Category: Filling & Sealing

Innovia Films, a material science pioneer and major producer of BOPP films, has announced that they will be showcasing their latest portfolio for the labels, packaging and graphics industries at Labelexpo Americas in Chicago.

Some of the highlights are sustainable and functional BOPP label materials for Pressure Sensitive, Wrap Around and In Mold Labels along with Rayofloat shrink sleeve film specifically developed to support the recycling of PET, HDPE and PP bottles and containers.

“As the industry leading filmic label solution provider for all major decorations technologies, we have been working on materials that not only follow the principle of reduce, re-use and recycle but also support recycling of the finished package, while at the same time providing the right barrier functions needed to prevent food waste”, explains Jon Knight, Vice President & General Manager – Americas.

Thinner films that support material efficiency and have a lower carbon footprint “With continued capital investment in the pressure sensitive label segment including top coating and extrusion we have new technologies that offer unparalleled performance while improving sustainability”, says Knight.

Innovia will be presenting their newest innovations in the market with our Rayoface™ CPE and WPE, thinner printable label films with reduced carbon footprint and Rayoface™ JBD, a semi-solid film has an enhanced yield and opacity compared with solid white films.

Sustainable shrink sleeve film that has been endorsed by APR

Innovia recently announced the extension of its award-winning low density, floatable polyolefin (PO) RayoFloat shrink sleeve that is a sustainable alternative for existing materials that are detrimental to recycling. The RayoFloat material has been endorsed by APR (Association of Plastic Recyclers) as being compatible with existing waste streams in the United States.

“We are proud to share our extended range of floatable shrink sleeves that work in established PET, HDPE and PP waste streams,” says Knight. “We can now offer several options – from a high shrink version to a thinner version to a white version that is ideal for light-sensitive products like dairy, vitamins and supplements.”

PVC-free graphics films that are a sustainable alternative

Rayoart™ PVC-Free Graphic Films significantly lower the environmental impact of self- adhesive graphics. They are based on biaxially-oriented polypropylene (BOPP), a type of plastic with clear sustainability advantages that is inherently more recyclable compared to PVC. These innovative graphic films are suitable for most short and intermediate indoor and outdoor applications and offer a product performance comparable to PVC-based graphic films.

“We are excited to showcase these innovations to our customers and other visitors at the Labelexpo Americas and discuss how these filmic materials can help deliver a better future for our industry and facilitate our stakeholders goals of re-designing packaging to become more circular”, concludes Knight.

Labelexpo Americas will take place from September 10 to 12 in Chicago. Innovia will be exhibiting in Hall A, Booth 1221.

About Innova Films:

Innovia Films is a major producer of highly differentiated speciality Biaxially Oriented Polypropylene (BOPP), Bubble and Tenter technologies and Cast Polypropylene (CPP) films. The company holds a leading global position in the markets for high performance coated films, tobacco overwrap, graphic media solutions, label and security films. We employ >1400 people worldwide and have production sites in Australia, Germany, Poland, Mexico and the UK.

Packaging in the crowded deli retail environment demands an exclusive and premium appearance to attract consumers while also focusing on freshness of the product.

Following a trend that started during the pandemic, many supermarket delis are focusing on meat products that offer convenience while keeping products fresh longer, which is largely a function of their packaging solutions.

“Innovative and unique look and feel from print technologies continues to evolve and innovate into new and trending technologies,” said Melanie Bandari, senior marketing manager for meat, poultry and seafood at Amcor Flexibles North America, Oshkosh, Wis. “New entrants in the deli meat space focus on smaller, more premium brands versus large, mass-produced brands.”

Ryan Spencer, product market manager for chambers, portioning and slicing at Multivac Inc., Kansas City, Mo., has noticed more demand for grab-and-go packaging that is designed to look like it was cut and packaged at the in-store deli counter.

“The footprint of the in-store deli in many grocery stores is either shrinking or disappearing entirely, as offerings such as prepared meals, in-store restaurants, sushi bars and the like are becoming more prevalent,” he said. “Grab-and-go packaging allows retailers to provide sliced meats and cheeses in a familiar-looking package that customers are seeking, without requiring a fully staffed deli section.”

Multivac offers many solutions in this area, starting with slicing and running all the way to palletizing.

“When it comes to package design, we have the experience to provide best practices and ideas, or we can take concepts from the customer and recommend the best way to achieve it,” Spencer said.

Furthermore, grab-and-go pre-packaged deli meat packaging is a growing segment for enhanced retailer convenience with the added benefit of a product delivered safely direct from the manufacturer.

“Our pre-packaged grab-and-go deli line offers a freshly sliced deli packaging’s look and feel, but the retailer doesn’t incur the labor costs of packing it on premises,” Bandari said. “The products are packaged on TFFS as well as new HFFS flow wrap lines.”

For 40 years, Kansas City, Mo.-based Weber has been a global leader in industrial high-speed slicing systems. Five years ago, Weber acquired a thermoform packaging company, and got into the packaging game.

“There’s a ton of innovation that we’ve rolled out where we feel we are pushing the industry forward in how these solutions are put together holistically,” said Zach Bearson, director of new business development for Weber. “Instead of 6-7 machines on a line that work together in a simple way, we’re thinking of these lines as one solution that works within itself, communicating within machines.”

For instance, customers utilize Weber’s solutions from hygienic product preparation to weight-accurate slicing and automated insertion, to the desired presentation in the packaging, whether they want trays or tubular bags.

“We can integrate tray sealers or flow packers into the Weber line as alternative packaging machines to the thermoformer and take care of seamless integration without interfaces for a smooth production process,” Bearson said.

Carlo Bergonzi, product manager for Tray Seal at Harpak-ULMA Packaging, noted in terms of pre-made containers, there’s been an increased need for reclosability, whether it’s peel/reseal or rigid lid.

“Easy open and re-close is key so you can use a portion of the product, and open and close as much as a dozen times,” he said. “Grab-and-go is big right now, so anything that offers convenient packaging is in vogue.”

Dave Favret, product manager for Thermoforming at Harpak-ULMA Packaging, added that suppliers are slicing and delivering grab-and-go packages that are being handled at a facility outside of the grocery store, though it looks like it is done on site.

“The perception of freshness is important,” he said. “But there’s a number of different things that are on the mind of consumers, such as packaging formats that use less plastic, are easier to manufacture and are more sustainable.”

Environmentally sound

Sustainability continues to be important and top of mind for environmentally conscious consumers and resealability is a very important function of deli packaging today.

“The focus on sustainability continues to grow and mature,” Spencer said. “Customers are not only more concerned with the product inside the package, but with the package itself as well. What materials is it made of? Is it recyclable? If not, has the packaging been reduced to limit the impact on the environment? These are not theoretical questions anymore. Consumers are making buying decisions based on the answers to these questions.”

A good example from Multivac is the spray interleaving system on its slicer. Instead of using paper or plastic sheets between pieces of sliced meats and cheeses to allow for proper slice release, its spray system applies a small amount of oil that is allergen-free, tasteless and does not produce any additional waste.

Bergonzi has recently seen more interest in sustainability with molded fiber trays with a pouch inside and a rigid lid, or a PED tray with reseal — something that’s reducing plastic as much as possible, but also re-closeable.

“They are trying to use as much sustainable material as they can — with some deli products even packaged with a paper-feel material,” he said. “That has an appeal to many.”

Amcor’s SmartTack EZ Peel Reseal and SmartTack Die Cut Resealable Label lines are popular as they allow customers the convenience of resealable packaging while maintaining the freshness consumers expect in a deli meat package. These resealable options also offer substantial tamper evidence for added consumer safety.

“Our Catalyst program helps our customers solve market and sustainability needs through packaging innovation,” Bandari said. “Through smart insight, imagination and innovation, we collaborate to spark meaningful ideas, accelerate growth and move brands forward. Amcor’s ASSET is a third-party certified tool for performing new package sustainability metrics and can support customers’ on-pack messaging.”

On the rise

One area poised for significant growth is paper-based solutions as they offer consumers a positive end of life story with existing curbside recycle streams.

With this in mind, Amcor is bringing multiple high barrier paper-based formats to market, including Amcor Packpyrus, a new line of thermoformable paper in combination with high oxygen barrier materials for extended shelf life and a significant reduction in fossil derived materials.

“The product is widely sold in Europe today for deli meats and is expanding into the Americas,” Bandari said. “The structure is 85% paper with a barrier layer to ensure product freshness and maintain shelf life. Its lightweight footprint offers space reduction with upscale merchandising for shallow draw applications like shingled deli meats.”

The labor market was a catalyst for many companies automating and reducing the lines on the floor, and Weber is coming up with solutions so customers can repurpose labor and be more efficient through its packaging solutions.

“From a manufacturing perspective, we take a different approach,” said Mike King, technical solutions manager of packaging for Weber. “We own our own vision company, so all the components on the line are engineered and programmed by Weber in-house, which is a completely different philosophy than what else is going on out there.”

Looks matter

Packaging in the cluttered retail environment requires an exclusive look and premium appearance to stand out on the shelf and to attract consumers.

For instance, Amcor’s Amplify finishing technologies create a “stop the cart” experience with a portfolio of sensory solutions designed to create engagement opportunities, according to Bandari.

“Amcor has invested in another Amplify production asset in order to meet the high demand for shelf differentiated print technologies,” she said. “This asset came on-line in 2022 and was built for handling shorter runs with added flexibility. We are now equipped to handle demanding flexo and roto designs covering short to long run production needs with redundant manufacturing operations.”

KANSAS CITY, MO. – Multivac Inc. recently announced its universal flowpacking solution which will feature a W500 and W510 model.

The machine uses precise servo drive technology for maximum output and optimum process control. 

The company said products with a maximum width of 200 mm and a height of 120 mm can be packed with or without a tray. 

Other available features include the independent speed setting of the rollers for crease-free longitudinal sealing along with cross sealing to keep temperature and pressure at needed levels. 

The machine also has an integrated gas analysis system for MAP packing with modified atmosphere.

“When it comes to labeling or marking the packs on a flowpacker, Multivac offers a wide choice of solutions,” the company said. “These range from inline labelers to direct web printers and even combined systems. All these solutions are characterized by their extremely compact construction and optimum hygiene features. They are perfectly matched to the Multivac flowpacker in terms of their control technology and mechanical functions.”

Sustainability is no longer just a buzzword – consumers, corporate boards, and retailers have declared it a priority. More than 136 countries and 1200 companies have pledged to reach net-zero emissions by 2030. Canada, France, Spain, the UK, and India have banned single-use plastics.

While the most critical function of meat packaging is to protect the product and extend shelf life, increasing the recovery of packaging materials post-consumer and using fewer materials when producing the package improves package sustainability. Any package change may have tradeoffs such as higher cost, lower shelf life, and heavier weight. “We have the tools and know-how to help processors navigate a very complex process,” says Gregg Poffenbarger, business unity director of Materials for MULTIVAC Group.

SUSTAINABLE MEAT PACKAGING IS A HUGE OPPORTUNITY

Large retailers are driving the sustainability push. For example, by 2025, Walmart plans to use 100% recyclable, reusable, or industrially compostable packaging with a minimum of 17% post-consumer recycled content for its private brands. Similarly, ALDI announced that by 2025, 100% of ALDI-exclusive products would have reusable, recyclable, or compostable packaging and use 20% post-consumer recycled content. Virtually every leading grocer in the United States has announced sustainability initiatives for reducing packaging and food waste. A 2021 PMMI Study found that 80% of CPG manufacturers minimize packaging to reduce waste and 89% design recyclable packaging.

HORMEL FOODS REDUCE MATERIALS IN PACKAGING

One of Hormel Foods’ 20 By 30 goals focuses on improving packaging sustainability with research, innovation, on-package communications, optimizing package weight, and shipping efficiencies.

“When we looked at the original Jennie-O ground turkey packaging, we knew we could improve it, not only from a sustainability perspective but also from a retailer and consumer point of view,” says Kim Anderson, brand manager of Retail Marketing for Hormel Foods. “For example, the paperboard sleeve was not ideal for retailers as a refrigerated environment could sometimes cause issues with tearing.”

Hormel Foods takes a team approach to packaging design. A dedicated group of employees consistently looks for minimization opportunities, collaborates with other departments, and examines the entire supply chain for sustainability initiatives. “MULTIVAC was involved in the project from the very start,” says Doug Muzik, plant manager at the Jennie-O Turkey Store plant in Montevideo, MN.

“We communicated our vision and what we were looking for from a product appearance standpoint,” says Muzik. “Through numerous meetings and line trials, MULTIVAC helped us get the (thermoformed) tray we were looking for, and we achieved line throughput speeds comparable to our previous foam trays.”

The final solution was a thermoformed tray with a printed plastic lidding film. By printing directly on the film, Hormel could eliminate the paperboard sleeve. “For this specific project, our team was able to reduce both plastic and paper packaging, saving 1.5 million pounds of material annually,” says Anderson.

There are also indirect benefits to choosing a thermoformed package. “Because thermoforming equipment uses rollstock, rather than ready-made trays, our customers typically benefit from lower shipping costs and reduced storage space needs,” says Poffenbarger.

Collaboration is critical to introducing more sustainable meat packaging. “We’ve seen that collaboration drives innovation in other packaged-food industries, such as beverage and shelf-stable goods,” says Kachook.

Auras concurs. “R&D, marketing, engineering, and operations all play a crucial role in understanding the impact and the tradeoffs of the product, product loss and waste, and the packaging systems to implement for achieving sustainable development,” he says. “Without complete integration of these members, it’s tough to fully comprehend the benefits of implementing sustainable packaging and avoiding greenwashing.”

“MULTIVAC was very hands-on from start to finish, and we could count on them to have a representative present at all meetings and line trials,” says Muzik. “They had numerous techs on site to officially install the new lines ensuring the smoothest startup possible. MULTIVAC has continued providing great support whenever we need it.”

Unfortunately, not all clients involve equipment suppliers early on. “When we aren’t involved until late in the game, the process becomes more challenging,” explains Poffenbarger. “Material changes can change functionality such as opening features, shelf life, or puncture resistance.”

“Manufacturers of machinery and equipment are critical partners in developing sustainable packaging because they can help determine the necessary specifications and performance of packaging,” says Kachook. “Manufacturers can help brands understand how to navigate tradeoffs like cost, shelf life, and barrier properties as they look for packaging options that are more sustainable with recycled content or compostable films.”

INCREASING USE OF RECYCLED MATERIALS

Many processes are looking at replacing multilayered plastics with mono materials, including PP (polypropylene) and APET (amorphous polyethylene terephthalate) to improve recyclability. “It’s important to consider the change in barrier properties compared with composite materials,” says Poffenbarger. Adjusting running parameters on the packaging machine must be considered when switching to mono materials.

Packs and trays made from APET and other mono materials are already being used instead of composite materials to pack fresh products. “To achieve reliable packaging results, upper webs with a thin sealing medium are used,” says Poffenbarger.

A HOLISTIC APPROACH TO SUSTAINABILITY

Close cooperation with material manufacturers is fundamental to developing successful sustainable packaging. According to Poffenbarger, MULTIVAC works with leading material manufacturers consistently. To help with the essential task of testing, MULTIVAC’s Innovation Center has the capabilities to support customers in rolling out new concepts. “Our sales and technical support teams are ready to help processors step up to the opportunities in front of them,” says Poffenbarger. “MULTIVAC is fully committed to more sustainable packaging solutions.”

When evaluating various packaging concepts, processors need to recognize that the recyclability of packs is linked to the existing recycling structure. Achieving targets for recyclability should maintain product protection, especially with a high-value product like meat. Learn more about sustainable packaging solutions by contacting the MULTIVAC Group at 1-800-800-8552 or by visiting our website at multivac.com.