Marriage of convenience
Transcription
Marriage of convenience
impressive innovations FROM 2011 January 2012 Packaging materials and equipment expected to impact the market. 29 Marriage of convenience Popular packaging elements merge in functional design 22 Flexibility fosters frozen bonanza 26 Tray lids a perfect fit 36 www.packagingdigest.com form/fill/seal Zippy new carton is revolutionary Plantation brand sugar from U.S. Sugar Co., is the first product to be packaged in the new carton. Zipbox, a new carton technology that consists of a poly-coated paperboard carton incorporating an integral plastic header with an attached zipper, could revolutionize consumer cartoning. A Jack Mans, Plant Operations Editor A new carton technology could be opening new marketing vistas for U.S. Sugar Corp. It is the first company in the world to market its product in a revolutionary new cartoning concept that integrates a poly-coated paperboard carton with an attached flexible film header containing a zipper. Zipbox is a joint venture between T.H.E.M. and the Zip-Pak division of Illinois Tool Works Inc. (ITW). An innovative package format that combines the stability of a carton with the convenience of a resealable flexible package, Zipbox facilitates direct-filling of products without needing an inner liner. T.H.E.M. (Technical Help in Engineering and Marketing) is the primary inventor of Zipbox. ITW is the worldwide licensee and commercial interface to brand owners and converters. Plantation brand sugar is first The first product to be packaged in the new carton is Plantation brand sugar from U.S. Sugar Co., but the Zipbox is suitable for a variety of consumer applications, including cereals, snacks, cookies, frozen foods, pet foods and powdered laundry detergents. In fact, anything that can be packed today in a carton with a liner, pouch or canister is a candidate for the Zipbox. Among the many features of the new Zipbox is a DoubleZip pressto-close zipper on top that allows for easy opening and closing. An airtight seal configuration on the package bottom eliminates the need for an additional liner to maintain product freshness. The zippered pouch folds down before filling for efficient sealing and shipping and is easily opened when the top flaps are lifted up by the consumer. According to Neil Kozarsky, president and CEO of T.H.E.M., the liner-less design provides for a minimum of 10 to 40 percent additional content, and/or source Zipper and film are on rolls on the front of the assembly machine (top). It attaches the zipper to the film (bottom left) and then attaches the plastic header to the carton. (bottom right). through directional and tensioning rollers insights, product shelf-life and as it enters the machine and is then folded other testing. to form a “C” shape with the trough of “Bringing a brand new the “C” facing upward. The zipper is package format to market can be challenging for brand managers,” pulled directly into the machine and is inserted down into the trough in the film, Kozarsky says. “As we learned which is heat sealed above it. with our stick pack business, by The film then passes over a right-angle enabling short-run production, plough so it is traveling beside the cartons. we can provide guidance Ploughs open the sides of the film and to companies who want to rollers fold it over the edges of the carton, implement the Zipbox, allowing after which heated bars come together them to conduct research and and heat seal the film to the cartons. bring it to market faster.” Registration marks on the film regulate T.H.E.M. has a fully Ultrasonic units seal the film between the cartons, and a the film travel so it is always perfectly operational on-site R&D guillotine cutter descends to cut the cartons apart. aligned with the cartons. center located at its Marlton, reduction, when compared to traditional Ultrasonic units seal the film between the NJ, headquarters, with pilot bag-in-box packaging and 40 to 60 percent production to scale up capabilities. cartons, and a guillotine cutter descends to better cube-out on pallets. In fact, he says Frank Kelly, business manager of Zipbox cut the film, producing Zipbox blanks. The that the Zipbox’s rectangular footprint Zipbox blanks discharge onto each other on for ITW, says, “The Zipbox concept has offers better space efficiency than standa conveyor that gives a speed blip every 20 generated considerable excitement from up pouches and canisters all the way from cartons to separate the stacks into groups. CPGs and consumers as an intuitive, manufacture to retailer shelves. easy-to-use carton unlike any William McDaniel, president and CEO package style on store shelves of U.S Sugar Corp., says, “My customers today. Demonstrating the are always looking for new packaging ability to produce Zipbox ideas, and there has not been a lot of on a broad scale is the next innovation in the sugar category for a step in revolutionizing the number of years. I like the idea that the way products are brought to Zipbox offers the best qualities of cartons market.” and resealable pouches.” Producing the Zipbox According to McDaniel, the Plantation The Zipbox cartons are line extension offers some key potential produced on a Model MP2 benefits for U.S. Sugar. “It will address a Assembly Machine from Zipnumber of issues that retailers have with pouches throughout distribution. First of all, Pak Systems. This is the same machine that is used to apply it’s unique; it will stand out on the shelf in comparison to the traditional packages. The zippers to flexible bags. In this operation, folded Zipbox merchandises well on shelf; it is very cartons, which are supplied by stable and secure. Malnove Inc., are fed from a Zipbox cartons are placed in a magazine with the zipper “It is priced competitively with the section facing upward. The cartons are filled through the magazine at the inlet end of traditional offerings, particularly when bottom, so the cartons are rotated 180 deg and are placed in the machine onto a vacuum you consider total distribution and the carrier with the tops facing downward. conveyor that transports them logistics costs. To emphasize the last through the machine. The point, cost is very, very important. Our vacuum helps maintain the analysis on a total system basis resulted in spacing between the cartons, us moving forward with the Zipbox.” which is critical, and top belts McDaniel continues, “We are in the travel simultaneously with the early testing stages with key retailers. If cartons to help maintain exact our activities with the [Zipbox] raw sugar control and spacing, which is product are promising, we plan to expand ¾ in. in this case. to a complete line of sugars. In fact, we Zipper and film are on rolls think retailers will almost require it.” on the front of the machine. To facilitate implementation of this new The zippers are DoubleZip packaging concept, T.H.E.M. installed zipper profile from Zip-Pak a short-run demonstration packaging and the high-barrier EVOH/ line at its headquarters in Marlton, NJ. PC/PE coextruded film is This enabled consumer-packaged goods Fingers on the two sides of the chain squeeze open the supplied by Curwood Inc. companies (CPGs), like U.S. Sugar, to carton, after which hot-melt glue is applied to the two ends of the plastic header. The flat film is pulled source filled Zipbox packages for consumer The cartons are filled through their bottom ends by an auger filler that uses a race-track arrangement of 10 funnels that travel above the cartons during filling. Carton erecting, filling and sealing Carton erecting, filling and sealing is done on a system designed and built by Yeaman Machine Technologies. In this process, the Zipbox cartons are placed in a magazine with the zipper section facing upward. Suction cups on a rotating arm pick individual cartons out of the magazine and travel in a circular path to place the cartons into the lug chain of the erecting section. The cartons are filled through the bottom, so the arm rotates the cartons 180 deg during the transfer, so that they are placed in the carrier with the zipper tops on the bottom and the open carton bottoms facing upward. According to Bill Yeaman, president of Yeaman Machine Technologies, handling cartons with the zipper attached is what separates this operation from standard cartoning operations. “We had a lot of trials and challenges before we finalized the system to properly seal the cartons,” he says. The box must have side gussets so that the film headers will take shape properly when the carton is erected. To erect properly, the plastic headers have to be partially folded in the same direction as they enter the lug chain, so the cartons travel past an upward sloping steel plate that pushes them all backward as they enter the chain. Fingers on the two sides of the chain then come together to squeeze open the carton. Next, hot-melt glue is applied to the two ends of the plastic header, after which lugs rise and fold the plastic up onto the two end panels of the carton. The next difficulty was that the folded plastic end flaps would pull loose before the glue set. To solve this, Yeaman installed metal brackets that slide down on each side of the carton to hold the end flaps in place. They rise to allow the cartons to be transferred to the filling section. Yeaman is designing a different style carton erector that uses a horizontal ram to form the carton and Hartness Intl. Inc., which is a sister company to Zip-Pak, is also working on a proprietary carton erector for use with the Zipbox. The formed cartons make a rightangle transfer into the carrier chain that transports them through the filler. The sugar is filled by an auger filler from All-Fill Inc. The filler uses a race-track arrangement of 10 funnels that travel above the cartons during the filling process. In this operation, the cartons are upside down and are filled through their bottoms. After filling, the cartons are transported through the sealing zone of the cartoner. During Packaging Digest’s visit, T.H.E.M. was gluing the sift-proof bottoms with hot-melt glue. The gluing system can be replaced with a heat-sealing system if the customer prefers that bottom. The entire ZipBox production line is being moved to the Power Packaging contract packaging plant in Batavia, IL in January 2012. Production for U.S Sugar and future production of other products will be done there. Power Packaging, an Exel company, is the nation’s largest contract manufacturer of consumer packaged goods. According to Jim Ellis, senior director of sales and marketing, Power Packaging has partnered with T.H.E.M. on projects for years and was involved from the beginning with the Zipbox project. Ellis says, “Zipbox is an exciting first-to-world innovation that solves unmet consumer needs, meets CPG manufacturer and retailer green initiatives, and provides a unique branding opportunity for multi-serve products. “Generally, new packages resonate with some groups and not with others. Zipbox is highly intuitive and tested equally well across all demographics in focus groups. CPGs and retailers are no different— everyone is interested in Zipbox.” 0 More information is available: All-Fill Inc., 610-524-7350. www.all-fill.com Curwood Inc., 920-527-7300. www.curwood.com Hartness Intl. Inc., 800-845-8791. www.hartness.com Malnove Inc., 402-330-1100. www.malnove.com Power Packaging, 630-377-3838. www.exel.com/exel/pp_home.jsp T.H.E.M., 800-322-8436. www.them.net; www.zipbox.net Yeaman Machine Technologies, 847-758-0500. www.yeamanmachine.net Zip-Pak, Div. of Illinois Tool Works Inc., 773-715-3121. www.zippak.com Zip-Pak Systems, 770-921-1777. www.zippak.com Reprinted with permission from PACKAGING DIGEST, January 2012. On the web at www.packagingdigest.com. © A UBM Canon Publication. All rights reserved. Foster Printing Service: 866-879-9144, www.marketingreprints.com. For more information, contact Frank Kelly at [email protected]. Visit our website at www.zipbox.net to learn how Zipbox® can enhance your brand.