See new food packaging & processing solutions at PACK EXPO in Chicago
Discover new food packaging and processing innovations from 2,500+ suppliers, all under one roof at PACK EXPO International in Chicago.

PACK EXPO International 2018 Innovations Report: Machinery

Covering 1.2 million net sq ft of exhibit space and drawing 2,500 exhibitors, PACK EXPO International brought 50,000 attendees to the biggest packaging event of the year.

PACK EXPO International
PACK EXPO International

Each year the editors at PMMI Media Group roam the aisles of PACK EXPO looking for the next big thing in the packaging sector. Of course, with a show this size it’s never one big thing we find but rather a multitude of things big, medium, and small, all of them innovative and meaningful in one way or another to packaging professionals of today.

This report sums up what we found in six main categories. We present them here for your review knowing full well that, inevitably, we missed a few. Probably more than a few. That’s where you come in. Let us know what we missed and we’ll look into it. Or at the very least, we’ll know to be on the lookout for it at the next PACK EXPO.

Our report comes to you from the following:

Matt Reynolds, Editor, Packaging World

Pat Reynolds, VP Editor Emeritus, Packaging World

Anne Marie Mohan, Senior Editor, Packaging World; Editor, Contract Packaging

Stephanie Neal, Senior Editor, Automation World; Editor-in-Chief, OEM

Joyce Fassl, Editor-in-Chief, ProFood World

Maya Norris, Managing Editor, ProFood World

Natalie Craig, Managing Editor, OEM

Jim Butschli, Editor, Healthcare Packaging

Keren Sookne, Director of Editorial Content, Healthcare Packaging

MACHINERY

CODING & MARKING
ID Technology, a ProMach company, announced at PACK EXPO the launch of a digital thermal ink-jet technology called Clearmark (1). HP Indigo cartridges are used to print high-resolution text, graphics, or codes on nonporous as well as porous substrates. Suitable for primary, secondary, or tertiary packaging applications and purpose-built from the ground up, it uses a 10-inch HMI with large buttons and typeface fonts. Additional information is displayed clearly along the bottom of the HMI screen to update the operator on key indicators like production rates, how much ink is left, how soon before a new ink cartridge is needed, etc.

In addition to the HMI, the complete standalone system comes with a print head as well as an easily adjusted tubular bracket system for mounting to a conveyor or to permit use as a floor-standing unit. The print head is described as a “smart” print head, so it can be disconnected from the HMI and the HMI can be shared among multiple print heads. It will continue to run and print on its own with no need for the HMI to be connected. Within the cartridge itself, ID Technology is using the HP 45 SI cartridge, which encompasses the Smart Card. That makes it possible to put ink parameters and such into the system and lets the system read that without the need for an operator to go in and program anything. So if you change colors or cartridges, there is nothing other than simply changing the cartridge that the operator need do. The Smart Card also records the amount of ink that’s been used. So if an operator removes the cartridge and stores it for awhile and then perhaps puts it into another printer, that cartridge will be recognized by the other printer and it will know exactly how much ink is left.

For customers that require the highest print quality, ClearMark can be set to achieve a resolution of up to 600 dpi. If set to print 300 dpi, ClearMark typically maintains speeds of 200 ft/min (61 m/min) and can reach higher speeds when printing at lower resolutions. It offers a print height of 1⁄2 in. (12.5 mm) and unlimited print length.

“This is the first in our new ClearMark family of smart thermal inkjet printers. As HP continues to introduce new TIJ technology, we’ll design new systems around it and further expand the family’s capabilities,” says David Holliday, Director of Product Marketing at ID Technology. “For many customers, TIJ systems offer huge advantages over CIJ. In addition to eliminating the mess of flushing a CIJ printer, new TIJ systems are able to offer a lower total cost of ownership after the labor and downtime of maintenance are factored in. ClearMark reliably produces high-quality print while presenting an easy-to- use, maintenance-free system.” For video of the printing system in action, go here: pwgo.to/3948.

LASER CODING
Over a decade ago, Domino Printing invented Blue Tube technology to safely print onto PET bottles with CO2 lasers. At PACK EXPO, the company introduced to North America its solution for aluminum can CO2 laser coding with the Domino F720i fiber laser portfolio (2), which it says is a reliable and consistent alternative to conventional ink-jet printers.

According to Domino, fluids consumption, downtime for cleaning procedures, and long changeovers due to packaging variations are creating efficiency challenges for beverage manufacturers. This presents problems in many areas, including the date and lot coding for traceability purposes. To address these challenges, Domino developed a turnkey system for the beverage production environment, The Beverage Can Coding System. Central to the system is the F720i fiber laser printer with an IP65 rating and robust design, capable of maintaining continuous output in extremely harsh, humid, and temperature-challenging production environments up to 45°C/113°F.

“The Beverage Can Coding system offers clean and clear indelible marking, ideal for compliance purposes and brand protection on aluminum cans,” says Jon Hall, Laser Product Marketing Manager for Domino North America. “Further, Domino’s system can achieve codes on concave surfaces with high quality and a high speed—one system can mark up to 100,000 cans per hour, with over 20 characters per can… The code quality is consistently excellent even with condensation present on the can.”

There are five other key components to the system that complement the fiber laser: 1) the DPX Fume Extraction system, which extracts fumes from the processing area and keeps dust from covering the optics or absorbing the laser power; 2) optional camera integration; 3) a Domino-developed guard with full compliance to laser class-one standards; 4) a quick-change system, which allows for easy changes for various-sized cans; and 5) a protection window for lens protection to sustain the highest print quality and simplify cleaning.

TIJ PRINTING
As a key partner of HP Specialty Printing Systems, CodeTech has sold numerous Digital TIJ printers into the packaging space, especially in food packaging. Exhibiting at PACK EXPO in the PACKage Printing Pavilion, CodeTech was highlighting two new HP-based technologies at the show. One was a fully sealed, IP 65-rated wash-down printer. The other, which was making its official debut at PACK EXPO, was a self-sealing, self-wiping shutter system for TIJ print heads. It obviates the need to remove the cartridge from the print head during the sanitation cycle. Built inside the shutter print head are dual silicone wiper blades, a purge well, and a sealing system, so the cartridges can be left in place for weeks without ever having to be wiped or have any other maintenance performed.

This system is also IP-rated and designed hygienically with major food packaging users in mind. It can easily be integrated into f/f/s machines commonly found in meat, cheese, and poultry plants. Go here: pwgo.to/3949 for a video of this technology taken at PACK EXPO.

CIJ PRINTING
InkJet, Inc. announced the launch of DuraCode™, the company’s new, reliable, and durable Continuous Inkjet (CIJ) Printer. DuraCode became commercially available this month for a wide range of industrial applications throughout the world. And at S-4260 in the South Hall of PACK EXPO, the rugged new printer was on display.

DuraCode is designed with a robust IP55-rated stainless-steel structure and delivers the best quality code continuously, day in and day out, says InkJet Inc. This printer is manufactured to withstand extreme temperatures, humidity, vibration, and other industrial environments with the added benefit of ease of operation via a high-resolution interface.

DuraCode’s reliability is enhanced by InkJet, Inc.’s comprehensive portfolio of ink and make-up fluids, which undergo several quality control processes that are unmatched in the industry. This printer offers print data options through network and local scanners as well as quick filter and fluid changeouts, which ensure powerful performance with a low cost of ownership.

InkJet, Inc.’s Technical Services Group is working hand-in-hand with customers, guaranteeing the right ink for specific substrates and processes as well as installation support to ensure a stress-free experience, focused on maximizing production uptime.

“Providing the best quality, highest performing equipment and fluid to our customers is our top priority. DuraCode represents a continuation of a commitment to meeting and exceeding the expectations of our distributors and end users,” says Patricia Quinlan, Chairwoman for InkJet, Inc. “Through our ongoing product development initiatives, we anticipate and address the needs of our customers, so that we are well-equipped to deliver the right type of printer, fluids, parts, and service.”

For a video, go here: pwgo.to/3950.

THERMOFORMING FROM SHEET
Material input reduction and sustainability were major trends this year at PACK EXPO, as brand owners look for ways to simultaneously improve their sustainability profile and cut costs.

An in-line thermoforming machine from Harpak-Ulma all but eliminates scrap and reduces material input by nearly 40%, the company says. The new Mondini Platformer™ in-line tray thermoformer (3) cuts rollstock film into rectangular sheets and then forms the trays using proprietary technology. The machine can produce both rectangular and square formats of varying depths up to 2.36 in. at speeds of 200 trays/min, depending on the film thickness and tray design, using 98% of the forming material.

The current approved film range is from 12 to 28 mil for PET and barrier PET as well as HIPS. A #3 case-ready tray can run up to 120 trays/min. The machine can easily and quickly change formats—typically, in less than 10 min. Cutting-edge tool design reduces changeover cost and complexity, taking a bite out of the time and costs that can burden new product introductions. This process produces a high-quality finished tray with turned-down flanges that give the tray remarkable rigidity for a thermoformed part. Most impressive is that the process produces only 2% scrap loss versus the 15% waste typical of both preformed tray production and conventional thermoform fill/seal systems that produce a matrix of scrap.

Those kinds of savings add up. Consider this scenario: A single whole-muscle line running 50 trays/min of #3 padded case-ready trays at 80 hours per week produces approximately 12 million trays annually. The Platformer produces that volume at a material cost of 10.7 cents per tray—an average savings of up to 38% per pre-formed tray on materials alone, or $700k on 12 million units. An additional benefit is a 75% space reduction by inventorying rollstock versus pre-formed inventory. In this scenario, customers can create their own new tray formats for approximately 2⁄3 less than they’d pay a commercial tray supplier.

Sustainability is an important social and business goal in our times, but it is also a fundamental aspect of lean philosophies. In the above scenario, film stock can be delivered with 22 deliveries versus 71 deliveries for pre-formed stock. That’s a whopping 49 fewer truck trips and 2,744 pallets eliminated. This translates into a reduced carbon footprint (~92 metric tons), lower freight and handling costs, as well as less waste removal (340 lbs. of landfill) and reduced storage costs.

In keeping with lean customer concepts, Mondini sought to include relevant “value-add” opportunities. A significant benefit of forming your own trays is the opportunity to emboss trays with a company’s logo or insert seasonal or other marketing messages. This can be achieved at a substantially lower cost as compared to current market options.

Of course, even the most innovative solutions must pass the ROI sniff test. While ROI calculations will vary based on assumptions and inputs, some rough conclusions can be drawn based on the scenario above. Simple calculations point to an estimated annual operational savings of $770k to $1M with paybacks that range between 10 and 13 months (ROI will change based on the size of tray and output).

Kevin Roach, President of Harpak-ULMA, says, “Our customers can realize up to 38% in material savings, reduce labor as well as their warehouse space requirements, all while improving their carbon footprint. That’s the very tangible impact of this innovation.”

THERMOFORMING
Another well-known maker of thermoforming equipment showcased its new X-Line thermoformer (4) at its PACK EXPO booth. To ensure maximum flexibility and uptime, the X-Line lets operators change package configurations in less than 10 minutes.

Connectivity for data collection is also a feature of the X-Line, which as Multivac Vice President, Sales & Marketing Pat Hughes explained has been engineered to meet the requirements of Industry 4.0. To fully implement the technology, Hughes said the company is looking for “partners that want to use a common platform to gather data and use the cloud.”

Features of the X-Line touted by Multivac include maximum packaging reliability, more consistent pack quality, and a higher level of process speed, as well as easy and reliable operation. Among its features are seamless digitalization, a comprehensive sensor system, and networking with the Multivac Cloud and Smart Services.

Additionally, the X-Line’s connection to the Multivac Cloud gives users access to Pack Pilot and Smart Services, which provide a constant connection and up-to-date information on software, film availability, machine settings, and other pertinent data that enable the machine to be used even without special operator knowledge.

The X-Line comes with X-MAP, a gas flushing process that can be precisely controlled for packing with modified atmosphere. Finally, users can operate the X-Line through its intuitive HMI 3 multi-touch interface that corresponds to the operating logic of today’s mobile devices. The HMI 3 can be set up for individual operators, including different access rights and operating languages.

ASEPTIC FILLING
What would a PACK EXPO be without innovations in liquid filling systems, including one that hails from India? That’s where Fresca, a leading and fast growing beverage juice brand, is the first to launch product in eye-catching holographic aseptic juice packs. The aseptically filled 200-mL juice packs with holographic decoration are the world’s first commercial example of Asepto Spark technology (5) from Uflex. Both the holographic containers and the aseptic filling equipment come from Uflex.

Fresca has three manufacturing facilities with a strong presence in multiple regions of India. But the Tropical Mix and Guava Premium Juice products shown here represent the firm’s first foray into Asepto Spark technology. The August launch came just ahead of Diwali, the November 7 festival of lights, which is one of the most popular festivals of Hinduism.

“We believe this is the ideal time to launch when people are on the lookout for something new and appealing for gifting,” says Akhil Gupta, Managing Director of Fresca. “With the help of Uflex’s brand Asepto we are able to revitalize the consumer experience in the sparkling holographic packs of Fresca’s 200-mL Tropical Mix Premium and Guava Premium. The packaging not only serves as marketing differentiator from the retail standpoint but also takes care of the key components for safe journey of products from production to consumption. The smoothness and superior taste is very pleasing, as it has a higher percentage of fruit pulp, giving a great drinking experience to consumers.

“On the first day of market launch we have been able to bag massive orders for the upcoming festive season. With this format, avenues that we were looking to get associated with have now agreed and welcomed us to fill their shelves in the Fresca Holographic packs. We are aiming at 15 million packs in 2019 and definitely plan to increase our geographic reach in India in the next 2-3 years.”

Like other structures on which food and beverage producers rely for aseptic packaging, this one is a six-layer lamination that includes paperboard, foil, and polyethylene. Uflex says its aseptic filling equipment has a rated speed of 7,800 200-mL packs/hr.

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