Plant-based dairy on trend

Transcription

www.sig.biz
Edition 1/2015
Plant-based
dairy on trend
combidome: new products | combisafe: additional 440 ml-volume | Brazil: plant extension
completed; new projects | frischli: new customer opts for food option filling machine |
screw cap combiSwift now also for food composite | 40 % of all SIG cartons FSC-labeled |
web-shop and print portal online | Fully automated feeding of sleeves for high-speed
filling machines
IMPRINT ///
SIG COMBIBLOC MAGAZINE 1/15
Published by
SIG International Services GmbH
Rurstrasse 58; D-52441 Linnich
Editors
Carolina Boni, Ingo Büttgen,
Bea Callanta, Luciana Galvão, Jan
Gansow, Norman Gierow, Sandra
Hallaschka, Dominik Haug,
Matthias Krusche, Claudia Meza,
Bianca Roßkopf, Heike Thevis,
Jörg Trebels, Julia Trebels
Concept and design
Arnold.KircherBurkhardt AG,
Uerikon, Switzerland
SIG International Services
Pictures
SIG Combibloc
Flamisch Foto + Film
istockphoto
fotolia
Diego Pisante
Jaqueline Alves
Lithography
Appel Grafik, Frankfurt
Print
Appel Grafik, Düsseldorf
Contact
T: +49 2426 79 -0
[email protected]
Internet
www.sig.biz
SIG Combibloc Magazine is
published in German, English,
Spanish, French, Italian,
Portuguese, Polish, Russian
and Chinese.
All rights reserved. Articles
indicated as being contributed
by other writers do not
necessarily reflect the views
of the publisher. No part of this
publication may be r eproduced
or electronically distributed
without the prior permission of
the editorial team.
Dear readers,
We hope you’ve had a great start to the New Year. In 2015, again
our mission is to offer our customers added value that makes their
lives easier. A recent example of this is SIGdesign2print, a new
website which we’ll be introducing to you in this issue. With this
website, we’re supporting our customers to make the process from
packaging design to preprint faster and easier. In addition, the new
Online Spare Parts Shop offers our customers the chance to order the
spare parts they need, anytime and in a simple way.
We also want to offer our customers technical solutions and
packaging options that are tailored to their needs and unique in
our industry. In this respect, we offer with combisafe in a 440 mlvolume a first in the field of autoclavable carton packs: food products in carton packs are now also available in exactly the same
drained weight consumers know from the food metal can. Another
example is our combidome cardboard bottle, which is proving a success. Dutch company HERO, for instance, has opted for this innovative packaging. Industry specialists are excited about it too:
combidome won numerous design and innovation awards last year.
As unique as combidome is our Food Option Technology. German
dairy group frischli has opted for this technology, establishing the
basis for a range of innovative products. Thanks to the Food Option
Technology, frischli is able to fill highly viscous products and products with particulates in carton packs using the slightly adapted
standard filling machine for beverages. And in the push towards
greater automation, we’ve taken a big step forward: with the
Robotic Magazine, we can now offer a fully automated magazine for
our high-speed filling machines.
I hope you’ll enjoy reading about these and other topics in our new
customer magazine.
Markus Boehm, Chief Market Officer SIG Combibloc
2 SIG COMBIBLOC MAGAZINE 1/15 ///
Contents
04
A world first in retort carton
combisafe now also available in
440 ml volume.
14
combidome:
A real hero for 'Hero'
Netherlands: popular juice
brand now available in the
innovative carton bottle.
16
Fully automated sleeve feeding system for high-speed
filling machines
Save time and costs with the
Robotic Magazine.
20
combiSwift now also for
food carton packs
Ultimate convenience: screw
cap now available for carton
packs specially made for food
products.
22
frischli creates the basis for
innovative of products
German dairy company invests
in Food Option Technology:
more than 100 products filled
in combiblocStandard.
26
20 years of FSC™
Recognition and popularity are
increasing. 40 per cent of all
SIG carton packs carry the
FSC-label.
06
COVER STORY
Plant-based dairy on trend
They are among the fastest-growing beverage
segments world-wide: plant-based beverages as
alternatives to dairy products. And soy is no
longer the main driver of this growth. Innovative
beverages made from nuts and grains are more
in demand than ever.
28
Success in fast-growing
market
Start of extrusion line at SIG's
production plant in Brazil. And
six new filling machines have
been installed at the premises
of Quatá Alimentos.
32
Useful tips for designing
SIG Combibloc carton packs
With a new, special website,
SIG is supporting its customers
to make the design process
more efficient.
34
Ordering online:
SIG Spare Parts Shop
With the new spare parts shop,
it is now possible to order spare
parts any time, quickly and
easily.
/// SIG COMBIBLOC MAGAZINE 1/15 3
A world first in retort
carton
Germany: Three ‘Bio Sonne’ brand vegetable varieties have been
launched in combisafe. For the first time, the heat-resistant carton pack
is available in the 440 ml-volume – exactly the same drained weight
consumers know from the food metal can.
440 ml
W
ith the launch of peas, corn,
and peas & carrots in the
heat-resistant carton pack
from SIG Combibloc, the first
combisafe carton packs in the new 440 ml-
volume are on sale in Germany. The ‘Bio
Sonne’ brand vegetable varieties are filled by
German food manufacturer Jütro.
appearing all the time. World-wide, more and
more retailers, food companies and consumers are being won over by the advantages, and
are reaching for products in carton packs." The usual quantity, greater convenience
The 440 ml-volume is an innovation in the industry, because products which consumers
have traditionally bought in standard food
metal cans are now also on sales shelves in carton packs, packaged in exactly the same
drained weight like in metal cans. It means
consumers do not need to get used to a new
product quantity when they opt for traditionally canned products packaged in a carton
pack. On the contrary: They can get the usual
product quantity, and benefit from the many
advantages of the carton pack. The perforation
right across the carton top makes it possible to
open the pack easily without additional tools
such as scissors or knives, and empty it out
completely: Another reason for consumers to
rethink their opinion and start making use of
traditionally canned products packaged in cartons packs.
Until now, combisafe has come in 200, 300,
400 and 500 ml volumes. Now, the 440 ml-
volume can also be offered. All can be filled on
a single SIG Combibloc filling machine.
Dominik Haug, Global Product Manager Food
at SIG Combibloc: "The major strengths of carton packs are their convenience, their product
protection qualities and their good environmental characteristics. And in terms of logistics and advertising effectiveness on the sales
shelf, cartons clearly outperform competing
packaging solutions. In addition, our carton
packs are, of course, free from Bisphenol A.
More than 200 products are currently sold
in the heat-resistant carton pack, and more are
combisafe
combisafe is a carton packaging from
SIG Combibloc that is suitable above all for
particularly chunky foods, and for all food
products that cannot pass through a pumping
system and an aseptic process – such as pulses
and vegetables, fruit, convenience foods and
stews.
Through the use of three modular filling
units, including a high-precision multi-head
weigher, a hugely diverse range of products can
be filled in combisafe. After the products have
been filled into the carton pack, which is open
at the top, the carton top is sealed ultrasonically.
The carton packs are then automatically conveyed into an autoclave, which can be either
static or rotary. In the area of long-life food
carton packs, the use of rotary autoclaves is a
world first. Not only do these rotary autoclaves,
in which package and product are sterilised
together, guarantee maximum product quality;
through the continuous rotation of the carton
packs during heating, they also make it possible
to fill and process certain products in the first
place.
Plant-based
dairy on trend
They are among the fastest-growing beverage
segments world-wide: plant-based beverages as
alternatives to dairy products. And soy is no longer
the main driver of this growth. Innovative beverages made from nuts, grains, seeds and ancient
grain varieties are more in demand than ever.
I
t is estimated that in 2013 alone, more than
these products for other reasons, these days
1,000 new plant-based dairy alternative
soy no longer has to be the first choice as an
products came onto the market – around
alternative. Some consumers even develop altwice as many as five years ago. And soy is
lergies and intolerance problems with soy.
no longer the main driver of this growth. A lmond milk, on the other hand, is one of the
I nnovative beverages made from nuts,
products seeing very dynamic growth.
grains, seeds and from ancient
And coconut, rice and oat drinks are
grain varieties such as quinoa,
also high on consumers’ popubuckwheat and millet are
larity scale”.
“Market research
more in demand than evThe trend for consuming
institutes suggest that
er. In addition, vegetable
plant-based beverages as a
up to 2018, world-wide
protein beverages made
growth in the plant-based protein source has its roots
from coconuts and pulses
in Asia. Cows have never
dairy market will be in
are also finding a ready
been very prevalent in the
excess of 15 per cent
market with consumers.
history of Asian civilisation.
per year.”
The reasons for this
Consequently, the number of
Matthias Krusche
growth in the segment are
people who suffer from lactose
many and varied. Lactose inintolerance is higher than in
tolerance is one of the drivers. In
western countries. The production
addition, more and more consumers are
and consumption of dairy substitutes is
making a conscious effort to eat healthily. For therefore traditionally higher in Asia than in
this reason, they pay close attention to the
the west. However, in western countries too a
foods they consume. The ingredients analysis
turn
around is now becoming noticeable, in
of the food plays just as much of a role as its
terms of the consumption of milk and milk alprovenence, cultivation and processing. Plant- ternatives. Matthias Krusche: “Until just a few
based dairy alternatives are naturally lac- years ago, most market launches of plant-based
tose-free and are generally considered to be
dairy alternatives were appearing on retail
lower in cholesterol and fat than milk from an- shelves in Asia, but now it’s the USA, Brazil,
imals. But they usually offer a similar protein, South Africa and European countries such as
mineral and vitamin content. From a health
the UK, Belgium and Spain where growth
viewpoint, plant-based dairy alternatives are
rates have jumped substantially, and where
often more easily digested than dairy products
there is still further potential in the future.
– this also applies for people who do not suffer Surveys conducted by various market research
from lactose intolerance.
institutes suggest that up to 2018, worldwide
Matthias Krusche, Global Market Segment
growth in the plant-based dairy alternatives
Manager at SIG Combibloc: “More and more
market will be in excess of 15 per cent per
consumers are experiencing sensitivity reac- annum”.
tions to particular foods, and so are paying
closer attention to what they eat. More than a
Soymilk: no lactose, little fat
third of all consumers now specifically avoid
Beverages made from soy continue to be popproducts due to allergies or intolerance prob- ular as dairy alternatives, even though they
lems. For many consumers who, due to issues
are no longer the main drivers of growth in
such as lactose intolerance, have to avoid ani- the segment. To make soy milk, soy beans are
mal-origin products, or who choose to give up
shelled, soaked and ground with hot
Plant-based dairy market (in million litres)
2009
2013
2019
America North
336.2
434.4
584.9
America South
120.0
134.3
164.4
2,886.0
5,010.5
8,797.0
426.3
465.6
506.3
14.4
34.0
69.5
3,782.9
6,078.8
10,122.1
Asia Pacific
Europe
Middle East/Africa
Total
Wordwide, the segment of plant-based milk alternatives shows continuous growth.
Source: SIG Business Intelligence
Tofutown: Vegetarian treats from Germany
I
t all started in 1981, with a small vegetarian
whippable organic soy cream. The cream products,
‘hippie collective’ called Soyastern. This collec-
and the company’s rice and soy drinks, are on sale
tive has now grown into Tofutown, a pioneer
in carton packs.
and innovator in the field of vegetarian foods,
For Drosihn, healthy, moderate growth is the
which is garnering world-wide attention with its
company’s motto. In pursuing this aim, ‘Dr. Tofu’,
products. In Europe, Tofutown is one of the lead-
as he is sometimes known, is taking a fresh and
ing producers of meat and dairy alternatives man-
novel direction. For instance, in his video cooking
ufactured from plant sources. The company relies
blog he presents, among other things, self-tests
on filling technology from SIG Combibloc, and
of Tofutown products: www.youtube.com/user/
uses a CFA 310 filling machine to fill a range of
VianaTV. Drohsin also runs the Tofumusic record
soy and rice drinks in combiblocSlimline.
label: At www.youtube.com/user/TofumusicTV,
After initially having the products filled in
viewers can judge his musical activities.
SIG Combibloc carton packs by a co-packer, company founder Bernd Drosihn decided that Tofutown
should invest in a SIG Combibloc filling machine of
its own: “We’ve been won over by the efficiency
and flexibility of the machine. The individual processes are perfectly coordinated with one another.
It runs like a toy on a slot car track – smooth as silk!”
More than 110 vegetarian products
Bernd Drosihn: “In a single sentence, our business
model is: we make foods that people like eating
and drinking, without resorting to the use of animal products. We use organic raw materials such
as wheat, soy beans and organic vegetables. Overall, at our three German factories in Wiesbaum
(Vulkaneifel), Lüneburg and now also Neukirchen
in North Hesse, we make more than 110 vegetarian products – around 35 per cent of which are
exported”. And not just within Europe. Tofutown
products are also available in North America and
in some parts of Asia, Australia and the Middle
East. The product portfolio extends from vegetarian burgers and sausages to tofu products, sandwich spreads, vegetarian lards and cheeses, soy
and rice drinks and pasta sauces. In addition, in
2004 Tofutown developed the world’s first
More on Tofutown products at www.tofutown.com
water. Soy milk has a high protein and
vitamin content, comparable to that of cow’s
milk. 100 ml of a soy drink delivers about
3 grams of protein; cow’s milk has around
3.2 grams. But soy milk is much lower in fat,
and thus also lower in calories, than cow’s
milk, and is free from cholesterol and gluten.
Almond milk: the favourite alternative
It is almond milk that accounts for much of the
global growth in the plant-based dairy alternatives market. To make almond milk, toasted and ground almonds are mixed with water.
Almond milk is low in fat and sugar, and so
has few calories – about 20 per 100 ml. But at
0.5 grams per 100 ml, the protein content is
comparatively low. Just like soy drinks, almond milk is cholesterol- and gluten-free.
Seeds and grains: high in carbohydrate
and fibre
Dairy alternatives made from grains or seeds
such as rice, oats, hemp or quinoa look
similar to cow’s milk, but have a lower protein
content and a higher carbohydrate and fibre
content. Beverages made from grains and
seeds also contain no lactose and are low in fat.
Rice drinks are popular because of their
creaminess. They have the highest sugar content among the plant-based dairy alternatives.
To make the beverages, rice is ground, boiled
in water and mashed. After sieving and filtering, safflower or sunflower oil is added to the
filtrate, which emulsifies it and refines the
taste. The rice itself is virtually fat-free. The
protein content in rice drinks is 0.1 grams per
100 ml, so it is low compared to other plantbased dairy alternatives.
sugar and fat, and they are well-received by
consumers particularly thanks to their creamy
texture.
Less water, a plus for the environment
The popularity of plant-based beverages is given a further boost by consumers’ growing
environmental awareness. According to manufacturer’s information, producing one litre of
soy, almond or coconut milk, filled in a carton
pack, requires around 70 per cent less water
than is needed to produce the same quantity
of cow’s milk.
Carton packs have established themselves
as a particularly apt packaging solution for
plant-based beverages because they fit with
the philosophy of most food manufacturers,
for whom naturalness and the responsible use
of resources are important issues. To make oat drinks, which are climbing
up the popularity scale with consumers,
dehusked oats are coarsely ground, added to
water and boiled. The liquid is fermented for
several hours, then sieved and filtered. In this
case too, the filtrate is emulsified with sunflower or rapeseed oil, to give it the white colour characteristic of milk. An oat drink delivers around 1 per cent protein per 100 ml, and
an equivalent quantity of beta-glucane. This is
a substance which helps lower the cholesterol
level in the human body.
Coconut milk: plenty of potential
Coconut milk too has plenty of potential in the
area of non-dairy protein sources. Depending
on manufacturer, these beverages, made from
finely ground coconut flesh and water, have up
to 2 grams of protein per 100 ml. These products are also cholesterol-free and have little
New coconut beverages make not just
holidays ‘So Delicious!’
organic coconuts, are guaranteed dairy-free,
T
ed extraordinary growth of more than 30 per
and ‘So Delicious!’: the creamy coconut bev-
cent. For Murray proof that the dairy-free pro
erages from US food manufacturer So Delicious
ducts segment has some of the best prospects in
Dairy Free are made for everyone who, for health
the food industry. In contrast to soy-based dairy-
reasons or simply on principle, wants to avoid
free products, it is in particular almond and coco-
dairy products, or is just looking for new ways to
nut milk that have strong potential. The reason for
eat a varied and healthy diet. Following the mar-
this lies in the growing number of consumers who
ket success of Cococcino Latte and Cococcino
are using dairy-free products not due to tolerance
Mocha, summery iced coffees made from organic
problems, but because they place value on sus-
coconut milk and Fairtrade coffee, for the winter
tainable consumption and are looking for ways to
season, So Delicious Dairy Free launched the three
eat more healthily. Mike Murray: “Many people
flavours Pumpkin Spice (pumpkin flavoured), Nog
prefer the taste of almond and coconut milk, and
(eggnog with nutmeg) and Mint Chocolate (cocoa
often consumers also like the texture of the prod-
and mint) in the aseptic carton pack combifitMidi
ucts better than that of other dairy-free products.
with combiSwift screw cap.
At the same time, these days many people have a
hey are made exclusively from GM-free
In the last five years, the company has record-
sceptical attitude towards soy products, in terms
Successful for more than 25 years
of genetic modifications. When consuming al-
For more than 25 years, So Delicious Dairy Free
mond and coconut milk, it’s a completely different
from Oregon has been developing high-quality,
story. We guarantee consumers that our products
dairy-free and plant-based beverages.
are made exclusively from GM-free ingredients”.
Mike Murray, Vice President Marketing/R&D at
So Delicious Dairy Free: “Our company philosophy
is based on treating everything with respect –
people, animals and plants. For that reason, we
have specialised in dairy-free products made from
ingredients that are proven GM-free”. And success
has followed. The ambitious company’s product
range now includes beverages, coffee creamers,
ice cream desserts, yoghurt products and various
products such as soups and sauces, as well as ingredients for fancy cakes and other baked goods –
all entirely without milk.
More on ‘So Delicious!’ at www.sodeliciousdairyfree.com
or on Facebook
combidome:
A real hero for ‘Hero’
Netherlands: popular juice brand now available in the
innovative carton bottle.
N
othing suits a real ‘hero’ better than superhero
packaging. So well-established Dutch company
Hero (part of the Swiss-based Hero Group) is pack
aging its newly introduced ‘Hero’ Fairtrade juices in
combidome. The innovative carton bottle, which pairs the best
features of a bottle with the best features of a carton pack, has
already won multiple high-profile international packaging and
design awards.
“When exacting quality standards, technical expertise and
attention to detail come together, something very special is created. Consumers experience this every single day when they
drink our ‘Hero’ Fairtrade juices. The standards we set for ourselves are the same ones we demand from the packaging in
which our products are put on the market”, says Ralf Wijnveldt,
Channel Marketeer at Dutch food manufacturer ‘Hero’.
For that reason the company, founded in 1914 with offices in
Breda, has now opted for the combidome carton bottle from
SIG Combibloc. The juices with 100 per cent fruit and Fairtrade
ingredients come in Orange, Apple and Multivitamin flavours.
They are available in the Netherlands in combidome 1,000 ml.
Ralf Wijnveldt: “The prize-winning combidome carton bottle
gives our ‘Hero’ products not just optimal protection, but a fitting, interesting face as well. We’re committed to keeping up
traditions, but we also aim to move with the times and set the
benchmark when it comes to outstanding quality – so we’re on
the right track with combidome”. 14 SIG COMBIBLOC MAGAZINE 1/15 ///
Fully automated sleeve
feeding system for highspeed filling machines
Save time and costs with the Robotic Magazine from SIG Combibloc.
“Thanks to a special
line set up and the
Robotic Magazine, we are
now able to run a highspeed packaging line with
one operator at a high
efficiency rate.”
Peter Bratsch, Arla Foods
W
ith the new Robotic Magazine
(R-CAM) for high-speed filling
machines, capable of filling up
to 24,000 carton packs per
hour, SIG Combibloc is now offering customers
a packaging line component that is of interest
on the road to more automation. The new
Robotic Magazine fully automatically loads the
filling machine with carton sleeves which improves the organisational efficiency and reduces
labour costs.
Food and beverage manufacturers using filling machines from SIG Combibloc receive the
carton sleeves in shipping boxes on pallets. Up
to now, the shipping boxes had to be removed
from the pallet and loaded into the high-speed
filling machine's magazine by an employee.
With six tracks and a top speed of up to 24,000
cartons per hour, this ties up personnel.
Jan Gansow, Global Product Manager responsible for line automation at SIG Combibloc:
“The aim was to develop an automatic magazine for high-speed filling machines similar to
the Combibloc Automatic Magazine (CAM) which
is already available for other types of SIG
Combibloc filling machines. With the new
Robotic Magazine, we even went one step further
and developed a fully automated magazine: the
shipping boxes are removed from the pallet,
opened and the filling machine is loaded with
carton sleeves. This process does not require
any action from the machine operator. This
means using the Robotic Magazine reduces costs
as it saves labour time and improves organisational efficiency”.
Running up to 2.5 hours – without the need
to load a new pallet
The Robotic Magazine consists of two parts: a pallet magazine and an unpacking station. The
pallet magazine offers space for a Euro pallet,
industrial pallet or Australian pallet. Once the
pallet is inside the magazine, a scanner
R-CAM 724: Pallet magazine
reads the pallet pattern, i.e. how the shipping boxes are loaded on the pallet. The gripper
arm moves the shipping box to the unpacking
station. The Robotic Magazine includes an internal buffer to ensure that production can continue to run smoothly even while a new pallet is being loaded into the pallet magazine.
This buffer can hold up to 20 shipping boxes
of carton sleeves. The magazine operates for
up to 2.5 hours (CFA 724/124) without the
need to top it up with a new pallet. Inside the
unpacking station, the shipping boxes are
opened and the sleeves are removed from the
box. The sleeves are automatically filled into
the appropriate track of the filling machine.
The shipping box is folded flat and placed into a container for disposal.
Prototype successfully running at Arla Foods
The first R-CAM 724 prototype was installed
at Arla Foods in Pronsfeld, Germany. “With
the new Robotic Magazine and an optimised line
layout where the tray packer is positioned close
to the filling machine, we are able to run a
complete high-speed packaging line with one
operator at a high efficiency rate”, says Peter
Bratsch, responsible for the R-CAM Prototype
at Arla Foods.
R-CAM 724: Robotic Magazine at Arla Foods production plant.
Jan Gansow adds: "The Robotic Magazine
also paves the way for a fully automated packaging line of the future, where Laser Guided
Vehicles (LGV) automatically transport the
pallets with the packaging material from the
central warehouse to the R-CAM. This is an
important step towards fully automated lines
for the smart factories of tomorrow."
In an initial step, the new Robotic Magazine
is available for the CFA 724 high-speed filling
machine for filling products in the small-size
packaging format combiblocSmall. In a next
step, it will also be offered for CFA 124 for filling products in the small-size carton packs
combiblocMini. Fully automated solutions for
machines filling beverages in the medium-sized packages combiblocStandard and
combiblocSlimline are planned to follow.
All CFA 724 and CFA 124 models already
installed can be upgraded with the Robotic
Magazine which can also be integrated into
the SIG Combibloc ECS Line Monitoring
System.
Benefits at a glance
• Fully automated depalletising and unpacking
of sleeve boxes
• Reduction of labour costs and increase of
organisational efficiency
• Continuous operation for up to 2.5 hours
without changing the pallet
• Internal buffer: no stop when changing
pallets
• Empty shipping boxes are compressed and
collected in a small container
• Integration into SIG Combibloc's ECS Line
Monitoring System
combiSwift now also on
food carton packs
Ultimate convenience: screw cap is now also available for carton packs
made of a special food composite.
T
he convenient combiSwift screw cap
is now also available for food carton
packs from SIG Combibloc. This screw
cap offers ultimate convenience when
opening the carton packs, and when pouring
and portioning out long-life foods such as
soups, sauces, tomato products and desserts.
Because the carton packs can be reclosed, the
products are still protected after initial
opening.
Hanno Bertling, Global Product Manager
for Opening Solutions at SIG Combibloc:
“combiSwift is one of our most modern screw
caps. It’s designed specifically to suit consumers’ need for convenience. The closure, made
from high-quality, recyclable plastic, can be
opened effortlessly with a single twist."
With the launch of combiSwift for carton
packs made of a special food composite to fill
food products on aseptic food filling machines
from SIG Combibloc, the product range is expanding once again. These food carton packs
are aimed for more viscous products that also
have a higher free-fat content. Hanno Bertling:
“When handling products such as sauces and
soups containing chunks of meat or vegetables, stocks with a higher free-fat content,
chunky tomatoes or more viscous desserts, an
easy-to-use and reclosable screw cap is very
practical. And it gives an added benefit for food
manufacturers, also: with this extra feature,
the products are clearly differentiated from
competing packaging on the sales shelf, and
grab the interest of consumers to whom our
combiSwift offers a high degree of additional
convenience”. One of the first customers to bring out products in food
carton packs with combiSwift is Gallina Blanca.
combiSwift
combiSwift made its market
debut in 2006 and was initially
applied to carton packs for milk
and dairy products. It was very
well-received by consumers.
Since then, more and more manufacturers have opted for carton
packs with combiSwift. The
closure has since also become
widely established in the field of
non-carbonated soft drinks, and
in the area of liquid food products which can be filled on
standard filling machines from
SIG Combibloc for Liquid Dairy
and NCSD products. The closure
is applied over a laminated hole,
and on first opening the consumer only has to pierce razor-thin
aluminium and polymer layers.
To make this technique work,
holes of the correct size are first
punched into the carton and are
then coated with aluminium and
polymers. The closure consists of
a flange with an integrated
cutting ring and a cap. The ring
integrated into the flange opens
the thin layers with a twisting
motion. combiSwift has an overall height of 12.6 mm and weighs
2.7 grams. At the premises of
SIG Combibloc’s customers, the
three-part closure is applied to
the outside of the carton pack
after the aseptic filling of the
product and subsequent sealing
of the carton pack inside the filling machine.
frischli creates the basis
for innovative products
German dairy company opts for the Food Option Technology:
more than 100 products filled in combiblocStandard.
D
airy company frischli has opted for
filling
technology
from
SIG
Combibloc. With the installation
and bringing into service of two
CFA 512 filling machines, including a Food
Option filling machine, frischli is putting
things in place to enable it to launch a wide
range of innovative products in aseptic carton
packs from SIG Combibloc. frischli, a well-
established owner-operated company founded
in 1901, is today one of the biggest dairies in
Germany, and internationally markets its
dairy products and foods for retail sale, food
service and industry.
High performance and low overall system
costs are the outstanding features of the highspeed filling machines from SIG Combibloc.
With the CFA 512 filling machines that are
now in operation at frischli, up to 12,000
combiblocStandard carton packs can be aseptically filled per hour. This speed is combined
with an unrivalled low wastage rate and
Food Option Technology:
Be able to do today, what will be needed tomorrow
Food Option filling machines are
filling machines based on SIG
Combibloc’s standard filling
technology: A few minor technical adjustments are made to the
standard machine prior to delivery which allow food manufacturers to fill a whole range of
additional food products.
And SIG has done this in a very
straightforward way, without
bringing additional complexity
into the overall system and without high investment costs. If a
filling machine has been fitted
with the Food Option capability,
the content of chunky product
ingredients can be up to 10 per
cent, the size of the particulates
up to 6 mm, and the size of the
fibres 1 x 15 mm; viscosity can
potentially be up to 3,500 mPas.
This means Food Option filling
machines make it possible to
aseptically fill an unrivalled spectrum of food products – quickly
and without major investment.
The flexibility of the filling machine technology is also the key
to products that allow higher
margins.
+ Food Option:
• particulates up to 6 mm
• fibres up to 15 mm
• viscosity up to 3,500 mPas
Standard:
• viscosity up to 1,000 mPas
• fibres up to 5 mm
one-of-a-kind flexibility in formats, volumes, decor and products. Their robust,
well-engineered construction ensures the machines will continue to run reliably for many
years.
Extra possibilities
One of the filling machines installed at the
premises of frischli, is a Food Option filling
machine. It is based on SIG Combibloc’s standard filling technology, but is additionally designed to fill a whole range of further pasty and
highly viscous food products, and products
containing particulates. For frischli the new
filling machines offer the chance to further
expand the company’s extensive range of longlife dairy products. A total of around 100 different frischli products are set to be available
in carton packs from SIG Combibloc. Facts & Figures: frischli
€ 497 mio
annual turnover
676
employees
1,330
milk producers
823 mio kg
of milk is processed every year
About 100 different frischli products will be available in combiblocStandard
Interview with Dr. Timo Winkelmann and M
ichael Dökel.
»First-rate service and flexible technology
open up new possibilites.«
Dr. Timo Winkelmann, General
Manager at frischli and M
ichael
Dökel, Production Supervisor at
frischli, about the decision in favour
of the SIG Combibloc filling
technology.
Mr Winkelmann, what is the
advantage of the filling tech
nology from SIG Combibloc?
Winkelmann: By choosing
the filling technology from SIG
Combibloc, we’ve created a
strong basis to enable us to respond flexibly and efficiently to
shifts in the market, which are
dictated primarily by the needs
of our food industry customers
and the requests of consumers.
With the two filling machines
we’re now highly flexible as far
as the product range, decors and
volumes are concerned.
What products will be avail
able in the new packages that
you could not fill into carton
packs before?
Winkelmann: With these two
filling machines, we are now
able to fill not only milk, cream
and milk mix drinks, but also
more viscous sauces, puddings
custard and rice pudding – even
products with particulates like
pieces of fruits or vegetables,
herbs and spices are possible.
Mr Dökel, these two ma
chines are the first SIG
Combibloc filling machines
at your plant. Can you say
something about the cooper
ation with the SIG team
when installing the new
machines?
Dökel: We were impressed by
the outstanding service the team
from SIG Combibloc provided
when they installed the new
filling machines and brought
them into service. The special
challenge in that task was to
keep the regular production
process running. The team
made sure everything worked
smoothly, and the machines
were able to be brought into
service on schedule. /// SIG COMBIBLOC MAGAZINE 1/15 25
20 years of FSC™:
recognition and popularity
are increasing
In its 20-year history, the Forest Stewardship Council™ (FSC ™) has faced
a number of challenges and accomplished many things. Today, the FSC
is one of the leading forestry certification systems.
Facts & Figures: FSC
184 mio ha
of forest is FSC-certified world-wide
28,300
Chain-of-Custory certificate holders
in 81 countries
150,000
smallholders around the world are
FSC certified
T
he Forest Stewardship Council is an independent, notfor-profit organisation that campaigns for responsible
management of the planet’s forests. Through its forest
certification programme, the FSC works world-wide to
promote responsible forest management. Today, the FSC is one
of the world's leading forestry certification systems in terms of
its global reach, robustness of certification criteria and the
number of companies certified.
More than 28,400 companies are FSC certified – in more
than 80 countries. Added to this are 150,000 certified smallholders. In a global market survey conducted by the FSC in
2012, 98 per cent of FSC-certified companies stated that FSC
certification increased the value of their company and their
products, and that they planned to maintain their certification
and thereby retain the right to put the FSC label on their
products.
FSC label enables purchasing decisions that benefit the
forests
This sort of qualifying label on products can generate a key
stimulus in the consumer. The number of consumers who take
a very responsible attitude to their own consumption behaviour has been increasing for many years. These people are
aware that with their purchase choices, they
can personally contribute to the success of
sustainable and responsibly produced goods. It
is crucial that the labels on the products be
credible. FSC is currently the most rigorous
and the most widely accepted certification for
responsible forest management.
Studies in various parts of the world have
shown that the level of public awareness of the
FSC label is increasing. In Germany, for instance, in 2012 the level of prompted awareness of the FSC label was around 33 per cent.
In a repeat survey conducted by the market research institute TNS Emnid in September
2014, this had increased by 17 per cent, to a
current level of 50 per cent, in just two years.
72 per cent of respondents who recognised the
label also said that they trusted it. Another example is the UK, where awareness is also at 50
per cent – signifying an increase of 12 per cent
in just one year. The level of awareness of the
label has actually more than doubled there
since 2007. In Brazil, 90 per cent of industry
representatives and 23 per cent of consumers
recognize the FSC-label and know what it
stands for. (Sources: www.fsc-deutschland.de/
aktuelles; FSC UK annual review 2013/2014;
FSC Brazil). FSC label on 40 per cent of
all SIG carton packs
In 2009, in cooperation with
German trade chain Lidl,
SIG Combibloc put the first
juice drink carton packs with
FSCTM label on Europe’s
supermarket shelves. The label
shows consumers that appropriate quantities of wood sourced from FSC-
certified, responsibly managed forests and
other controlled sources were used to make the
cartons. Since then, the label has become
increasingly popular and more widely recognised among food and beverage manufacturers,
and also among retailers and the public.
More than 3,000 different products packaged
in SIG Combibloc carton packs now carry the
FSC label – in 27 countries. By the end of 2014,
40 per cent of all SIG carton packs carried the
FSC label. “We’re very proud to have been the
trailblazer in our industry on the issue of the
FSC label. It is one of SIG Combibloc’s fantastic
success stories”, says Michael Hecker, Head of
Global Environment, Health and Safety.
20 billionth carton pack
with FSC label produced
In September 2014, the
20 billionth FSC-labelled
carton pack was produced
at SIG Combibloc's packaging plant in Rayong,
Thailand, for our customer
FrieslandCampina.
Extrusion line at SIG Combibloc's production plant in Brazil.
Success in fast-growing
market
The installation of the extrusion line completes SIG Combibloc’s major
investment in its Brazil production site. Business relations with customers have been developed further: at the premises of our customer Quatá,
for instance, six new filling machines have been put into operation.
B
razil is currently South America’s biggest market for aseptic carton packs;
and world-wide, in fact, the country is
in second place, right behind China.
According to market research institute
Canadean, Brazil is the world’s biggest market
for UHT milk, with annual consumption of
around seven billion litres. For SIG Combibloc,
building a local factory was simply a logical
step to meet the demands of this fast-growing
market.
Extrusion plant at Paraná factory put into
operation
The starting signal for this long-term building
project in Brazil was given in 2010, when
SIG Combibloc began construction of its first
packaging plant in South America. In mid2011, the factory came on line. With the production line installed, the pre-laminated packaging material used to make the carton packs
was printed, cut to size, stamped and sealed.
In 2014 an extrusion line was added, where
the unprocessed cardboard is laminated with
poly
mers and aluminium. The facility will
laminate around 250 million metres of packaging material each year.
Optimally prepared
Ricardo Rodriguez, Director and General
Manager South America at SIG Combibloc:
“We’ve captured this market by offering our
customers a real alternative, unique added
benefits and a tailor-made service. With this
fresh major investment of around 40 million
Euros for the installation of the extrusion
plant, we’ve laid the groundwork to be optimally prepared to meet the ever-increasing demand for aseptic carton packs. We can now
produce on-site in Brazil the packaging material needed in South America for our carton
packs”.
Market Brazil
According to the Canadean research institute, in 2014
more than 15.5 billion carton packs for long-life food
were sold in Brazil. This figure is expected to rise to more
than 21 billion by 2019, equivalent to an increase in
volume of around 7 % per annum (in units). Milk is now
the product most commonly filled in aseptic carton
packs in Brazil. In the 1980s, unpasteurised milk dominated
the market. The share of UHT milk has increased slowly but
steadily, to a current level of about 60 %.
SIG Combibloc’s prospects in Brazil are
very promising, in part because, thanks to the
new factory, business relations with existing
customers have been further strengthened.
Rodriguez: “Again, we managed to end the
2014 fi nancial year with a considerable growth.
We’ve been able to win new customers, and
further consolidate our ties with existing
customers”.
Successful customer relations: Nine filling
machines for Quatá Alimentos
One example of successful customer relation is
the cooperation with the food manufacturer
Quatá Alimentos. In 2012, the company opted
for the filling machine technology and aseptic
carton packs from SIG Combibloc. Since August 2012, two filling machines – a CFA 512
and a CFA 712 – have been in operation at
Quatá’s Campo Belo facility in the Brazilian
state of Minas Gerais. Another one is running
at Quatá's prouction plant in Bom Jesus dos
Perdões.
José Henrique Coutinho, managing director of Quatá, remembers the company’s first
SIG Combibloc filling machine: “For the modernisation of our factory in Campo Belo, we
chose the filling technology from SIG
Combibloc, as this flexible technology met
all our requirements. The filling machines
perform very well and have low waste rates –
we’ve significantly improved our p
roductivity”.
The filling technology from SIG has obviously convinced Quatá: in 2014 alone, a further five filling machines were installed, and
at the beginning of 2015 an additional one
started production. There are now nine filling
machines in operation at three Quatá production sites filling UHT full milk, UHT semiskimmed milk, UHT skimmed milk, UHT
chocolate flavoured milk, cream and sweet
condensed milk in combiblocStandard and
combiblocSmall. 30 SIG COMBIBLOC MAGAZINE 1/15 ///
Quatá Alimentos
Quatá Alimentos was founded in 1990 and has
specialised in two product lines: UHT milk products and cheese. The products are sold under
the brand names Quatá, Gloria and Cristina,
through retail and wholesale channels (for
cafés, restaurants, catering establishments etc).
Quatá is active predominantly in the states of
Rio de Janeiro, Espirito Santo and Minas Gerais.
The company has seven production plants:
three in Minas Gerais, two in São Paulo and
one each in Rio de Janeiro and Paraná.
SIG Combibloc filling machine at Quatá's production plant in Campo Belo.
Just a few clicks:
useful tips for designing
SIG Combibloc carton packs
With a new, special website, SIG Combibloc is supporting its customers to
make the design process more efficient.
O
ur customers’ marketing departments and design agencies invest a
great deal of time in redesigning
cartons or creating new carton designs. Once the customer is happy with the
design, it is sent to SIG Combibloc so the cartons can be produced in one of the packaging
plants. Before production, the design must go
through preprint. “Preprint is where the design is checked and adjusted so that our printing machines can produce the sharpest, most
optimal print image”, says Erol Öztürk, Head
of Preprint Management Europe.
The more information packaging designers
have about the characteristics of the printing
process SIG Combibloc is using, the more they
are able to take these features into consideration at an early stage in the creation of the design files, and the fewer adjustments need to
be made later on. That saves time spent on
rounds of corrections, and ultimately it saves
money.
SIG Combibloc is now making all this
information available on the new website
www.SIGdesign2print.com, so every packaging
designer worldwide can view it whenever they
want. The most important tips from the
34-page SIG Combibloc print manual are
clearly demonstrated in an explanatory video.
“In just three and a half minutes, packaging
designers can familiarise themselves with the
key information”, says Boris Remmler, Print
Manager at SIG Combibloc, who was involved
in compiling and producing the contents of the
video and the website. The website further
provides useful tips and downloads like keylines, background information on the SIG
printing process as well as contact information
for every region. Features at a glance
Video and factsheet
A three-minute explanatory video gives the
most important information on packaging
design for SIG Combibloc carton packs.
All figures and values are also summarized
in a factsheet.
Keylines
Keylines form the basis for all carton designs
on SIG Combibloc carton packs. For each
format and volume, there is a file with all the
technical information such as cut lines and
crease lines, as well as text areas.
Artwork manual
The artwork manual contains all the information that needs to be considered when planning
and revising a design – from working with the
keylines, to the opening devices and the colour
composition, right up to the data transfer.
SIG colour book
The SIG colour guide contains all spot colours
that can be used in the specific rotogravure
printing process and on the packaging material.
FSC labelling guide
The FSC labelling guide shows how the
FSC label can be displayed on the carton packs.
Checklist for data transfer
The checklist contains all information on data
and documentation SIG Combibloc needs in
order to be able to print a final, finished and
edited design.
FAQs
The FAQs provide the answers to the most
frequently asked questions regarding the
SIG Combibloc printing process.
www.SIGdesign2print.com
Ordering online:
SIG Spare Parts Shop
With the new spare parts shop, it is now possible to order necessary spare
parts any time, quickly and easily – seven days a week, 24 hours a day.
T
he SIG Combibloc Spare Parts Shop
allows our customers to order spare
parts quickly and easily. It takes just
minutes to place an order. New technology, advanced functions, modern look and
feel – users are responding very positively.
A variety of search options takes the user
straight to the correct spare part. Pre-defined
shopping carts make it even easier to order
frequently needed parts. And any time our
customers need to order a large number of different spare parts, they can simply upload an
Excel file containing the required part numbers. Of course, all orders and their delivery
status can be viewed at any time.
Before the launch of the new spare parts
shop, customers usually ordered the spare
parts they needed by telephone or fax. The
new online shop is set to change that. Customers now order their spare parts directly online
at the shop. This leads to a reduction of processing time and makes spare parts ordering
even faster. This is one more example of how
SIG provides added value for its customers.
“A wide range of search options help customers to find the required parts easily. The
shop shows detailed order status and tracking
information which gives our customers full
transparency about their purchase orders.
Thus customers can plan their resources
efficiently”, says Norbert Schmitz, Head of
Global Service Projects. “We’re also particularly pleased to see that our shop is receiving
a lot of praise in comparison to those of our
competitors”. Features at a glance
Ordering any time
Easy ordering 24 hours a day / 7 days a week.
Various search options
Quick and easy identification of correct parts.
File upload
‘File upload’ to order a large number of spare
parts at once by simply uploading a file with
part numbers and desired quantity.
Spare parts catalogue
Order directly by browsing the ‘spare parts
catalogue’ featuring equipment and part
images in 2D and 3D.
Pre-defined shopping carts
Less time and effort for large orders and re
ordering parts by using saved shopping carts.
Order status/tracking
Know your order and delivery status by checking online at any time via order status tracking
option.
Our customers receive login data for the SIG Combibloc
Spare Parts Shop from their Service Account Manager
or from the regional service contact partners.
For any further questions or
comments, please contact:
[email protected]
www.sig.biz

Plant-based dairy on trend

Transcription

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Publication No. 200919 - Notice 23