from the environment and landfills, co-creating integrated waste management solutions with local governments to move communities up the waste management hierarchy. In the Global North, much of our work focuses on pioneering the innovation needed to create more circular plastic economies. This includes investing in intelligent waste sorting, incentivizing new solutions to recycle a broader range of plastics, and scaling reusable packaging systems. Think of the Alliance as a global laboratory that allows everyone to share solutions and lessons openly. In just over three years, we have supported well over 50 projects across the world, reducing over 38,000 tonnes [approximately 42,000-plus tons] of unmanaged plastic waste. This is despite interruptions caused by the 2020 coronavirus pandemic.

In China, the Alliance has supported the installation of 1,400 smart bins from Lovere to address the plastic waste challenge at a municipal level. The bins use cameras to identify recyclable materials to reward consumers with credits tied to the country’s WeChat app.

What is the Alliance’s stance on plastics— in particular on single-use plastic packaging? Measures across the entire lifecycle of plastic are essential and urgent to achieve a circular plastic economy. The reality is that plastic is a material ever-present in modern life and serves a purpose in essential industries such as medical packaging and food safety. It is the increasing prevalence of single-use plastics and their tendency to be littered after a short period of use, combined with the mismanagement of the resulting waste, that

1/24/24 3:36 PM

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pose challenges the Alliance seeks to address. We work on solutions that include improving design for reuse and recyclability, supporting clear labeling on packaging around recycling, and informing consumers on how to recycle properly. The Alliance also supports projects on reuse and refill models, which will result in the reduction of single-use plastics.

FIRST PERSON

To summarize, our objective is to develop, test, and scale solution models that prevent the leakage of plastic waste into the environment and advance a circular economy for plastics. Solution models must be environmentally beneficial, socially responsible, and economically viable. Regarding financials, the majority of our funding comes from membership fees. From inception to the end of 2022, $225 million has been allocated to projects and mission-related activities. More specifics can be found in our latest Progress Report (see pwgo.to/8178).

If I understand correctly, the role of the Alliance is to raise funds, select new innovations and technology to advance recycling and the circular economy, and foster collaboration to get these projects off the ground. Is the Alliance also an active participant in the Where do the ideas for these projects come from? What are some projects? How much of its funding comes from its members? of the criteria you look at when selecting a solution to invest in? Why are these measures important? Yes, these are all parts of our work. The Alliance is catalyzing impact by finding, further developing, and de-risking solution models intended Similar to our diverse membership, we develop and implement to end plastic waste leakage into the environment. However, we can’t projects across the entire plastics value chain through the lens of how solve the plastic waste issue alone. Our work they fit into our solution models. needs to inspire others to also act, to replicate The Alliance looks across the three tiers and scale solutions that work. of waste management hierarchy, which As an independent non-profit organization, are prevention, such as design models to we foster collaboration across said value enhance reuse, refill, or easier recycling; waste chain to develop infrastructure and invest management, including collection, sorting, by providing grants or concessional loans treatment, and conversion; and enablers, which in systems to improve the collection and include policy and business models, capabilitymanagement of plastic waste. building ecosystems, and innovations like A sizable percentage of our projects renewables and data management. deal with waste management, which is an We source projects based on the solution important component to achieving circularity. models they help fulfill, the latter of which To grow recycling, waste management systems were identified from our Plastic Waste that allow for proper disposal, sorting, and Management Framework (see pwgo.to/8179) processing are required. and market needs. From there, we estimate One example is our partnership with envirotheir projected medium-to-long-term impact, tech company Lovere and its smart bins for prioritizing the scale of the problem to be recycling. In China, the Alliance has supported addressed, their ease of implementation The Bersih Indonesia: Eliminasi Sampah the installation of 1,400 smart bins across or replication across various markets, and Plastik supports Indonesia’s efforts to Chengdu and Xi’An to address the plastic waste achieve near-zero leakage by 2040. Once supporting factors such as policy frameworks challenge at a municipal level. The Lovere and capital allocations. fully operational, more than 2.6 million smart bins use cameras to identify recyclable These measures enable us to maximize people are expected to benefit from endmaterials such as plastics, paper, metal, and available resources that will quantifiably to-end waste management services. textiles to reward consumers with credits tied address some of the most pressing aspects of to the country’s ubiquitous WeChat app. To date, over 3,400 tonnes plastic waste management while being mindful of the replicability [approximately 3,700-plus tons] of plastic waste from these bins have and scalability challenge when exported to other settings. been collected and sent to sorting centers, where they are separated into 72 individual streams before being sold to recycling companies. In your 2022 Progress Report, you talk about how gauging To my earlier description of the Alliance as a global laboratory, progress and success upon tonnage of plastics diverted from the beyond just funding or providing technical expertise to projects, the environment and landfill doesn’t tell the whole story. Can you talk Alliance also uses the findings from these projects to develop what a bit more about this and how you developed the metrics by which we call “solution models.” These solution models are developed with you will now gauge the Alliance’s impact? How will these metrics the intent to be replicable across multiple markets, after factoring in better provide a full picture? on-ground variables such as available resources, consumer behavior, Beyond tonnage diverted or where recycling value was captured from, existing waste management infrastructure, and more. social responsibility is also a major component in how we evaluate We already know from experience that there is no “one-size-fitseach project’s success. Our experience tells us that in many emerging all” approach to plastic pollution. Hence these solution models are economies, informal waste pickers play an integral role in addressing intended to inform governments and private-sector players on the municipal waste. It is incredibly important that any infrastructure considerations and permutations to undertake when addressing or programs we put in place to address waste management support, uniquely local challenges. integrate, and fairly compensate waste pickers for their contributions.

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ˈˁʿʸʴˆʻ ʴˈˇ˂ˀʴˇʼ˂ˁ ʸˋʶʸʿʿʸˁʶʸ ʶ˨˧ ˦˧˔˙˙˜ ˚ ˖ ˦˧˦ʔ ˂˨˥ ˠ˔˖˛˜ ˘˥ ˘ ˦˨˥˘˦ ˘˙˙˜˖˜˘ ˧ ˣ˔˖˞˜ ˚ ˜˧˛ ˨˧ ˘ ˧˘ ˦˜˩˘ ˠ˔ ˨˔ ˔˕ ˥ʡ

ʸ˔˦ ˧˥˔ ˦˜˧˜ ʔ ˂˨˥ ˨˦˘˥ʠ˙˥˜˘ ˗ ˦ ˦˧˘ˠ˦ ˘˘˗ ˠ˜ ˜ˠ˔ ˧˥˔˜ ˜ ˚ ˙ ˥ ˛˔˦˦ ˘ʠ˙˥˘˘ ˔˨˧ ˠ˔˧˜ ʡ

ʻ˔˦˦ ˘ʠ˙˥˘˘ ˣ˘˥˔˧˜ ˦ʔ ˂˨˥ ˖˔˦˘ ˣ˔˖˞˘˥˦ ˔˥˘ ˗˘˦˜˚ ˘˗ ˙ ˥ ˠ˜ ˜ˠ˔

ʵ˂˂ˇʻ ʴʠʤ ʧʤ

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ˠ˔˜ ˧˘ ˔ ˖˘ ˠ˔ ˜ˠ˜ ˜ ˚ ˣ˥ ˗˨˖˧˜˩˜˧ ʡ

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As a direct result of our efforts, over 4,200 jobs were created or received improved working conditions, the latter specific to informal waste pickers. Their communities have also benefited, with more than 4.3 million people now gaining access to new or improved waste management. On to a more technical perspective, developing and demonstrating solutions requires the nurturing of individual projects, while considering how to create the enabling conditions for the future replication or scaling with or by others. In addition, there is a significant time lag between initiating projects and the generation of positive impact on the environment and affected communities, typically in the range of two to three years, but it can be up to five years. However, that depends on the type of project and the local circumstances. Meaningful measurement of the Alliance’s impact progress, therefore, requires balancing among three types of metrics. These are indirect metrics, which measure current activities that will lead to an increased impact in perspective; forward-looking metrics, which project future impact; and outcome metrics, which measure the actual impact achieved today.

The Digital Watermarks Initiative HolyGrail 2.0 is a pilot project with the objective to prove the technical viability of digital watermarks for accurate sorting of packaging waste as well as the economic viability of the business case at large scale. Building on this experience, we have defined seven topics to transparently measure and demonstrate our impact. The first is developing replicable solution models accompanied by a blueprint that can be successfully applied by others in the plastic ecosystem. This metric ensures solutions are technically feasible and replicable, economically sustainable, and socially and environmentally acceptable. The second is enabling the entire plastics ecosystem to bring about rapid and large-scale replication of effective solutions. This requires aligning and empowering public and private-sector stakeholders to drive a collective understanding of the policies, systems, and infrastructure needed to meet the scale of the challenge. The third involves mobilizing financial capital from private and public institutions towards major investment in infrastructure and systems transformation that reduce environmental plastic pollution and advance plastic circularity. The fourth is reducing cumulative unmanaged waste through additional collection, proper disposal, and reduction schemes in highleakage geographies. The fifth is capturing value from waste through the reporting of the total volume of plastic waste processed into useful raw materials and the aggregated nominal annual input capacity of facilities that have been added, or are under construction, for the valorization of the plastic waste supply and its suitability for processing. Sixth is creating social benefit through increasing household access to basic or improved waste collection and recycling systems,

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FIRST PERSON

as well as the creation or significant improvement of jobs in terms of wages, benefits, and working conditions for the informal waste sector. And last is mitigating climate impact through the adoption of circular solutions that enable a significant reduction of greenhouse gas emissions. Such solutions should not only consider recovery and recycling, but also upstream activities to reduce, reuse, or substitute fossil-based plastics or virgin plastic feedstock.

What are a couple of examples of projects that the Alliance has funded that you believe will have wide-reaching and scalable impact? Globally, the End Plastic Waste Innovation Platform has been a very successful accelerator program for startups to-date. The collaboration was launched with California-based technology accelerator Plug and Play in 2020. The platform fosters startups from across the plastic value chain to transform plastic waste management around the world. Through this program, over 160 startups dedicated to ending plastic waste across the entire value chain have been accelerated across the eight hubs in Johannesburg, Paris, Riyadh, Sao Paolo, Shanghai, Silicon Valley, Tokyo, and Singapore. More than $185 million in capital has been invested and deployed into these startups, with a resulting 220 commercial pilots in progress. On a more local level, the Bersih Indonesia: Eliminasi Sampah Plastik supports Indonesia’s efforts to achieve nearzero leakage by 2040. Once fully operational, more than 2.6 million people are expected to benefit from end-to-end waste management services. The system will create an estimated 3,000 local jobs and aim to collect more than 300,000 tonnes [approximately 330,000 tons] of municipal solid waste annually, including up to 50,000 tonnes [approximately 55,000 tons] of plastic waste, targeting an annual recycling rate of over 60%. A key element of the program is the establishment of a public utility, locally known as a Badan Layanan Umum Daerah (BLUD), operating under the regency’s Environment Department, a first in Indonesia’s waste management sector. Enabled by the Alliance’s funding, the BLUD will assume full responsibility for the operations and maintenance of the waste management system and is critical to ensuring the long-term financial sustainability of the initiative. Editor’s Note: Among the other projects funded by the Alliance include Europe’s HolyGrail 2.0 program, a pilot project with the objective to prove the technical viability of digital watermarks for accurate sorting of packaging waste (see pwgo.to/8180), and a new facility from flexible film recycler Myplas in Rogers, Minn., that promises circular film-to-film recycling (see pwgo.to/8181). What are your thoughts on the Global Plastics Treaty? International coordination between governments, environmental organizations, industry leaders, and civil society is indisputably necessary to tackle the magnitude of the plastic waste challenge. While other environmental challenges, such as climate change, biodiversity degradation, and ozone depletion are addressed through international frameworks, the global plastic waste challenge has no equivalent yet. A well-structured global agreement on plastic pollution would help to harmonize metrics and reporting requirements for plastic waste and could reduce the complexity for governments and

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FIRST PERSON

We recognize that beyond waste management and recycling, there is so much more that needs to be done. This is evident when you examine our project portfolio of solution models, which run the gamut from building recycling infrastructure and piloting a reusable food-delivery packaging system to driving behavioral-change program at a local-community level. There is also a social responsibility component to policymaking, namely, ensuring a just transition that is as fair and inclusive as possible to informal waste pickers. One example of this is our work with the Johannesburg-based African Reclaimers Organization (ARO). Millions in the Global South rely on waste management for their livelihood, such as those who scour waste heaps to collect and sell PET bottles. ARO is a non-profit that unites 6,000 waste pickers under a single umbrella to represent and advocate for their needs. These informal workers are a critical component to keeping the streets clean, but they work long hours under difficult and often dangerous conditions, earning very little. Through our collaboration with ARO, waste pickers now have a new safe and hygienic sorting center, where plastic waste is compacted on-site with mobile balers, making them easier and more economical to transport. Previously, waste was brought to a makeshift base of operations under a highway overpass. The project helps to divert hundreds of The Johannesburg-based African tonnes of plastic waste from entering the Reclaimers Organization (ARO) is a nonenvironment or landfills and provides more profit that unites 6,000 waste pickers than 4,000 people access to improved waste under a single umbrella to represent and management services. advocate for their needs.

businesses of addressing plastic waste by creating a more harmonized policy framework. It could also help to mobilize capital via new, strong financial mechanisms to tackle the challenge and thereby accelerate innovation and the development and deployment of solutions that enhance resource efficiency. Importantly, we believe any agreement should grant countries the flexibility to develop National Action Plans and measures to eliminate plastic waste leakage and promote a circular economy for plastics. Ideally, this legal instrument should adopt an inclusive approach that takes into consideration national and local needs and capacities as well as promotes cooperation among local communities, the informal sector, municipalities, civil society, the scientific community, and the private sector. This would allow nations to develop responses that are most appropriate to their national and local context while incentivizing and prioritizing the collection, sorting, and recycling of plastic waste.

What is involved with being an accredited business and industry representative to the United Nations Environment Programme (UNEP) and the United Nations Framework Convention on Climate Change (UNFCCC)? As we talked about earlier, creating solutions to this complex challenge requires systemwide collaboration and collective action by governments, businesses, civil society, financial institutions, and academia at the global, national, and local levels. At these multilateral forums, the Alliance participates as an observer to understand national and local needs and requirements and share our specific experience, expertise, and scientific knowledge about waste management and recycling solutions. Upon request, we also support governments and other stakeholders in articulating the on-the-ground realities of existing policy decisions.

What do you see as some of the largest challenges facing the globe in terms of plastic pollution/leakage and moving toward a circular economy? Today, 3 billion people still lack access to proper waste management services. Much of the waste generated ends up buried, openly burned, or dumped. Solving just the waste management component of this challenge will cost an estimated $1.2 trillion. And it’s hardly a panacea for such a multifaceted issue that impacts almost every single person and industry on the planet. From an economic perspective, expenditure in adequate waste management has traditionally not been high on the priority list for developing nations with more pressing concerns. However, we see that starting to change. Many governments have until now simply lacked the capital to invest in existing waste management models. At the same time, the economics of waste management and recycling have been perceived as challenging.

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How do you respond to recent criticisms that the Alliance has not made enough progress towards its goals? The challenge to end plastic waste leakage in the environment is huge, but not insurmountable. Since our inception, we have been working to create solutions that will make a positive impact and a meaningful difference for communities around the world in the long term. Earlier, I mentioned that over 38,000 tonnes [approximately 42,000 tons] of plastic waste have been reduced by our efforts, but on top of this, there have been an additional 39,000 tonnes [approximately 43,000 tons] of plastic waste from which we have captured value, primarily through recycling. Upon the completion of the projects in our existing portfolio, we estimate that more than 156,000 tonnes [approximately 172,000 tons] of new recycling capacity per year will be made available. The Alliance has done a lot, yet we also recognize there remains much to do. At the same time, I want to highlight that the Alliance is not the whole solution. Not one business, government, or organization can tackle the challenges alone, it will require all stakeholders to come together. It is the sum of the efforts of all the actors in the ecosystem that will help solve the problem of plastic leakage into the environment. —Anne Marie Mohan

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FIRST PERSON

The Case for Smaller Packs of Concentrated Product in the Era of Shrinkflation Tanu Grewal, Chief Cleaning Officer AlEn USA, manufacturer of emerging cleaning brands Pinalen, Cloralen, and Ensueno Laundry, approached Packaging World with an interesting perspective on a simple packaging decision that can offset economic pressure for brands. It might seem counterintuitive with consumer fears of so-called “shrinkflation,” but concentrated product in smaller packs can present more value instead of less while checking a lot of boxes for both consumers and brands. PW asked her to explain. Packaging World:

What’s the current landscape for CPGs like yours, as you see it?

Tanu Grewal: The past several years have presented a challenging economic environment for manufacturers. The pandemic economy, coupled with 2020’s rampant supply chain disruptions, rocked the industry—leaving lingering fears that have persisted through today. In fact, recent data shows that a weakened domestic economy now ranks among CPG manufacturers’ top concerns according to NAM (National Association of Manufacturers) data, and a shrinking number of manufacturers are feeling optimistic about their business’s future as a result. At the same time, consumers are demanding more from manufacturers than ever before. When it comes to Environmental, Social, and Governance (ESG) measures, consumers are becoming increasingly aware of not only what’s in their products, but what’s behind them—from logistics and Scope 3 emissions to resource use. These ESG values, while incredibly important, are building the pressure on CPGs to innovate quickly, amid what is already a tumultuous environment.

more cost-efficient with a lighter product. Over the long run, these changes can make a huge difference for manufacturers, especially in today’s harsh economic climate. These benefits mean that manufacturers who switch to compacted products can often pass down savings to their consumers, too. That’s a win-win for customers looking for a more sustainable product that also gives them great value.

Tell us more about the environmental impacts of this pack design choice. It’s no secret that packaging can be a huge contributor to environmental impact. In fact, 40% of all plastic produced in the U.S., according to National Geographic, is packaging that’s used just once and then discarded. When making a compact product, instead of adding water during the manufacturing process, the key active ingredients are concentrated, and consumers add their own water at home. That means consumers are getting the same amount of product and potency that they expect, while also eliminating the need for large plastic bottles or cartons.

So what can CPGs like yours do to navigate this landscape? Doubling down on smaller packaging with compact, concentrated products is an interesting way to thread the needle. Concentrated products contain the same active ingredients as traditional ones, just with less water added. This means the same amount of cleaning power can fit in much smaller packaging. What are some of the benefits of compact packaging, and why should manufacturers of CPG products should consider them? Ultimately, you’re passing on savings to the consumer. Compaction also presents an opportunity for CPGs to cut costs. Consider, first, the decreased resource usage needed. Compact products require less water, as well as less plastic packaging. Shipping and logistics are also

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• • • •

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What about lightweighting for the supply chain, there must be benefits there, too, no? Beyond pollution, compact packaging can make for a more sustainable logistics process, too. With a lighter product, logistics is often more efficient and produces less emissions, helping brands move closer to their carbon zero or carbon neutral goals. How are consumers reacting to Pinelan’s efforts in concentration and smaller packs? This approach can be effective at grabbing consumers’ attention. A study by McKinsey found that 43% of consumers say environmental impact is an extremely or very important packaging characteristic when making purchasing decisions. By tapping into those thought processes, your brand can become top of mind for consumers seeking sustainable options that are also incredibly impactful. What about a CPG’s direct customer: the retailer. How are they impacted by this pack design choice and what’s their reaction? With 78% (according to McKinsey) of U.S. consumers saying that a sustainable lifestyle is important to them, more grocery and convenience stores are looking for sustainable products they can offer consumers. By offering a more sustainable packaging option, plus reducing Scope 3 emissions, manufacturers can ensure their product stands out among an incredibly competitive retail environment. When retailers support compacted products by offering them

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in-store and giving them preferred shelf space, it’s mutually beneficial. In doing so, retailers help brands advance their sustainability goals, while also showcasing to their own shoppers that sustainability is a priority. Retailers are always looking for ways to optimize room on their shelves, too. Prioritizing a smaller, compacted product is always something to highlight when pitching retailers who are looking to save some of that valuable space.

What are some challenges to this approach? Are consumers or retailer wary of charges of “Shrinkflation?” Ensuring that consumers understand why you are moving to a compacted product is paramount. Without the right education, when consumers see a smaller bottle, they may assume they’re paying more for less. Being intentional about the packaging redesigns you choose, as well as marketing and communications around the changes is essential to making this strategy effective and driving more consumer engagement. While today’s economic environment may feel unprecedented, it’s surely not the last hurdle that CPGs will face in the COVID-era economy. By switching to concentrated products, manufacturers can reap long-lasting benefits, including increased customer loyalty and a competitive edge in retail, all while moving closer to their sustainability goals. With the right positioning—and some help from retailers eager to feature these products—brands can see more revenue, more success, and, most importantly, happier consumers. —Matt Reynolds

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THE LEGAL SIDE

By Eric F. Greenberg, Attorney-at-law

The Long Reach of FDA Accusations responsible for a product and take action against that company For those of you who think that regulators only, or first, that doesn’t mean they can’t also go after all the other only pick on the small companies, have companies that had anything to do with that violative product being I got a story for you. And this story is also eye-opening if you have on the market. wondered who the government is most likely to go after when a That’s because of the expansiveness of the law’s list of “prohibited problem arises, in a world of complicated chains of commerce acts” in section 331 of the Federal Food, Drug and Cosmetic Act, involving multiple actors making and moving and bringing packaged helpfully titled “Prohibited Acts.” The darn thing is kind of a monster: products to market. Section 331 has 59 subsections, each one listing a thing that you can The short version of the story is that the Food and Drug get into trouble for doing. Many of the subsections are rather specific, Administration took action against Amazon for products sold on its describing violations like failing to make legally required reports, or website. Yes, that Amazon, the one with the big website where you violations relating to medical devices, or tobacco, or other narrow can buy essentially everything for handy delivery. And this wasn’t the product categories. But the first few subsections of the Prohibited Acts first time FDA has warned Amazon about products available on its section read like Congress was trying to describe broad concepts that popular website. encompass everyone in the chain of commerce, and I think they do. In November of 2023, FDA wrote to Amazon, warning the huge Those early subsections say that doing these things is prohibited: seller of things that seven companies’ products that Amazon helped The introduction or delivery for sell were unlawful “new drugs.” FDA introduction into interstate commerce alleged that Amazon had violated the FDA considers a number of of any food, drug, device, tobacco law by “introducing or delivering these factors in deciding who to product, or cosmetic that is adulterated products for introduction into interstate take action against, including or misbranded; or the adulteration or commerce” via Amazon’s fulfillment service. FDA also sent similar letters to at the seriousness of the alleged misbranding of any such product; or the receipt in interstate commerce of any least five of the seven companies whose violation, and how it appears to such product, or the delivery or proffered products were involved. delivery of any such product for pay That “introducing or delivering … for have been caused. or otherwise. Or, on top of all that, the introduction” business is derived from the causing of any of the above actions. That’s a lot of verbs. Federal Food, Drug and Cosmetic Act, the key law FDA enforces. One implication of this “causing” violation is that even if you I suspect that the common understanding about how FDA works contract with another company to make or package or label your goes like this. When it believes a product is unlawful in some way, it product, you still have responsibility to ensure that what that other typically targets the company whose brand is named on the label. But company does is compliant with FDA requirements, lest you end up that isn’t necessarily so. Probably that’s the most common scenario, being accused of causing whatever violation that company commits. but FDA considers a number of factors in deciding who to take action Another important point about all this is that no company can against, including the seriousness of the alleged violation, and how it absolve another of liability for FDA violations. For example, in a appears to have been caused. contract between a contract packager or manufacturer and its client, This FDA letter to Amazon is an excellent reminder of the allit’s common that there are provisions that talk about indemnification encompassing nature of the Federal Food, Drug and Cosmetic Act. I and guarantees where one company covers the other’s costs should often remind clients of the fact that essentially any role with respect something go wrong. Those are important and useful as far as they to an allegedly violative FDA-regulated product is covered by the Act, go, but they cannot and do not provide that one company will be the and that as a result you can find a “prohibited act” listed in the law only one liable for FDA violations if they arise. that describes pretty much any and every function. It’s an important As I regularly explain to clients (and advise that they include in fact to keep in mind for those we might not think of as first in line written contracts), each company making or packing or repacking for FDA scrutiny, including service providers like Amazon, and also or holding or shipping or receiving an FDA-regulated product has contract packagers and manufacturers, and those who transport its own independent obligation to be in compliance with the FDA’s and store FDA-regulated products such as foods, drugs, devices, and requirements. The FDA warnings to Amazon are a useful reminder of cosmetics. that fact. PW Just because FDA might usually try to figure out who is most Eric Greenberg can be reached at greenberg@efg-law.com. Or visit his firm’s website at www.ericfgreenbergpc.com. INFORMATIONAL ONLY, NOT LEGAL ADVICE.

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THE BIG PICTURE

By Sterling Anthony, CPP, Contributing Editor

Vapor Transmission Rates in Barrier Flexible Packaging Water vapor transmission rate (WVTR), also known as moisture vapor transmission rate (MVTR), measures the permeation of water vapor through a membrane—for this discussion, that membrane is a flexible packaging material. Permeation can occur inward or outward, meaning that the interior of a package can gain moisture or lose moisture. Either scenario can be harmful, depending on the product category, as exempified by foods, beverages, pharmaceuticals, medical devices, personal care items, and cosmetics. Rather than detail the harmful effects, suffice it to say that dry products need to stay dry and wet products need to stay wet. Directly affected are expiration dating and shelf life to be sure, but ramifications extend throughout the supply chain, particularly for inventory management. In the vast majority of flexible packaging applications, moisture barrier is provided by a polyolefin, either polyethylene or polypropylene. Their moisture barriers range from fair to good, however they are achieved cost effectively. High-density polyethylene (HDPE) is better than low-density polyethylene (LDPE) and oriented polypropylene (OPP) is better than polypropylene (PP), with OPP and HDPE being close in performance. But PP beats LDPE by a wider margin. An understanding of how the polyolefins compare helps in understanding WVTR. First, such an understanding establishes performance expectations, even before any testing and calculations. It also shortcuts the list of candidates when excellent moisture barrier is not needed, as provided by aluminum foil, metallized film, and PVDC. Similarly, it facilitates decision making when a package is a monolayer, coextrusion, or lamination in which the polyolefin’s role is to provide moisture barrier as opposed to being a tie layer. In a competitive environment that emphasizes speed-to-market, all possibilities for streamlining should be used. The international standard for reporting the results of WVTR testing is grams per square meter per 24 hours: g/m2/day. In the U.S., typically, it’s grams per hundred square inches per 24 hours: g/100 in2/day. In both standards, the lower the rate, the higher the barrier. And each standard has its expected range. For example, the expected range for the international standard is 0.001 to 2400 g/m2/day. A rate expressed in one standard can be converted to a rate in the other standard. There is an inherent element of imprecision (however slight it might be) in the conversion. During permeation, moisture collects on one side of the material, goes through it, and emerges on the other side. That’s a simplistic but accurate description, albeit one that belies the complexities of the theory of permeation. The process proceeds at a rate affected by temperature and relative humidity (RH) such that, for test results to be

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comparable, those two variables have to have been controlled. One of many possible standardized pairs of test conditions is 100°F (37.8°C) and 90% RH. The importance of test conditions does not reside solely in their standardization, rather the conditions should be relevant to the conditions that a given product is expected to encounter within its supply chain. Permeation is affected by additional factors. One is thickness—a thicker material provides more barrier than is provided by its thinner self. Logical and intuitive, yes. Still, it doesn’t eliminate certain tradeoffs, such as between competing materials that provide acceptable barrier, but at different thicknesses and at different costs. Another factor is molecular makeup. It’s understandable to feel beset by talk of crystallinity, density, chain length, chain branching, orientation, etc., but take heart. They all affect the paths water molecules travel through and out of the material. The more tortuous the path, the slower the permeation and the lower the WVTR. Conversely, the more straight the path, the faster the permeation and the higher the WVTR. As for the conducting of WVTR testing, standardized protocols are published by various organizations, such as TAPPI, ISO, and ASTM. Since they share the same objective, discussing ASTM will serve for the others in this column. ASTM F1249-20 is applicable to barrier flexible packaging, whether film or sheet and whether monolayer or multilayer. The barrier flexible packaging test sample is sealed between a wet chamber and a dry chamber. Moisture passes through the material, driven by the pressure differential created between the two sides. A modulated sensor measures the passage, from which a WVTR value is calculated. It sounds so scientific and matter-of-fact, but that perception is in disguise of certain realities. The ASTM F1249-20 abstract acknowledges as much, to wit: “Values for water vapor permeance and water vapor permeability must be used with caution.” That’s sage advice, cautioning that matters are not necessarily absolute. It’s consistent with the bedrock idea that packaging requires a systems approach, consisting of components and their tradeoffs. In illustration, the calibration of the equipment plays a role. So too, does the attention and care exercised by the test conductor. Those realities are to be kept in mind, especially since most packaging users don’t conduct their own WVTR testing. Instead, they rely on packaging suppliers (converters) and laboratories that specialize in such testing. The requirement, “all other things being equal,” rarely (if ever) applies to WVTR, accounting for why the testing is complex, timeconsuming, and challenging to interpret. None of that, however, subtracts from its importance. PW

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PROFESSIONAL PERSPECTIVE

By Chris O’Clair

Secret Synergies Between Packaging and Entertainment I’m often asked why I chose to study packaging and what exactly it is that we do as packaging professionals. Like many folks fresh out of high school, I went to college without a clear direction. I figured I wanted to do something engineering-related—maybe architecture, mechanical design, industrial design, or even something more abstract like computer science. When I discovered packaging as a potential career choice, I saw a confluence of many specialized disciplines and a unique opportunity to touch them all rather than pigeonhole my career into one thing. Packaging is a melting pot where design, engineering, manufacturing, marketing, research and development, and logistics— just to name a few—converge to create a holistic product experience. From my first internship in a manufacturing facility to my second internship in an R&D center, I was able to experience two opposite ends of packaging. My first internship dealt with the practical and tangible— what currently is but shouldn’t be? My second internship dealt with the theoretical and conceptual—what currently isn’t but could be? Over the years my direct reporting line has been drawn and redrawn through restructurings, role changes, and job changes. Regardless of whether the solid line went to procurement, engineering, R&D, marketing, or logistics, dotted lines have always connected them all.

Keep an open mind Beyond my professional endeavors, my decade-long experience as a trivia host has equipped me with valuable communication and interpersonal skills. These capabilities, although seemingly unrelated, have seamlessly intertwined with my work in the packaging industry, enhancing my ability to engage with diverse audiences and adapt to evolving circumstances. My career journey has highlighted the transformative power of keeping an open mind. Leveraging the “what currently is but shouldn’t be?” experience from my first internship, one of my earliest projects involved a disruptive package redesign that spanned multiple brands and product lines. By embracing the diverse reach of packaging, I was able to anticipate and mitigate the range of impacts posed by the project. This led to higher efficiency, less waste, lower cost, more cohesive branding, more consistency in the warehouse, and improved overall package performance. My experience hosting trivia helped me to tailor the presentation of project information to a diverse audience, anticipate negative reactions and prepare solutions, and sprinkle in light humor to keep folks engaged while softening the blow of any bad news. A mistake we often make as engineers, especially on projects we initiate and lead ourselves, is to assume we have it all figured out when

presenting to key stakeholders. By keeping an open mind, I was able to quash my ego and listen to all feedback, positive and negative, enabling me to make required changes swiftly. As a result, crossfunctional approval was achieved with minimal resistance. On the other side of the spectrum, a different project utilized my second internship’s “what currently isn’t but could be?” experience. A customer presented us with a lucrative opportunity, but only if we were able to deliver an entirely new—and at the time undefined— packaging format within four months. This included ideation, prototyping, design, tooling, and testing of the new package, in addition to the purchase and installation of an entirely new packaging line. It posed a daunting, seemingly impossible task, but a combination of pure grit, open-mindedness, creativity, and dumb luck allowed our packaging team to pull it off and exceed the customer’s expectations.

Insight provided Again, my experience as a trivia host contributed to this success. Picking up on some common writing tropes from trivia questions showed me the power of making something out of nothing, while having access to everyone’s answers—both correct and incorrect— provided me with insight into how different people can interpret the same thing in many different ways. The silver bullet in this project was using naturally occurring patterns and textures rather than any bespoke design. The final design was largely inspired by a random piece of rock. Without open-mindedness—not just from myself but from all parties—a design based on a rock surely would have been shot down. Reflecting on my journey, I’ve realized that the dynamism of the packaging industry, and embracing opportunities beyond its conventional confines, has been the cornerstone of my professional evolution. Packaging isn’t confined to rigid tasks; it encourages interdisciplinary collaboration and continuous exploration. By keeping an open mind and actively seeking opportunities beyond conventional boundaries, one can uncover an array of rewarding career pathways. In my case, spending a night or two each week asking trivia questions in a bar helped me develop communication and interpersonal skills that immediately contributed to project success and professional growth. In essence, the key to unlocking the full potential of a career in packaging lies in embracing its multifaceted nature. It’s about fostering a spirit of curiosity and a willingness to embrace the unknown, recognizing that each experience, no matter how seemingly distinct, contributes to a vibrant spectrum of professional advancement. This mindset opens doors to an enriching and fulfilling journey, transcending conventional limits and leading to a world of endless possibilities. PW

The author, Chris O’Clair, is an IoPP member and Packaging Engineering Manager at Sun-Maid Growers of California. For information on IoPP membership, educational offerings and networking opportunities, visit www.iopp.org.

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SUSTAINABLE PACKAGING

Packaging Policy Update and 2024 Outlook In this annual Q&A, AMERIPEN Executive Director Dan Felton and the association’s principle lobbyist, Andy Hackman of Serlin Haley, provide updates on current state and federal policy along with insights on what to expect in the coming year.

Packaging World:

The trend of more states enacting full packaging producer responsibility, also referred to as extended producer responsibility [EPR], laws did not continue during 2023, although two states, Illinois and Maryland, did enact groundwork laws. Can you tell us more about that and what we might expect to see on additional EPR legislation in 2024?

Dan Felton: In 2023, we saw nearly 40 bills in play across at least 18 states dealing with packaging producer responsibility in one way or another. AMERIPEN was deeply engaged in advocacy efforts and negotiations in many of those states on behalf of the packaging industry, but in the end, only two bills, in Illinois and Maryland, made it across the finish line. Both new laws require a needs assessment to be conducted to help inform any full packaging producer responsibility programs that might advance in the future and establish an advisory council to help advise on the needs assessment and Dan Felton potentially other matters in the future. Both states began naming members for their advisory councils in December. Maryland’s law also requires the selection of a single producer responsibility organization [PRO] to advise on the needs assessment. In October, the Maryland Department of the Environment [MDE] announced that it had selected Circular Action Alliance [CAA] as the PRO, which is the same organization that the Colorado Department of Public Health and Environment [CDPHE] selected in May to be Colorado’s only PRO.

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Andy Hackman: We fully expect the heavy volume of proposed packaging producer responsibility legislation to continue in 2024, but it’s difficult at this point to say with any certainty how many bills will have significant traction and if we’ll see any new EPR laws enacted in 2024, given that it’s an election year. We’re currently actively engaged in several states, including Hawaii, Minnesota, New Andy Hackman Jersey, New York, and Washington State and are already deeply involved in the discussions and negotiations in these states to help shape the best possible outcomes for packaging producers and the recycling system. Michigan and New Hampshire are a couple of other states we’ll be watching closely.

A significant amount of activity took place in 2023 to advance implementation and rulemaking for the four existing packaging producer responsibility laws in California, Colorado, Maine, and Oregon. Can you tell us more about that and what you’re expecting in 2024?

Felton: CalRecycle, one of California’s environmental agencies, completed an extensive series of stakeholder workshops in 2023 to help inform preliminary draft regulations that were released in late December, 2023. Keep in mind that California has some unique producer performance goals and requirements, including 25% source reduction. CalRecycle is expected to name a single PRO as soon as this month, and while they may require producers of covered packaging materials to register with the PRO as soon as this year, those producers will not have

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to be compliant with requirements in California until January 2027. Editor’s Note: At press time, PW learned that California/CalReycle has joined Colorado and Maryland in selecting CAA to be its PRO. Visit pwgo.to/8217 to read more. Colorado’s Producer Responsibility Advisory Board has been meeting regularly for the past year to help inform implementation of the EPR program, and CDPHE has hired consultants that are in the process of completing a required statewide needs assessment to help shape producer requirements. In early December, CDPHE released four informal draft rule concepts for which it will host informational webinars and take public comments in January and February, and then initiate formal rulemaking around May of this year. This is an excellent opportunity for Packaging World readers to directly engage in helping shape what will become the final rules. Starting in July 2025, producers in Colorado will have to join and participate in CAA or submit their own individual program plan to the state.

Hackman: Maine’s Department of Environmental Protection [DEP] has significant decision-making authority under the law. It will select and award a 10-year direct contract to one PRO, and it will approve the needs assessment, annual reports, and investment budgets submitted by the PRO. This level of engagement by a state agency is unique in contrast to the other states, which let industry drive more. Conceptual draft rules for the EPR program were released in September and October following a nearly 18-month stakeholder engagement process, and the state initiated the formal rulemaking process in late December. It is anticipated that the final rules will be adopted sometime in 2024, but producer compliance won’t begin until the fall of 2026. Oregon’s Department of Environmental Quality [DEQ] has the authority to approve one or more PROs, which will be responsible for setting and collecting membership fees and certifying that covered products are indeed recycled. Rulemaking for implementing Oregon’s law is steadily progressing, with the first major rule approved this past November and development of a second now underway and anticipated to be approved later in 2024. Producers must start paying fees and reporting to a PRO by July 2025.

SUSTAINABLE PACKAGING

full effect this month. However, enabling regulations from the New Jersey DEP are still not in place to help brand owners and packaging manufacturers fully understand how to be compliant with the law.

Felton: Following the enactment of California’s landmark labeling for recyclability law in late 2021, which prohibits the use of the chasing arrows or any other indicator of recyclability on products and packaging unless certain criteria are met, we continued to see other states introduce similar language in 2023, but none gained any significant traction. We expect more states to consider labeling legislation in 2024, including for compostability. There was an increased focus on “toxics” in packaging in 2023, with ongoing interest from policymakers in certain chemicals, like PFAS [per- and polyfluoroalkyl], either in or used to manufacture packaging and other products. This trend is expected to continue in 2024 and could expand well beyond PFAS to other chemicals and additives. There was also an increased focus on advanced recycling, also known as chemical recycling, in 2023 that will likely continue during 2024—if not standalone legislation, then at least within the context of packaging producer responsibility and recycled-content discussions. Finally, there is now a consistent policy discussion about the potential for additional deposit return systems (DRS), or bottle bills, in the U.S. as some material sectors see that as a viable path forward to increasing the use of PCR. This may result in more traction for bottle bill proposals at the state level and the potential for more pressure at the federal level for a national bottle bill.

What other packaging policy received consideration in the states in 2023 and may continue in 2024?

Hackman: We continued to see some states consider post-consumer recycled[PCR] content requirement legislation in 2023, but only Connecticut enacted a new law mandating rates and dates for the use of PCR in plastic beverage containers. Washington state considered legislation to expand its 2021 recycled-content mandate law to additional forms and types of plastic containers, but that bill failed to advance. AMERIPEN expects to see Washington state introduce some form of that language again in 2024. In addition, several other states will also likely consider recycled-content mandates as standalone legislation or wrapped into packaging producer responsibility proposals. In the meantime, we’re keeping a close eye on New Jersey, where a new recycled-content mandate law covering rigid plastic containers, glass containers, paper and plastic carryout bags, and plastic trash bags went into

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Is there anything happening at the federal level?

Hackman: We saw a lot of legislation introduced for potential consideration in Congress in 2023, but most of it did not gain any significant traction. This included the Break Free from Plastic Pollution [BFPP] Act [S.3127/ H.R.6053], which was reintroduced and includes packaging producer responsibility language, the Rewarding Efforts to Decrease Unrecycled Contaminants in Ecosystems [REDUCE] Act [S.2844/H.R.5564], which proposes a virgin plastic resin tax, and the No Toxics in Food Packaging Act [H.R.6105], which would declare five classes of substances—orthophthalates, all PFAS, all bisphenols, including A, B, S, F, or AF and

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related compounds, styrene, and antimony trioxide—as unsafe for food contact. Two other bills that AMERIPEN has actively supported were reintroduced in 2023. These were the Recycling Infrastructure and Accessibility Act [S.1189/H.R.6159], which would establish recycling access pilot grant programs for rural and underserved communities, and the Recycling and Composting Accountability Act [S.1194/H.R.4040], which would support/fund data and reporting for accurate recycling and composting rates. While all these bills will be eligible for further consideration in Congress in 2024, it’s unclear how much traction any of them might gain given the partisan split in Congress as well as more pressing legislative priorities during a major election year. However, discussions on packaging and recycling continue to grow in Congress, and in the long-term, there is potential for some legislation to pass if the politics align.

Felton: While we didn’t see significant traction on federal legislation in 2023, we did see quite a bit of federal administration and regulation activity in 2023. This included the U.S. Environmental Protection Agency [EPA] rolling out some elements of its National Recycling Strategy, including a Draft National Strategy to Prevent Plastic Pollution. In November, the EPA released proposed updates to its voluntary Safer Choice Standard program for cleaning products and disinfectants, which would significantly expand requirements for packaging, and in December, the EPA joined the U.S. Department of Agriculture [USDA] and the U.S. Food and Drug Administration [FDA] to release a Draft National Strategy for Reducing Food Loss and Waste and Recycling Organics. All these proposals will receive further consideration in 2024, and AMERIPEN will continue to be engaged in all of them through comments and industry discussions. Additionally, just over a year ago, the U.S. Federal Trade Commission [FTC] began the formal 10-year review of its Guides for the Use of Environmental Marketing Claims, also known as the Green Guides. It’s currently unclear if the FTC will modify the Guides after soliciting and receiving comments in 2023 from AMERIPEN and tens of thousands of other interested stakeholders, but we will be paying close attention, as we believe that some of the content in the Guides is ripe for consideration of federal uniformity in light of the California labeling law mentioned above, which is slated to go into full effect in 2025. With other states actively considering similar legislation, AMERIPEN believes that the FTC, EPA, and Congress are good forums for coordinated efforts to establish national definitions and labeling language so we can avoid multiple, state-specific labeling standards, which we believe will result in increased consumer confusion and additional packaging material going to landfill. In closing, AMERIPEN believes 2024 will be another very active year for packaging policy. We encourage PW readers to get involved with their trade associations, state chapters and chambers, and/or AMERIPEN to ensure their voices are heard. —Anne Marie Mohan

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DESIGN IMPACT

Chobani Pursues ‘Living and Breathing’ Package Designs By Anne Marie Mohan, Senior Editor For food and wellness-focused company Chobani, best-known for its Greek yogurt made from natural ingredients, package design is anything but an afterthought; it begins within a few months of the development of a new product line, with the design team working hand-in-hand with everyone from sales to marketing to ensure the design elements and creative pieces come together in a seamless way. That’s according to Chobani Creative Director Lauren Hodges, who recently spoke with Packaging World about the company’s packaging design process, particularly as it relates to packaging for a new line, Chobani Creations, and a limited-edition Halloween design. According to Hodges, Chobani applies the same logic to everything it does, whether for the first time or the hundredth time: The goal is to “surprise and delight the consumer by crafting a design system that has a little bit of magic,” she says. “It’s not easy, but it’s simple, strategic, and delicious. “Our packaging and product platforms are living and breathing designs. We need to make sure they stand out at the shelf through creative, eye-catching design and that the packaging meets consumer needs.” The design process for a new package begins with a brief from Chobani’s New Product Development Team, led by Chief Innovation Officer Neil Sandfort. The brief outlines the flavor, particulars about the new item, and all the specific ways the creative team can help bring it to life. To ensure that the look, feel, and functionality of a new package are all spot-on is a time-intensive process, says Hodges, often taking up to a full year, when testing, design, development and release are taken into account. For Chobani’s most recent product

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line, Chobani Creations, launched in December, the timeline was even longer, as it was the first time the brand used clear plastic for the yogurt cup. Chobani Creations was inspired by classic desserts and is made with whole milk Greek yogurt and fruit on the bottom, offering consumers a decadent, yet wholesome, dessert alternative. “We have noticed the rising trend of permissible indulgence amongst consumers,” said Sandfort at the time of the launch. “We recognize people don’t want to eliminate their indulgences but want to enjoy them guilt-free with better-for-you ingredients. That is why we launched Chobani Creations in six nostalgic fan-favorite flavors like sweet orange cream pop or a warm apple pie crafted with only natural and thoughtful ingredients.” The design strategy for the new line was driven by insights from Chobani’s in-house data team and R&D and hinged on that promise of permissible indulgence. The design itself was led by the in-house creative team, along with outside contributions from Commercial Type for the typeface and illustrations drawn by Meryl Rowen. Graphics for the Chobani Creations cup include the same illustration style as found on Chobani’s classic Greek yogurt packaging, but emphasize the line’s nostalgic flavor profiles. “We paired those designs with full-flooded, colored lids and an enchanted swash serif logotype to evoke the feeling of a magical bake shop,” says Hodges. “The allure is compounded by the new packaging itself. Seen through the clear cup, the product creates a backdrop of naturally beautiful waves of food on the bottom that blend into varying elevations of flavored creamy Greek yogurt throughout.”

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DESIGN IMPACT

Chobani Creations represents the first new line introduced by the brand since the launch of Chobani Zero Sugar in 2021, but it’s not the first new packaging the creative team has designed since then. Among its more recent projects, the team developed interactive Halloween

packaging for multipacks of Chobani Flip. The Halloween overwraps were “the first of many seasonal packaging takeovers Chobani is planning for its various Greek yogurt platforms,” the company noted at the time of the launch. Packaging for both Chobani Creations and the Halloween multipacks exemplify Chobani’s willingness to bring in outside resources when needed. Explains Hodges, “We have a really special, robust team that is continuing to evolve to meet the needs of today’s consumers, but we also look outside ourselves to external partners who add their specific touch to our projects on a case by case basis. A recent example was when we brought in Tool of North America for their specialized AR [augmented reality] expertise ahead of our Halloween Flip campaign.” Sitting at the intersection of design, technology, and marketing, the multipack sleeves for the Halloween takeover used illustrations that included witches, ghosts, and skeletons, among others, and included a QR code that allowed consumers to “step into the world of Halloween-themed Chobani Flip” through an AR experience. It also enabled them to unlock a “treat,” such as a phone screensaver, coloring pages, keychains, and more. Through its in-house design team and outside partners, Chobani continuously strives to bring to market the best of its brand, Hodges shares. “Since packaging is a high-priority touchpoint with the consumer, the creative team takes immense pride and applied precision to each item and innovation we are tasked with.” PW

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Diageo & Bacardi’s Circular Spirits Format Emerges by Land, Sea, & Casino The big spirits brands and their channel partners seek to eliminate tons of single-use packaging waste in bars, casinos, and even cruise ships with the disruptive ecoTOTE and SmartPour reusable packaging format.

By Matt Reynolds, Chief Editor capital of the world, this emerging packaging format just might have legs—and not just sea legs. The ecoSPIRITS format can most simply be described as a watercooler-style or keg-style model, only the 5-gal PET water bottle or aluminum beer keg is replaced in this format by a glass bottle of around 4.5 L, depending on the model. A bar or restaurant that serves a sufficient quantity of a certain spirit—say Smirnoff as a house vodka or Bacardi Superior as a house rum—can simply swap out these large glass bottles into a dispensing device behind the bar, akin to a watercooler or beer tap. This saves a lot of single-use glass bottles to begin with—at a clip of about 4x since a typical spirits bottle is 1 L. But since those 1-L bottles are single-use and ecoSPIRITS glass bottles are reusable, the material savings is really amortized over at least 100 cycles in the bottle system’s lifetime. But large glass bottles are heavy, their cylindrical shape makes them prone to rolling (especially on a lurching cruise ship), and glass shatters, so they’re precarious to transport. The ecoSPIRITS model solves for this by enclosing these 4.5-L glass bottles in what it calls its ecoTOTE, a squat, protective secondary package that’s equally reusable to the tune of 100 cycles. The whole ecoTOTE system consists primarily of glass, HDPE, and aluminum. Brand information is displayed on a brand plate, which is inserted into the system and is displayed through a cut-out Containerized, semi-automated packaging and refill window on two sides of the ecoTOTE. facilities dubbed ecoPLANTs can be placed at local bottling The ecoSPIRITS model consists of several facilities to reduce the distance the heavy 4.5-L bottles must travel. different formats, sizes, and dispensing tech-

In what project stakeholders call a global first, Bacardi and Carnival Cruise Lines introduced a reusable, closed-loop packaging system called ecoSPIRITS to ships in the ocean cruise line industry. Meanwhile, British spirits brand owner Diageo, the maker of Johnnie Walker whisky, Don Julio tequila, and Guinness beer among other popular brands, announced its own global agreement with the circular economy technology company. And most recently, yet another partnership between ecoSPIRITS, a Las Vegas hotel, and a local craft distillery has landed the format on terra firma in the U.S. Having earned the interest of two spirits giants while gaining a toehold in the entertainment and revelry

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nologies, and they’re evolving and getting more sophisticated as the system matures. But more generally, they all use large, multi-liter refillable glass bottles that are filled with spirits, then affixed in a decorated, protective cube case, and finally used in a bar setting in a branded dispensing mechanism. The glass bottles carried by these cubes are filled, cleaned, and refilled over many cycles. A bar or restaurant works its way through its supply of this spirit in the 4.5-L bottle while refill bottles are safely stored in their respective ecoTOTEs behind the bar or on a pallet in the backroom. Bottles are removed from the ecoTOTE for use, then returned to snap into place in the waiting ecoTOTE container when they’re empty. This patent-pending closed loop system was first developed ecoSPIRITS in 2018. The company says it’s the world’s first low carbon, low waste distribution technology for premium spirits and wine. Onboard Carnival Cruise Lines, bartenders can simply swap these large glass bottles of Refilling can be done at local bottling facili- Bacardi Superior into and out of a SmartPour automated dispensing device behind the ties that contain a proprietary filling technology, bar, akin to a watercooler or beer keg with tap. a containerized semi-automated packaging facility be sent to the bar (or ship or casino), and returned to the same location dubbed the ecoPLANT, to reduce the distance the heavy bottles must containing the ecoPLANT. travel. A year ago in December 2022, the first two ecoSPIRITS ecoPLANT “The ecoTOTE remains in the same form and assembly when it derefilling stations came online at Mango Bottling in Cocoa, Fla., and at parts from our co-packing partner Mango Bottling and when arrives on the spirits brand Chareu in Southern California. A third is coming online the boat and in the venue. Once in the venue, the ecoTOTE is paired in Las Vegas now—more on that later. In the Bacardi at Sea application, with the SmartPour 1.1S/2.0S [dispensing device, like a keg tap or wathe ecoTOTEs are shipped to Carnival Cruise Line docks in pallet format tercooler base] and is used until depletion. When the ecoTOTE is empty from nearby Mango Bottling. In all cases, the ecoTOTEs are designed a full ecoTOTE replaces it, and this full one is again paired with the to nest together to facilitate stacking, and 125 ecoTOTEs fit on a pallet SmartPour technology. The SmartPour 2.0S connects with the ecoTOTE with a 5 x 5 x 5 configuration. All filling, both new and refill, is done via the ecoTOTE Connector and this ensures a secure connection,” says at a nearby ecoPLANT location—Mango Bottling in the Carnival and Bob Syihabuddin, head of circular operations, ecoSPIRITS, of the BaBacardi collaboration. All sanitizing and refilling of ecoTOTEs is done at cardi and Carnival application. This Bacardi at Sea format, with some these ecoPLANT locations, then ecoTOTEs are sent to the distributor to application-specific tweaks, applies generally to the Diageo and Las Vegas initiatives as well.

Why Bacardi got onboard with Carnival for a pilot

These ecoTOTEs are designed to nest together to facilitate stacking, and 125 ecoTOTEs fit on a pallet with a 5 x 5 x 5 configuration.

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Collaborators say the Bacardi at Sea application is an effort to significantly reduce single-use glass waste in the tourism and hospitality segment. “This partnership involves three companies: Bacardi Limited, Carnival Cruise Line, and ecoSPIRITS. The aim of the collaboration is to showcase a scalable circular packaging solution for spirits for the cruise industry, dramatically reducing the packaging waste and carbon footprint per spirits serve and saving weight and space onboard,” Paul Gabie, CEO, ecoSPIRITS told PW at the outset of the pilot in August 2023. “The trial will test the operational integration of the new technology. At the end of the pilot, the three companies will explore rolling the technology out across additional spirits and ships within Carnival’s fleet.” Carnival’s house-pour rum, Bacardi Superior, is one of the most-ordered spirits across Carnival’s fleet. Until this pilot, consumer demand for cruise ship favorites like daiquiris, mojitos, or other tropical rum drinks would typically be satisfied by bartenders with pours out of single-use glass 1-L bottles of Bacardi—the same single-use bottles found

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U.S. Distribution Partnership Announced

The ecoTOTE 3.0SC Cruise Edition is similar to the ecoTOTE 3.0S Ocean Blue ecoTOTE (above), but with added features for the maritime environment such as fasteners that replace existing rivets for secure storage at sea, and black aluminum anodizing for enhanced resistance to salt water-based corrosion. on retail shelves. Under this program, however, pours from those classic bottles are being replaced by pours from reusable 4.5-L glass bottles nested in the durable drink dispensing system. The glass packaging material savings is manifest. Specifically for this Bacardi and Carnival collaboration, ecoSPIRITS developed a specialized version of its 4.5-L ecoTOTE, what it calls its ecoTOTE 3.0SC Cruise Edition. This is similar to the ecoTOTE 3.0S Ocean Blue ecoTOTE, but with some added features to suit the maritime environment, such as fasteners to replace existing rivets for secure storage at sea, and black aluminum anodizing for enhanced resistance to salt water-based corrosion. “As we strive to become the most environmentally responsible global spirits company, we are continuously looking for opportunities to deliver our beautiful drinks in more sustainable packaging and formats, helping us build to a greener future,” says Rodolfo Nervi, VP, global safety, quality & sustainability for Bacardi. “Innovating in closed loop packaging has been a top priority for us for a number of years, so launching our very first ecoTOTE for Bacardi rum on a Carnival cruise ship and seeing the doors this trial will open is an incredibly exciting step forwards in that journey.” For several months beginning in August 2023, Bacardi was delivered in ecoTOTE format to three of Carnival’s ships operating out of Miami:

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At press time, ecoSPIRITS USA announced that Breakthru Beverage Group, one of the largest North American beverage alcohol distributors, joined the ecoSPIRITS Climate Partner Program as an Official Distributor Partner. Breakthru distributes a diverse portfolio of brands across many territories in both the U.S. and Canada and it already has spirits brands ready to be deployed in ecoTOTE format in Florida, followed by California in the coming months. The partnership will also accelerate ecoSPIRITS USA’s expansion in the state, bringing new brand partners, venues, and distribution resources to the circular economy. The U.S. is known for its three-tier system—comprising of producers, distributors, and retailers—for distributing alcoholic beverages, which was set up after the repeal of Prohibition. The three-tier system mandates that producers can sell their products only to wholesale distributors who then sell to retailers (and bars and restaurants), and only the latter group can sell to consumers. Distributors therefore play an essential role in the market, and while they have no involvement in manufacturing, they act as the representatives of the brand and supplier in determining their route to market. There are around 4,000 beverage alcohol distributors in the U.S., with the 10 largest controlling more than 72% of the market between them. The largest multi-state distributors—such as Breakthru— differ from each other in their combination of size, service, and portfolio. “Breakthru is very excited to work with ecoSPIRITS as a pioneering distributor partner and reduce our single-use packaging in the Florida market. While it is up to all of us to protect our planet, we as distributors have a special responsibility to work with our supplier and customer partners to undertake such eco-friendly efforts across the industry. We are proud to work with Coconut Cartel and Barr Hill Gin on this climate-friendly venture,” says Will Fulghom, region president, East U.S., Breakthru Beverage Group. PW

Celebration, Horizon, and Sunrise. Each of these vessels has a capacity of up to 6,338 passengers and 1,450 crew members. The largest is Carnival Horizon, which has 16 dining areas and several bars, including the RedFrog Pub and its sister venue, the RedFrog Rum Bar, where Bacardi rums feature prominently. “As we continue to work towards our sustainability goals, the collaborative work of our beverage team, ecoSPIRITS, and Bacardi is a great example of thinking in ways that are truly out-of-the-box—or in this case out-of-the-bottle—to develop new partnerships and practices that further our ongoing efforts,” says Zachary Sulkes, senior director of beverage operations at Carnival Cruise Line.

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The pilot will determine if reusable containers developed by ecoSPIRITS can be used to serve Bacardi rum on other Carnival ships. Stakeholders claim that by switching to ecoTOTE format, the Carnival ships will eliminate 95% of the single-use packaging waste associated with their house-pour rum, dramatically reducing the carbon footprint per spirits serve and saving weight and space onboard. Within this pilot phase, approximately 9,400 bottles will be replaced by the ecoSPIRITS packaging system. The rum is transferred from the ecoTOTE to serving format using ecoSPIRITS’ SmartPour dispensing technology. New silver and red Bacardibranded SmartPours were placed in select bars on the three ships for beverage team members to serve cocktails featuring Bacardi Superior rum. Notably, Carnival currently recycles single-use glass items. Each ship in the fleet is outfitted with a recycling center, where crew members sort paper, plastic, and glass recyclables. Last year, Carnival processed more than 11 million pounds of recyclables.

Diageo rollout Unlike the localized closed loop pilot at sea, the agreement between Diageo and ecoSPIRITS is longer term and broader, providing a flexible framework that allows the brand owner to pilot and scale packaging in an expected 18 markets over the next three years. The collaboration will initially be across Diageo’s Gordon’s gin, Captain Morgan rum, and Smirnoff vodka. The global agreement follows the success of Diageo’s ongoing ecoSPIRITS program in Indonesia with Smirnoff, which started

in 2022 and is now active in 38 bars. “This is another example of a triple win where the planet, consumers and Diageo will all benefit. We will be able to reduce both carbon and cost and the pubs and bars will benefit from the ease of having reusable spirits packaging,” says Ewan Andrew, president, Global Supply Chain & Procurement, and Chief Sustainability Office at Diageo. The ecoSPIRITS technology will enable Diageo spirits to be distributed in a 4.5-L ecoTOTE, similar to the Bacardi application.

Visit pwgo.to/8210 or scan this QR code to watch a video of the circular ecoSPIRITs system in action. The collaboration is expected to deliver sustainability benefits to Diageo with reductions in carbon emissions and waste with the exact figures to be confirmed on conclusion of the three-year period. Beyond the elimination of up to 1,000 glass bottles over their lifespan of 100plus cycles, there is also an anticipated carbon footprint benefit after the only sixth use, compared to that volume of liquid in 70-cL glass bottles. The first markets in the global agreement are expected to go live in 2024. This is a step towards Diageo’s goal of reducing carbon emissions across the supply chain by 50% by 2030 and reaching net zero by 2050. “ecoSPIRITS’ mission is to end single-use glass in the spirits and wine industry. For the circular economy to achieve global scale, innovators like ecoSPIRITS need the support of industry leaders like Diageo in catalyzing the linear-to-circular packaging transition,” Gabie concludes. “As such, this new global partnership is a significant milestone for ecoSPIRITS and our journey to a circular future. We are grateful to our partners at Diageo for the seriousness of their commitment to a more sustainable and inclusive world.” Diageo first started working with ecoSPIRITS through the Diageo Sustainable Solutions program in 2021. The program aims to find technology innovators that can bridge the innovation gap across Diageo’s supply chain to help the company reach its ESG targets.

Viva Las Vegas

A 4.5-L bottle is removed from its protective ecoTOTE and placed in a SmartPour (left) dispenser designed to reside behind a bar. The bottles are reused 100 times, with each use cycle replacing four 1-L single-use bottles (right).

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In Las Vegas—an appropriate spot due to its high concentration of casinos, hotels, and bars—ecoSPIRITS’ licensed operator for the U.S. eS Operator USA I LLC is launching another application of the model. As part of the Nevada launch, a new ecoPLANT, the third in the U.S. market after Mango and Chareu, will be brought online in partnership with 17A Stillery LLC, a Las Vegas-based distillery. South Point Hotel, Casino & Spa will act as the launch customer, piloting the closed loop spirits technology for high-volume casino beverage operations. As part of the launch, ecoSPIRITS has also developed a new technology solution to make its ecoTOTE format compatible with back-of-house systems known as pump rooms, which are commonplace in the casino industry. The Nevada ecoPLANT is now deploying spirits in ecoTOTE format, starting in January 2024. The ecoPLANT host for Nevada, 17A Stillery, produces City Light Shine, which is 100% distilled in Las Vegas from a traditional southern moonshine recipe using a whiskey-style mash to create moonshine in flavors such as blueberry and salted caramel. 17A Stillery was founded

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by Brendan Gaughan, whose family also owns the South Point Hotel, Casino & Spa. The South Point will be the first hospitality venue in Nevada to take delivery of spirits in ecoTOTE format, starting in January 2024, with others set to join shortly after. “We are delighted that South Point Casino, Hotel & Spa will be the

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first venue in Las Vegas to work with ecoSPIRITS and we hope this paves the way for venues across the city to follow suit, so that we can work together to eliminate single use glass waste,” says Gaughan. “We are also excited about 17A Stillery acting as the host facility for ecoSPIRITS’ ecoPLANT in Nevada, we are certain this site will become very busy very soon, as more venues look to make the transition to circular packaging technology for spirits.” Though the Las Vegas Strip has elaborate neon lighting displays, many of the hotel resort properties have made extensive sustainability efforts, including water conservation, recycling, waste reduction, and energy efficiency programs. Renewable energy is generated and used on the Strip, while energy efficient buildings are also being implemented and this area has one of the highest concentrations of LEED-certified buildings in the world. The South Point casino is among those with sustainability high up on its agenda and its efforts include a focus on reducing water, waste, and energy usage. By taking delivery of spirits in ecoTOTE format, The South Point says it will help demonstrate the benefits of reducing single-use glass waste in Las Vegas on a large commercial scale. PW

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Automating Snack Bag Line Cuts Labor Costs by 40% Two continuous-motion baggers feed into a single case packing operation that has made it possible for Darlington Snacks to double production while cutting labor costs. By Pat Reynolds, Contributing Editor Darlington Snacks is a thriving family-owned snack manufacturing and packaging facility located in the vibrant city of Joplin, Mo. Established in 1982, the company has grown from a small local operation to a respected national player in the snack industry. Darlington Snacks prides itself on producing high-quality, innovative, and delicious snack products that cater to a diverse range of consumer tastes. Serving daycares, schools, and the healthcare industry, Darlington Snacks is committed to sourcing the finest ingredients for their products.

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Two high-speed vf/f/s machines are at the heart of the new line, and each runs at 150/min. Inset shows the continuous-motion sealing jaws closing on the flexible film. They partner with local farmers and suppliers whenever possible, supporting the local economy while ensuring that the freshest and highestquality ingredients go into their snacks. This dedication to quality has earned the company a reputation for producing some of the tastiest and healthiest snacks in the nation. Not long ago, management at the snack food company recognized that they faced significant challenges where staffing was concerned. Located as they are in an area dense with food manufacturing plants, they faced tough competition when it came to finding talented workers. With many open manufacturing jobs, they were scrambling to fill positions and overstressing current employees when trying to keep up with demand. Also challenging was delivering packaging accuracy and being able to meet customers’ product handling requests. Being in the foodservice business for schools and healthcare institutions, the firm faced increased demand for snacks in single-serve containers that weren’t going to be handled by multiple parties, especially during the COVID pandemic. At PACK EXPO Las Vegas 2021, representatives from Darlington Snacks saw the impressive speed of the Viking Masek Velocity vertical form/fill/ seal packaging machine filling single-serve pouches. Brad Schweiss, vice

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Above the baggers are two combination scales fed by vibratory conveyors. president of manufacturing at Darlington Snacks, was already familiar with Viking Masek’s packaging equipment. “I’d been with Darlington for six years but in the industry for more than 30,” explains Schweiss. “So I was familiar with Viking Masek and what their services and capabilities were.” After collaborating with Viking Masek’s team of snack packaging experts, Darlington Snacks purchased an entire snack packaging system consisting of two bagging lines that merge into a single case packing line. On each bagging line, the process looks like this.

Vibratory infeed

Snack products first make their entrance into the automated packaging system through a vibratory infeed hopper from Eriez and then are fed to a Whiz Lifter Model C bucket elevator from Frazier & Son. It conveys the snacks vertically to an Eriez feeder that delivers the product to an ADW-0-0120F 20-bucket combination scale from Yamato where it is quickly and precisely weighed. Next the snacks are gently dropped into bags that have been formed on the vf/f/s Velocity packaging machine at a rate of 150 bags/minute on each machine. Featuring controls from Rockwell and patented servo-driven dual-jaw technology, Viking Masek calls the Velocity the “fastest vf/f/s packaging machine in the world.” One is capable of production speeds to 300 bags/min, though here two are used at a slower pace for a 300 bag/min total line speed. The unique center-mounted filling tube and naturally counterbalanced sealing profile are designed to provide vibration-free, extremely smooth operation at all speeds. The machine is also versatile, producing packages as small as 60 x 90 mm (.66 x 3.54 in.) or as large as 300 x 1000 mm (11.8 x 39.37 in.). Its versatility was appealing in Darlington’s case as the firm produces bag sizes ranging from 4.25 x 5.5 in. to 8 x 10 in. Integrated into the Velocity bagger is a continuous ink-jet coder from Linx that marks each bag with date code information. The bags are sealed shut and drop onto a Z-shaped takeaway conveyor supplied by Multi-Conveyor. The finished bags pass over a Yamato CSJ22L-00/CE31 checkweigher to ensure accuracy before dropping from the Z-shaped Multi-Conveyor and Corrugated cases are erected on this system and sent on a roller conveyor that brings through the basket of a batch gate from AS&E them to one of two right angle conveyor spurs, each leading to a batch gate that counts right into a waiting case below the gate. Inside bags into cases. the basket is a light curtain, so each time a bag

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constantly in and out. This bit of agitation ensures that the pouches are spread evenly across the case rather than grouping all in one part of the case. As for case erecting, it takes place not far from where the two AS&E batch gates are located. A Veritiv Lantech C-400 erects corrugated cases from flat blanks. It puts them on a roller conveyor that leads to two right angle conveyor spurs. Each of these spurs leads to an AS&E batch gate, and cases move into these gates based on demand. Once a case has received its batch of bags from a batch gate, it’s carried away at another right angle on a roller conveyor that takes cases in a single file to a Veritiv Lantech CS-300 Shown here is one of the two conveyor infeeds leading to the batch gate counter. case taper. A short distance later the cases pass through a Foxjet ProSeries Trident ink-jet printhead controlled by a drops through that curtain it gets counted. When the correct number of Foxjet Marksman Matrix controller. bags has been counted, a signal is sent to the controller of the Velocity As finished cases reach the end of the line, they are stacked manualbagger and that controller sends a signal to the batch gate to close long ly onto pallets, and the pallets are then moved to a storage area where enough for the filled case to be conveyed away and for a fresh case to they await their journey to schools, daycares, and health care facilities be conveyed in. With the fresh case in place, the batch gate opens and across the country. bags continue dropping into the basket for the next batch. This entire snack packaging line was set up, tested, and perfected One minor feature worth mentioning is that when a case is being at Viking Masek’s US headquarters in Oostburg, Wis., before it was even filled, a pair of vacuum cups attached to pneumatic devices attach loaded on a delivery truck. themselves to the bottom sidewall of one side of the case and stroke

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Trial run “Before delivery of our automation, I took my plant engineer to Viking Masek to see the system’s capabilities, slow-motion videos for assessment, and a trial run of the line before it shipped with everything labeled the way we needed it to be,” explains Schweiss, who adds that he was quite impressed with Viking Masek’s comprehensive testing and checkout process. Viking Masek assembled the entire system onsite at Darlington Snack’s plant. The new snack packaging lines fit seamlessly into their packaging configuration, resulting in precisely the solution their customers were asking for. “We didn’t have to worry about integration because Viking already took care of that for us,” comments Schweiss. “We bought it as a complete system and it’s functioned perfectly since.” Darlington Snack’s biggest victory with the automated packaging system is the accuracy of the batch gate–they report it’s consistently spot on. “The real trick for me was the downstream stuff to be able to make the counters work right,” explains Schweiss of the accuracy of their packaging line. “We had to be able to get the cases erected and into the two stations in the right sequences at the right time, and then on out to the palletizing operation. It has worked seamlessly.” Today, Darlington’s packing operation, case conveyance, and case closing are all automated. Staff members who formerly were required to conduct such operations have been relocated to other areas of the

facility. Since embracing automation, Darlington Snacks has seen substantial improvements with the throughput and labor-related challenges they were facing. “Automation has cut down on our waste, overpacking, and amount of giveaway,” reports Schweiss. “It has made our customers’ experience better because we’re not coming up short on products. And I’m pleased to report we’ve doubled production with about 40 percent less labor on the line.” As a single-source provider, Viking Masek takes care of everything, from sourcing the packaging line components, to assembly and testing, to delivery and setup, and finally technical support of the entire system.

Visit pwgo.to/8212 or scan the QR code for an inside look at Viking Masek’s automated snack packaging line at Darlington Snacks. “Viking Masek helped us tremendously as a single-source provider for the entire line. Our post-sale support has been beneficial and responsive. When we have an issue, Viking Masek takes care of it,” comments Schweiss. “I’d definitely recommend Viking Masek to anyone looking at automating their packaging operation. The fact that I’ve worked with Viking Masek in the past and wanted to work with them again demonstrates how much I value their expertise.” PW

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Collaboration is Vital to Driving Recycling Success Stakeholders spanning the full recycling value chain gather at the inaugural Packaging Recycling Summit to share solutions for more effective, profitable, and sustainable recycling of packaging materials in the U.S. By Anne Marie Mohan, Senior Editor Over the last three decades, Consumer Packaged Goods brands have been exploring a number of strategies to minimize the environmental impact of their packaging. Recently, these brands, their suppliers, and environmental organizations have begun to coalesce around a singular approach: a circular model, where the focus is on keeping existing materials in use for as long as possible. Considering that recycling, by definition, transforms waste into reusable materials, and that theoretically, all packaging can be recycled, you might expect the industry to be well on its way toward a fully circular economy. However, in looking at the dismal rates of package recycling in the U.S.—for example, the plastics recycling rate is just 9%—the desperate appeal from suppliers and brands for more recycled content, and the packaging waste littering the environment, that’s clearly not the case. A primary cause is the lack of communication and collaboration among the stakeholders—the suppliers that produce the packaging, the brands that use it, the consumers who dispose of it, the material

recycling facilities (MRFs) that collect and sort the waste, and the reprocessors who turn the waste into new materials. In November, Packaging World brought these all groups together for the first time at the inaugural Packaging Recycling Summit in Atlanta. Over three days, attendees learned about the current state of recycling, the business of MRFs, how to design and test for recycling, and ways to reduce consumer confusion around recycling. Most importantly, they learned from brands, MRFs, and NGOs about how they have been partnering to build end markets for hard-to-recycle materials and increase recycling rates.

To access videos of all the presentations from PRS23, go to: pwgo.to/8221 Despite the significant challenges to recycling, attendees at PRS23 were energized. Said Chris Max, research lead - packaging sustainability for Kraft Heinz, “I think we’re at the tipping point, that magic moment when an idea or social behavior crosses a threshold and spreads like wildfire. We need to take advantage of this moment. We’re all here for a reason—people care. We just need to do a better job and collaborate to increase recycling rates.”

Understanding the business of MRFs

Jane Fridely De Bigit of Myplas USA, Inc. and Myles Cohen of Circular Ventures, LLC discuss the business of MRFs.

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In the lead up to PRS23, Myles Cohen, founder of Circular Ventures, LLC, and former president of Pratt Recycling and Sonoco Recycling, validated the disconnect between CPGs and MRFs, saying, “MRFs don’t often have the ear of brands.” At the conference, Cohen, along with a panel representing MRFs and reprocessors, had both the ears and eyes of brands during a discussion that pulled back the curtain on the business of MRFs. Indeed, one of the main messages was that, contrary to a common perception that MRFs operate from altruistic motives, material recycling is a business. “MRFs want to make money, they’re part of the capitalist system,” said Cohen. “If they don’t make money, they’ll go out of business.”

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One of the biggest barriers to MRFs’ success, however, is contamination. Said Jeff Snyder, director of recycling for Rumpke Waste & Recycling, of the 30,000 tons of single-stream materials processed by the MRF each month, 15% to 20% is contamination. Of that, 2% consists of recyclable materials that aren’t recovered due to the sortation process, and the rest results from consumers “wish-cycling”—or putting packages in the recycling bin and hoping the MRF will deal with them—as well as brands designing packaging that is technically, but not practically, recyclable. When there’s too much contamination in a bale, for example, too many shrink-sleeve labels in a bale of aluminum, the MRF’s customer, in this case, an aluminum smelter, will reject it. Extensive contamination in MRFs has also led to cities shutting down their recycling programs.

that will buy them and turn them back into products,” said Snyder. Regarding other packaging formats and materials, glass, while highly recyclable, is being accepted by fewer MRFs of late, as its weight and quality concerns make it less profitable. Emerging materials include PET thermoforms, coffee cups, coffee capsules, small-format packaging, and mixed-substrate tubes. Non-curbside-recyclable materials include polystyrene, polyvinyl chloride (PVC), flexible film, and plastic tubes, among others. Shared De Bigit, flexible film, such as monolayer PE film, is a particular anathema to MRFs and reprocessors, as it wraps around the sorting equipment and causes jams, many times resulting in timeconsuming shutdowns. But there is reason to be optimistic. Snyder shared that emerging technology for MRFs—including AI [artificial intelligence], IR [infrared optics], and anti-wrapping shafts for flexible film—are enabling more accurate sorting along with sortation of a greater range of materials. “If someone had told me five years ago I was going to be collecting polypropylene tubs, I would have said no way, but here we are, and we want them all day long. We’ve got a great market for them, and we can effectively sort them,” he said. “So the technology is definitely out there, and it’s awesome.”

Strategies for designing packaging for recycling

Rumpke Recycling’s Jeff Snyder and Mark Agerton of P&G provide examples of how the two companies have worked together to ensure new P&G packaging designs make it through the sortation process. To help reduce contamination, Snyder, along with Jane Fridely De Bigit, procurement and sales manager for film recycler Myplas USA, Inc., encouraged brands to simplify their packaging so it can be accurately sorted. One way to do this, said De Bigit, is to use the same material for the entire package. The other is to collaborate with local MRFs to test a new package design’s ability to make it through the sortation system. At a minimum, brands should visit their local MRF to understand how materials are sorted based on factors such as size, dimensions, color, material composition, etc. The current mix of materials in most recycling streams favors fiber, primarily old corrugated containers (OCC), at 55% to 58%, with the majority coming from commercial customers. Other materials in the mix include aluminum, PET (plastic #1), high-density polyethylene bottles and jugs (#2), cartons, and more recently, polypropylene tubs (#5). These materials are considered “widely recyclable,” meaning 60% or more of U.S. households have access to recycling for these packages. But the most recent recycling rates recorded for these materials are low, and most have remained flat for years: from 40% to 68.2% (depending on the source) for fiber, 45.2% for aluminum, 28.9% for HDPE, 29% for PET, 20% for cartons, and 15.4% for PP. “Seventy percent of the ones, twos, and fives in the U.S. go to landfills today, and we want them all day long; I have an end-user network

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While the list of the most common materials accepted by the majority of MRFs seems fairly clear-cut, material type is just one consideration. According to Kelly Murosky, sustainable packaging manager for Unilever, “you have to look at the entire packaging system to determine recyclability.” As with most major brands, Unilever has a very specific goal around its use of post-consumer recycled materials: 25% by 2025. To reach this goal, Murosky said the company is working to ensure its packaging contributes to a clean recycling stream in order to increase the availability of high-quality PCR for both its own needs and for other companies. In auditing its portfolio, Unilever learned how factors such as inks, labels, and adhesives can affect the recyclability of PET bottles. If a label is too large, a MRF’s NIR [near infrared] sorters will identify it by the plastic the label is made from, rather than the bottle material. To ensure the bottle is sorted as PET, label coverage must be less than 55% of the surface area of a container (for bottles less than 550 mL). Another guideline for labels: Avoid PVC and paper, which can cause black flakes in PCR PET. Also critical is the label adhesive. If the label stays with the bottle during recycling, it can cause contamination of the PCR and a yellowish discoloration in the final packaging. Therefore, Murosky advised brands to use washable, rather than permanent, adhesives, which allow the label to separate from the bottle in the recycling sink float tank. When a PP or PE label is used with a washable adhesive, the label will separate from the bottle and float to the top, where it can be removed. “What it really comes down to is, think about your labels and make sure they’re not affecting the sorting and recycling process,” said Murosky. “There’s no such thing as a recyclable material, only a recyclable design.” Another tool in the design for recyclability toolbox is collaboration with MRFs, a topic that was discussed in a presentation from Mark Agerton, group scientist – Hair Care Packaging Platform for Procter & Gamble, and Rumpke’s Snyder. Agerton shared how P&G routinely works

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with MRFs to gather insights during the design process for a new package, as well as conducts real-world tests in their facilities to understand how the packaging moves through the sorting process. P&G has tested both new packaging formats, as well as harder-to-recycle packaging to drive end markets for the materials. In one trial with Rumpke, P&G introduced PP canisters for Old Spice and Secret brand anti-perspirants affixed with RFID tags into Rumpke’s sorting system to learn where the materials would end up. “Again, full-scale commercial operations, not hypotheticals that are being done on paper or Pilot technology developed by MIT ChemE NSF Graduate Research Fellow Alexis Hocken uses a a two-by-two grid scenario,” said Agerton. cyclone process to separate glass and small-format packaging during the MRF sortation process. After running thousands of the containers practices around the use of recycled cartons from other countries. To through the sortation system, P&G and Rumpke found that, for the most increase participation, it created school milk programs where cartons part, they went where they were supposed to go: with PP. are collected for recycling. And to help MRFs effectively sort cartons, In another example, P&G worked with Rumpke, Clean Tech Recycling, it provided grants for new sorting equipment. One of the grant recipiand Penn Color to increase the collection of colored PET containers, ents was Lakeshore Recycling Systems, also presenting at PRS23, which such as its green Gain and orange Tide PET laundry detergent packaging, was able to invest in an optical sorter for aseptic cartons and PP using to drive greater availability of rPET for its white Pantene shampoo bottle. the funds. Rumpke was another beneficiary of grant funding from the As a result, P&G is now able to produce its Pantene bottle with 25% PCR. council. It used the money to help purchase an optical scanner that “So as we start looking at the recycling infrastructure, certainly there are uses IR technology to identify and sort cartons. already a lot of operations on the mechanical side,” said Agerton. “But Through its efforts, the council expanded access to carton recycling if we don’t innovate as we move forward, we will just continue to collect from 18% of U.S. households in 2009 to 62% in 2023. Likewise, the reclear PET and natural HDPE as the most valuable materials.” cycling rate for cartons has also significantly improved—from 6% to 20% in the same time frame. Another example of collaboration is the The theme of collaboration, such P&G’s small-format coalition, which was created in partnership with MRFs, pervaded nearly every 2022 by The Sustainability Consortium (TSC) session in the PRS23 program. In fact, “coltogether with a collection of brands—among laboration” was mentioned no fewer 60 times them Colgate-Palmolive, P&G, the Esteé and “partner/partnerships” nearly 80 times. Lauder Companies, L’Oréal, and Haleon—as Many of the examples involved partnerships well as MRFs, non-profits, and universities. created to drive collection, recycling, and reThe goal of the coalition is to determine the use of hard-to-recycle materials. feasibility of enabling small-format curbside Among them was the Carton Council’s recycling. Currently, small-format packaging efforts to divert cartons, both gabletop and (items measuring less than 2 in. in at least aseptic, from U.S. landfills. The council was two dimensions) is not recyclable due its size; formed in 2009 by carton manufacturers Tet- Patrick Keenan of General Mills explains how at a MRF, one of the first steps in the sorting ra Pak, Elopak, SIG, and Pactiv Evergreen brands can drive MRF investment to handle process involves a glass breaker screen, which with the goal to expand access and increase curbside recycling of flexible film by building participation in carton recycling. That’s ac- critical mass through more packaging designed is essentially a mesh screen that allows shattered glass to slip though into a glass stream. cording to Larine Urbina, vice president of for store drop-off. Due to its size, small-format packaging drops communications for both Tetra Pak, U.S. and out during glass sorting and contaminates the stream. Canada, and the Carton Council, who explained that the council worked For the coalition’s purposes, small-format encompasses both packacross the value chain to achieve its goals. aging, e.g., caps, lip balm tubes, personal care sample packs, etc., as The initiative involved a number of strategies, shared Jason Pelz, well as small-format items such as toothbrushes and disposable razors. vice president of sustainability – U.S., Canada, Central America & the The first phase of the project involved gathering data through traCaribbean, for Carton Council member Tetra Pak. To drive end markets ditional waste characterization studies as well as data modeling and for the material, the council consulted with brands to understand what analysis to build a business case for small-format recycling. The results it would take to get them to use more of the material and shared best

Collaboration drives recycling for new materials, formats

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indicated that an estimated 25% to 40% of plastic packaging is small format by number of items, and 5% to 10% is small format by weight. “That’s a significant amount of material,” said Jennifer Park, TSC director of engagement. “Within the last number, we estimate from 0.8 to 1.6 million tons of small-format packaging is produced each year.” While the consortium continues its data collection, including auditing how much small-format packaging is ending up in the glass stream, it’s also working with MIT, specifically a team led by MIT ChemE NSF Graduate Research Fellow Alexis Hocken, to look at potential technological solutions that could be implemented at the MRF level. Hocken’s proposed solution is to create a second screening process for broken glass that uses cyclone separation technology. “So basically, any of the material that falls through the glass breaker screen would then be fed into this secondary screening,” she explained. The cyclone process would separate the materials by density and would result in two “theoretically pure” outlet streams: a plastic outlet and a glass outlet. The ultimate goal would be to refeed the plastic outlet back into the main conveyor belts that lead to optical sorters so they can be further sorted by resin type.

What Makes Packaging Recyclable? • Is there an actual demand for it as a raw material? • Are there multiple consumers of the item? • Can the item be incorporated into existing collection systems? • Can the item be effectively separated in the recycling process into a marketable form? Source: Jeff Snyder, director of recycling, Rumpke Waste & Recycling

noted, MRFs don’t want this material, as it gums up the works.) “Right now, when you look at the data, 89% of the material is a jumble of things that have no value, so why would a recycling facility even consider installing capital to collect this?” he said. “But if we all collectively think about designing for the store drop-off stream, it starts creating value in that 10.8 billion pounds of flexible film produced in the U.S. each year [per 2021 data from The Recycling Partnership (TRP)’s Film & Flexibles Coalition]. Once critical mass is shifted to the store drop-off stream, we might start to see a couple of MRFs pick up this material, and we might get to the ‘check locally’ designation [via the How2Recycle label].” Currently, consumers have significant access to store-drop off recycling; there are 18,000-plus drop-off bins in the U.S., loIn 2021, General Mills launched a new wrap for its Nature Valley Granola Bar that uses a cated in grocers and large retailers. These mono-material film, making it store drop-off recyclable. systems accept plastic bags, wrap, and film made from a single material, 99% of which is low-density PE, for recyHocken has developed a small-scale prototype of the technology to cling. Access to these bins is widespread as well, with 72% of the U.S. popshow proof of concept. From the trials, she shared, the team has been ulation living within five miles of a drop-off location. Most of the material able to achieve a separation efficiency of greater than 94%. “It’s really is downcycled by composite decking brand Trex for use in its products. exciting to see,” she said. “By no means is this a fully optimized system, According to Keenan, despite the extensive availability of store dropso I really see this 94% as a baseline that we can continue to improve.” off and despite the fact that 52% of consumers are aware of the option, To determine the environmental benefits of such a system for a MRF, just a small fraction of the 11% of monolayer flexible film collected Hocken performed a life-cycle assessment. The result showed that the today is from store drop-off. The majority comes from commercial readdition of cyclone separation for small-format packaging can provide cycling, such as back-of-house pallet wrap and shrink film, agricultural MRFs with an additional savings from 132,000 to 1.25 million kg of CO2 film, boat wrap, etc. On the bright side, he noted, the percentage of film equivalent each year. A techno-economic analysis (TEA) showed that in that’s being recycled is growing. all scenarios, the cyclone is economically beneficial. To help build critical mass for curbside recycling of flexible film, General Mills recently engineered a new film wrap for its Nature Valley Granola Bar, which involved converting a non-recyclable, multi-material One package type that checks off the majority of low-CO2-footprint film to a mono-material store drop-off-recyclable structure (see pwgo. boxes but has been vilified for its lack of recyclability is multi-material to/8218). Three years in the making and representing millions of dollars flexible packaging. To tackle this issue, in recent years brands have been of research, the wrap is made entirely of biaxially-oriented PE. Keenan innovating to create barrier packaging that uses a single material, maksays the company designed the structure according to The Association ing it eligible for store drop-off recycling. According to General Mills of Plastic Recyclers’ (APR) Design Guide for PE film and worked with R&D Principal Engineer Patrick Keenan, by designing more packaging Trex to verify it could be recycled within their stream. Vital to the success for store drop-off, CPGs can drive curbside recycling of flexible film. (As

Strategies to increase film recycling

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Packaging Recycling Summit 2023 Advisory Board • Peter Adrian, Recycling Coordinator, SWALCO • Mark Agerton, Group Scientist, Procter & Gamble • Michelle Bryson, Global Sustainable Packaging Leader, BW Packaging • Kim Carswell, Sustainable Packaging Leader, formerly of Target, General Mills, Kraft, the Sustainable Packaging Coalition, and The Recycling Partnership • Myles Cohen, Founder, Circular Ventures, LLC • Dylan de Thomas, VP of Public Policy & Government Affairs, The Recycling Partnership • Ana Espinosa, Packaging Sustainability Manager, ELC Management LLC • Dan Felton, Executive Director, AMERIPEN • Katherine Huded, VP, Recyclability Solutions, The Recycling Partnership • Marija Massey, Strategic Sourcing Manager, Circular Feedstocks, North America, Eastman • Kelly Murosky, Sustainable Packaging Manager, Unilever • Cory Nook, VP, R&I, Packaging, Danone North America • Michael Okorafor, Chief Sustainability Officer, McCormick & Co. • Jeff Snyder, Director of Recycling, Rumpke Special thanks to advisory board member Roger Zellner, President, Rogue Zebra Consulting, for assistance in conference strategy

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of the project was the inclusion of clear, on-pack messaging through the How2Recycle label to advise consumers on store drop-off. Said Keenan, “What’s really cool about this is that our brand really thought about the data, saying, ‘Okay, we need to move to polyethylene. It’s the only film that’s being recycled today, so let’s target something that’s actually being recycled. And then let’s explain the [store drop-off] program to consumers, so they’re aware it exists, and they know how to use it.” “We don’t believe store drop-off is the end state,” he added. “We see it more as a step along the journey to get to widely recyclable. We know our consumers want curbside, but flexible film is not there yet. We see store drop-off as a signal [to brands]—you need to design your film better for the end markets so we can create enough critical mass so there’s value in collecting this material at a MRF.” Until single-stream curbside recycling of flexible packaging does become available to consumers, Jeff Snyder of Rumpke shared in his presentation that in late November, Rumpke rolled out an intermediate step to collect the material. Through the Hefty ReNew program, developed in collaboration with Dow, Rumpke’s Cincinnati customers—both household and commercial—can purchase orange bags into which they can place hard-to-recycle packaging, such as candy wrappers, snack bags, salad bags, and plastic bags,

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(l.to r.) Patrick Keenan of General Mills, Katherine Huded of The Recycling Partnership, and Paul Nowak of GreenBlue discuss how the How2Recycle and Recycle Check labeling programs might be used in tandem.

along with packing products like bubble wrap and foam peanuts. At Rumpke’s sorting center, operators pull the bags from the line in the presort stage, bale the material inside the bag, and ship it to end users. Said Snyder, “We don’t want film in the MRFs, but if we can get it all in one bag, that is acceptable.” As for efforts to increase recycling of film from commercial sources, members of the MBOLD (Minnesota Bold) Circularity Initiative spoke on how they are collaborating to drive the recovery and recycling of PE film, including shrink wrap, hay bale wrap, pallet wrap, boat wrap, etc., as well as develop end markets for the material in the Upper Midwest. Partners in the project include the state of Minnesota, brand owners/retailers Cargill, EcoLab, General Mills, Schwans’ Company, and Target, and film converter Charter Next Generation, among others. Together, the partners have made a joint $9.2 million equity investment in Myplas for a new mechanical film recycling plant in Minnesota, which opened in December. Shared JoAnne Berkenkamp, managing director of MBOLD, “Through Myplas’ new facility, we will help drive a new regional circular economy, giving Midwest film users new opportunities to have their material recycled close to home and increase the supply of recycled resins.” For more details on the MBOLD initiative, see pwgo.to/8114.

On-pack labeling reduces consumer confusion One segment of the circular value chain that has been notoriously difficult to activate is the consumer. Whether it’s the result of confusion, apathy, or other factors, a 12% to 16% residential recycling rate for most municipalities is about as good as it gets. That’s according to Myles Cohen of Circular Ventures, who noted that more common is a 9% to 10% recycling rate. Yet collection is one of the most important pieces of the circularity puzzle. According to Gracy Wingkono, principal scientist for The Coca-Cola Company, in a session on the future of recycling, “collection is critical for the circular economy to be a functioning system, rather than an ideal.” One organization that has spent considerable time trying to understand how to motivate consumers is The Recycling Partnership. TRP is a

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non-profit with more than 80 partners dedicated to improving the recycling system through data, people, and solutions. For the “people” part, Katherine Huded, vice president, Recycling Solutions, for The Recycling Partnership, said that reducing friction along with providing outreach and education are key to engaging consumers. One learning TRP has put to good use over the last decade is its research on consumer behavior around recycling bins. According to Huded, a typical single-family household generates 800 pounds per year of recycling. The challenge is getting that material into the bin. If you ask them to drop off the materials, you get minimal material back, she said. If you ask them to pick up the phone and pay for a recycling bin, you’ll get maybe an eighth of the material back. If you give them a small recycling tote, you’ll get a fourth back. And, if you give them a 96-gal roll cart, they’ll fill it, and they’ll fill it with good-quality material. But that still only gets you to 375 lb per household. To get more of the remaining 425 lb requires consumer education to reduce confusion. Given there are 9,000 local recycling systems across the country serving more than 30,000 communities, with recycling rules varying across municipalities, it’s no surprise consumers are confused. In 2012, the Sustainable Packaging Coalition (SPC), a program of environmental non-profit GreenBlue, was the first to create a standardized label, the How2Recycle Label, to provide on-pack guidance for residential recycling. While some naysayers argue the label hasn’t had an effect on recycling rates, GreenBlue Executive Director Paul Nowak reminded attendees that 11 years is not that long to move the needle. According to Nowak, How2Recycle is now the most recognized label for recycling and is being used by more than 740 brands on more than 200,000 SKUs. He emphasized that the label is not the chasing arrows, although it uses the chasing arrows symbol within the logo because it’s widely recognized by consumers. Rather, How2Recycle is a messaging hierarchy based on science and applicable law, per the FDA’s Green Guides for the use of environmental marketing claims. In May 2023, TRP launched a separate on-pack labeling platform, Recycle Check, which features a QR code that consumers can use to access real-time, localized recycling information for the specific package.

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Through dynamic labeling, the QR code can remain the same, while the information can be changed based on new data. The label is being driven by TRP’s extensive and frequently updated database of local recycling systems across the country. For more details, see pwgo.to/8225. General Mills is the first brand to pilot the use of Recycle Check, adding it to its Pillsbury pie crust packaging in the lead up to the holidays. “Our consumers want to understand what to do with their packaging at the end of life, and we want to make it as easy as possible for them,” said General Mills’ Keenan. “The How2Recycle label continues to be great for the binary state, where a package is or isn’t widely recyclable. But for check locally, we want to be able to give a tool to our consumers that makes it easier to find out if they can recycle it in their community.”

Watch a video of Chicagobased Lakeshore Recycling’s new sortation facility that was featured at PRS23 at: pwgo.to/8222 The brand hopes the pilot will provide information on how consumers use the QR code, how it makes them feel about the brand, whether they have a negative perspective after using it, and other insights. “Having some of those early learnings will help us figure out how best to implement Recycle Check throughout our portfolio,” said Keenan. In creating the platform, TRP partnered with GreenBlue to learn how

the two systems can work together, leveraging TRP’s extensive database and GreenBlue’s expertise in labeling hierarchy. Will this mean a change in the appearance of the labels in the future? Probably. But the process will be deliberate and iterative. “For this to work, we’re going to have to pull together on those changes,” said Nowak. “You won’t love all of them as they come through … there will be some tears. That’s not purposeful. But for us to get to a future state that’s sustainable in your world of print and packaging, we have to look at this.”

Insights on the future of recycling While the majority of PRS23 focused on mechanical recycling, there are other technologies poised to play a role in the future of recycling. Most notably are organics recycling, or composting, and advanced— otherwise known as chemical or molecular—recycling. Composting of renewable material-based packaging is not new, but there has been more interest in it of late from municipalities, consumers, and brands. So much so, that a recent study of future trends in material use, conducted by PMMI – The Association for Packaging and Processing Technologies and AMERIPEN (see pwgo.to/8220), indicates that compostable packaging material is expected to increase by 15% to 16% over the next decade. “When we surveyed the CPGs, it was all about compostable packaging, which was really a surprise to us because we weren’t expecting to see that,” shared PMMI Director of Custom Research Rebecca Marquez. If this prediction is true, industry will need to fast-track R&D on com-

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postable packaging, as well as investments in composting infrastructure. Playing its part is Clemson University in South Carolina. Through its FRESH food, packaging, and sustainability institute, Clemson has launched a compostable research initiative to serve commercially compostable packaging producers’ testing needs, merging the school’s R&D capabilities with a campus-wide organics recycling system. The final phase will be a new composting facility that will triple the current center’s capacity of 700 tons of organic waste per year. According to Anne Barr, executive director of FRESH, Clemson’s program is focused on the best application of compostable packaging, i.e., food packaging. Barr shared that one of the biggest challenges faced by organics recycling, which mirrors that of mechanical recycling, is contamination. Misleading labeling—oftentimes purposeful—of packaging leads to non-compostable packages entering the stream, leading to “significant contamination rates,” she said.

(l. to r.) Clemson’s Anne Barr and Marija Massey of Eastman share the challenges and opportunities associated with composting and molecular recycling, respectively. Other challenges include the performance of the materials, cost “because there’s more waste with compostable packaging,” and the lack of infrastructure. “And of course, we’ve all read a lot of articles about the reticence of industrial composters to take compostable packaging,” Barr added. In contrast, advanced recycling deals with fossil-based plastics and offers an alternative recovery route for hard-to-recycle packaging and mixed-plastic waste. Advanced recycling encompasses a number of technologies, including purification, depolymerization, and conversion, that either purify or break down a plastic to its molecular building blocks so that it can be used to create new, virgin-quality plastic materials. Representing molecular recycling at PRS23 was Marija Massey, strategic sourcing manager, Circular Feedstocks, North America, for materials innovation company Eastman. Eastman’s process uses methanolysis to depolymerize PET and polymer waste to create monomers that can be used to make new PET. Advanced recycling is designed to be a complement to mechanical recycling, so as strategic sourcing manager, Massey is responsible for creating new business models to source PET

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materials that are not being processed by mechanical recycling, such as polyester waste from textiles and carpet and colored PET. According to Massey, Eastman has already secured enough feedstock to power its new state-of-the-art molecular recycling facility in Kingsport, Tenn., which, once operational, will convert more than 110,000 metric tons of plastic waste into new raw material. But for many advanced recycling facilities, it may be a challenge as they work toward commercial scale to source enough feedstock to feed their operations, since many of the materials are not being collected. When asked to predict the future mix of recycling technologies in 10 years, both Barr and Massey opted to trade “a crystal ball for a magic wand,” as Barr put it. “I would really want to see there being more access and more education, because I think that’s what will really impact where we are 10 years from now,” said Barr. “We can have the greatest packaging formats in the world, but if people don’t understand them, and there is not access to a recycling stream, then we have not advanced at the rate we need to advance. As far as what I think it will look like, I believe it will continue to be a mix, but I think the proportions will shift. Mechanical, I would expect, will continue to be a majority, but I believe there’ll be more of an increase in compostability and certainly advanced recycling as a complement to mechanical.” Using her magic wand, Massey said, “What I would see as a best case scenario is innovation for growth—so anything related to access to recycling and the infrastructure to collect, sort, separate, and provide feedstocks for recycling of all packaging formats, for both mechanical and chemical recycling. Compostability certainly also plays a part. So I’d love to see us get to the point where the customer can just throw everything they have into a recycling bin without worrying whether it’s a bottle, a tub, a #1, #2, or #3 plastic—whatever it may be. “I would say the worst case scenario is the status quo. If we don’t do anything different, and we just continue to recycle what we are recycling today, and we stay stagnant, I would say that’s a failure.” PW

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Is Smart Packaging Hitting its Stride? The stars are aligning on multiple relevant fronts: consumer behavior, legislation, technology, and data management and capacity. This confluence of advancements is slowly but surely unlocking the potential of active and intelligent packaging.

By Matt Reynolds, Chief Editor Active, intelligent, and connected packaging, or more simply “smart packaging,” is a catch-all category that comprises a host of disparate, outwardly unrelated technologies. But in practice—for our purposes, that means in CPG, FMCG, food/bev, or pharma applications—this suite of tech shares a common attribute: using the package itself to connect, record, communicate, and add value across the supply chain far beyond that package’s original duties of delivering a product to a consumer intact. In-market examples of smart packaging are varied. On-carton sensors that change color as your milk spoils, or antimicrobial packaging from suppliers like Aptar to extend the shelf life of your produce, are two examples on the “active” side of the coin. Pharma is using this tech for medicines like biologics that must stay within certain temperature ranges during transport, otherwise lose efficacy. When it comes to connected packages, those carrying RFID or NFC radio transmitters—once prohibitively expensive components for anything but spirits and cosmetics that are falling in price accordance with Moore’s Law—communicate directly with consumers via smartphones. This was once was a

Active and Intelligent Packaging Association’s (AIPIA) 2023 World Congress, Amsterdam.

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Amazon’s Güneri Tugcu (second from left), senior partner manager, transparency, led a panel on fostering greater interoperability between disparate smart packaging. The aim was go get started on journeys toward on-pack authentication technology stacks to prevent counterfeiting and protect their brand, especially in e-commerce channels like Amazon’s. “We see that the first step is the hardest for most of the brands, but that’s why brand owner education is so important, because at stake is your brand, your brand awareness, and consumers’ trust in you,” Tugcu said. “That’s why at Amazon, we make it as easy as possible to just get started, because most of the brands we see don’t have any solution [for authentication]. And while we’re certainly an advocate for multi-layer interoperable systems for authentication, sometimes a small solution is better than no solution. Sometimes we need to give brands a little help to get something going, and then layer on top of that to build to a more advanced, more mature solution.”

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one-way street, with brands sending messaging toward their consumers, hoping to be heard. That model is evolving into a feedback loop as brands learn to collect that consumer interaction data to glean behavior insights, then adapt their offerings to match. Even the once lowly QR code is storming back after an inauspicious start, and standardization by organizations like GS1 are consolidating tons of data and multipronged utility in a single, unique, consumer-friendly 2D datamatrix. And perhaps most loudly reported in Europe this past year vis a vis HolyGrail 2.0, digital watermarks printed covertly on packs carry data on product and package make-up called a digital passport. Material recovery facilities (MRFs) can scan this digital watermark to instantly ID the material constitution of a discarded package, improving sortation and recovery for recycling. Clearly, smart packaging describes a diverse landscape. Any new packaging tech is bound to exhibit Reacting to recent French regulations, McDonald’s and its tech/tableware suppliers are an adoption curve all its own and evolve toward making strides in the management of reusable foodservice packaging materials. U.S.greater degrees of sophistication and complexity. based Checkpoint Systems revealed a practical application of RFID technology in tracking For smart packaging in particular, this is hardly and managing reusable tableware for the major fast-food chain. The company remained a linear journey, as the many disparate tech- unnamed during the presentation on-stage for confidentiality reasons, but it’s widely nologies within the category mature at different known the chain is McDonald’s. paces. Changing consumer pressures—the recent The sustainability piece, or at least the potential for it, has always advent of the sustainability-minded consumer for instance—tend to existed under the smart packaging umbrella. But only more recently move the goalposts. Plus, the fragmented nature of different technology has it come to the fore—so much so that it’s almost subsuming smart providers, and different technologies that don’t always integrate easily packaging’s other attributes. Since this Nov. 2023 World Congress was with one another, make it difficult for brands who have to cobble toco-located with Packaging Europe’s Sustainable Packaging Summit, gether a single solution out of a stack of possible tech. there was a more pronounced sustainability flavor to the event than But even with this scatterplot distribution of results and uneven usual. Manly is fine with that, so long as brands don’t lose sight of the pace of change, trend lines are visible when all the data points are plotother legs of the smart packaging stool, namely harvesting and acting ted. And nowhere in the world is that picture clearer than at the annual on consumer insights, and supply chain optimization. World Congress, hosted every November in Amsterdam by the Active and Intelligent Packaging Association (AIPIA). With practically all the relevant parties in the same room, it becomes apparent that the adoption curve for smart packaging is steepening. That’s due in part to regulation, especially in Europe, and in part to sheer utility for brands “Some of the things we’ve heard over the last year that are top of mind and retailers. More importantly, the brand owners employing smart now at this event include educating consumers on how to use smart packaging are beginning to take better advantage of the full suite of packaging, and also educating brands and retailers on how to manage applications, not just the consumer engagement piece that often serves and put to use the data they’re getting via smart packaging. If we’re honas their on-ramp to smart packaging. est, we feel the development of some areas of smart packaging is being “When we talked to brands back when we first started, they were held back by that lack of [brand and retailer] education and a lack of talking about consumer engagement. Even though we knew the poability to share data. Instead of not having enough, they have loads too tential was so much more, it was all about the consumer engagement much that they often don’t know what to do with, or can’t share it with piece. They just wanted to form closer relationships with their customer people who would know what to do with it,” Manly observed, referring base,” Andrew Manly, communications director of AIPIA remembered to a type of data paralysis that brands experience when their outgoing of the World Congress’s early days. “Now, the narrative has shifted tocommunications suddenly start generating feedback loops of valuable, wards delivering impactful information about their environmental, actionable, but overwhelming consumer behavior data. social, and governance (ESG) efforts. Brands are now more focused on “But that’s silly, the know-how is there,” he said, pointing to a preimparting information that reflects their sustainability efforts, not just sentation by Jenny Stanly of Appetite Creative, a company devoted to to their consumer, but to the wider world.” creating consumer experiences and gamification via connected packag-

Biggest hurdles: data management and consumer education

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ing, such as brand owner Schweppes’ Jus de Fruits Caraibes campaign that PW covered last year (pwgo.to/8224). The Appetite model collects a wealth of data on consumer behavior via their interactions with the package and feeds that data back to brands in a feedback loop. According to Stanly, it’s true that brands don’t use that data as much or as well as they should, but she notices that it’s improving. “According to Jenny, they’re going to have to use that data, partly because they’re being pushed by legislation to do so, and partly because the culture in the companies is changing as this new era of data and data management comes online. It’s breaking down the silos that house this data, and more easily sharing it, that’s going to be the hardest part.” Notably, legislative pressures on packaging-borne data use and ownership are more advanced in Europe than in the U.S. Consider our Drug Supply Chain Security Act (DSCSA), which originally had a series of phased milestones—some of which were delayed—leading up to the 2023 deadline for full compliance. That enforcement deadline has been extended again, another year, into 2024. Still, legislative drivers in Europe will impact packaging-derived data sharing practices the U.S. market. That will be sooner than later for multinational brand owners like Nestlé, P&G, Unilever, and Mondele- z since a singular approach to data management is simpler and more economical than a piecemeal-by-market system of approaches. Successful data management by brands and retailers may unlock the potential for not only smart packaging, but an entire smart retail ecosystem with smart shelves populated by smart packaging. Consider

automated and autonomous grocery stores (smart stores) based on NFC or RFID, with NFC-based AIPIA presenter ST Microelectronics and retail pioneer Blockstore Group at the leading, bleeding edge. There’s a consumer engagement element since the NFC can communicate with smartphones, but there’s also a strong inventory management and replenishment element for the brands and retailers. The automated payment potential with consumers’ connected smartphones may further reduce retailers’ reliance on trained human workforce. “You’ve got Walmart [in the U.S.], who seems quite wedded to RFID and traceability elements of smart packaging, but it’s not yet translating through to consumer engagement and the full integration of a smart store. Meanwhile, such retailers are always under pressure from lack of trained personnel and workforce scarcity, so a smart store with smart packaging on smart shelves is a logical outgrowth that I’m sure we’ll see.”

Platform interoperability is an issue for brands An aggravatingly persistent attribute of smart packaging is the fractured nature of its technologies and technology suppliers. Brands and retailers seek turn-key smart packaging solutions but find themselves instead having to erect their own layered stacks of technology to create one-off, bespoke, and proprietary smart packaging solutions and data streams. And when a combination of solutions is necessary to provide a total answer, data sharing can be tricky between layered and sometimes competing technologies. “I just heard on the show floor that sometimes simple is best,” Manly

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said. “Don’t overengineer something that you don’t need, or find too confusing, or find too costly to implement. You can go step by step and scale a smart packaging solution as you become more sophisticated along with it. You can add elements as you go, and as you become able to cope with them.” From the technology suppliers’ point of view, the brands and retailers are themselves fragmented—each brand owner has a different product with different marketing and supply chain aims, so each is looking for a different suite of smart packaging technologies. A provider can’t exist to solve a problem that only one brand faces. Standardization by the likes of GS1 and its Digital Link, alongside market consolidation, are both working to align technologies and terms in smart packaging and reduce fragmentation. Events like AIPIA, where the disparate techs connect under one roof, also serve as standardizing steering bodies. “Ultimately, we’re making progress in smart packaging. There are more implementations, there’s more QR, there are more chips out there and their prices are getting lower. There are just more mass rollouts of some smart packaging technology than ever before,” Manly summarized of the state of the smart packaging landscape. “But those mass rollouts are not enough. A company like Coca-Cola has done countless smart packaging campaigns, but each one is its own, compartmentalized, self-contained effort that has a beginning and an end date. The benefits of smart packaging are fully realized when it’s a sustained effort, not just singular campaigns. If we can get a retailer to implement that, then it would really get that momentum rolling. Walmart has done this for some of its SKUs, but I don’t see any supermarket or grocery chains who have done this, other than in the apparel sector where RFID is now almost universal for inventory management, shrinkage control, and warehousing. But apparel isn’t CPG or FMCG, and that’s where we need to get some sustained, mass-market traction. AIPIA exists to try to keep on plowing through, jointly facing headwinds, keeping people connected to make [smart packaging] happen.”

to the brand. Most of all, it’s an integrating part of the consumer experience. So why not take it to a digital level?” AB InBev has attended previous AIPIA World Congresses and Correa even spoke at the event in the past. As such, they’ve been able to watch the smart packaging market evolve over the years, chronicling its evolution and cataloging advancements that could scale, even at a massive beverage company like AB InBev. To Bensadoun, November 2023’s event might have been a threshold moment for smart packaging. “Speakers and companies attending have practical and available solutions that are in-market (or close) that could be implemented in the short term and eventually at scale. We also look at emerging technologies, but there is a need to better understand how we can answer to our consumers’ experience expectations now,” Bensadoun said of this year’s event compared to previous years. “From my point of view, I see that there were more market executions, testing, trials, and practical ways to go forward. I also see a more consolidated way forward on some technologies, like using pack features to identify unique markers of packaging without the need of a dedicated tag—for example Alitheon’s technology [FeaturePrint, which takes a photo of a pack and uses AI to uniquely identify it through existing features rather than applied marks] or Systech’s [packaging coding, product authentication, and traceability tech that combats counterfeiting and diversion].”

AB InBev Challenges Smart Packaging Suppliers Now a venerable fixture of the World Congress, the AIPIA Packaging Challenge gives smart packaging technology suppliers a chance to pitch their solutions to a featured major brand owner in a lightning round of tailored presentations, each only three minutes. Challenging these suppliers was none other than a pair of smart packaging seekers from beer giant Anheuser-Busch InBev. Luiz Andre Correa, global manager, supply chain of the future (digital innovation), and Farida Bensadoun, global engineer, packaging innovation, both of AB InBev, were at the AIPIA World Congress on the hunt for digital and connected packaging solutions. Bensadoun focuses on consumerfacing entertainment and engagement through packaging. Correa is tasked with understanding supply chain challenges, and learning how emergent digital tech can solve them. The pair made good use of the Packaging Challenge stage to vet smart packaging vendors. “As a packaging innovator, I am always striving to find the best way to make our packaging functional, ergonomic, and appealing to the consumer,” Bensadoun said. “As we see an increase in digitalization, there is an opportunity to bridge the physical to digital through packaging. Packaging’s primary purpose is to protect the product it transports and to interact with the consumer. But packaging is so much more. It’s there to inform the consumer, help differentiate, and bring recognition

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Packaging Challenge judges Farida Bensadoun (left), global engineer, packaging innovation, AB InBev; and Luiz Andre Correa (right), global manager, supply chain of the future (digital innovation), AB InBev; join Eef de Ferrante (center), managing director, AIPIA, to explain their choice of winners. Correa and Bensadoun had four distinct requirements of the Packaging Challenge supplier participants. They came into the challenge knowing that no single supplier could scratch all four itches—as previously discussed, this is just the reality in the nascent world of smart packaging. The first AB InBev requirement related to the 2D datamatrix (QR code), and how to improve readability with smartphones when laser-engraved on clear surfaces, like on beer bottles. “The presence of 2D codes on-pack is increasing and it’s used in a plethora of applications. As a FMCG business, we have the possibility to

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use these codes for tracking and tracing, consumer engagement, transparency, etc.,” Bensadoun said. “With datamatrix codes, as you know, more information can be encoded in less space which makes them very attractive. In fact, they can be small yet easily scannable. It’s mainly used in supply chain activity (e.g. asset tracking) and it makes sense to leverage the same code for consumer engagement to prevent multiple codes on pack as this could be confusing for the consumers.” Another task AB InBev sought to accomplish with smart packaging was semi-serialization for validation in rewards programs. The company wanted to execute a perfect hidden semi-serialization mark that could be validated with a photo. “When connecting with the consumer, there is a need to have a frictionless way to do so. In rewards programs where proof of purchase is required, one needs to be able to confirm that the pack is from the right brand and only scanned once. Having it hidden or semi-serialized allows the always-on approach and keeps the cost down,” Bensadoun explained of the requirement. Engagement with legal-drinking-age consumers via augmented reality-based gamification was another desirable smart packaging feature. “In the past years, previous campaigns have shown consumer interest in brand experiential marketing campaigns such as the one the Budweiser brand led during the 2022 Qatar World cup using a (serialized) QR code, or the Michelob Ultra Like a Pro campaign,” Bensadoun said. “This helps build a stronger connection between the consumer and our brands.”

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Finally, Bensadoun and Correa sought a computer vision model without the need for real, physical samples when training the model. “Computer vision, the way that I understand it, needs physical assets to train the model,” Bensadoun said. “Training through images or even technical drawings isn’t enough. This leads to a long lead time to get the model trained and to go live. The goal was to understand if there are advanced solutions that would remove the need of physical assets, which saves shipment time and cost.” Correa and Bensadoun had the difficult task to shortlist three solutions out of the eight pitches. They say the winners that they selected responded to specific challenges that were put forward in a way that made the technology seem frictionless. Sure enough, three supplier participants were able to deliver on what the AB InBev pair considered to be viable solutions. With a submission from Alitheon, Correa and Bensadoun saw potential to accomplish not one, but two of its four requirements—computer vision without marking, and semi-serialization for consumer rewards. That tech is a patented capability that Alitheon calls FeaturePrinting. The term intentionally conjures images of fingerprints, but instead of tiny skin ridges on a human fingertip to ID people, it uses tiny, naturally occurring variations from pack to pack to identify unique items. The system uses an optical-AI that detects the authenticity of an item—such as a Budweiser bottlecap—by irrefutably identifying each original. The company pitched its ability to eliminate counterfeits, shut down grey market activity, and enable tracking and tracing, all with one photo

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And finally, Experience is Everything, a company specializing in “always on” connected packaging, caught AB InBev’s eye with an exciting consumer engagement piece. Bensadoun, who specializes in consumer experience and engagement, was specifically impressed with “the way they made 2D code visually appealing and versatile enough to match our brands visual brand identity. I appreciated their expertise in AR and gamification, and the way to do it seamlessly,” she said. With her experience judging smart packaging vendors, Bensadoun now advises them “to put emphasis on the consumer, brand, or technical challenge one is solving. Focus on AlmaScience solves for AB InBev’s desire for semi-serialization using 2D datamatrix codes one strength that will set you apart and pitch built right into Corona beer logos, and laser etched into the glass bottles. it well and quickly. Live demos or visuals say a thousand words and showcase how your technology can make a differusing a standard camera. “Your item is its own identifier,” said Roei ence. If you cannot describe your solution in three minutes or less, then Ganzarski of Alitheon. it may not answer the challenge.” AlmaScience was another winner, earning high marks from AB InBev for its smart, sustainable (cellulose) solutions for datamatrix and semiserialization. The proposed solution uses a sensitive, cellulose-based ink coating on the bottle, followed by laser engraving, to create high-fidelity GS1’s Digital Link is a standard 2D (QR or datamatrix) barcode archiimages that are easily read by vision systems or even mobile phones, all tecture that, when printed on a package, singularly accomplishes a lot while remaining mostly covert (invisible to the consumer). of parallel tasks for supply chain stakeholders and consumers alike. At

Digital Link and the 2027 sunrise of 2D barcodes

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“Consumers demand more information about the products they’re purchasing, regulators require the disclosure of more information and there’s an ongoing need to more effectively track and trace products through the supply chain. We can resolve this with 2D barcodes with GS1 standards inside—a single barcode that has the power to provide all the information consumers need and desire, improve traceability through the supply chain, and scans at checkout,” said Jon Moeller, chairman of the board, president, and CEO, Procter & Gamble, in a November letter sent to the Board of Directors of the Consumer Goods Forum (CGF). In support of the advent of the Digital Link standard, the Sunrise 2027 program was launched as a project to popularize the technology with a benchmark date by which proponents hope to have industry (brands, retailers, consumers, and the supply chain that connects them) ready to move from 1D GTIN to 2D datamatrix for on-pack barcodes. This involves getting all scanner manufacturers, the printers, and the soft(l. to r.) Caspar, Thykier of Zappar, Mark Hewitt of Connected Experience Consulting (CEC), ware that supports them, ready for the switch. “Sunrise 2027 is less about the brands, they’re Marc Powell of the Royal National Institutes of the Blind, and Sarah Masters of Unilever revealed accessible packaging to the visually impaired community through the use of QR more or less ready. And it’s less about the smartcode technology. Unilever’s Masters emphasized the scale of the issue, noting that “there phones, they’re ready to read the URLs. It’s more about ensuring the infrastructure is ready in the are 39 million people around the world that are blind and many, many more, hundreds supply chain, like in scanners at point-of-sale in of millions, that are partially sighted.” Unilever and its partners are making packaging retail, and in warehousing and logistics,” Guinard more accessible via the (once) humble QR code. The enhanced QR code, developed in said. “That change is primarily, even overwhelmcollaboration with Zappar, features a distinctive pattern around its edges, enabling it to ingly, a software change only. Some older scanbe detected and scanned more easily, and at a greater distance, by visually impaired ners or smartphones simply cannot read this users. The application then reads the product information aloud and presents it on a code, but that’s very rare.” smartphone screen in large font. Read more at pwgo.to/8226. The idea behind Digital Link was to start to make GS1 identifiers accessible to consumers, a segment that 1D GTIN AIPIA, Dominique Guinard, VP of Innovation at Digimarc and founder had never reached. A lot of stars had to align for this to happen. The of EVRYTHNG, which Digimarc acquired, explained that Digital Link first was that nearly all mobile phones now have a native capability to is about ready for prime time. The standard has matured over the six read 2D barcodes. Apple was a holdout in offering this native readabilyears since its 2018 launch, emerging out of the mission-specific workity. But now and going forward, a special app is no longer required for group that Guinard co-chaired, and has graduated into normal stanan iPhone to read a QR code. Also, consumer familiarity with QR and 2D dard maintenance for standardizing body GS1. barcodes received a big boost during pandemic, as contact-free menus The Digital Link 2D barcode can be said to be the direct descendent in restaurants taught even luddites to scan QRs. And societally, conof the good ol’ GTIN 1D barcode that has served brands and retailers sumers now demand to know a lot more about the brands they shop, for 50 years. The on-pack GTIN is what currently makes your packaged looking for information on product provenance, package sustainability product go “beep” at the retail register when scanned. But that GTIN profile, or brand social stances, among other preferences. means nothing to consumers—it’s simply a serialization method for Meanwhile, complex supply chains require more visibility and traceinventory and SKU management that’s used upstream in the supply ability, and Digital Link allows a brand to attach a singular identity to a chain, and again at checkout. Digital Link, on the other hand, unlocks a product and follow it throughout its entire lifecycle—from printing on consumer component among many other functions carried in a single, the package substrate, to packaging the product, through the supply unique 2D datamatrix barcode. chain to retail and the consumer in the aisle, at the checkout counter, “Digital Link is what has happened now that the GTIN 1D barcode after the purchase in a consumer’s home, and even post-disposal for has met the internet,” said Guinard. “The little change that had a big impackage recycling purposes. That single product generates a lot of data pact was transforming the GTIN into a URL, and representing that URL through its lifecycle, but supply chains now have much more capacity as a QR code, which made them smartphone- and scanner-readable.” and computing power for data than they once did, especially now at the The big consumer brands are lining up to get on board.

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dawn of AI. Broadly, supply chain stakeholders are better equipped to harness the data their scannable packages generate than they ever were before. Simultaneously, in the EU, regulations like the Digital Product Passport (DPP) are pressuring brands to account for the end of life of their products’ packaging. Since Digital Link appears to be tailor made for DPP programs, it’s almost a surprise to learn that DPP didn’t have Digital Link specifically in mind to accomplish DPP’s goals. “The stars really were aligning, and the time was really right to start to make the transition to 2D barcodes,” Guinard said. “We just needed a standard like Digital Link to align the language globally.” Digital Link’s trick, to put it into layman’s terms, is that the singular URL code is so many different things to so many different stakeholders. The URL represented as a QR is always the same, but the One of the “godfathers” of Europe’s HolyGrail, Gian De Belder (second from right), information that’s extracted—each small chunk is technical director, packaging sustainability at P&G, led a panel on the future of called a key—is different depending on who is doing digital marking to help material recovery facilities (MRFs) identify and properly sort the extracting, and with which software. Consumers packaging. While HolyGrail 1.0 served as a proof-of-concept for digital watermarks scan the code and are directed to a website, where and digital product passports (DPP), HolyGrail 2.0 is a full supply chain assessment of a brand can place any consumer-facing information how the tech can enable better sorting, higher-quality material, and better recycling they choose—the provenance of a certain wine vin- rates as part of a circular economy. Powered by the Alliance to End Plastic Waste and tage, for example. A scanner at the checkout reads the European Brands Association (AIM), HolyGrail 2.0 continues to be an R&D program that same QR and goes “beep,” but the software re- where the objective is to increase the technological readiness up to a metric where solves the URL only for a simple GTIN number key visual sortation machinery and software are commercially available. “We are now in that also resides within the longer code. Every link the last trial phases of this R&D program where the brand owners and retailers have of the supply chain might have a corresponding key been putting digital watermark-enhanced products into the marketplace in Germany, that they use to extract relevant darta, such as batch France, and Denmark, and we’re now in the process of the real industrial test, which information or a serial number for brands’ track and means that some of the existing NIR (near infrared) readers that we built to support trace efforts, or an expiration date for retail inven- the first trial phases will be moved into industrial sites,” De Belder reports. The core tory management. Any number of specific keys, or standard specification for the Digital Product Passport was ratified by the EU on pieces of information, can placed within the code. December 12, 2023, just a few weeks after AIPIA. A URL could theoretically contain limitless inconsumer products already have finite label space. formation, but there are practical limitations on how much data can But the bigger picture is that standards like Digital Link work to be usably coded into each Digital Link. The longer, more key-laden erode a common challenge in smart packaging, and that’s interoperthe URL becomes, the denser the pixilation of the 2D datamatrix beability between technologies and applications. comes. When the QR becomes too granular to be read by a scanner or “Nobody gets fired for using a standard,” Guinard said. PW smartphone, the size of the QR code must increase. And fast-moving

An example of a Digital Link, which is a URL that is graphically represented as a 2D datamatrix (QR code) on a packaged product. Each section in orange is a key that’s read by scanner hardware and resolved or interpreted by purpose-built software.

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AUTOMATION

OEM APPLICATION NOTE

Intelligent Automation Means Productivity, Precision Supply chain delays pushed Balpack to investigate new servo-electric VFDs, PLCs, and HMI components. Integrator HPE suggested Mitsubishi Electric.

By Matt Reynolds, Chief Editor For 20 years now, packaging machine builders and end users alike have been incrementally drifting away from pneumatics and hydraulics toward all-digital, electric automation. Florida-based OEM Balpack, Inc. is no exception, and the company makes heavy use of servo and VFDs controlled through HMIs to provide their customers with both standard and custom machinery, packaging everything from food to cosmetics to nutraceuticals and more.

Balpack’s new Star Wheel Capper. One customer came forward asking Balpack for an application that would cap small bottles. The customer wanted something that could deliver the pre-programmed precision that would easily handle the capping of delicate containers filled with pills, liquids, or powders. None of Balpack’s existing equipment could meet this need, so engineers at the OEM decided to build a new machine. But pandemic-induced component

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Scan the QR code or visit pwgo.to/8211 to watch a video describing the project leading up to the new machine, Balpack’s Star Wheel Capper. availability delays were a problem, forcing Balpack’s hand in widening its pool of preferred suppliers. After interviewing several new vendors, they chose intergrator HPE Automation, a Mitsubishi Electric distributor. Teams from Balpack and HPE worked hand-in-hand to develop a machine based on a star wheel design, what it calls the Star Wheel Capper. “We recommended going with Mitsubishi Electric Automation through and through,” says Joe Small, HPE’s electrical controls engineer. “Sometimes, if you have components from several different companies, you get into a quagmire of frustration. Getting it to work together is a pain. But with Mitsubishi Electric, the compatibility is built right in.” With a complete Mitsubishi Electric solution, the development time was shorter. And with HPE, Balpack had a single point of contact to answer every question. Not only was HPE only a phone call away, one of its subject matter experts temporarily rented an apartment down the street from the Balpack facility. Picture a powerful machine driven by a world-class VFD and servo. Now picture that machine placing a delicate plastic cap on a small plastic bottle at a rate of 100 caps/min. The slightest error in torque or positioning could destroy multiple caps and bottles, or cause the product to leak. What prevents this? According to Balpack, the programming expertise of HPE, and the precision controls from Mitsubishi Electric. “I have to say that Joe Small at HPE was quite proud of his programs. When we finished the first Star Wheel Capper, we ran it, and I looked at Joe and I said, ‘You know what? I think this is the best machine we ever built. Thank you,’” remembers Roman Balcar, EVP at Balpack.

Easy Configuration “We ran all Ethernet-based controls for our VFDs,” says Brian Hord, HPE president and co-owner. “That gave us easy configuration and adjustability. We also ran the SMC valves via Ethernet for ease of setup. In the past, the wiring time was considerable. Now they just plug-in RJ45 cables.”

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AUTOMATION

And according to HPE’s automation sales and technical products manager, Jason Schmidt, “In older machines with analog controls, you could get only 16 speeds for torque. Now, the number of speeds is unlimited. And torque control is adjustable to one tenth of one percent.” To make new settings easy, HPE worked with Balpack’s controls engineer to make programming uncomplicated. To create a new setting, the operator simply positions everything as needed, then presses the button marked SET. “It’s a very operator-friendly machine,” says Balcar. “And HPE provided the training, which enabled our Balpack operators to do the programming … And the value that Mitsubishi Electric brought to Balpack allowed us to give our customers a lot of bang for the buck.” All settings can easily be controlled through a user-friendly HMI from Mitsubishi Electric. And recalling those recipe-driven settings for changeovers is even easier. In the past, changeovers were often done manually with an Allen wrench. The process could lead to significant All Ethernet-based controls are used for VFDs, providing easy configuration and downtime. But with the system’s digital controls adjustability. The integrators also ran SMC valves via Ethernet for ease of setup. In the and Ethernet connections, changeovers can be past, the wiring time was considerable. Now they just plug-in RJ45 cables. done in minutes. Caroline Shipp, Balpack general manager, valued the partnership By consulting with HPE and Mitsubishi Electric, Balpack says it’s been that was created. “The most important thing to me is the relationship able to build a capping machine that not only delivers as promised but with HPE. I worked very closely with their team on everything: timecan be assembled and running not in two weeks but in two days. lines, availability of products, programming, and how we can stock for the future. Just having that relationship and a vendor I can lean into is amazing. Mitsubishi Electric was literally the savior of this project. They got us what we needed when we needed it. Plus, they were open about pricing. That’s important for a company of our size.” The relationship continues into new projects. For instance, Balpack customers have been asking for a dual function machine that can not only cap but fill. And when it comes to the development of Balpack’s new monoblock system, HPE and Mitsubishi Electric will be ready to assist. “The most important thing to me is the relationship with HPE. I worked very closely with their team on everything...just having that relationship and a vendor I can lean into is amazing,” adds Shipp. PW

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All settings are controlled through a user-friendly HMI. Recalling recipe-driven settings for changeovers is easy.

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INNOVATIONS REPORT

PACK EXPO Las Vegas 2023 Innovations Report By PMMI Media Group Editors The packaging and processing community came together this past September for perhaps the most important PACK EXPO Las Vegas in its history, according to show producer PMMI, The Association for Packaging and Processing Technologies. Nearly 32,000 attendees, the most in the show’s history, actively engaged with more than 2,300 exhibitors across 1 million net sq ft of exhibit space at the Las Vegas Convention Center. This event not only stands as the largest packaging and processing trade show in North America last year but as the largest PACK EXPO Las Vegas in the show’s history. “PACK EXPO Las Vegas was a huge win for the packaging and processing industry,” says Jim Pittas, president and CEO, PMMI. “From attendance to exhibition space to educational sessions—the show surpassed expectations to provide our largest, most comprehensive show to date. This is proof that the industry continues to thrive and show up to provide the most innovative, sustainable, effective solutions the world has to offer.” As PMMI’s State of the Industry report highlights, industry growth remains steady at a healthy 3.4 percent with the total size of the market in the U.S. reaching $10.2 billion. Looking to capitalize on this growth, more than 2,300 exhibitors displayed and promoted their latest innovations to make connections with decision makers in packaging and processing.

The Winners of the 2023 Technology Excellence Awards at PACK EXPO Las Vegas (Sept. 11-13; Las Vegas Convention Center), Owned and Produced by PMMI, The Association for Packaging and Processing Technologies, are: • Food/Beverage Category: Aneko, Emsys • General Packaging and Processing Category: Harpak-Ulma, AI Enabled Augmented Reality for Transforming Packaging Operations • Personal Care/Pharma Category: Catalyx, Digital Line Clearance Assistant™ • Sustainability Category: Amcor, HealthCare Recycle Ready Sachet Visit pwgo.to/8170 to learn more about them.

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Get the Full PACK EXPO Las Vegas Report What follows is just the tip of the iceberg! If you are looking for coverage of robotics, controls, food processing, and pharmaceutical packaging—plus a lot more equipment and sustainability innovations that we couldn’t quite fit—scan the QR code or visit pwgo.to/8229.

As in years past, the editors of PMMI Media Group were hard at work covering the many innovations shown by the exhibitors. Our report begins on the next page, and it’s divided into two main categories: machinery, and sustainable packaging. This report is brought to you by: Matt Reynolds, Chief Editor, Packaging World Pat Reynolds, Contributing Editor, Packaging World Anne Marie Mohan, Senior Editor, Packaging World Keren Sookne, Director of Editorial Content, Healthcare Packaging Aaron Hand, Editor-in-Chief, ProFood World Michael Costa, Senior Editor, ProFood World Melissa Griffen, Editor, Contract Manufacturing & Packaging Joe Derr, Digital Projects Editor, PMMI Media Group Casey Flanagan, Digital Editor, PMMI Media Group Lilián Robayo Paez, Editor, Mundo PMMI Next up in the PACK EXPO portfolio of events is PACK EXPO East (March 18-20, 2024, Philadelphia) followed by PACK EXPO International (Nov. 3-6, 2024; McCormick Place, Chicago). Information for the upcoming shows can be found at packexpo.com.

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INNOVATIONS REPORT

MACHINERY Marking and coding solutions are many and varied in the packing space, so why not begin this review of innovations shown at PACK EXPO Las Vegas 2023 with a look at what’s new in marking and coding? We begin with ink-jet printing, where innovations aimed at simplifying maintenance—in some cases even eliminating maintenance altogether—is clearly a trend. Hi-speed industrial ink-jet printer manufacturer Leibinger took advantage of PACK EXPO Las Vegas to unveil IQJET (1). Described as a whole new platform, Leibinger on its Web site succinctly blasts out its fundamental value proposition this way: “Plug & Print. 5 years no maintenance. The first intelligent coding and marking system.” According to Volker Teufel, head of product development at Leibinger, this new platform is based on new technology that leverages more intelligent systems. One example is the new HMI, which can be operated a lot like a smart phone. It makes it easy to see what your tasks are, what you are currently printing, the status of the printer, the status of the ink reservoir, and so on. The no-maintenance-for-five-years part of the platform means an increase in productive time through elimination of regular care measures, printhead cleaning routines, and unplanned downtime. Plus the new XXL cartridges used in the IQJET empty down to the last drop and do not require separate disposal. The system even provides video assistance on cartridge removal and replacement right on the HMI. “The printer has an integrated solvent recovery system to reduce the consumption of the solvent,” says Teufel. “So it is the printer with the lowest solvent consumption in the market because the evaporated solvent is condensed and returned back into the system.” A unique nozzle-sealing system called Sealtronic makes a key contribution to the five-year no-maintenance guarantee. When more conventional ink-jet nozzles are used, any pause in production can result in dried ink and blocked nozzles. This is not the case with Sealtronic nozzles. When production stops, the nozzle retracts, closing the ink loop and preventing it from drying out. To start again, the nozzle extends out again and carries on printing—without the need for cleaning or rinsing cycles. And since no cleaning cycle is required, there’s no need for additional cleaning solvent, which is good for the environment and the bottom line. Nor is there any adverse impact on the viscosity of the ink or the quality of the first few prints, either.

printer and label editing are as easy as using a smartphone, with only a few touches on the integrated touchscreen using Domino’s QuickStep user interface needed. The user interface can be password protected to ensure labels are protected and correct. The system is also easy to maintain. According to Domino, exchanging the ITM (integrated technology module) service module is simple— a less-than-10-minute task performed annually by an operator. A key feature of the Domino printer system, the ITM minimizes the need for conventional maintenance, such as manual filter replacement, which can help reduce labor costs and downtime. Fluid changes are also easy and said to be “mistake-free,” through auto-identification of consumables, and they can be done without stopping the printer. The fluid system itself features accurate control systems that enable optimum printer performance and code quality in varying ambient temperatures. In addition, fluid levels are continually monitored, alerting operators when it’s time to replenish them.

an informative video describing Sealtronic technology at pwgo.to/8118, and a video of Teufel demonstrating the system at PACK EXPO Las Vegas at pwgo.to/8119.

LOWER COST CIJ Domino’s new Ax130i continuous ink-jet (CIJ) printer (2) is designed to print simple and quality batch codes consisting of up to five lines of variable or fixed data through CIJ onto a wide range of substrates for products in a variety of industries that include food, dairy, and cosmetics. Simplicity and ease of use are the watchwords for the Ax130i, says Domino. In terms of ease of use, the company says that operation of the

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MACHINERY Like the other Ax-Series printers, the Ax130i is built with a Dominomade print head technology called i-Pulse, designed to create codes with a nine-drop resolution as opposed to the seven-drop resolution traditionally used in CIJ printing. According to the company, because of this higher drop resolution, the Ax-Series printers can create highly readable codes, deliver extended periods of uptime, and save users up to 24% in ink usage.

LASER TECHNOLOGY Videojet Technologies’s new Videojet 3350 and Videojet 3350 Smart Focus 30-watt CO2 laser marking systems have been added to the company’s range of CO2 lasers in response to customers’ demands for high-performance laser marking solutions (3). That’s according to Videojet, which adds that both systems offer “unlimited font, code, and graphic options.” Among the features of the new laser marking systems, the 3350’s flexible marking head includes 32 standard beam delivery options, while the 3350 Smart Focus laser’s marking head provides zero to 90-deg rotation without the need for additional parts. In addition, the 3350 Smart Focus is equipped with automatic focusing and marking capabilities for easy product changeovers without moving the laser. The Smart Focus option enables multi-level marking with the benefit of an auto-adjustable focal distance, uniform flat field correction, a pilot PMMI PackWorld_PSA_July2023_Half Horizontal.pdf 1 6/13/2023 6:11:26 PM to Videobeam focus finder, and a flPage exible range/size mode. According

INNOVATIONS REPORT

jet, these features help reduce operator touches, improve mark quality, and increase uptime. Both new lasers print text, barcodes, graphics, and other information at speeds up to 2,000 characters/sec to support product traceability and anti-counterfeiting. The systems can print on a range of substrates, including PET, glass, high-density polyethylene, flexible film, foils, and labels, rubber, and wood and lumber.

According to Videojet, the laser systems have been engineered to help users meet their Industry 4.0 goals with built-in Wi-Fi and cellular connections that help to minimize IT workload and reduce the cost of connecting equipment to a network. Advises the company, “Housed in

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INNOVATIONS REPORT

MACHINERY an access box, these Wi-Fi and cellular connections enable easy software updates and fewer service interactions while improving overall equipment efficiency with the availability of more production information.” Big news at the Squid Ink booth at PACK EXPO Las Vegas was the introduction of the Co-Pilot Gemini UV system. It prints up to 5.6 in. high at 360 dpi vertically and 300 dpi horizontally. New water-cooled UV system requires up to 6 liters of water to keep the system cold. The main idea here is to be able to print non-porous substrates that are generally difficult to print because solvent inks typically used need drying time. With these UV-cured inks, the printed image is completely dry and smudge-free.

a video of the system at pwgo.to/8120.

LINERLESS LABELS While linerless labels have been successfully commercialized in other parts of the world, notably Europe, they’ve never really caught on in the U.S. FOX IV set out to change this with the PACK EXPO Las Vegas launch of the L3904E all-electric, linerless label print-and-apply system (4) featuring a Sato print engine.

which wouldn’t be much of an improvement over having to dispose of a release liner. The print engine thermally prints onto continuous, direct thermal, linerless label stock. Then a reciprocating blade cuts the stock to size and automatically applies it using a servo-driven application cylinder and pad. Labels up to 4.65 in. wide can be printed and applied to products, cases, pallets, and other items—eliminating release liners, label matrix waste, and ribbon waste while reducing operating costs. Also busy on the linerless label front is Switzerland-based Collamat. Its fourth-generation Linerfree print-and-apply direct thermal label printers have been designed to accommodate linerless labels, resulting in both cost and environmental advantages. “Essentially you can have twice as many labels on a roll because we don’t occupy the label roll with the release liner,” explains Collamat’s Torben Zerlang. “That means you can cut down on the number of label rolls you need, and your inventory and transportation costs are less.” This also results in longer uptime per roll due to fewer roll changes. According to the company, Collamat’s Linerfree contributes to four of the United Nations Global Compact Sustainable Development Goals (SDGs), including #9, Industry, Innovation and Infrastructure; #12, Responsible Consumption and Production; #13, Climate Action; and #15, Life on Land. Points out Zerlang, the label industry is responsible for 40 billion square meters of backing paper annually, with 50% to 60% of that material going to landfills. Linerfree is available in a wipe-on and tamp-on version, with the transfer components designed with a surface pattern that resists adherence by the label material. Both models can produce labels of variable length, as cutting is done on-the-fly. This is especially helpful when applying different formats for shipping labels, when the information on each label is different, or when a different length format is needed on the same run. Specifications of the machine include a 12-in. label roll dia, a 2- to 4-in. label width capability, and a maximum label roll length of 2,460 ft. The stepper motor-driven unit uses a 4-in. Zebra direct thermal printer module and can print in 203-, 300-, and 600-dpi resolution.

HEIGHTADJUSTABLE LABELING OPTION Linerless labels, as the name so clearly suggests, are decidedly unlike pressure-sensitive labels in that they have no release liner. Also setting them apart is that label size need not be fixed. A brand owner could run a batch of 1,000 3-in.-long labels and then switch to a batch of 5-in.long labels by entering new data at the menu-driven HMI. The idea is to eliminate labeling waste, reduce energy usage, streamline inventory, and make the print-and-apply labeling process more efficient. The social, cultural, and regulatory landscape of the U.S. has never created all that much demand for this kind of sustainability-driven technology. Another reason that linerless has lagged, suggests Fox IV director of sales Craig Preisendefer, is that there really hasn’t been an offthe-shelf linerless label print engine module readily available to OEMs like FOX IV. “What we’ve done on the L3904E is take a desktop thermal transfer printer and build it into our printer/applicator,” says Preisendefer. The print engine he refers to is the CL4NX Plus from Sato. Though capable of both thermal transfer and direct thermal printing, in this case thermal transfer wouldn’t make much sense from a sustainability standpoint because there’d still be a roll of ink ribbon to dispose of,

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WLS, a ProMach brand, introduced an innovative height-adjustable labeling option for its popular VR-72 labeler. This first-of-its-kind solution automatically adjusts the height of the conveyor, and thus the containers, to effectively change the label height right at the point of application when conditions call for it. The high-speed VR-72 can be programmed for a label height for one entire batch or programmed to dynamically adjust the height of each label applied. When equipped with the height-adjustable labeling option, the VR72 primarily runs vials and bottles containing liquid pharmaceuticals, biotech products, nutraceuticals, personal care products, cosmetics, and other consumer goods. According to WLS sales engineer Harry Anderson, there are a couple of scenarios where this height-adjustable capability is useful. One scenario might involve an injectable drug product that must be administered in varying concentrations. For Batch A the health professional or consumer may need to add some other solution to a fill line, preprinted on the label, that is exactly X mm from the bottom of the vial. But for Batch B, that solution must be added to a fill line that is Y mm from the bottom of the vial. Without the adjustableconveyor feature, two different labels would have to be inventoried,

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MACHINERY

INNOVATIONS

one printed with a fill line for Batch A and one printed with a fill line for Batch B. But with the height-adjustable menu-driven VR-72, the same label can be used for both batches and still the fill line will be exactly where it needs to be for both batches. Not only does that reduce cost, it simplifies inventory and improves production efficiencies. Another scenario has more to do with how consistent the placement of a pressure-sensitive label is on its release liner. Where the label is positioned on the release liner may be different in the middle of a reel of labels than it is at the beginning or end. The new feature on the VR-72 lets the conveyor dynamically adjust to compensate for these inconsistencies so that every label is applied accurately. Anderson says the adjustable-height function is suitable for speeds to 200 containers/min. He emphasizes that the only portion of the flex link tabletop chain conveyor that gets adjusted is the section right at the vacuum drum that actually receives the label from the release liner and applies it to the container. “While the label is on that drum we have a vision system detecting where the bottom of the label is on the drum,” says Anderson. “Once we know where the bottom of the label is, that data is sent to a linear motor that determines if any adjustment in conveyor height is needed.” The vision system on the labeler demonstrated at PACK EXPO Las Vegas was from Cognex and the linear motor was provided by Linmot.

CASE AND TRAY PACKING Plenty of case and tray packing solutions were on display at PACK EXPO Las Vegas, including the LSP Series case packer from Delkor Systems. The firm describes it as a single top-load case packer that’s suitable for any shipper style. This newly developed loader can pack pouches and large bags into deep cases at speeds as fast as 180 products/min, depending on the application and number of picking robots employed. The LSP is available in one- to five-robot configurations to meet practically any speed requirement and can place a variety of pouches into multiple types of cases. The Fanuc M10 robots employed by the system work together to pick pouches in any orientation on the infeed conveyor. As demonstrated at PACK EXPO Las Vegas, the LSP series representative in action was an LSP 150 case packer using three Fanuc M10 robots. The demonstration at the time of PW’s visit was of a club-store tray of pouched licorice. Unique to this demo, products enter the case packer flat on the conveyor, but pick heads load the product to stand upright within the tray, requiring the robots to orient them accordingly. A tilted conveyor feature simplifies upright loading in this application, allowing them to gently stack against one another upright at a slight angle. Still, when pick flat/load flat is necessary instead of pick flat/load upright, it’s easy enough to flatten the tilt and bring the conveyor down to horizontal without needing any tools at changeover. Given the size and shape of the licorice pouches being packaged, each robot could handle roughly 40 pouches/min. With three robots, that made for about 120 packages/min for line speed on the system demonstrated. Notably, case packaging operations as demonstrated at the show were fed by two upstream case and tray forming modules. The Trayfecta G901 former quickly and efficiently forms retail ready cases (RRCs), regular brown cases (FSCs), club store trays for loading

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MACHINERY products upright, or other corrugated case formats, all from 2D blanks with extremely quick, 3-min tool-less changeover. A Trayfecta X module was also on the line, demonstrating the flexibility to run warped board. In this module, patent-pending tech pulls misshapen or warped corrugated blanks taught, into true 2D, prior to forming. Tandem 250-blank magazines on this Trayfecta X, holding 500 blanks at a time, minimize manual loading operations. Changeover on the entire line demonstrated is only about eight minutes total—three minutes on the Trayfecta former being used, four minutes on the LSP case packer, and an extra minute on the case sealer at the end of the LSP line.

a video of the new LSP case packaging system in action, with fully automated upstream case forming and downstream case sealing, at pwgo.to/8123. Also deploying robotics in its newest case packer offering is Brenton Engineering, which launched its XCP Series continuous motion, direct load case packer. Nick Szczechowski, regional sales manager at Brenton, was on hand at the show to provide insight into the capabilities and features of this new machine. The XCP handles wraparound cases or trays for products in bottles, jars, canisters, cups, and other rigid packaging for the food, personal care, chemicals, and beverage industries—on the show demo, cylinder-shaped sanitary wipe packs were being case packed. The equipment offers flexibility by being able to process between 30 to 70 products/min. This scalability makes it suitable for a range of ap-

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INNOVATIONS REPORT

plications and industries, Szczechowski said. The XCP features a robotic laner, developed in-house, that’s versatile enough to handle both round and square products. As Szczechowski guided PW editors through the machine, he highlighted the enhancements made to the case blank magazine. To prioritize user convenience, the magazine has been ergonomically positioned at floor height to simplify reloading operations—with a press of a button, the magazine advances forward, making the loading process efficient. The conveyor feed case blank loading system accepts three 26-in. stacks of blanks at a time. In another ergonomic feature, Brenton also ensured that the machine is accessible from multiple points, which is beneficial during maintenance operations. Operators can open any of the machine’s doors to get close to parts they might want to inspect, repair, or replace—they also can get within 6 in. of the corrugated blank at all operator-side entry points. Such design considerations make routine checks and troubleshooting straightforward for operators. The XCP makes interesting use of QR codes, too. In today’s fast-paced industrial landscape, swift access to machine information can drastically reduce downtime. With these QR codes, operators can quickly view the bill of material for any specific zone of the machine. For instance, if one is examining zone one and requires a detailed bill of materials, the information, presented with clear number indications, is readily available. To make matters even more streamlined, users can further expedite the process by ordering necessary parts online directly from the QR code information.

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MACHINERY The XCP Series includes the XCP-30, XCP-40, and the XCP-C30, which are customized versions of the case packer.

a video walk-through of the XCP Series case packer at pwgo.to/8124. The SOMIC 434 wraparound case packer (5) delivers different packing configurations, while improved accessibility in all areas of the machine enables up to 70% faster format changeovers. The case packer offers users in the food, non-food, cosmetics, and pet food industries greater flexibility in end of line packaging. This machine can accommodate formats from flexible films, pillow packs, stand-up pouches, and flow packs to cartons, bottles, rigid contain-

INNOVATIONS REPORT

ers, and thermoformed packages, explains CEO Peter Fox. “This machine can also be set up to run display trays, or with an added module we can run trays with covers for the ultimate retail-ready case,” he says.

a video of the new wraparound case packer in action at pwgo.to/8125. The system is compact while featuring full-length doors for easy access into the machine. 180-degree opening of the machine guard doors makes it possible to use the entire space around the machine. The frame’s support structure—which has been moved to the inside—boosts access to the machine’s interior and ergonomic working conditions. The machine uses the SOMIC CORAS collecting and grouping unit, integrated in a separate frame construction for flexibility when changing packaging concepts. CORAS employs a 5 drive-and-positioning system using planar technology and carriers matched to the customer’s product. The system enables definable, 360-degree orientation for products in cartons and allows for mixed formats with different product types. SOMIC reports that grouping and sorting tasks can be completed in a fraction of the space required by pick-and-place applications. Carriers and the transport field are designed for ease of cleaning. Controls play an important role in both packing and format adjustment. “This machine is unique in that it’s using the ArmorKinetix decentralized servo control system. This is new for both SOMIC as well as for Rockwell,” says

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Fox. Most of the format adjustments are controlled by servomotors. By using the SOMIC QuickChange System to adjust folding tools, gluing positions, and the blank magazine, and to change individual format parts, the SOMIC 434 allows for time savings of up to 70% compared to its predecessor. Sometimes stalwart existing machines or series of machines can benefit from customers requiring specialty or custom features. That was evident at the PMI Kyoto booth at PACK EXPO Las Vegas as a new version of the HCP-20 wrap-around case packer, which PW editors have seen for years at the event—sometimes as RSC, sometimes as top load, and sometimes as side-load. But this year, a wraparound version of the HCP-20 was on the floor sporting a new, custom rotating plate. This rotating plate was designed to spin carton collations 90 deg before pushing them into a chute for wraparound case packing from a single 2D corrugated blank. “We needed the ability to rotate the collation because in this case, the customer had a need to take the entire 24-count and turn it from long edge-leading to short-edge leading,” said Bryan Kreig of PMI Kyoto. “With the rotating plate, we can rotate the collation 90 degrees before loading it into the case.” In the demonstration, 1-lb cartoned products were conveyed into the HCP-20 at 140 cartons/min, then arranged into multiple collations—such as 12- or 24-ct for the 1-lb cartons in the demo. Also available was a 12-ct collation for 14-oz cartons, or a 4-lb large carton at a 6-ct. In the demonstration, 4 x 6 rows of 1-lb cartoned products were collated square for a 24-ct, and that was split into two 2 x 6 rows by a separation plate. Each of those rows were side-loaded into the wraparound case blanks individually, after rotating from long-edge leading to short-edge leading on the plate.

a video of the collation rotating plate in the HCP-20 case packer at pwgo.to/8126. JLS Automation debuted its robotic Hawk case and tray loader (6) for food and beverage applications. Beyond case and carton loading, the top-load system also works well with flowwrapped or bagged products, trays, bars, clamshells, bottles, jars, cans, and other formats.

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Says JLS’ Garrett Wampler, “We can use vacuum or mechanical tools to pick-and-place products into the cases. A very unique aspect of this machine is its small footprint—a typical machine sits in about a 4x5-ft footprint.” The system uses Rockwell Automation architecture, and as Wampler notes, “Everything from the case controls to the product controls is cantilevered, so it’s easy to make adjustments and it can be easily moved in and out of production lines. This is great for co-manufacturers and copackers that need the flexibility to move it from line to line.”

CARTONING MACHINES ON DISPLAY Among the many cartoning systems highlighted at PACK EXPO Las Vegas was one from Econocorp that had an integrated pick-and-place feature (7). The magazinefed cartoner erects a carton from a magazine of flat blanks and brings it by way of a flighted belt conveyor from Dorner to the loading station. In this case it was a plastic bottle being cartoned. When a bottle hits a sensor, a signal is sent to a Linmot linear actuator to pick the bottle with a vacuum pickup and stroke over to place the bottle into the open carton at speeds to 40/min. “This brings us into a new age of understanding that customers want more from us,” says Econocorp director of operations Samuel Goldberg.

a video of the system in action at PACK EXPO Las Vegas at pwgo.to/8128.

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Historically, low density polyethylene (LDPE) bags used in dry bag-in-box operations—with bagged product being automatically loaded into paperboard cartons—present a difficult prospect for horizontally oriented end-load cartoners. Such product has often remained the realm of top-load cartoners since the “pushing” action most end-load cartoners employ is problematic. Putting standard laminated films into cartons for small loose product like cereals or crackers is one thing, since the bags are designed to be more forgiving. But another matter altogether is doing so with LDPE film bags, which are now often preferred for their mono-material structure. This is especially true for such bags holding larger loose product like frozen appetizers or frozen waffles. Horizontal pushing across a static plane creates the problems. For instance, “frozen waffles have traditionally been difficult for typical end load cartoners. That’s because you have maybe two stacks of five frozen waffles, and when you push them into a carton, they tend to shingle. And once they shingle and overlap, they’re very hard to get into the carton,” says John Cooke, director of sales, Triangle. “Because our Flex Cartoner uses technology that ‘shoots’ the bagged product into the carton instead of just pushing it in, it’s a gentler loading and we don’t have problems with shingling and bags getting stuck in the openings of erected cartons.” Here’s what Cooke means by “shooting” the bags. Instead of being pushed off the conveyor into the carton by a pusher, LDPE bags with frozen waffles are conveyed at speed into the carton. Overhead belts can be added as a safety, in case there is a bulge or clump in the bag to try and settle it prior to being inserted into the carton. But when the cartoner is set up properly, the overhead belts never touch the top of the bag, the conveyor does the work of “shooting” the bag into the waiting carton. Meanwhile, the cartons themselves aren’t resting on a plane. Instead, they’re being held in place by eight lugs, one at each corner on both open sides of the carton. When the cartons are erected and oriented for filling with bags, they are squeezed a bit to bow the top and bottom of the carton, giving the bags a larger target to hit as they’re shot from the conveyor across the air gap into the carton mouth. “But on traditional end-loads, you’re compressing, nearly crushing the bag to make sure it gets into the carton,” Cooke added. “We’re really excited about this.” All in all, the Triangle dry product bag-in-box Flex Cartoners are a compact solution that the company says automates the production process while providing greater flexibility, lower maintenance, and reduced downtime. Automatic carton filling machines easily load one or more bags

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into the same box with single, twin-, and triple-pack bag-in-box capability, in both laminated multi-layer films and mono-material LDPE. This makes these cartoners a strong alternative to top-load carton loading, the company says.

a video of the new bag-in-box end-load caroner in action at pwgo.to/8129. Bradman Lake’s new SL 903 edition, an automatic end loading machine designed for user convenience and efficient product handling, minimizes the impact on operator health while retaining efficiency. The machine is capable of processing up to 130 cartons/min and caters to a range of packaging requirements: • The in-feed can be adapted based on the needs of the operation. • Whether businesses opt for robotic loading or hand-loading for specific products such as ready meals, the SL 903 is equipped to handle both. As products move through the machine, they reach the barrel loading section. Here, they are automatically pushed into the carton. The SL 903 addresses issues of filling cartons correctly by incorporating a mechanism to detect the presence of a product. If there’s no product detected, the machine won’t use a carton, which optimizes resources and reduces waste, according to Joey Barfe, the technical sales manager at Bradman Lake. Once a carton has been filled, products head toward the glue closure area. This section isn’t just limited to sealing; it’s also equipped for additional functionalities. As Barfe explains, users have the option to add various markers to the cartons, such as laser codes or inkjet codes, providing essential information or traceability. For increased ease of operation, the SL 903 comes with an internal LED lighting system that provides practical signals to operators. For regular operations, a solid green light illuminates the workspace. When a guard door is opened, the light transitions to white, enhancing visibility for operators and maintenance personnel. If adjustments are needed, the machine’s lighting will flash blue, signaling a required reset. Post adjustments, a green light prompts operators to restart the machine. Barfe further highlights the machine’s open design, allowing for good visibility that can help operators monitor the process and more easily identify issues before they escalate. More than ease of operation, the machine is designed for improved operator safety and health as well. The SL 903 has a low-level carton hopper designed for straightforward loading. This design ensures that cartons cascade up to the top where the carton picking heads are located, streamlining the entire process, while also reducing the impact to operator backs and joints.

a video of the machine in action at the Bradman Lake PACK EXPO Las Vegas booth at pwgo.to/8131. Debuted in the U.S. at PACK EXPO Las Vegas, a Schubert TLM cartoner (8) sporting the new Comfort Feeder feature represented a compact, efficient, resource-saving solution to automate the infeed of carton blanks to the packaging machine, saving brand owners and CPGs money and reducing the workload of production staff. With the Comfort Feeder, the entire pallet with the cartonboard blanks—still in the blank sheet—is packed into the machine. A Schubert F4 robot then pulls the blanks one by one directly from the sheet and feeds them into the erecting process at a rate of 60 cycles (cartons)/min.

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“What we are doing is removing the manual loading of blanks into the magazine,” said Stefan Hoffmann, sales account manager, Schubert North America. “We can load a whole pallet of blanks into the magazine and let the machine run for two to three hours completely by itself. The blanks are perforated, but not yet cut. We do that kind of cutting with a down holer and the F4 pick-and-place robot… The result is a machine in a very small footprint that’s loading up to 500 bars per minute.” With the TLM cartoner with Comfort Feeder, the sheet cutting process can be optimized to maximize packaging material utilization—saving material, resources, and costs. The combination of this new type of sheet infeed, a high erecting capacity, and loading and sealing in a small space offers users an attractive machine concept. Also of note, Schubert’s Comfort Loader takes advantage of 3D printed parts and components. End users of this equipment can 3D print their own replacement or wear parts in-house. “That eliminates lead times for manufacturing and shipping of parts by the OEM—the end user can just click and print,” Hoffman added. “It’s very convenient, and very sustainable.”

a video of the new Comfort Feeder feature in action at pwgo.to/8132.

PALLETIZING ON FULL DISPLAY Columbia Machine showcased its latest palletizer, the FLD2500 (9), at PACK EXPO Las Vegas. What sets this palletizer apart from its counterparts is its compactness without sacrificing speed. While other Columbia machines may offer higher speeds, they often come with a considerably larger footprint. This new machine is 40% smaller than its predecessor, the FL 3000, measuring at 13 feet eight inches long by seven feet wide. Despite its reduced size, it can handle nearly the same case rate on equal or given patterns.

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The FLD2500 is designed to handle narrow, tall cases with a high center of gravity, along with other package shapes and sizes. The smooth transitions between components help ensure stability for packages, regardless of their dimensions. Changeovers require zero tools and zero downtime. Operators can simply input the product ID or SKU into the HMI, triggering an automatic changeover to the recipe for that specific product. Considering the machine’s modular design, the FLD2500 can be setup for various infeed and inline flow configurations. The palletizer runs at 27 cases/min on a 10-case layer, or 23 cases/min with integrated wrapping. “It’s a dual hoist concept where there’s a row accumulation hoist and a layer accumulation hoist. Both hoists are servo controlled and that allows for faster and more precise movements, easier for setup, easier for tuning the machine. And it’s extremely quiet,” says Ted Yeigh, Northwest regional sales manager and division marketing manager, Columbia Machine palletizer division. The FLD2500 also features full six-foot-tall light curtains, ensuring the safety of all employees, regardless of their height. The machine is fully compliant with Category 3 safety standards.

PALLETIZING PROGRESS For decades, BW Packaging has offered high-level bulk depalletizing systems that get the job done. However, shares Eric Rohlf, product manager – Palletizing & Depalletizing, the way in which they’ve gone about getting it done has remained the same. One longstanding challenge with this type of equipment has always been accessing the dunnage at the top of the machine following depalletizing. With its new Goldco Fortis high-level bulk depalletizer (10), the BW Endof-Line division has sought to optimize this process to improve worker safety and ergonomics and enhance production and reliability.

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“We decided to design a machine from the ground up that meets the needs of our customers today and in the future,” says Rohlf. “So we packed innovations in a lot of the different areas. It still sweeps packages and sends them out onto a conveyor, but we’ve tried to figure out ways to solve all the problems we’ve seen over the years, even if they’ve always been accepted as something you just did.” With traditional high-level bulk depalletizers, the layer pads and top frames from the pallet are loaded in a bin positioned around 15 feet off the ground. To collect the dunnage, a forklift driver must align the forks at the top of the depalletizer to retrieve the dunnage and then load a new pallet in its place. The process poses various ergonomic and safety concerns and requires the machine to be stopped, leading to lost productivity. The Fortis, however, streamlines this process by accumulating the sheets and top frames at the top of the machine in a dunnage stack. Once depalletizing is complete, these materials are transferred back to the empty pallet, which then moves to the ground level via a four-chain hoist. Once the materials have been moved to the floor, operators can use BW’s standard sortation option of robotic sorting of the sheets, top frame, and pallet, whereby the robot picks them and places them into separate bins. “Try to picture driving a forklift up to a bin 15 feet in the air and picking up a stack of 1,000 pounds of sheets—the sheets are heavy once you stack up enough of them,” says Rohlf. “And now you’re backing out, what happens if that thing catches and things fall? You can bump into the

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MACHINERY machine and knock a sensor out of alignment, now you’re down. By bringing it all down to floor level, all those problems go away.” Furthering the effort to reduce downtime, BW introduced sheet levelers, which are particularly beneficial when layer pads become misshapen. If a layer pad isn’t straight, products like cans or bottles can tumble and cause obstructions. The sheet levelers employ fingers that adjust these pads, ensuring a smooth transition and preventing potential jams. Vac-U-Max showcased its entire line of vacuum conveying bulk material handling equipment for processing and packaging applications at PACK EXPO Las Vegas (11). David Kennedy, business development manager at Vac-U-Max, details some of the company’s key uses in the marketplace. “Some of the most common applications that we fulfill in packaging is loading rotary fillers, bottle fillers, and high-speed stick pack machines,” he says. “We also do pharmaceutical-grade equipment so we’re loading tablet press machines, and soft gel conveyors for inspection equipment, but made to pharmaceutical standards.” Kennedy adds that vf/f/fs filling is another specialty of Vac-U-Max, as well as auger filling for dry ingredients like coffee. “Our vacuum conveyor is mounted above the auger filler, and our machine brings all the powder up to the top and keeps your auger filler operating to give it constant head pressure,” he explains. “One of the benefits of our equipment is that you don’t have to climb ladders to load packaging equipment. All the ingredients can stay at ground level and they’re all easily cleanable. So [our machines] have ergonomic benefits, safety benefits, cleanliness benefits, and it makes the packaging machine operate to its maximum efficiency.”

a video of Vac-U-Max’s vacuum conveyor moving coffee into an auger filler at PACK EXPO Las Vegas at pwgo.to/8137. New from Morrison Container Handling Solutions, the new Twist Block container inverting solution (12) uses backpressure rather than automation to invert cans and containers on a packaging line. The primary appeal of the new block lies in its simplicity. Traditional automated sys-

tems include a number of components, including motors and other mechanical parts, which drive up the cost of the system, often into the tens of thousands of dollars. Not only does this make these systems more expensive, but it also allows for additional points of failure and requires regular maintenance. “For years we’ve seen great success with our power twist timing screw machines, but many of our customers need to simply invert mechanically on a line with backlog present,” says Morrison President Chris Wilson. “The Morrison Twist Block is a simple way to invert these containers.” Further adding to the simplicity of the system, the design of the Twist Block comprises just two pieces, compared with traditional twist blocks, which use the standard sandwich production method, whereby dozens of pieces of plastic are used to create the twist. The simplicity of the Morrison design not only reduces opportunities for product contamination, but it also makes it easy for operators to wash down the unit. “You can use it for as high of a washdown environment as you want,” explained Dustin Lee, vice president of sales for Morrison at the company’s booth at PACK EXPO Las Vegas. “You don’t have to take apart 20 to 30 different pieces of plastic to clean it, there are only two. You separate the two halves, and it gets cleaned relatively simply. From an overall efficiency, cost, and ease of cleaning standpoint, it’s one of those things that as long as you’re okay with the backpressure pushing the package through the block and inverting it, it’s a good solution.”

a video of the machine in action at the Morrison Containers PACK EXPO Las Vegas booth at pwgo.to/8155.

VF/F/S FOR LIQUIDS A brand new compact vf/f/s machine called Versa Pak (13) was introduced at the Paxiom Group booth during PACK EXPO Las Vegas. “This is the most compact vertical bagging machine on the market today,” says Paxiom Group vice president Nicholas Taraborelli. “The machine stands just 3 feet tall, is 3 feet deep, and is about 3 feet wide. It produces up to 1,200 bags per hour.” A key goal behind the design and development of the machine was

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MACHINERY to avoid proprietary things like forming tubes or the need to purchase proprietary packaging materials. Roll-fed film fed into the all-stainlesssteel machine can come from anybody, says Taraborelli. Pouches can range from two to eight in. wide. “We can put an automatic weigh-filling machine or auger filler above it or it can be just hand-loaded,” says Taraborelli. “What customers love is you can just take it out of the crate and put it on a tabletop and you are automated.” The price point at PACK EXPO was $19,900. And Taraborelli emphasizes that only the highest quality components go into the machine, including Omron PLCs and SMC pneumatics.

a PACK EXPO Las Vegas video of the compact new machine being demonstrated at pwgo.to/8141. Syntegon used PACK EXPO Las Vegas to unveil in the U.S. its newest vf/f/s bagger solution: the SVX series 51 (14). Two of the machines were on display—the SVX Agile and the SVX Duplex. The SVX Agile is designed for high-speed production of 300 bags/min with one film lane and can handle the full bag range of any vf/f/s bagging requirements. The Agile’s patent-pending cross-seal control allows for custom and accurate sealing pressure. Meanwhile, its SVX Duplex counterpart can produce 600 bags/min—due to two accessible film lanes—while still maintaining a compact footprint for seamless integration into existing production lines. The company adds that the platform is user-friendly, allowing for easy and quick changeovers and adjustments. PW editors spoke to Jason D’Arcy, product group sales manager, ver-

tical - North America, at Syntegon at PACK EXPO Las Vegas, where he had this to say. “There are several features that make the SVX different from everything else out there, but first and foremost among them is our innovative new cross-seal drive system,” he said. “All the moving parts of our machine are contained within what we’ve called our front cylinder. The

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MACHINERY fact that all of the moving parts are contained within this front cylinder allows us to only have to guard the front end of the machine. That means that on the back end of the machine, operators have full access to the film path, to film reel loading and splicing, to code/date printers, and other elements without having to deal with guarding.” D’Arcy added that the SVX series is ideal for snack, baked, fresh and frozen, and powdered products, really “anything dry and free flowing, and we also have higher hygiene versions that are ideal for washdown applications.”

INNOVATIONS REPORT

Similar to prior PSA counter-pressure models, the CB100R is engineered for producers interested in canning beer, cider, seltzer, carbonated soft drinks (CSDs), and other beverages at carbonation levels of up to 4.1 vols (8 g/l) CO2. As PSA explains, adding a rotary three-spindle seamer allows for faster speeds and a smooth, continuous-motion transition from filling to seaming, eliminating unnecessary agitation. Cans

a video of the new SVX vf/f/s bagger system in action at pwgo.to/8143.

AUGER FILLING IMPROVEMENTS Laser focused on auger filling was Spee-Dee Packaging Machinery. Their compact rotary filler at an attractive price made its debut at PACK EXPO. The 12-pocket machine (15)) measures just 24 in. in diameter and is rated at 40 to 80 bottles/min. According to Spee-Dee vice president of sales Mark Navin, that makes it an especially good fit between in-line indexing systems that run between 20 to 50 bottles/min and high-speed rotary systems that go 100 bottles/min and higher. “And it comes at a lower price point and has a smaller footprint with all the benefits of Spee-Dee’s rotary filler design, including magnetic funnel attachments as well as our servo-driven auger filler,” adds Navin.

15 Especially innovative in terms of reducing complexity and cost is the way that Spee-Dee’s designers removed the timing screw and infeed starwheel on the infeed as well as the discharge. “We’re able to just peel the container off from the conveyor and then deposit it back onto the conveyor at the discharge end,” says Navin. Cost of the compact rotary system is around $250,000 to $260,000.

a video of the machine at PACK EXPO Las Vegas at pwgo.to/8145.

CANNING AND SEAMING Can filling and seaming was a focus at Pneumatic Scale Angelus (PSA), a BW Packaging company. The firm introduced the latest edition to its craft beverage canning line portfolio, the CB100R (16). The new line marries rotary counter-pressure filling with rotary Angelus seaming in a compact footprint, operating at more than 100 cans/min.

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are purged of oxygen prior to filling, with configurable purge and snift times to control foaming. Under-cover gassing at the turret lid feed and a bubble breaker positioned ahead of the Angelus seamer serve to keep Dissolved Oxygen (DO) levels to what PSA says is an industry-leading minimum. “Our CB100R builds upon the successes of our existing counter-pressure lines, with the added advantages of a full rotary system,” says Mike Davis, PSA’s product line leader for Can Filling. “The combination of a rotary filling turret with rotary seaming means we’re able to increase the number of cans traveling through the system, maintaining best-inclass Angelus seam integrity without creating any increase in product agitation. Ultimately, this allows us to eliminate the unwanted reductions in carbonation levels that are seen with other filling methods.” Also similar to PSA’s other counter-pressure models, the CB100R employs true isobarometric filling, with a gravity-fed onboard product filler bowl rated to 60 psi/4 bar, where the can being filled and the product going into the can are at equal pressure, maintaining carbonation solubility throughout the filling process. PSA explains that the filler uses precision magnetic flowmeters to ensure filling accuracy, with little to no waste. “The advantage of the full rotary CB100R design is a smaller footprint than other rotary and linear formats,” explains Adam Brandt, PSA’s vice president of Sales. “The addition of the rotary seamer means we can achieve faster speeds in a more compact design. This is great for brewers who want to increase production without requiring additional space, which is often already at a premium.” PW

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SUSTAINABLE PACKAGING When it came to suppliers of packaging materials at PACK EXPO, the focus from an innovation perspective was pretty clearly on sustainability. Fiber-based containers, expanded use of PCR, bio-based solutions, monomaterials that simplify recycling, and “green” developments in ecommerce were all front and center. Grouping these things into neat categories is difficult, so here they are in a somewhat—but we hope not entirely random—order. First up: a fiber-based bottle (1) now being developed for product categories including beverage, beauty, health, medicine, and food. Behind this notable development are two firms with considerable experience in sustainable materials. One is molded fiber packaging producer RyPax—the international division of The Wing Fat Printing Co., Ltd.— with offices and production facilities across the U.S., Macau, and China. The other is Scotland-based CelluComp, whose proprietary microfibrillated cellulose product known as Curran is made from the waste stream of root vegetables, primarily sugar beets. A quick look at what each firm brings to the table helps clarify what this ambitious fiber-based bottle development is all about.

The molded fiber that RyPax makes is a step or two up from the everyday molded-pulp egg carton. First, RyPax containers are fully recyclable and biodegradable, and they’re only made from materials sourced from responsible green suppliers. Often enough, the source materials are things like fast-growing bagasse and bamboo. Second, egg cartons are usually made on high-speed rotary pulpers followed by a drying process, and only then is the material pressed and formed in a secondary step. The resulting product does not have a smooth cosmetic finish—but then again, if the package being made is an egg carton, who cares how smooth the finish is? RyPax technology, on the other hand, is an inline process, as drying, finishing, and molding is all done inline. The resulting product is smooth, clean, and attractive enough for the high-end electronics, pharmaceutical, and health and beauty applications that RyPax specializes in.

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As for CelluComp, its microfibrillated cellulose product, Curran, has been used for some time as a thickener in household paints. Or to add structural integrity to a fishing rod or skateboard. When it comes to fiber, when Curran is added it also adds strength. But it also closes the porosity of the sheet and smoothens the surface, thus optimizing that surface’s ability to be efficiently coated. So it was only natural that CelluComp would begin marketing Curran for applications in paper and packaging. This led to a working relationship with the Danish Technological Institute, experts in materials science and green technologies. When CelluComp and DTI exhibited at Plastic Waste Free World Europe in November 2021, RyPax came to their booth and, as CelluComp CEO Christian Kemp-Griffin puts it, “We started building our relationship. We liked RyPax’s ability to react and their entrepreneurial spirit. We had some history in paper and packaging at this point, so what we started looking at with RyPax wasn’t entirely new to us. What was new was the idea of looking specifically at fiber-based barrier packaging.” Fast forward a few months and here is where the two firms are at. They’re developing a molded fiber bottle made of curran, bagasse, and bamboo. The Curran in the fiber brings added structural integrity. But just as important, its inclusion means that the interior surface is optimized for application of a coating. And the coating isn’t just any coating. It’s a thin, impermeable coating specially developed by CelluComp called Reef, and once again it includes Curran. So it’s a matter of molding a fiber bottle that is strong and has minimal porosity and then making it even stronger and even further reducing porosity by giving it a unique inner coating incorporating Curran—a coating that won’t interfere with recyclability or biodegradability the way an inner plastic liner does. Both RyPax and CelluComp emphasized at PACK EXPO that what they hope to do is push the packaging community forward by combining precision plant-based packaging production with a highly renewable feed stock ingredient to crack the code on the all-fiber bottle. The partnership is poised to scale production for industry applications to help brand owners reduce waste and meet consumer, government, and their own sustainability goals. Worth noting is that a threaded aluminum closure was used on the prototype bottle shown at PACK EXPO. Moving forward, RyPax and CelluComp will in close collaboration with DTI explore additional fiber packaging solutions including fiber screw threads, caps, and even thinner coatings. “Integrating RyPax’s and CelluComp’s proven technology, materials, and production expertise to produce the industry’s first all-fiber bottle at scale is a major evolution for the industry,” says CelluComp CEO Kemp-Griffin. “Our unique capabilities and entrepreneurial approach, including establishing a Minnesota-based Public Benefit Corp. to better serve U.S. operations, has finally produced a design most packaged goods companies, and their consumers, have been longing for.” “Combining our global expertise in fiber packaging design and production with CelluComp’s creative ingredient solution, we’re looking at

1/25/24 2:30 PM

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SUSTAINABLE PACKAGING a true barrier packaging breakthrough,” says Alvin Lim, CEO of RyPax. “This initiative will remove millions of tons of plastic waste from the environment.” When asked if the all-fiber bottle will be able to hold carbonated beverages, Kemp-Griffin said no. He added that the DTI is still in the process of testing to determine what the Oxygen Transmission Rate of the bottle will be. In the meantime, says DTI business development manager Alexander Bardenstein, this collaboration is genuine cause for excitement. “The RyPax/CelluComp bottle has been through all of our comprehensive testing to earn our endorsement and allows them to start tailoring this technology for the global marketplace.”

PAPER PACKAGING POSSESSING BARRIER PROPERTIES While barrier paper packaging was a major theme at PACK EXPO Las Vegas, it didn’t just materialize there out of the blue. Amcor Flexibles has been diving deeper into the realm of recyclable paper-based packaging in the months leading up to the event, and recent trials and tests in Australia and Europe have provided insights into their latest efforts. The main aim is to design packaging that’s efficient for recyclability, while also maintaining the necessary quality and protection for products inside. Just ahead of PACK EXPO Las Vegas, the company announced the North American launch of curbside recyclable AmFiber Performance Paper packaging (2), part of the company’s AmFiber portfolio. Prequalified by How2Recycle, performance paper meets the re-pulpability standards for curbside recycling, allowing brands to provide consumers with more sustainable end-of-life outcomes for packaging. PACK EXPO Las Vegas served as the first big debut of the tech. Paper-based packaging alternatives employ innovative technologies to deliver the right barrier, shelf-life, and machine performance to meet brand and product needs. Consumers often seek paper-based packaging to deliver a more sustainable end-of-life, due to widespread curbside paper collection and recycling. And on the shelf, paper-based solutions meet consumers’ preferences for a natural look and feel. “Brands now have more choices than ever when it comes to packaging their products in formats and materials that attract consumers and meet their sustainability goals, while still achieving the operational performance they require,” says Brian Carvill, Amcor Flexibles North America VP of R&D. “AmFiber Performance Paper, part of the AmFiber portfolio, along with our dedicated research and development team, can make the conversion from plastic to paper effortless and advantageous.” AmFiber Performance Paper is a high barrier laminated paper that is recyclable in most paper recycling streams, earning the How2Recycle pre-qualification of “widely recyclable.” It provides improved barrier and packer efficiency compared to the existing coated papers and is PVdC-free. “It’s great to receive this independent validation as it should help consumers easily recycle packaging made of AmFiber Performance Paper through curbside paper recycling,” adds Ilya Syshchikov, vice president global product management AmFiber. Amcor’s product portfolio includes options for confectionery, bars,

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INNOVATIONS REPORT

cookies, cereals, dry beverages, and dry mixes. Format applications are ideal for cold-seal flow wrap and three-side seal sachets. AmFiber Performance Paper runs on existing flexible packaging equipment, achieving machine speeds comparable to plastic-based packaging. At PACK EXPO Las Vegas, PW editors were able to get an up-close look at—and tactile tear of—the AmFiber packaging substrate. Desmond VanHouten, senior marketing manager at Amcor, described the trials they have been conducting in the UK and Australia, and how they relate to the new U.S. launch. Interestingly, while the essence of the product is consistent across these regions, its exact form varies due to the unique requirements of different recycling systems, ranging from curbside recycling methodologies to the capabilities of Materials Recovery Facilities (MRFs). Such regional customization ensures the packaging is most suited for its intended market. The primary challenge in developing recyclable packaging, especially those that combine different materials like paper and foil, lies in the recycling process itself. A significant point of emphasis for Amcor is to ensure that their packaging material has over 80% fiber content, which is the recyclability threshold for the U.S., a number that varies internationally. Furthermore, during the recycling process, barrier layers need to be removed to retrieve recoverable fibers.

Another critical requirement in the development process is maintaining fiber length and quality. For a product to qualify for curbside recyclability, fibers shouldn’t be too short or degraded. This ensures that the recycled material is still of high quality, essential for producing a good product post-recycling. Shelf life remains an essential metric for customers, especially in the confectionery and dry mix segments. According to VanHouten, Amcor’s new packaging solution offers a shelf life comparable to that of metalized OPP. It’s crucial to note that while the packaging possesses a commendable moisture barrier, it might not provide as formidable a barrier as traditional foils. However, its performance seems promising, as many of Amcor’s clients believe it will suit their needs. The aesthetics and tactile feel of the packaging haven’t been ignored. For those curious about the packaging’s appearance, it sports a paper exterior. When torn, the metalized interior becomes visible. VanHouten clarified that the version on display at the show used metal-

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SUSTAINABLE PACKAGING ized film, with several options under consideration—for instance, for applications where metal detection operations render metalized film unusable. In those cases, Amcor is also exploring alternatives to the metalized layer. Potential solutions could offer different layers of barriers that might not necessitate metalization. VanHouten says that ongoing developments and trials highlight their commitment to providing efficient, recyclable packaging solutions tailored to regional requirements. The company’s iterative approach, combined with feedback from their clients, should ensure that they remain at the forefront of this trend.

a video of the new barrier paper in the hand and in potential applications at pwgo.to/8171.

MORE NEWS IN BARRIER PAPER

Elsewhere at PACK EXPO, ProAmpac showcased its ProActive Recyclable RP-1000 High Barrier (HB) paper-based technology (3), designed to address packaging needs across a variety of food products. A standard barrier version is also available. RP-1000HB is a patent-pending extension of the existing ProActive Recyclable RP-1000 series. This new packaging system provides robust barrier against oxygen, moisture, and grease, which can compromise the shelf-life and quality of products like dehydrated fruit, frozen foods, confections, and flavored oatmeal. Many companies are looking to meet sustainability goals and incorporate recycle-ready content for regulatory requirements, consumer desires, and more. But a major challenge faced by the industry is that some sustainable material changes may require equipment slowdown at the plant. Nathan Klettlinger, global marketing director at ProAmpac, says that the RP-1000HB integrates easily with existing equipment and maintains speeds. By ensuring compatibility with already established infrastructure, it “simplifies the transition process and minimizes costs compared to other sustainable alternatives,” he adds. This release is part of ProAmpac’s “Kick it to the Curb!” focus, geared toward ensuring the product remains protected while making recycling convenient for consumers. Adam Grose, chief commercial officer, notes, “Here in the U.S., curbside is the easiest way to get people to recycle. So that’s what we’re focused on, without sacrificing the performance of the package.” Grose also says that the material is pre-H2R-qualified [How2Recycle] for customers who plan to take their package through the process of featuring the popular symbol for recycling instructions. RP-1000HB is made from bleached paper—there is also a Kraft option. The packaging not only ensures the longevity of its contents but enables clear branding and product information for shelf appeal. It’s available in a variety of formats, including rollstock and pre-made, three-side-sealed pouches. Amir Saffar, director of global sustainability innovation for ProAmpac, elaborates on the product’s performance under challenging conditions; in tests simulating up to 85% relative humidity, the RP-1000HB maintains its barrier properties. “Unlike conventional paper solutions

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that offer inadequate grease resistance and subsequent packaging vulnerabilities, RP-1000HB delivers superior grease resistance with excellent seal performance on horizontal and vertical form/fill/sealing lines. Its unique characteristics pave the way for integrating recyclable fiberbased packaging into numerous applications,” he adds. Suitable for items including granola, cereal, and more, its printability allows for easy brand promotion and customization without compromising its primary function of preservation and protection. Earlier this year, ProAmpac launched its patent-pending PRO-EVO Recyclable platforms to the ProActive Recyclable series of products. The system is a multi-wall, paper-based self-opening-sack (SOS) bag that is certified for curbside recycling and is ideally suited for dry pet food. It provides grease and edge-wicking resistance without intentionally adding per- and poly-fluoroalkyl substances (PFAS). PRO-EVO Recyclable is also available with high moisture barrier to maintain the freshness of pet foods. The package combines shelf appeal and robust structure with high drop resistance. “These patent-pending technologies are engineered to have various moisture barrier levels, excellent organoleptic properties for pet food applications, and run-at-rate on the standard filling equipment,” says Hesam Tabatabaei, senior vice president of global product development and innovation at ProAmpac. Also expanding the use of paper into the realm of v/f/f/s applications is BW Flexible Systems. At PACK EXPO the firm demonstrated its new Hayssen Mini vf/f/s bagger (4), which allows users to run either paper or film, with a changeover time of less than 10 minutes between materials. Explains Dan Irod, director of business development for BW Flexible Systems, the bagger is the fulfillment of a request from one of the company’s customers seven years ago who wanted to switch from plastic to paper for 100% of its bags. “Until that moment, we had never evaluated the possibility of working with paper, so it was a totally new thing for us,” Irod says. In developing the system, BW Flexible collaborated with materials suppliers to find a paper-based web material that could seal on its equipment. Options include a paper web with a peelable film layer that can be removed, allowing the paper to be recycled or composted, or paper with a thin layer of PE for barrier.

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SUSTAINABLE PACKAGING Simultaneous with finding a paper that could be sealed on BW Flexible’s equipment was the development of a machine that could handle the paper. Says Irod, running paper on a vf/f/s machine requires a different film path and unwinding of the material. “You have to control the pulling of the web and also the tension of the packaging materials,” he says. In engineering the machine to meet new packaging material requirements, however, Irod said he wanted to be sure that if the sustainability winds changed (again) with greater recycling of plastic, that customers would have the choice of running either material. “That was one of the challenges I brought to my team,” he says, “just to always be able to take a step back and retrofit the machine with different tooling that allows for the use of plastic.” Another notable feature of the machine is its small footprint: The Hayssen Mini is just 1.3 m high, or approximately 4 ft. Shares Irod, sustainability isn’t only about the material being run on the machine, but also a machine’s electrical consumption, the number of air compressors it uses, and its footprint. “As I like to say, the Hayssen Mini will allow a small customer to work even in a garage,” he says. “It’s not going to be a garage definitely, but that’s the concept.” The Mini also offers in-line printing with water-based inks as an option. Graphic Packaging International has introduced a new coated recycled paperboard (CRB) innovation, PaceSetter Rainier (5). Named after Mount Rainier, known for its pristine white snow-capped summit, the new paperboard offers many of the characteristics of solid bleached sulfate (SBS) in combination with recycled content.

INNOVATIONS REPORT

“One of the big trends that we see is the increase in the desire to have packaging made out of recycled content [paperboard], but one of the really big challenges with recycled content is that, while it’s fantastic, it doesn’t always work for every purpose just from a shelf-appeal standpoint because it has a brown appearance,” explains Jeannine Scherzer, marketing director at Graphic Packaging International, LLC. “For brands that want to have a really bright, impactful carton, having a slightly duller paperboard isn’t going to work for that. But now we’ve figured out how to make a recycled sheet that’s pretty bright white.” According to GPI, with a brightness and whiteness that exceeds that

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SUSTAINABLE PACKAGING of traditional CRB, PaceSetter Rainier can compete directly with SBS and folding box board (FBB). In addition, it provides improved surface smoothness for enhanced printability and tactile performance. Printability, in particular, is especially important for applications such as OTC packaging. “If you’re selling pain medication, for example, that requires you to date code on the side or that requires a lot of fine print, you can’t get that crispness and accuracy with recycled content material; you’ll end up having letters bleed, and then you won’t be able to read the date codes. That’s very critical for the healthcare segment,” Scherzer explains. “This is the first time that they [healthcare CPGs] are actually able to get packaging with recycled content that a lot of their consumers are asking for, a lot of hospitals want to move that way, without sacrificing the shelf appeal. This is really a game changer for a lot of these companies.”

PFAS-free Oxygen Absorber Mitsubishi Gas Chemical scored major sustainability points by way of what it removed from its oxygen absorbers. Debuting at MGC ‘s PACK EXPO booth was a first-ever PFAS-free oxygen absorber (6). It comes in response to the growing legislation against polyfluoroalkyl substances (PFAS). These so-called “forever chemicals” were once favored for their oil and water-resistant properties—until they became known for their inability to break down in the environment, which poses adverse health effects. The key to this advancement resides in the multilayer film structure used to contain the actual oxygen-absorbing components in the three-side-sealed pouch. Essentially a polyester/paper/PE construction, it’s the paper layer that has been altered. A coating on this paper is what always brought the grease- and moisture-resistant properties required, without which the oxygen-absorbing iron inside would not be able to perform its task. This coating is now PFAS-free. “The contents inside the three-side-sealed pouch are unchanged,” says Sean Hael, MGC sales and marketing general manager. “It was just the coating that contained PFAS.” What this “advanced proprietary coating” is Mitsubishi isn’t saying. But the firm emphasizes that this “game-changing” innovation is preceded by more than 40 years of proven AGELESS technology, MGC’s well known and established brand, now reengineered to support the industry’s progress towards ambitious sustainability goals. Also, notes MGC, this 100-percent PFAS-free solution doesn’t compromise quality, performance, or safety in the many applications where it is found, including processed meats, meat snacks, baked goods, dried fruits, coffee, pet treats, pharmaceuticals, and nutraceuticals. “PFASfree AGELESS oxygen absorbers are oil-resistant and can deoxidize the interior of sealed packages to maintain flavor, color, fragrance, and nutrition of freshly prepared food as well as dramatically extend shelf life,” says an MGC press release. Hael adds that MGC scientists have been working

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The ability to produce new PaceSetter Ranier is the result of Graphic Packaging’s recent investments in CRB, which total an estimated $1.7 billion combined for projects in Kalamazoo, Mich., and Waco, Tex. According to Scherzer, the company’s new CRB line in Kalamazoo—the first new paper machine investment in nearly four decades—features a range of new technologies and high-speed capabilities that allow it to handle advancements such as different coatings or a different process. “It really speaks to the quality and capabilities of that machine—it’s really impressive,” says Scherzer. “That investment and expanding that capacity is allowing us to really hone in on making our already sustainable products even more sustainable.” The new paperboard grade is initially available in 12 to 18-pt calipers and is suited for a range of packaging applications, including healthcare, beauty, confectionery, dry goods, dairy, and more.

steadily for some years now on a technology that would meet regulatory requirements regarding PFAS that were emerging in Europe. But it turned out that requirements in the U.S. got fast-tracked in a way that required MGC to pivot. “We had to solve this as soon as humanly possible, because when we originally thought we had a couple of years, it ended up being more like a couple of months. R&D had to reprioritize if we were going to eliminate PFAS from our products in time. At this point the technology development is finished and it’s just a matter of getting it into production and into our warehouses.” When asked about the cost of the new oxygen absorber, Hael said this. “We’ll have two different types of oxygen absorbers. One will be the oil-resistant version for use with products high in fatty oils. Being a new technology, there will probably be a slight increase in cost as things get leveled out. But what we found during our testing and studies is that some products not so high in fatty oils only require a non-oilresistant version, so we’ll also offer that. And this non-oilresistant version won’t see a cost increase.” PW

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SUSTAINABLE PACKAGING CONTINUED DEVELOPMENT IN MONOMATERIALS At PACK EXPO Las Vegas, TC Transcontinental revealed its big bet on recyclable monomaterial BOPE films (7), with a new $60 million BOPE facility. These films still rely on consumers to use store drop-off, but infrastructure and adoption are improving. Why BOPE? The packaging industry is in the midst of a significant transformation, driven by the growing demand for sustainable packaging solutions. One outgrowth of this evolution lies the utilization of biaxially oriented polyethylene (BOPE) materials.

TC Transcontinental Packaging invested $60 million to accelerate the commercialization of recyclable BOPE flexible plastic packaging through the development of cutting-edge mono-material providing high-performance and polyethylene films with more heat resistance. In addition to a new innovative film line that will produce BOPE, a first in North America expected to be operational in spring of 2024, the investment includes ancillary equipment and a 120,000 sq ft building expansion in TC Transcontinental Packaging’s Spartanburg, South Carolina facility. According to Josh Ball, director of innovation and sustainability platforms at TC Transcontinental, BOPE is emerging as a game-changer in the world of flexible packaging. Unlike traditional poly films, BOPE materials offer a unique set of properties that make them highly desirable for environmentally conscious brands. But what exactly sets BOPE apart? “The orientation process in BOPE gives it physical properties that are hard to replicate with standard extrusion techniques,” he said. The stretching during production results in enhanced strength, toughness, and tear resistance, making BOPE a versatile choice for a wide range of applications. One of the driving forces behind the adoption of BOPE materials is their eco-friendliness. The issue of end-of-life disposal has long plagued the packaging industry. However, BOPE offers a solution by being easily recyclable. This is especially crucial in the U.S., where recycling infrastructure for films is lacking. “Most of our current packaging solutions don’t have a good endof-life plan; they end up in the waste stream,” Ball said. This is where BOPE comes in, aligning with the sustainability goals of brands. BOPE materials can be recycled through store drop-off programs, ensuring a second life for packaging materials. Currently, the store drop-off program remains the primary avenue

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for recycling PE film, including BOPE materials. Industry experts acknowledge that the adoption of this program has been slow, but it remains a significant part of the recycling landscape. “Store drop-off is the platform for PE film recycling right now,” Ball said. While there are efforts to explore other collection methods, such as regional initiatives and chemical recycling, store drop-off remains the dominant player. To bolster the recycling ecosystem, collaboration between packaging companies and organizations like the Association of Plastic Recyclers (APR) is essential. Companies like TC Transcontinental are actively engaged with APR’s Films Committee, working towards expanding recycling opportunities. “We’re striving to make PE film recycling a broader platform accessible to more people,” Ball says. By adhering to APR guidelines and securing pre-approvals from How2Recycle, TC Transcontinental and other forward-thinking companies are paving the way for recyclable packaging solutions. “The market today is ripe for the taking, in PE monomaterial solutions,” Ball said. “We feel like BOPE offers us the best ability to convert our customers out of our standard, non-recyclable solutions, into a monomaterial recyclable flexible pack.” Notably, increasing the North America supply of recyclable PE also will increase the supply of available recycled PE as feedstock. Ultimately, this helps to feed demand for post-consumer recycled (PCR), like TC Transcontinental’s vieVERTe line. This sustainable product portfolio leverages the benefits of flexible packaging, such as extending shelf life, reducing food waste, and providing product protection, while reducing its environmental footprint. vieVERTe includes packaging solutions that are recyclable, compostable, and made from PCR content. Virgin BOPE production is a spring of content that should be recoverable and reusable as PCR in the same packaging applications that virgin BOPE was initially used in, thus strengthening circularity. BOPE materials have already found their place in a myriad of packaging applications. In dairy packaging, BOPE is used for products like shredded cheese packages, serving as the primary packaging material. This versatile material is also employed in overwraps for multi-pack bundles, offering strength and sustainability in a single package. Brands like Kellogg’s are leading the way by incorporating BOPE materials into their packaging, showcasing the How2Recycle symbol, and encouraging consumers to use store drop-off. TC Transcontinental, along with other converters, is actively working with such brands to provide sustainable packaging solutions that meet consumer demands. As the packaging industry marches forward in pursuit of sustainability, BOPE materials are poised to play a pivotal role. With their unique properties and recyclability, BOPE materials offer a sustainable alternative that resonates with eco-conscious consumers and brands. The industry’s continued collaboration with organizations like APR, coupled with innovative solutions from companies like TC Transcontinental, is set to accelerate the adoption of BOPE materials and drive the transformation towards a more sustainable packaging landscape. Recyclable monomatierials like BOPE, when imbued with barrier properties, represent a significant step forward in the packaging industry’s journey towards sustainability. While challenges remain, the commitment to creating a circular economy for packaging materials is unwavering, and BOPE is at the forefront of this movement.

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SUSTAINABLE PACKAGING Also pressing forward with monomaterials is Toppan, which used PACK EXPO Las Vegas to debut stateside its newly developed all-polypropylene (PP) mono-material barrier packaging (8). Uniquely, the pack exhibits outstanding heat and water resistance, making it suitable for retort sterilization. Efforts to reuse resources from packaging waste in a circular fashion are underway across the globe. In fact, the EU is aiming to make all packaging reusable or recyclable by 2030. Employing mono-material compositions for packaging is an effective way to improve recyclability, and there is demand for barrier films and packaging for PPbased mono-material packages. 8 The new mono-material PP packaging takes advantage of Toppan’s GL Barrier vapor deposition and coating technologies to provide the heat and water resistance needed for retort sterilization, something that has proved challenging with conventional PP films until now. In addition, the absence of metal in the packaging enables microwave heating and the use of metal detectors to check for foreign objects. The new PP substrate adds to the lineup of GL Barrier products that meet growing demand for mono-material solutions, particularly in Europe and North America. Toppan is now supplying all-PP packaging to food manufacturers, with samples having first become available globally in spring of 2023.

INNOVATIONS REPORT

medical device packaging: the company received ISCC Plus certification through the International Sustainability & Carbon Certification (ISCC) at three of its manufacturing facilities in North America and Europe. The new certification allows the company to use chemically recycled raw material using mass balance, such as Eastman’s Eastar Renew resin. Tom Priewe, product manager for medical device films explains: “By utilizing chemically recycled polymers like [Eastman’s Eastar] Renew for our medical device films, we are not only reducing the burden on virgin raw materials, we are also supporting the successful diversion of waste that would otherwise be landfilled or incinerated.” With a booth highlighting a variety of more sustainable packaging, a key new development on display from Mauser Packaging Solutions was its UN-rated tight-head container (10) made with 100% post-consumer resin (PCR). This is the first of its kind, according to Chris Bradshaw, explaining the difficulty of making such a container durable and reliable.

PCR CONTENT FROM THE OCEAN On show at the Klöckner Pentaplast booth was the kpEnhance RM1, a clear nutraceutical blister film produced using a minimum of 30% post-consumer recycled material that is certified, Prevented Ocean Plastic (POP) material (9). The POP program is a global recycling initiative in which tens of thousands of people around the world earn their living collecting bottles from coastlines and preventing ocean plastic.

The RM1 material is designed to be recycled in the RIC 1/PET recycling stream and the company reports that it is a “plug & play” option that runs on existing equipment. “Typically, when you run a sustainable product, you may have to dial it back—slow operations down and buy new tools. Not with this material or our kpNext,” says Jeff Cole, director of marketing communications. Two-layer, three-layer, and symmetrical structures come standard. Applications include vitamins, probiotics, fish oil, gummies, and more. In September, Klöckner Pentaplast also announced a big step in

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Mauser’s closed-loop system is key, Bradshaw says, to better control the consistency of materials being recycled. “We are able to reuse our own resin and create a fortified package,” he says, explaining the different melt levels in various resins. “This is probably a 4 or 6 melt. You might have other resins that are going to be a 30 melt, and that’s going to be a lot more degraded; you’re going to have a bit more impurities with that resin, so it’s not going to allow you to get the stack strength that you need out of it.” The new tight-head container is made with recycled HDPE produced at Mauser’s own industrial packaging facilities. The closed loop also enables Mauser to get a solid color that’s relatively consistent throughout. “That’s very rare when you’re dealing with post-consumer anything or PIR, post-industrial resin,” Bradshaw says. Available in 19- and 20-L capacities, the tight-head containers have a range of uses, from flavored syrups for the beverage industry to fertilizers for cannabis growers. The container is UN-rated 3H1W/Y1.8/100. It satisfies California Prop. 65 requirements for rigid plastic packaging containers (RPPCs) and meets requirements for Prop. 65 heavy metal PPM. The recycled HDPE gives the container about a 60% smaller carbon footprint vs. tight-head containers made with virgin HDPE.

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SUSTAINABLE PACKAGING ECOMM DRIVES DEVELOPMENT OF SUSTAINABLE PACKAGING With Forbes projecting that online sales will account for 24% of all retail purchases by 2026, e-commerce and Direct-to-Consumer (D2C) sales continue at a steady clip. Machinery and material solutions for that sector, especially those offering sustainable packaging options, were a highlight of this year’s PACK EXPO Las Vegas. Hugo Beck, whose new paper e-com fit packaging machine defies easy categorization, was one of a handful of e-commerce machines that had booth visitors doing a double take. Germany-based Hugo Beck is a leader in horizontal film packaging machines, flow packing, and paper packaging machines as well as automation solutions. At PACK EXPO Las Vegas it introduced its paper e-com fit packaging machine, a brand-new solution for paper packaging that is especially suitable for e-commerce applications (11). The roll-fed machine automatically adapts the size of shipping bags to the varying length and width of products placed onto its infeed belt. Products up to 200 mm (7.87 in.) tall can be packaged using a minimum amount of paper. The precisely fitting paper bags are especially notable in that they feature two sewn sides plus a glued top overlap. While sewing a bag closed is common enough in the vertical fill/seal space, this is believed to be a first where horizontal systems are concerned. Both uncoated and coated recyclable papers can be run on the machine. Optional as an inclusion into the system is a print-and-apply labeler, as well, which can come from a variety of sources. Not only does the machine offer a sustainable solution for e-commerce shippers using paper, cotton stitching, and less chemicals, the ecom fit offers flexibility for busy fulfillment, D2C, and e-commerce lines. “The machine can also choose between two different printed papers, for example, for two different brands,” says Timo Kollmann, managing director at Hugo Beck. “The machine itself chooses which paper has to be taken for the product.” According to Hugo Beck, PACK EXPO Las Vegas marked the first showing of the new system in North America. Shows held earlier this year, including interpack, generated considerable interest in the concept and several installations of the machinery are in commercial operation in Europe. “Building upon our successful track record of European exhibitions this year,” says Kollmann, “PACK EXPO is a chance for Hugo Beck to high-

light our commitment to the American market, with our continuous investment in cross-industry machine innovation for efficient and sustainable packaging concepts.”

a video of the machine in operation at pwgo.to/8172. Also developing a bagger capable of handling paper is PAC Machinery. The firm’s FW 650SI Servo Box Motion Inverted Flow Wrapper (12) makes bags to product length at high speeds and can accommodate products up to 12 in. wide or 8 in. high. According to PAC vice president Greg Berguig, the wrapper runs up to about 80/min with film or 30/min with paper. It also incorporates a thermal transfer printer for printing directly on the package or on a label. Berguig adds that the system is especially suitable for apparel and other soft, delicate products. “It’s easy to underestimate how challenging it is to go from plastic film to paper on a flow wrap operation,” says Berguig. “There are so many different grades and thicknesses of paper. Also, how extensible is the paper? Does it have a PE coating or some type of heat-sealable coating?

Let’s just say it’s been quite a learning process. We’ve been working on getting the paper right for some time now. It’s a curbside recyclable paper, but it’s important to point out that the machine can run film or paper. We feel that flexibility is terribly important from the customer’s point of view. They want to future-proof their machinery investments.” Berguig chooses not to identify the source of the proprietary heatactivated coating that goes on the paper, which, during demonstrations at PACK EXPO Las Vegas, was a 55-lb virgin material. He acknowledges that using it instead of film is a more costly proposition. That’s largely why, when a customer chooses to go with paper rather than film for flow wrapping, the decision is not made at the operations or procurement level but more typically in the C suite, notes Berguig.

a video of the FW 650SI Servo Box Motion Inverted Flow Wrapper in action at pwgo.to/8173.

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Also at the booth, PAC Machinery spotlighted the new version of the Rollbag R3200 XL, which can customize the bag’s size according to the item being packaged. Catering to diverse products, it efficiently handles a variety of bag lengths, providing options for both long and shorter packages on the same machine. Because the unit features poly tubing rather than pre-made bags, it lets the user adjust bag length on the fly, resulting in less material waste and delivering a lower total packaging cost, says Berguig. “With the same machine, you can right-size the bagging material so that you’re using less material,” says Berguig. SEE (formerly Sealed Air Corp.) not only unveiled their new corporate brand name but also highlighted a new paper-based addition to its popular AUTOBAG line of bagging and printing stations.

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SUSTAINABLE PACKAGING The AUTOBAG brand 850S system uses paper mailers instead of poly bags, offering a sustainable solution for mail order fulfillment and ecommerce paper applications that run curbside-recyclable paper bags. The 850S can open, label, and seal 7-10 bags per minute, handling two bag sizes: 14 X 19 in. and 19 x 24 in. It also automates the packing process and improves productivity by enabling inline printing of shipping label information. Its air pocket bag-opening technology allows for easy loading of orders and enables inline printing of shipping label information. At the show, SEE representatives demonstrated the unit printing white mailers with no label and kraft envelopes with white labels. Both paper mailers demonstrated crisp graphics like shipping addresses, barcodes, and QR codes. SEE says it is ideal for apparel or soft goods and reduces shipping costs compared to standard corrugated shipping. It is also ergonomic and easy for operators to use, with a small footprint that saves valuable warehouse space. “This machine has a compact design and can easily fit into a work cell,” says Giancarlo Bobbio, marketing director for automation at SEE. SEE also showed a fulfillment work cell loaded with sustainable packaging extensions of its well-known BUBBLE WRAP product. Natalia Balogh, executive director, Fulfillment Platform at SEE, showed us their new paper bubble mailer, which is 100% curbside recyclable and made with virgin and recycled paper. “Not only is it curbside recyclable, but it provides a great level of cushioning by mimicking our iconic [plastic]

BUBBLE WRAP,” says Balogh. SEE also unveiled BUBBLE WRAP Brand Paper Cushioning, which can be fed through a semi-automated wrapping system for fulfillment operations. SEE also highlighted its void fill air pillow solution made with 95% recycled content—out of which 50% is PCR, says Balogh.

SEE present its sustainable fulfillment machines and materials at pwgo.to/8174.

FOCUSED ON RIGHTSIZING Packsize highlighted how two integrated systems—its new software platform and a new machine—can help e-commerce and directto-consumer (D2C) brands reduce waste for sustainability while driving efficiency. The first product is the PackNet Cloud platform, which offers businesses the ability to optimize box packaging efficiency, boost productivity, and reduce their carbon footprint. “PackNet Cloud represents a significant leap forward in packaging technology, making Packsize the industry’s pioneer and sole provider of cloud capability,” says Rod Gallaway, chief executive officer at Packsize. “PackNet Cloud empowers businesses to optimize their packaging operations, reduce expenses, enhance customer satisfaction, and decrease their carbon footprint.” The innovative cloud-based system seamlessly integrates with Packsize’s On Demand Packaging machines, helping e-commerce brands manage carton machines, streamline box production, and integrate packaging workflows.

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SUSTAINABLE PACKAGING Designed to help businesses thrive in a dynamic and ever-growing e-commerce market, PackNet Cloud makes operations both more efficient and more sustainable through several features. First, PackNet Cloud enables multi-tenant environments, allowing businesses to scale flexibly and eliminate IT infrastructure concerns without compromising security and performance. The platform also provides real-time advanced data and analytics capabilities, offering businesses comprehensive insights to make data-driven decisions and optimize packaging operations. Also embedded in the platform is PackNet Cloud Cube, a tool that accurately calculates the dimensions and weight of packages, determining the optimal box size for every order. Included with PackNet are security measures such as data encryption, device authentication, and real-time threat detection, ensuring comprehensive risk mitigation. Packsize’s booth was also abuzz with the company’s X5 solution, a machine released in 2023 that the company describes as the “the world’s first fully automated erected box system and the most advanced, flexible, efficient and sustainable platform available for the e-commerce industry.” The X5, which integrates seamlessly with PackNet Cloud, has already been installed at Crutchfield, a leading e-commerce electronics retailer, as featured in the August issue (pwgo.to/8182) of Packaging World. Packsize says the box-making machine is designed to produce readyto-pack, right-sized erected boxes at industry-leading speed to enhance ecommerce providers’ and manufacturers’ ability to meet customer demand, while addressing labor shortages, associated costs, and waste concerns.

“Unpredictable marketplace challenges over the last two years have compelled retailers and manufacturers to solve complex challenges around packaging technology, labor shortages, and throughput issues to meet consumer demand with sustainable solutions up and down the supply chain,” said Gallaway in an earlier statement. “Our innovations with the X5 solution alleviate these concerns while increasing efficiencies at scale and reducing the environmental impact of e-commerce. We continue to reimagine the future of packaging and create solutions at the nexus of technology, efficiency, and sustainability.” The X5 reduces packaging waste caused by oversized boxes, negates void fill like plastic air pillows, reduces shipping emissions, and improves the end-consumer’s overall experience. Delivering up to 600 ready-to-pack, right-sized erected boxes per hour while automatically and accurately applying up to two labels per box, the X5 is designed to provide an advantage for high-volume e-commerce centers, especially when integrated with Packsize’s software offerings, the company says. Gallaway sees Packsize’s new software/hardware offering as an integrated system that will help e-commerce brands become more sustainable while meeting their logistics needs. With e-commerce and D2C showing no signs of slowing down, right-sized packaging helps companies minimize their costs and environmental impact associated with extraneous and unneeded corrugated boxes while improving parcel logistics, fitting significantly more boxes on freight and delivery carriers. “We know that over-sized boxes are about 40 percent too large and take 20 percent more corrugated than we really need,” says Gallaway.

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SUSTAINABLE PACKAGING “Our machines, paired with the cloud and software, make right-sized packaging for any size order that customers need.” For Gallaway, supplying integrated packaging solutions that allow their brand customers to provide an impactful e-commerce experience for consumers is what it’s all about. “We’re hoping to delight them as they open the package when it gets to their doorstep.”

a video walkthrough of Packsize’s new e-commerce products at pwgo.to/8175.

REUSABLE BAGS, BOXES FOR CIRCULAR B2C In e-commerce materials, one first-time exhibitor grabbing attention in Las Vegas was Boox, whose sustainable products stand at the crossroads where business-to-consumer (B2C) and circularity meet. Boox’s new shipping bag employs Dow Chemical REVOLOOP resin with 50% PCR. Displaying products from its partnership with Gwyneth Paltrow’s lifestyle brand Goop and several others, Boox offered an overview of their B2C packaging system’s approach and capability, emphasizing sustainability and simplicity of use for the consumer. “We’re a mission-driven start-up, supplying reusable shipping boxes and bags to help both brands and consumers eliminate single-use waste from their shipping stream,” says Paige Russell, Boox’s design director. Boox’s bags and box approach focuses on making circular packaging easy to use. For example, each Boox box is embedded with a QR code that, when scanned, instructs the end user on the process for returning

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INNOVATIONS REPORT

the box to Boox. Boox then cleans and refurbishes them before returning them to the client, such as Goop. This cycle ensures that the boxes enjoy a prolonged lifecycle, being used repeatedly for different shipping needs. As B2C continues to grow, Russell sees that the circular solutions provided by Boox will be increasingly in demand. “We’re one of the only companies here at PACK EXPO that provides B2C reusable shipping containers, so we’re really excited to bring this opportunity to brands and consumers,” says Russell. Another new product Boox highlighted was its new polyethylene shipper, the Boox Bag, presented as an alternative to single-use fulfillment poly bags that currently dominate the market. The fruit of a partnership with Dow Chemical and Pregis, the Boox Bag uses Dow’s REVOLOOP recycled plastics resins with 50% Post-Consumer Recycled (PCR) content. According to Russell, Boox’s shipping bag can be used up to 15 times before reaching its end-of-life status, after which it can be repurposed into more bags. In addition to its strong material, the Boox Bag features simple but elegant innovations in packaging design. For example, Boox Bag’s shipping label plays a dual role, also acting as a tamper-proof seal, thereby eliminating the need for an extra piece of tape and further helping to reduce waste. Once shipped, the consumer can also follow simple procedures to open the package without scissors that cause damage to the product. The bag also includes return instructions embedded in the design.

Boox give a tour of its sustainable B2C circular products at pwgo.to/8176. PW

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PMMI Loyalty Members We are proud to recognize the following PMMI member companies who participated in all PACK EXPO and EXPO PACK events in 2023. What a year it was! Thank you for all your support in making these events a huge success.

A. C. Horn Manufacturing

Eagle Product Inspection

Marchesini Group USA Inc.

Schenck Process LLC

ABB Robotics & Discrete Automation

Eam-Mosca Corporation

Massman Companies

Schmalz Inc.

Accraply, Inc.

EBS Ink Jet Systems USA, Inc.

Matrix Packaging Machinery, Inc.

SEW-EURODRIVE, Inc.

AFA Systems Ltd.

Econocorp, Inc.

MBF North America Inc.

Shurtape Technologies, LLC

All-Fill, Inc.

Edelflex

Mespack

Sidel Inc.

ALLIEDFLEX Technologies, Inc.

MoistTech Corp

SIPA North America

AmbaFlex, Inc.

Eirich Machines - American Process Systems

SMC Corporation of America

American Holt Corp.

Elesa U.S.A. Corporation

Morrison Container Handling Solutions

Ampco Pumps Company

Elmar Industries, Inc.

MSSC, LLC

Sneed Coding Solutions, Inc.

APS Packaging and Automation

ELPLAST America Inc.

Multivac, Inc.

Spee-Dee Packaging Machinery, Inc.

Aripack, Inc.

Enercon Industries Corporation

Nalbach Engineering Co., Inc.

Squid Ink Manufacturing, Inc.

AROL North America

Epson America, Inc., Epson Robotics

START International

Axon

EQUITEK

New England Machinery, a Massman Company

Euchner USA

NIMCO Corporation

Balluff Inc.

Ferrum Packaging Inc.

NORD DRIVESYSTEMS

Banner Engineering Corp.

Festo Corporation

NorthWind Technical Services

BellatRx Inc.

Fette Compacting America, Inc.

ORBIS Corporation

BluePrint Automation (BPA)

FILTEC

P.E. Labellers

Boix Machinery USA LLC

FlexLink Systems, Inc.

Pace Packaging, LLC

Brother USA Machinery LLC

Fogg Filler Company

Pacific Packaging Machinery, LLC

BUNTING

Fortress Technology Inc.

Patlite (USA) Corporation

BW Flexible Systems

Fresh-Lock By Presto Products

PDC International Corporation

BW Integrated Systems

H.B. Fuller Company

PFM Packaging Machinery Corp.

BW Packaging

Haver & Boecker USA, Inc.

Piab Inc.

Cablevey Conveyors

Heat and Control, Inc.

Pneumatic Scale Angelus

Cama North America

Henkel Corporation

Polypack, Inc.

Carlo Gavazzi Inc.

Herrmann Ultrasonics, Inc.

Posimat

Cavanna Packaging USA, Inc.

Heuft USA, Inc.

PPi Technologies Group

Cheer Pack North America

Viking Masek Packaging Technologies

Hiperbaric - High Pressure Technologies

PPM Technologies Holdings LLC

Clevertech North America

Vorne Industries

Pressco Technology Inc.

WAGO Corporation

HP Inc.

ProMach, Inc.

Weber, Inc.

Ideal Pase, a Massman Company

ProSys Fill LLC

Weidmüller, USA

Industrial Physics

R.A Jones

WEIGHTPACK, Inc.

Coesia Group Columbia Machine, Inc. Combi Packaging Systems LLC Commercial Manufacturing

SMI USA Inc.

Syntegon Packaging Technology, LLC Teledyne TapTone TOMRA Food TriEnda Holdings LLC Tri-Tronics Company, Inc. U.S. Tsubaki Power Transmission, LLC United Barcode Systems Universal Robots USA, Inc. Urschel Laboratories, Inc. Vacuum Barrier Corporation Valco Melton VC999 Packaging Systems Inc. VDL Packaging Videojet Technologies Inc.

Industrias Tuk S.A De C.V / Hystik Inc.

Reading Bakery Systems

Container Handling Systems Corporation

Wipotec

InkJet, Inc.

Rehrig Pacific Company

Yamato Corporation

COPA-DATA

Intralox

Robatech USA Inc.

Cousins Packaging Inc.

J.W. Winco, Inc.

ROBOPAC / OCME / TopTier

Yaskawa America, Inc., Drives & Motion Division

CSi Palletizing

Jowat Corporation

Palletizers

Key Technology, Inc.

ROBOTIQ

Yaskawa America, Inc., Motoman Robotics Division

Del Packaging, LTD

KHS USA, Inc.

ROVEMA North America, Inc.

Zalkin, A ProMach product brand

Della Toffola USA

Langguth America Ltd

Ryson International Inc.

ZANASI SRL

Domino Amjet, Inc. Dorner Mfg. Corp.

Marburg Industries, Inc.

SACMI USA Group

Please visit packexpo.com to check out the 2024 events and beyond. Untitled-1 2

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INDUSTRY WATCH

Companies Schneider Packaging Equipment Co., Inc., a Pacteon Co., entered the high-speed robotic palletizing market through a strategic licensing agreement with the ITW Hartness Division. TNA Solutions opened a confectionery manufacturing facility in Sydney, Australia, to meet the demands of the global confectionery and nutraceuticals sectors. SOMIC expanded its sales, aftersales, and engineering expertise covering the southeast Asian markets from its newly founded subsidiary, SOMIC Packaging Asia Pacific Co. Ltd., in Bangkok, Thailand. ProMach acquired Sentry Equipment & Erectors Inc., expanding its product portfolio and bolstering its position as a provider of systems integration solutions. Ardagh Metal Packaging and Crown Holdings have partnered to fund two additional recycling facility grants for can capture equipment. The Recycling Partnership launched the Recycling Program Solutions Hub, an interactive tool and resource designed for local recycling staff to connect, optimize, and propel their recycling programs forward. Comexi opened a service and sales hub in Monterrey, Mexico, that will provide service to its customers in Mexico, Central America, and the Caribbean, especially in terms of aftersales service and spare parts supply. Italy-based CMP Phar.ma, a member of the Marchesini Group, opened a 5,000-sq-ft production facility in Vicenza.

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Amcor and SK Geo Centric partnered to strengthen Amcor’s ability to provide access to recycled content for food and healthcare customers in the Asia-Pacific region and globally. Dow and Circusil announced a partnership to construct a state-of-the-art, commercial-scale silicone recycling plant in Kentucky.

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People John Linker was appointed chief financial officer for Husky Technologies. Jen Doxey was named director of sales for Fox Packaging and will be responsible for overseeing the sales operations of Fox Packaging and Fox Solutions. Dan Schmidt was appointed vice president and general manager for ESS Technologies, a Pacteon Co. NJM, a ProMach product brand, announced the appointment of Adam Ellicson to regional sales manager for the Midwestern United States and named Marshall Rutter aseptic applications engineer. Morrison Container Handling Solutions announced the following promotions: Kristin Geiger, director, business operations; Seth Licke, director, assembly operations and service; Garrett Sudicky, director, IT; and Allison Wagner, director, marketing and business strategy. Sutherland Packaging hired Jake Sutherland as chief innovation officer. Tim Kelley was named technical sales and marketing manager for Encoder Products. Pat O’Connor retired from his position as president of Columbia Machine - Palletizer Division, and Mark MacDonald was appointed the new president. Tobias Wetzel rejoined KHS as managing director of sales and service. Alexandra French was appointed CEO for Xampla.

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ADVERTISER WEBSITE

PAGE

A-B-C Packaging Machine Corp. www.abcpackaging.com Aagard Group, LLC. www.aagard.com All-Fill, Inc. www.all-fill.com ALLIEDFLEX Technologies, Inc. www.alliedflex.com American Film & Machinery www.afmsleeves.com Anritsu www.anritsu.com B&R Industrial Automation Corp. www.br-automation.com BellatRx Inc. www.bellatrx.com Bell-Mark Sales Company www.bellmark.com BestCode www.bestcode.co Brenton www.brentonengineering.com Busch Vacuum Solutions www.buschusa.com Cama North America www.camagroup.com Catalynt www.teamcatalynt.com Clysar LLC www.clysar.com Columbia Machine, Inc. www.palletizing.com Columbia/Okura LLC. www.columbiaokura.com CTM Labeling Systems www.ctmlabelingsystems.com Delkor Systems, Inc. www.delkorsystems.com Domino Amjet, Inc. www.domino-na.com Douglas Machine Inc. www.douglas-machine.com DTM Packaging www.dtmpackaging.com Eastey www.eastey.com Econocorp, Inc. www.econocorp.com EDL, a Massman Company www.edlpackaging.com Encoder Products Company www.encoder.com Enercon Industries Corporation www.enerconind.com Eriez www.eriez.com Fallas Automation, Inc. www.fallasautomation.com FANUC America Corporation www.fanucamerica.com FlexLink Systems, Inc. www.flexlink.com FOCKE & CO www.focke.com Formost Fuji Corporation www.formostfuji.com Frain Industries www.fraingroup.com Frazier & Son www.frazierandson.com Glenroy, Inc. www.glenroy.com Graphic Packaging International www.graphicpkg.com Heat and Control, Inc. www.heatandcontrol.com High Tek USA www.hightekusa.com Hitachi Global Air Power www.hitachiglobalairpower.com Hitachi Industrial Equipment & Solutions America, LLC www.hitachi-iesa.com Ideal Pase www.idealpase.com ID Technology www.idtechnology.com IMA FLX www.ima.it INSITE Packaging Automation www.insitepackaging.com Intertape Polymer Group www.itape.com ITW Hartness www.hartness.com James Alexander Corp. www.james-alexander.com JLS Automation www.jlsautomation.com Kaufman Engineered Systems www.kes-usa.com Label-Aire, Inc. www.label-aire.com Material Transfer & Storage Inc. www.materialtransfer.com Markem-Imaje www.markem-imaje.com Massman Companies www.massman.com Metsä Board Americas www.metsagroup.com Mpac Group www.mpac-group.com Modular Conveyor Express www.modularconveyor.com

39 71 75 65 91 81 3 83 48 85 100 17 128 30 51 94 15 148 57 69 11 35 77 13 36 122 31 28 41 9 90 80 29 49 93 47 45 67 22 79 63 35 5 113 141 124 73 23 OBC 64 6 104 43 33, 37 95 27 164

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Multivac, Inc. www.multivac.com 121 Nercon Conveyor Systems www.nerconconveyors.com 24, 134 New England Machinery www.neminc.com.com 34 Nita Labeling Systems www.nitalabeling.com 25 Niverplast NA Inc. www.niverplastna.com 59 Novanta www.novantaphotonics.com 53 ONExia Inc. www.onexia.com 127 Orion Packaging Systems www.orionpackaging.com 115 Packsize International www.packsize.com 117 PAC Machinery www.pacmachinery.com 119 PakTech www.paktech-opi.com 55 Paxiom Automation, Inc. www.paxiom.com 101 PDC International Corporation www.pdc-corp.com 131 Piab Inc. www.piab.com 123 Plan IT Packaging Systems Inc. www.planitpackaging.com 61 PMI KYOTO www.pmikyoto.com 7 PMMI, The Association for Packaging and Processing Technologies www.pmmi.org 161, 163, 169 IBC Pneumatic Scale Angelus www.psangelus.com 118 Point Five Packaging, LLC www.p5pkg.com 129 Precision Automation Company, Inc. www.precisionautomationinc.com 155 Pregis LLC www.pregis.com 165 Printpack www.printpack.com 125 Quadrel Labeling Systems www.quadrel.com 149 R.A Jones www.rajones.com 26 Robatech USA Inc. www.robatech.com 111 Rychiger Canada www.rychiger.com 143 Schubert North America LLC www.schubert.group.com 153 Serpa Packaging Solutions www.serpapackaging.com 105 Shurtape Technologies, LLC www.shurtape.com 97 Signode www.signode.com 126 Sleeve Seal, LLC www.sleeveseal.com 74 SMC Corporation of America www.smcusa.com 137 SpanTech, LLC www.spantechconveyors.com 159 Squid Ink Manufacturing, Inc. www.squidink.com 133 Standard-Knapp, Inc. www.standard-knapp.com 162 Starview Packaging Machinery Inc. www.starviewpackaging.com 147 Syntegon www.syntegon.com 1 Taisei Lamick USA www.taiseilamick.com 167 Teledyne Taptone www.taptone.com 87 TNA North America, Inc. www.tnasolutions.com 107 TRIPACK LLC www.tripack.net 103 Uline www.uline.com 138 Universal Labeling Systems, Inc. www.universal1.com 160 U.S. Tsubaki Power Transmission, LLC. www.ustsubaki.com 82 Valco Melton www.valcomelton.com 139 VDG (Van der Graaf) www.vandergraaf.com 88a Verbruggen Palletizing Solutions Inc. www.verbruggen-palletizing.com 21 Vibac Americas www.vibac.com 135 Videojet Technologies Inc. www.videojet.com 151 Viking Masek Packaging Technologies www.vikingmasek.com 157 WEIGHTPACK, Inc. www.weightpack.com 109 WestRock www.westrock.com IFC, OFC Wexxar Bel www.wexxar.com 158 Wipotec www.wipotec.com 130 Yamato Corporation www.yamatoamericas.com 60 Yaskawa America, Inc. www.yaskawa.com 19 Yaskawa Motoman www.motoman.com 145

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THE INSIDER

By Ben Miyares, Packaging Sherpa

Fossil Fuel Era’s End? characterizing it as “laying the ground for a swift, just and equitable The U.N.’s 28th annual Climate Change transition, underpinned by deep emissions cuts and scaled-up finance.” Conference (COP28) did not agree on “We didn’t turn the page on the fossil fuel era,” said U.N. Climate how best to prevent climate change. It Change Executive Secretary Simon Stiel at the event’s conclusion, “but did agree “to transition away from all this outcome is the beginning of the end. Now, all governments and fossil fuels in energy systems,” a historic businesses need to turn these pledges into real-economy outcomes, if irrelevant declaration. It’s historic because it was the first time the without delay.” annual conclave addressed fossil fuels in relation to climate change, “COP28,” says Luciana Pellegrino, newly elected president of the doing it during a session presided over by one of the world’s largest oil World Packaging Organisation, “was a milestone enabling WPO to producers; irrelevant because the body lacks enforcement mechanisms. raise the voice for packaging on a global stage. COP28 brought a wave The agreement is being parsed for clues to its possible of new international pledges, covering everything from oil-and-gas repercussions and is still being applauded, criticized, and dismissed company emissions and tripling renewables to food systems and by observers at every point on the climate change scale. how the world can better integrate action on climate change and That the meeting came to any consensus at all is amazing, biodiversity loss. since delegates must deliberate under a U.N. protocol mandating “Another milestone for this edition of COP,” says Pellegrino, “was a unanimous vote on any declarations. Also surprising was this the signing of a Global Treaty on Food Systems, due to its relevant consensus came in Abu Dhabi, with the United Arab Emirates impact in carbon emissions from farm hosting COP28. What’s more, Sultan We didn’t turn the page on the to fork and anaerobic degradation, and, Ahmed Al-Jaber, minister of industry and advanced technology for the UAE, fossil fuel era, but this outcome is at the same time, hugely affected by climate change.” and CEO of Abu Dhabi National Oil Co. the beginning of the end. Now, all Pellegrino notes that COP28 not only (ADNOC), a UAE-owned oil company that’s one of the world’s biggest, served governments and businesses need set out the objective of transitioning away from fossil fuels but also, set as president of COP28. to turn these pledges into real2050 as the deadline for achieving Some climate advocates are economy outcomes, without delay. carbon neutrality, declaring as “crucial” disappointed that COP28 didn’t the current decade for climate efforts accomplish more. But others are – Simon Stiel, U.N. Climate Change aimed at curbing the rise in the planet’s heartened that even in this oil-rich Executive Secretary temperature. location, the the summit reached Lindy Hughson, president of the International Packaging Press consensus to “transition away” from all fossil fuels in energy systems Organisation (IPPO), believes “COP28 outcomes signify considerable “in a just, orderly and equitable manner in this critical decade to momentum in recognizing the need to transition away from fossil enable the world to reach net zero emissions by 2050, in keeping with fuels.” For packaging that would mean reducing our reliance on virgin the science.” plastic raw materials and shifting towards renewable energy. The conference didn’t unveil any specific new tactics for lowering “The clear message emerging from COP28,” says Hughson, “is global temperatures or sea levels. It did, however, issue a report, that the world’s food value chains are inefficient and unsustainable. called a Global Stocktake (read it at pwgo.to/8209), that touts what it It is estimated these value chains produce a third of the world’s sees as its accomplishments, and characterizes some of its failures as greenhouse gas emissions, yet one third of all food harvested is lost as-yet unaccomplished challenges. or wasted, driving deforestation and biodiversity loss. After energy Among COP28’s posted achievements generating the loudest transformation, food systems transformation is a vital unlock for headlines was its call to transition away from fossil fuels—the first addressing climate change.” COP28 discussions, adds Hughson, time a U.N. climate summit broached reducing use of fossil fuels. “recognized the circular economy as an important way of mitigating Although not directly addressed, packaging interests are sensing climate change.” potential impacts on their operations from COP28’s “transition President Sultan Ahmed Al Jaber labelled the fossil fuel agreement away” message, as the edited and abridged comments of two of my “historic,” adding that its true success would be in how it is colleagues will later note. implemented around the world. “We are what we do, not what we Underscoring what it considers the significance of the COP28 say,” he told the audience. “We must take the steps necessary to turn agreement, the U.N. declared at the conclave’s conclusion that the this agreement into tangible actions.” PW agreement signals the “beginning of the end” of the fossil fuel era, Ben Miyares, Packaging Sherpa, is a packaging market and technology analyst and is president of The Packaging Management Institute, Inc. He can be reached at bmiyares@packmgmt.org.

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