Packaging prolongs
freshness of wine. 36
LEDs spotlight packaging
Packer bottles up savings
Sun-care product line
dresses up its look
Compostable bags align
with brand’s image. 18

See what’s really new in
packaging design. 8
Hitachi has sold more than 85,000
Ink Jet Printers worldwide and
remains the industry leader in
manufacturing inkjet printers that
utilize cutting edge technology and
minimize impact on the environment.
With every new generation of Continuous
Ink Jet Printers, improvements are made to
meet the changing needs and requirements
of customers globally. Product superiority,
reliability and innovation are key components
in our new generation Continuous Ink Jet Printer.
To learn more about how Hitachi can save you money,
visit www.hitachi-america.us/takethechallenge today!
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Tel: 704.494.3008 ext 21 www.hitachi-america.us/inkjetprinters inkjetprinters@hal.hitachi.com
www.automationdirect.com/c-more-micro or www.c-moremicro.com
We squeezed the features of our popular TFT 6-inch C-more Micro into
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FREE programming software offers the choice of using many built-in
objects, such as buttons, bar graphs and data entry keypads. Or import
your own custom graphics, and save to libraries for use in multiple projects.
Alarm control, recipes and a built-in project simulator are time-saving tools
for more complex applications. All these features at a competitive price,
in a rugged and reliable package, give you a sweet HMI for even the
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* The programming software is free when downloaded from the AutomationDirect Web site, or
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Also Available
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* All AutomationDirect programmable controllers
* Modbus® RTU
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Go online for complete list
3-inch touch and
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• Recipes
• Built-in project simulator
• UL, cUL, CE, NEMA4 and 4X indoor ratings
Go online or call to get complete information,
request your free catalog, or place an order.
new technology
FEBRUARY 2011 volume 48 no. 2
30 PROVEN EQUIPMENT A contract packager finds value in
purchasing used machinery to build a new line.
34 DOUBLE QUICK Nestle relies on automation to boost production
of single-serve coffee portions.
20 COVER STORY A popular line of sun-care products devises a
new look for the beach.
23 BETWEEN FRIENDS New lip balm packaging allows friends to
share—just the product.
26 GOOD TRANSLATION What designers need to consider when
brands adopt a new packaging format.
28 CITY LIGHTS Cosmetic company’s stylish pack evokes
glamor of New York.
36 RIGHT PARTS Innovative components in bag-in-box packaging pay off
for wine and edible oils packaging.
38 SAFE TRAVELS Walmart supplier uses pyramid-shaped paperboard
packing to protect dinnerware packages.
next month
KRAFT FOODS executives
explain their strategy to apply
“open innovation” to their
packaging design process.
Association recognizes 2010’s best
examples of flexible packaging.
co-op adds a new filling line to
boost productivity in their yogurt
ROAD SHOW A mobile filling
line helps small wineries in Canada
bottle their product without major
capital investments.
l 4
We’ve made history – history
of label printers that don’t allow you to
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system. We’re introducing an intelligent label printer
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>> Make more money with easy private labeling
The Vivo! Touch puts intelligent label printing at your fingertips –
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Introducing the NEW
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Sr. Group Publisher
Patricia Spinner,
Executive Officers
Chief Executive Officer Paul Miller
Chief Financial Officer Fred Gysi
Vice-President/Executive Director, Stephen Corrick
Sr. Vice President, Events Division Kevin O’Keefe
Vice President, Operations Roger Burg
Vice President, E-Media Jason Brown
Lead Art Director Marco Aguilera
Associate Art Directors Tim Burns, Laura Pappada,
Hector Torres
Production Director Jeff Tade,
Production Manager Martin Schneggenburger
Senior Production Artists Jeff Polman, Derric Treece
Production Artists William Baughman, Ricardo
Esparza, Lucia Corona
Production Coordinator Adrienne Davis
Director of Circulation Sandra Martin
Circulation Manager Carlota Valle-Martinez
Marketing Manager Mary Williams
Foster Printing Service
800/879-9144, sales@fosterprinting.com
Editorial Director John Kalkowski
630/990-2364 john.kalkowski@ubm.com
Editor Lisa McTigue Pierce 630/990-7384
Senior Editor Linda Casey, 630/990-7385
Plant Operations Editor Jack Mans
630/990-4208 jack.mans@ubm.com
Associate Art Director Jennifer Field
Corporate Headquarters 11444 W. Olympic Blvd, Los Angeles, CA 90064
310/445-4200 Fax 310/445-4299 www.ubmcanon.com
Editorial: 1200 Jorie Blvd., Suite 230, Oak Brook, IL 60523
630/990-2364 Fax 630/990-8894 e-mail: john.kalkowski@ubm.com
11 COMMENT Mergers and acquisitions
18 GO GREEN Compostable packaging
19 SPC SUSTAINABILITY Life cycle analysis
39 ENGINEERS’ OUTLOOK Career strategies
For years, paper void fill
systems have made few
significant advancements.
Until now.
Introducing the FasFil™ Paper
Void Fill System from Sealed Air,
featuring a unique friction-free
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make the FasFil™ system the
next revolution in void fill paper
packaging. Find out more today
at pd.fasfilsystem.com.
The FasFil

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We’re Turning
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For years, pa
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featuring a un
swivel, which
to load the sy
the back or k e r
It’s one of ma
make the Fas
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at pd.fasfils
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The “9 Dot Logo” and “Sealed Air” are registered trademarks of Sealed Air Corporation (US). SC11090231
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Sealed Air’s paper products are made of 100 percent recycled
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FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com 8
New Product of the Month
aunch pad
Crave launches a dairy revolution with aluminum bottles
Upstate Niagara Co-op. launches Crave chocolate
milk in an aluminum Frost Flow milk bottle that chills
fast and stays colder, longer. Busy families can
beneft from the fact that the bottle’s twist-off cap
reseals, making Crave a portable and healthy snack.
And because of the pasteurization process, Crave
is shelf-stable. It can be stored and shipped at room
temperature just like soda or juice, making it an instant
hit with national retail buyers across the country.
The graphics are printed directly on the cans, which
are supplied by Universal Can, Japan. The caps are
supplied by NCC Japan Crown Cork Co. Ltd (www.
Crave uses social media tactics and pop-up
2GO drinks
Sold in self-heating cans, Fast Drinks’
2GO beverages are an example
of an exothermal process using CaO
(calcium oxide) to produce hot drinks for
immediate consumption most anywhere.
The 2GO drinks are encased in tinplate containers with litho-
printed instructions on wraparound insulating plastic labels. They
can be prepared in as little as three minutes, using a simple
sequence of actions: The consumer frst removes the bottom
lid from the can; he or she then presses frmly into the water
container; the consumer shakes the package until the colored
water disappears, then turns the package over; and he or she
removes the pull-ring on the upper end of the packaging. Three
minutes after the activation sequence, the packaged product will
be heated and ready to eat or drink.
This product retails in a recyclable 200ml pack, and is
available in fve varieties—black coffee, cappuccino, chicken
soup, hot chocolate, lemon tea and black coffee.
experiential events that Upstate Niagara calls “Craves,”
to engage consumers in unexpected ways. This was
apparent when Upstate Niagara took advantage of the
“Harry Potter and the Deathly Hallows” movie premier
on Nov. 19, 2010, to create a unique product launch on
the University of Nebraska Lincoln campus. Students
who sampled the product were given activation
cards encouraging them to become fans of Crave on
Facebook. The frst 125 students who became fans and
posted a secret code to the Crave Facebook page won
two free tickets to an exclusive midnight showing of
“Harry Potter and the Deathly Hallows” at a local theater.
“The UNL Crave event was a huge success
for us,” says Ken Voelker, director of marketing for
Upstate Niagara Co-op. “More than 500 students were
introduced to Crave during four hours of on-campus
sampling, and we were able to give 250 of them an
awesome experience with the Harry Potter premiere. It’s
our aim to really connect with our consumers through
events like these.”
Crave is the creation of
Upstate Niagara Co-op.
Inc., a group of dairy
farmers in western
New York. It is run
at O-AT-KA Milk
Products, Batavia,
NY. Upstate Niagara
is the majority owner
of O-AT-KA.
Source: Mintel Global New Products Database (GNPD)
New Products Launched in the U.S.

Mar- May-
10 10
Apr- June-
Beauty & Personal Care
Beauty & Personal Care
Source: Mintel Global New Products Database (GNPD)
New Products Launched Globally
Mar- May-
10 10
Apr- June-
Beauty & Personal Care
Beauty & Personal Care
The CX1200 Color Label Press delivers short- to medium-run,
full-color digital label printing at a breakthrough price. Utilizing
one of the fastest and highest-resolution color laser engines avail-
able, CX1200 delivers the quality, speed and flexibility of digital
presses costing many times more. Add Primera’s new FX1200
Digital Finishing System to laminate, die-cut, slit and rewind.
Call us today at 1-800-797-2772 (USA and Canada) or
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special limited-time bundle pricing when you purchase
both machines together.
New! Digital Label Press and Finishing System
Ideal for 10 to 10,000 labels at a time.
New! LX900 Color Label Printer
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Label Applicators LX400 Color Label Printer
Label Supplies
New Product Videos
NEW! Color RFID Printer
The LX900 Color Label Printer is Primera’s newest, fastest
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Features include print speeds of up to 4.5" per second, in-
dividual ink cartridges and up to 8.5" media width. You’ll
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Call Primera at 1-800-797-2772
LX400 is Primera’s most affordable desk-
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full-color labels for all of your short-run
products, helping you to sell more!
Call Primera at 1-800-797-2772
Primera’s AP-Series Label Applicators are the perfect
semi-automatic labeling solution for cylindrical con-
tainers as well as many tapered containers, including
bottles, cans, jars and tubes. See how fast and easy it
is at www.primeralabel.com/videos.
Call Primera at 1-800-797-2772
Primera offers ink cartridges and a large
selection of stock label sizes in various
shapes. Need a quote on a custom label
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on www.primerastore.com.
Call Primera at 1-800-797-2772
Want to see any of our digital color label
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Call Primera at 1-800-797-2772
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Ph: 1-800-797-2772
Ph: 763-475-6676
Fx: 763-475-6677
Ph: +61 3 8586 3030
©2011 Primera Technology, Inc. Primera is a registered trademark of Primera Technology, Inc. All other trademarks are the property of their respective companies.
Ph: +49 (0)611 - 92777-0
FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com 10
Bottling a fresh approach to ironing
StarBrands Ltd., a U.K.-based manufacturer of household cleaners,
has selected a PET bottle from RPC Containers Llantrisant
(www.rpc-llantrisant.co.uk) for a private-label ironing water product.
Made by StarBrands for multiple major retailers, the specially formulated
Fabric Freshener is poured into an iron to give clothing a long-lasting
freshness and fragrance.
StarBrands was looking for a rigid bottle with a dosing feature to enable
ease of pouring. The PET bottle from RPC Llantrisant offers a tapered
design, leading to an integral lipped spout that ensures a smooth delivery
of product. The bottle is then capped and labeled by StarBrands to meet
customer specifcations. “RPC Llantrisant has devised a highly convenient
solution for this ironing water product that combines durable handling with an
effective pouring mechanism,” comments David Mann, managing director of
StarBrands Ltd.
Seeking a way to extend its proprietary
effervescent technology, Tower Laboratories turned
to strategic branding frm CBX (www.cbx.com) to
help innovate new product ideas. Through extensive
ideation sessions, CBX helped zero in on the category
of proactive health and hydration for application of
Tower’s technology. The brand that grew out of this
research, which is named YZ (pronounced “wise”),
consists of “All Natural Hydravescent Crystals”
that are added to water to foster good health.
Once the concept was solidifed, CBX brought the
brand to life by creating the positioning, logo, name
and package design. Outthink (www.outthink.
com),Tower Brands’ marketing frm, developed
innovative ways to introduce it to the target audience.
“The name, YZ, speaks to the fact that this is an
intelligent choice for health-conscious consumers,”
says Gregg Lipman, managing partner, CBX.
“By placing the YZ name inside a circle logo and
surrounding it with bubbles, we’ve established an
iconic visual that links back to the effervescent nature
of the product.”
Henry McInerney, CEO of Tower Brands, agrees
with this brand positioning. “While there are many
other water-enhancing products on the market, the
effervescent bubbles in YZ are actually better, as
they help to disperse ingredients quickly and evenly.”
YZ favors are packaged in a box flled with seven
favor “stick” packets. A color-coded logo and beneft
bar—green for the Antioxidant packs, orange for the
Immunity packs and yellow for the Digestive Health
packs—makes it easy to understand the benefts and
clearly differentiate the products from one another.
UV-printed carton
carries natural appeal
To debut Nature’s Benefts, a granola-style food
line targeted to consumers looking for natural products
for their pet birds and small animals, Kaytee Products
Inc. chose paperboard packaging with visual cues
that convey the natural attributes of the product. “We
wanted to create a crunchy-granola feel that was also
very eco-friendly,” remarks Aria Grant, art director with
Directions Inc. (www.directions.com), Kaytee’s
design agency. This was achieved by using kraft
paperboard as a packaging material and muted tones
in the carton’s graphic design.
The package is UV-printed by Great Northern
Corp. (www.greatnortherncorp.com) using the web-
based StrataGraph process, which utilizes UV inks
and UV curing of inks and coatings. “For the Nature’s
Benefts boxes, we frst printed a thin coat of white as a
silhouette of the image to seal the uncoated substrate,”
Don Schroeder, president of Great Northern’s
StrataGraph operations, Oshkosh, WI, explains. “The
white makes the ensuing colors really pop out. As each
color of ink is applied, the substrate moves through
a fast-acting dryer. The dried ink forms a polymer
that sits on top of the paperboard instead of being
absorbed into it and acts as a base for the application
of the next layer of ink. After printing, the top sheet is
laminated to the paperboard.”
“The color and style of the package tells the
consumer, even before seeing the brand name
Nature’s Benefts, that this is a natural product,” says
Kay Thomson, senior marketing manager, Kaytee Pet
Bird. Nature’s Benefts is available at Petsmart, Petco
and independent pet retailers throughout the U.S.
Bubbly box shows off effervescent powder
www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011 11
John Kalkowski, Editorial Director
Like the first robin of spring, an increase in merger and acquisition
activity can be a harbinger of a changing season. Tat appears to
be exactly what is happening across the packaging industry. In the
last few months, there has been an uptick in these activities, with
numerous companies announcing purchases. Could this be a sign
that better economic times are blossoming?
Many of the large packaging mergers and acquisitions have been
among the large converters and materials suppliers. For instance,
RockTenn recently announced the purchase of Smurfit-Stone for
$3.5 billion. Even in the fragmented packaging equipment arena,
dominated by medium-sized and smaller companies, activity is
increasing. Pro Mach, for example, continues to build its network
of integrated equipment brands with its recent purchase of
Shuttleworth, a conveyor company.
As the Atlanta Constitution reported, “Rock-Tenn is
betting consumers will continue to loosen purse strings as
the economy leaves the recession behind. Analysts and
economists consider packaging a leading economic
indicator, as manufacturers and consumer-product
companies ship more goods.”
Brian Cornell, senior managing director of Mesirow
Financial, an investment bank, says there was a flurry
of transactions at the end of 2010 because many owners
wanted to take advantage of the Bush tax cuts that were due to
expire, but were finally renewed at the last minute.
Investors look highly at packaging, Cornell says, because it
performs better relative to other industries and is not as sensitive
to economic swings. He expects activity to remain strong going
into 2011, especially with companies valued between $25
million and $500 million (the middle market). “Investors want to
buy good businesses that are well-managed,” Cornell says, and many
that have survived the recession fit that description.
Recently, deals involving equipment makers have slowed because
many packagers have put capital-intensive purchases on hold during
the recession. Tom Egan, PMMI vp of industry services, says his
group hasn’t seen even a moderate increase in the acquisition rate
among PMMI members, which average less than $25 million
in annual revenues. He says PMMI membership has remained
relatively constant, adding that entrepreneurs are always starting new
businesses as other established companies are acquired.
One industry insider points out that a number of packaging
companies have been holding off trying to sell their businesses.
Reduced revenues caused by the recession also affect the market value
of the companies. “Before they sell, these companies want to build
their valuations coming off a couple bad years,” he says.
Tomas Blaige, CEO of Blaige & Co., an investment bank
specializing in packaging, says about 80 percent of the purchases
are by strategic buyers, who believe an acquisition will strengthen
the acquiring company through better integration of materials or
manufacturing, entering complementary markets or expansion in
new territories. Blaige says about 15 percent of purchases are pure
financial deals, without strategic value.
Cornell points out that private equity investment firms are sitting
on a lot of money that was raised between 2005 and 2007. Tese
investors are eager to add performing companies to their portfolios.
Merger activity could be sign of better times
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FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com 12
new productsequipment
Liquid fller The Pro/Fill 3000 Dual Lane Liquid
Filler is equipped with a new servo-controlled nozzle
lowering system that allows nozzles to dive into a
container within millimeters of the container bottom
with servo-controlled repeatability and accuracy. This
fully automatic inline liquid flling machine offers quick
changeover, easy product set-up and precise servo-
controlled repeatable nozzle positioning during flling.
Designed for “same machine” no-drip flling of foamy
and non-foamy, low- to high-viscosity products, the
fller provides a cost effective means to flling a range
of products and container sizes. It also offers increased
output with its dual-lane offset indexing system, the co.
Oden Corp., 716/874-3000.
Sterile fller The co.’s Servo Pump Fillers are
designed with sanitation in mind. The fller features
angled fat surfaces, round tubing to replace square
tubing and redesigned overlapping or recessed
surfaces that now eliminate pooling water. The servo
controller makes changeover from one size container
to another quick and easy without the need to change
parts, the co. states. The machine’s sanitary pumps are
CIP (clean-in-place); they sanitize themselves. The fller
is suitable for a range of fowable products (like sauces,
dressings, jellies, condiments and shampoos) and
products with particulates (like macaroni and cheese).
It can also handle alfredo sauce, fruit desserts with
particulates like whole pitted cherries or apple pieces
and lasagna sauce with meat fllings.
Hinds-Bock Corp., 877/292-5715.
Bottle washer The co. has developed a washing
process design for their HOD bottle washers for cleaner
bottles. The system utilizes a screw-drive to locate and
space the bottles and cam-actuated, spring-loaded gripper
bottle carriers in the washer. These carriers will allow a
much higher pressure spray of wash solution to be applied
to the bottles both inside and out. More PSI means more
gal/min, which leads to cleaner bottles. With the proper
pump, boosting the pressure at the nozzle from 30 to 90
PSI can increase the GPM fow by up to 75 percent, the
co. says. The new system also features an upgraded driver
train, advanced nozzle technology to cover the interior of
the bottles and water conservation to extend the life of the
wash bath.
CapSnap Equipment, 517/787-3481.
Robot The new IRB 2600 model of medium
capacity multipurpose robots features an optimized
compact design, an ultra-wide working range and
a payload capacity up to 20 kg. With an increased
payload, fexible mounting options and an increased
work envelope, the robot is suited for case packing,
process tray handling and loading, and small-format
palletizing applications, the co. states. The robot
features a total arm weight of less than 300 kg and can
improve cycle times by up to 25 percent with the co.’s
QuickMove motion control technology, the co. states.
ABB Robotics, 248/391-8400.
Exceptional expertise, craftsmanship, and service,
with every facet of our manufacturing process
housed under one roof!
“Made in the USA”
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Full Features of the 360A
Series Label Applicator
Labels Oriented to Specifc Product Feature
Descrambling/Accumulation Tables
High Speed for Maximizing
Product Output
Print and Apply Labels to
Varying Product Heights

360A WR
Variable Speed
Wrap Station
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Cost Competitive,
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www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011 13
Portable marking The Mini Mark is a small,
portable dot peen marking system designed for both
handheld applications and integration into existing
or new machinery. The system features preloaded
leadscrews and ball slides for machine tool quality
performance and durability while 12 mounting holes
are provided for fexibility in mounting at virtually any
position or angle. The detached controls feature the
latest in embedded technology with CF card storage
and network (LAN) and RS-232 connectivity.
Kwikmark Inc., 815/363-8268.
Shrink wrapper The co.’s new all-in-one
machines are robotic pick-and-place shrink bundles
with built-in case packers. With quick-change gripper
assemblies and adaptability to handle all types
and sizes of products, the all-in-one system groups
products and places them onto a bucket conveyor
for shrink wrapping. A discharge gantry
automatically places the bundles into an
erected tray/case. The shrink wrapper features
one-time handling, product stability, multiple
product confgurations, minimal changeover,
versatile loading and collation, and a color
touchscreen interface.
Polypack Inc., 727/578-5000.
Laser scanner The OS32C Safety Laser
Scanner features a 104.5-mm profle, light 1.3-kg
weight and low 5-W power consumption. Benefts
of the scanner include fast and easy equipment
commissioning and troubleshooting with patented
individual sector indicators. The scanner features up to
four times faster MTTR (mean time to restoration) than
other safety laser scanners with lower maintenance
cost and manufacturing downtime cost from equipment
damage. Using the scanner’s memory module, a
maintenance technician can get the manufacturing line
running again without using a computer. The scanner
also features system monitoring over LAN via the
integrated Ethernet port, low-profle equipment designs
with a small footprint and low power consumption, ideal
for battery powered mobile applications, the co. states.
Omron Scientifc Technologies Inc.,
800/479-3658. www.sti.com
Bagger The CFS Aquarius SmartPacker TwinTube
C high-speed bagger boasts a bag production output
of up to 500 bags/min., the co. states. The bagger has
the option of running a single flm reel for each tube
to simultaneously run packs with different sizes and
appearances. It forms bags of 40 to 145 mm, covering
mini treat size bags and overlong narrow bags for party
mixes and calorie packs. The bagger has a product-in-
seal detection system, which has proven to work above
460-bags/min. With the co.’s “CostFox” control system,
the machine boasts efficiencies above 98 percent. The
machine features low costs, thanks to low operator
and maintenance requirements. Its net result is a
measurably lower cost per pack, the co. states.
CFS Aquarius/Bainbridge Assoc., 616/583-1458.
A leader in miniature pneumatics, Clippard
provides quality products and
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packaging industry!
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FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com 14
new productsequipment
Cartoner The model CV6-350C
continuous-motion cartoner features
a streamlined, modular design,
patented dynamic carton cell chain,
volumetric fller and integrated vision
system. Ideal for food, confectionery
and nutraceutical applications, the
cartoner will load a variety of carton
sizes and styles, including theater boxes.
With a 4-spindle rotary carton feeder,
the cartoner is designed to operate
at a rate up to 350 cartons/min. The
cartoner features a patented product
streaming delivery system to increase
production and uptime, and eliminate
bridging and clogging. The cartoner
also features volumetric fllers with
automatic adjustment via feedback from
the integrated checkweigher, resulting in
less product waste, the co. states.
Z Automation, 847/483-0120.
Case packer The tissue tough
case packer (TTCP) enables versatile
packing of single or multiple rolled and
folded tissue product lines and multiple
SKUs. Ergonomically designed for easy
case removal, quick adjustments and
rapid setup and recovery, the case
packer is a low-cost solution for efficient
side- or end-load RSC or HSC cases.
The design incorporates case erecting,
collation, loading, folding and sealing,
and an be integrated with palletizing,
stretch wrapping, labeling, product
and pallet transport conveyor, pallet
dispensing, and slip-sheet dispensing.
Schneider Packaging, 315/676-3035.
Cap sealer The co.’s Super Seal Touch induction cap sealer system offers increased
sealing speeds, the industry’s frst completely integrated cap inspection system, an intuitively
designed touchscreen interface, simplifed set-up and operation, and a host of capabilities for
internal monitoring and remote network communications. The co. will also unveil its new all-in-
one universal sealing head. This design greatly simplifes setup to ensure operators correctly
position the sealing head across the entire range of cap sizes to be sealed, the co. says. A
positive locking mechanism and dead front label identify the correct positioning in a clear and
concise manner. The system is suitable for sealing a range of cap sizes from 24 to 120 mm.
Enercon Industries Corp., 262/255-6070.
ASME/ANSI Attachment
Resistance Lube Free Plastic Custom/Specialty
U.S. Tsubaki, Inc.
© 2008 U.S. Tsubaki, Inc. All rights reserved.
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Rigid packaging Cardia Biohybrid food-
contact rigid packaging products are compliant to
Europe’s Regulation (EC) 1935/2004 and USA’s FDA
CFR 21 for materials and articles intended to come
into contact with food. The product’s proprietary
technology combines renewable thermoplastics with
polyolefn material to reduce dependence on fnite
petroleum resources, while reducing the packaging’s
carbon footprint.
Cardia Bioplastics, 888/605-1488
new productsmaterials
Clear EAS labels The co. says its EP Clear
Labels is a frst-of-its kind clear label for placement over
a bar code without jeopardizing bar code scanning. The
enhanced performance electronic article surveillance
(EAS) labels reportedly offer the smallest-size EAS
label available for protecting small, thin,
un-carded cosmetics and other high-
value merchandise. The labels are
a visual deterrent to theft and have
been proven in retailers’ pilot studies
to reduce theft by more than 15
percent, the co. states. The high-theft
product category of health-and-beauty aids
is one of the key areas to beneft from these new radio
frequency label circuits, as the labels are small in size and can protect items
often targeted by thieves, such as cosmetics, perfumes and other small merchandise.
Checkpoint Systems Inc., 800/257-5540.
Formable paper packaging
FibreForm, a packaging paper with unique elasticity,
enables it to challenge plastic in new areas. The
paper’s formability creates opportunities for special
effects and personalized packaging based on
renewable raw material that is both compostable and
recyclable, the co. states. This renewable material
can undergo thermoforming in food packaging
machines and features high elasticity. The paper
is made with FSC-certifed primary fber and
meets requirements for traceability certifcation in
accordance with PEFC.
Billerud, +46 8-553-335 00.
Wine shippers WineLoc protective wine
shippers are made with 60 percent recycled-content
EPS. The WineLoc packaging uses EcoSix, a
recycled molding bead by RAPAC. The recycled
wine shipping containers are projected to reduce
material introduced into the supply chain by a total
actual weight of 240,000-lbs annually. The high-
performance protection of EPS reduces supply chain
waste of goods broken or damaged during shipping
and handling. The product also features insulating
qualities that protect perishables and fne wines
during transit.
ACH Foam Technologies, 866/896-1626.
Oxygen scavengers A new series of
oxygen scavenging additives can be dispersed
directly into packaging materials, which the co. says
offers a more convenient alternative to conventional
scavenging techniques such as UV-activated
and oxygen
additive is
designed to maximize shelf life for diverse packaging
made of materials such as LDPE and HDPE, PP,
PET and polylactic acid (PLA) for the food and
pharmaceutical industries. The technology uses
purifed and modifed layered clay as a performance-
enhancing carrier of the oxygen-scavenging iron.
Oxygen is depleted from the package by migrating
through the packaging material and reacting with the
dispersed active iron from the additive. The reaction
is swift and produces iron oxide, which is linked
inside the packaging.
NanoBioMatters, 617/273-8092.
Carry-handle tape The co.’s new Easy
Open Carry Handle Tape 8643 is an integrated
carry handle that functions as part of the shrink flm
package. The new tape is applied into the package
on the packaging line using an integrated tape handle
machine. The machine mounts at a right angle to
the shrink-wrap tunnel and applies the tape prior to
entering the machine. The tape is reinforced with
continuous PP monoflaments in the backing, providing
a straight “zipper-like” easy-open feature. This patented
feature enables consumers to pull the tabs and easily
open the package. Even after the consumer removes
a few cans or bottles from the case, the carry handle is
still functional, the co. states.
3M, 800/362-3550.
www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011 17
Secure unit-dose pack MedLock secure unit-dose package
combines a foil-laminated blister card locked within a tear-resistant formed paper
tray. Based on the co.’s BlisterGuard platform, the compliance package takes
pharmaceutical package security to the next level with a patent-pending locking
mechanism, resulting in a child-resistant, senior-friendly design, the co. states.
The secure packaging features a push-down, pull-out design with a unique
release and locking mechanism. The patient pushes down on a blister cavity that
protrudes through the lid to release the blister card and dispense the dosage.
The blister card is designed to remain intact within the outer protective paper
shell and lock back into place each time the package is closed.
Colbert Packaging Corp., 847/367-5990.
Wine closures The new
Select Series coextruded synthetic
closures are tailored to meet the
unique needs of artisan winemakers
and their premium wines. The
closures have a visual appearance
and texture almost indistinguishable
from natural cork and feature bark-
like roughness and a chamfered
(angled or beveled) edge achieved
using advanced cutting technology.
Using a proprietary process that can
replicate more detailed artwork than
the traditional fre-branding used
on natural corks, these are the frst
synthetic closures that can be end-
printed, the co. states.
Nomacorc, 919/460-2200.
Food grade polymers
A new family of products, designated
“FG” (food grade), meet demanding
requirements for use in food contact
applications. The new polymers
provide compliance with several
regional food contact regulations
including FDA (Food and Drug
Administration), European Food
Contact n° 2002/72/EC and GMP (EC)
n° 2023/2006. All FG products are
available globally to give customers the
fexibility to design and manufacture in
multiple regions.
DuPont, 800/438-7225.
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Go green
Snack’s compostable packaging
helps build ‘natural’ image for brand
Learn more
Boulder Canyon’s biodegradable packaging will be the
subject of a presentation by Chris Mitchell, Innovia’s sales
and marketing manager for packaging and sustainable
films, and Bill Reilly, development manager of Genpak, at
the Sustainability in Packaging 2011 conference to be held
Feb. 22-24 in Orlando, FL, for more information and to
register, please visit www.sustainability-in-packaging.com
John Kalkowski, Editorial Director
Healthy, active people often have high
expectations for the foods they eat and the
packaging in which it is sold. Snack maker
Inventure Group, Phoenix, AZ, aims to meet
both sets of expectations with its Boulder Canyon
Natural Foods brand of potato chips and dips. Tat
is why about a year ago Boulder Canyon adopted
compostable packaging for its chips.
Tick-cut, kettle-cooked chips such as Boulder
Canyon’s have grown in
popularity in
recent years. Many of the people buying these
products are concerned about both flavor and
the nutritional value of the snack, as well as the
environmental impact of the packaging.
Tanner Clark, product manager, says Boulder
Canyon, which was launched in 1994 in Boulder,
CO, has always been very eco-minded. Te earth,
he says, plays a central role in their customers’
When Boulder Canyon set out to design
compostable packaging, they wanted to “keep
the integrity of the brand at the forefront,”
he says, adding that they sought to keep the
same look and feel of the packaging they were
already using while adding environmental
Genpak, a Toronto-based converter that
was already supplying Boulder Canyon,
worked with them to develop the new
compostable bags. Bill Reilly, development
manager for GenPak, says his company
came up with a three-ply laminated
structure that met stringent requirements.
It includes an outside layer made with SFI-
certified paper; a middle barrier layer of
Innovia’s Natureflex metallized cellophane
made from wood pulp; and an inner layer
made with BASF’s Ecoflex biodegradable
plastic, which has properties similar to
Te new packaging had to meet
the American Society for Testing and
Materials (ASTM) 6400 specification
for compostable plastic, covering
plastic products that are designed
to be composted in professionally
managed municipal and industrial
composting facilities. Te standard
focuses on whether those materials will
disintegrate and biodegrade swiftly
and safely at a satisfactory rate.
In addition, Reilly says, numerous
other factors were considered, such as
the productivity in Boulder Canyon’s
packaging operations, shelf life and
Te package is also certified
by the Biodegradable Products
Institute, which involved
extensive testing to ensure
it contains no heavy
metals, supports plant
life and breaks down
within six months leaving no
harmful materials.
Reilly says the only other
biodegradable option was polylactic acid (PLA)
materials. However, he said they were concerned
with some of PLA’s properties, including how well
it machines, its sensitivity to heat and the growing
public concern that agricultural land is being used
for packaging and biofuel materials.
Beyond the materials chosen for the packaging,
Reilly says that Genpak tries to make the entire
manufacturing process more sustainable using
water-based adhesives and by using the eight-color
Opaltone printing process, which they say reduces
solvent use by 40 percent.
Tere were also concerns about the noise
associated with some PLA packaging. Te
biodegradable packaging that they chose gives the
look, feel and sound as their earlier packaging, says
Boulder Canyon’s Clark.
Te packaging features a green band across the
top that says, “Compostable Package.” Clark says
awareness of the bag’s environmental benefits is
growing, adding that “People who see it, really like it.”
An enterprising blogger decided to test the
compostability of several types of snack bags. This photo
shows the extent of deterioration of Boulder Canyon’s
bag (left) after four weeks in a compost heap.
Boulder Canyon Natural Foods
has found wide customer approval for a
biodegradable package it introduced in 2010.
19 www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011
A recent sustainability summit focused on the importance of packaging in the
sustainable or “green” product development cycle. At the heart of this discussion
is sustainable materials production and the need for near-closed loop material
flows in industrial systems.
At one end of the spectrum of considerations is the effi ciency of virgin resource
utilization, and at the other is the effi cient reclamation and recycling of materials.
Optimization of the materials that make up products and packages is a viable
sustainability strategy. Life cycle assessment (LCA) can be used to understand
the interlinked impacts of production, use and end-of-life processes. LCA is a
methodology to understand the implications of design decisions along the life cycle
of product and packaging. It offers powerful analytical information about potential
environmental and human health implications that can be fed into the product
development processes.
At the same time, it’s important to remember that LCA is a methodology
that is rapidly evolving. While many aspects of LCA methodologies are being
developed and tested, the availability of public life cycle inventory data that are
current, transparent and relevant remains the limiting factor for thorough, fair and
economical use of LCA. One of the most common arguments against the widespread
use of LCA is that it is not a good tool to capture human and environmental toxicity
impacts due to data and methodological limitations.
While this is a valid concern, at times the limitations of LCA are framed in such
a way as to imply that the methodology is defective if it cannot provide definitive
answers for everything. Tere is a strong desire among the user community for tools
that give a score or an answer for any and all questions about environmental and
human health assessment.
Tooling up
LCA is but one tool, and its strengths include
providing multi-attribute environment assessment, wide
applicability across industrial sectors and identification
of areas of greatest impact or greatest improvement. It
offers an objective and science-based framework for the
evaluation of alternatives.
As sustainability becomes a core strategic objective
for a growing number of businesses, it is understandable
to want one tool to give us all the answers. Yet the basic fact is
that “the environment” is by far the most complex system we could
ever attempt to assess, particularly under conditions of imperfect and incomplete
information. To expect one tool to provide all the answers is unrealistic and
unreasonable. We will ultimately need a suite of assessment and monitoring tools to
support understanding of sustainability issues, just as we currently use multiple tools
to inform us about other complex systems.
For example, every company relies on a suite of sophisticated accounting and
market analysis tools to assess its financial stability, its product offerings and other
decisions. Is it then reasonable to expect one tool—LCA or anything else—to
answer all the questions about the implications of industrial practices on eco
Let’s shift the discussion from what a given tool such as LCA cannot do to
what it can provide, while continuing to develop methodologies and tools for
other diffi cult questions such as human and environmental toxicity and other yet
unidentified issues that will arise at the intersection of industry and environment.
To fully implement strategies that produce the systemic changes needed to
achieve sustainability in the industrial system, we will need an assortment of
specialized tools and techniques that help answer specific questions leading to
informed decisions.
Life cycle analysis is powerful
but it can’t answer all questions
Minnal Mistry is project manager for the Sustainable Packaging Coalition,
a project of GreenBlue (www.greenblue.org). For additional information,
email spcinfo@greenblue.org.
to wan
www.therbdwyergroup.com e: custservice@therbdwyergroup.com
ph: 631-830-6222
Linda Casey, Senior Editor
Less than a year after its acquisition of Playtex
Products Inc. and its health-and-beauty aid
brands, Energizer Holdings Inc. embarked on a
complete redesign of the newly acquired Hawaiian
Tropic suncare line. “It was the summer of 2008,”
recalls Chuck Renz, senior manager of package
development and packaging innovation for
Energizer Personal Care division, “I was heading
up the package development group, when the
Hawaiian Tropic marketing head came to me
and shared their whole new strategy for brand
positioning.” Te entire line of sunscreens and
after-sun products were to get a luxurious, upscale
look and feel that also would offer more brand
consistency from product to product within the
Hawaiian Tropic line.
To help develop the graphics for the redesign,
the Hawaiian Tropic product team brought in
Phillips Design Group and charged it with the
task of targeting two primary demographics with
one look, while maintaining brand equity and
effectively communicating several messages.
“Tey were talking to the indulgent sun-and-
beauty seekers, who want to be out in the sun and
get dark, and the skin-involved age resistors, who
are people that want to be in the sun but don’t
want to wrinkle and ruin their skin,” explains Steve
Phillips, president of Phillips Design Group. “Tese
are two different kinds of audiences.”
Because the target markets were so different,
the agency created separate image boards for each
demographic to not only guide their graphic and
contextual messaging for these consumers but
also to look for alignment between the disparate
audiences. “What these two distinct groups have in
common is the desire to pamper and indulge their
skin with something special,” Phillips adds.
Capturing the
tropical experience



Designers, engineers and marketers collaborate on a PACKAGING REDESIGN that finds common ground between
two distinct consumer groups to provide more-consistent branding that also packs big sustainability benefits.
21 www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011
Te finding set the group off in what Phillips calls
“the experiential direction.” He says this direction
tries to capitalize on the emotion of the experience
of a sunny day by bringing in the visual reminders
of the tropics. Te group’s visual exploration of the
experiential direction is dominated by images of
lush tropical fruit, beautiful locations and refreshing
waters. Market research confirmed the experiential
direction’s appeal.
With a general market target identified, the agency
then charged a team of six—a design director
and five other designers—to develop graphic
concepts for the brand. “What we do initially
is throw the project at everyone so we get as
many ideas as possible,” Phillips explains.
“Te client narrows down the direction,
and then we narrow down our team to
the people who worked on the selected
Developed concepts included those
with an ingredient focus, more abstract
pictograms, masculine shapes, a play on
the Hawaiian Tropic palm tree logo and an
ethereal look that sought to convey how
easily the products are absorbed. Simple
more upscale looks and more cosmetics-
oriented designs also were considered.
Te Hawaiian Tropic group narrowed
down the designs to those created by Phillips
Design Group senior designers Cara King
and Angela Kowalczwk. But to determine
the final design direction, Phillips would
insist on consumer research. “A lot of us
make subjective decisions—you could
like yellow and I could like blue,” Phillips
remarks. “We want to see what our target
audience selects.”
Consumer testing identified hibiscus
flower design as the most effective.
Phillips attributes this to three
characteristics of the design. “It’s
reminiscent of the tropics; it’s easily
color coded; and it has a strong
bull’s eye effect on the package,”
he explains.
Before the design could
become an actual package though,
the agency would need to collaborate
more closely with Energizer’s Hawaiian
Tropic team on the look, feel and shape.
Parallel processes
bestow benefits
King and Kowalczwk worked with
Veronica Lewis and Jean Fulfidio from
Energizer to fine-tune the hibiscus design.
Camilla Medeiros, who held the position of
senior global business manager for Hawaiian
Tropic at the time, served as the primary
decision maker for graphics and color cues.
Te agency also collaborated with the
Hawaiian Tropic package development team
to increase the effectiveness between the
package structure and design.
“As marketing was developing graphics,
we were developing structures that would go
nicely with the graphics and work with the
new brand image,” Renz recalls.
Te “we” that Renz is referring to includes
him and independent, industrial designer
Diana Sierra, who created photorealistic
renderings of the package forms and shapes,
using McNeel North America’s Rhino
CAD software, a free-form 3-D modeling
Renz then creates more technically specific
drawings in Parametric Technology Corp.’s
Pro/Engineer (PTC) CAD software before
producing fused-deposition models (FDM) using
a Dimension Inc. 3-D printer. Te onsite creation
of working models made of ABS plastic enabled
the Hawaiian Tropic team to quickly test the form,
fit and function of the designs. “Within a day of
Continued on page 22 Ethereal concept
To help define the redesign’s overall direction, image boards were created targeting (left to right) the “indulgent sun seeker,” “skin-involved age resistor” and sunning experience.
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22 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com
having a design, we can have a model
that is a solid representation of the
actual design we’re coming up with,”
Renz explains. Te FDM models in
ABS plastic were the first prototypes
to be tested on the filling and packing
Production prototypes
To further refine its understanding of
how the new packaging would impact
filling and labeling, Energizer worked
with a variety of suppliers to create
production prototypes and identify
and obtain package components that
could be purchased as stock items. Tis
was no easy task because the redesign
applied to the entire sun-care product
line from oils to aerosol sprays. Te
restage involved 205 finished goods
across the U.S., Canada, Latin America
and Europe.
Te package development team
worked closely with both Graham
Packaging to develop the new, more
shapely tottle structures that can sit
on the cap end. and CCL Containers
on the new aerosol cans. Additionally,
they worked with AptarGroup Inc.
on new Emsar lotion pumps and
SeaquistPerfect Creme actuators and
twist-lock actuators; Berry Plastics
for a new child-resistant closure;
Polytop Corp. and Zeller Plastik
USA Inc. on new flip-top closures;
and TricorBraun and Giflor srl on
the latch force and fitting of a low-
profile closure into the tottle’s revised
Te components were tested on
existing equipment to optimize the
manufacturing process. Energizer
also took this opportunity to install
new packaging lines for the project.
In January 2011, it was putting the
final touches on a new tottle filling
line, which will be featured in an
upcoming edition of PD.
AptarGroup Inc., 815/477-0424.
Berry Plastics Corp., 812/306-2000.
CCL Container Inc., 724/981-4420.
Dimension Inc., 866/721-9244.
Giflor srl, +39 0444 380550.
Graham Packaging Co. Inc.,
McNeel North America,
206/545-7000. www.rhino3d.com
Parametric Technology Corp. (PTC),
781/370-5000. www.ptc.com
Phillips Design Group, 617/423-7676.
Polytop Corp., 401/767-2400.
TricorBraun, 800/325-7782.
Zeller Plastik USA Inc.,
0 More information is available:
The logo-based concept plays on the
Hawaiian Tropic palm tree to maximize
brand equity across the product line.
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23 www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011


Lisa McTigue Pierce, Editor
Balm Chicky Inc. founders Abby Schwalb and
Elizabeth Moskow didn’t take no for an answer
when one packaging supplier after another said
the package they envisioned wasn’t possible or they
weren’t interested in making it. Te two partners
knew their idea for Te Friend End—a lip balm
cylinder with a second stash of balm stored in the
base—solved an unmet consumer need.
“Te Friend End design idea stemmed from a
simple act that so many of us balm users encounter—
pulling a tube of lip balm out of your pocket or bag
and having a friend, co-worker or someone else ask
if they can borrow your balm for their own chapped
lips,” Schwalb says. “We’ve noticed that, like yawning,
using lip balm is almost a contagious act and so lip
balm borrowing runs rampant.”
Most people hand it over, some reluctantly,
because they don’t want to appear selfish or
uncaring. But being nice might not be best after
all. What they’re most likely sharing are germs,
especially during cold and flu season. Moskow
explains, “Te skin on our lips is very thin and
when lips are dry—the time we’re most likely to
use balm—they often have small cracks or tears in
the skin membrane. Germs more readily enter the
body through these dry lips, making people more
susceptible to germs and infection.”
Te Friend End is a simple, hygienic solution.
It’s similar to a typical lip balm tube, where the
main compartment holds the product and users
twist the bottom to raise and lower the solid lip
salve. But the bottom of this tube flips open to
reveal a second small pot of balm inside the base,
enough for about 20 uses.
When someone asks to borrow your lip balm,
you could, without hesitation, turn it upside
down, flick open Te Friend End and hand them
the tube. Tis way, you can share lip relief with
your friends while keeping the main stick pristine
for your lips only.
Finding the right friends
Commercializing Te Friend End has taken
about two and a half years. Schwalb and Moskow
first had the idea back in August 2008; then
registered their company in 2009. Te plan is to
launch their own branded product this spring,
Balm Chicky Balm Balm (inspired by the ‘70s adult
film genre), as well as to license Te Friend End to
other lip balm or cosmetic companies.
With no prior experience in packaging, the
partners learned as they went, making tweaks along
the way. “We hardly knew what injection molding
was two years ago,” Schwalb recalls. “We’ve done all
of our own research via communicating with plastics
companies, filling companies, engineers and filling
Hip lip balm…
for two
The owners of Balm Chicky Inc. envisioned an UNUSUAL
TWO-COMPARTMENT TUBE that lets consumers
share their lip balm with friends—hygienically. But
engineering and producing The Friend End package
took patience and persistence.
Trays holding The Friend End tubes will be flooded with
liquid lip balm to fill the main compartment. Once the
product sets, the tubes will be removed from the tray,
flipped upside down and reinserted so the bottom can be
filled, too.
Cutaway view
Top cap snaps on to main body tube
by lip and channel (interference fit).
When The Friend End portion is
turned clockwise, the main body lip
balm will rise out of the main body
Interior wheel snaps into main body
and is kept in by lip.
Exterior wheel and interior wheel are
timed by locking teeth and fasten
together by lip and channel.
The Friend End cap snaps into place
by interference fit of lip of exterior
wheel and channel of The Friend End
cap. The Friend End portion refers to
The Friend End lip balm and wheel,
which is one unit with the cap hinged
to the wheel.
Top cap (PP)
Main body (PP)
Interior wheel (PP)
Riser (PP)
Exterior wheel (PP)
Cap (PP)
(Inset) Living butterfly
hinge needs to be as
flush as possible and
have both an open
and shut state.
Wheel (interior)
Wheel (exterior)
The Friend End cap
Top cap
Main body
Exploded view
Continued on page 24
24 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com
tray manufacturers. It’s been a very
grassroots process.”
Te pair fielded disappointments
along with the thrills, as they
unexpectedly faced brick walls
when they approached a number
of established U.S.-based suppliers.
“No one wanted to risk working with
a new company—and they weren’t
interested in innovation,” Schwalb
says. “We were shocked that, rather
than helping us figure out how it
could be done, we were told over and
over why it could not. From salesmen
or reps not following up, to being
blatantly lied to, we were surprised
that, in this type of U.S. economy,
more companies weren’t concerned
with customer service or taking any
initiative into a new arena that could
prove to be wildly successful.”
Still believing Te Friend End
was viable, the team hired Seattle,
Wash.-based freelance engineer Jeff
McCasky of McCaskey Design and
Development to do CAD drawings.
Used in a Design Intent document, the
drawings show the package’s functional
design through multiple views,
including exploded and cutaway (see
both on page 23). Using McCasky’s
CAD model, they had a prototype
made so they had a physical sample to
show potential manufacturers.
Although Schwalb and Moskow
wanted to make the product and
package here at home, they eventually
had to broaden their horizons to find
a willing partner to make the unusual
tube. Tey met a number of Asian
injection molding companies at the
2009 HBA Global Expo and started
what turned out to be a long and
enlightening process.
“After a year of continued talks,
letdowns and poor options, I received
an e-mail from one of the Chinese
companies we had met at HBA,”
Moskow says. “Tey were willing,
able and now more English friendly
to engage in a partnership to produce
our mold for a reasonable price—
almost a tenth of what any U.S.
company was quoting us.”
As of press time (mid-January
2011), the Shanghai supplier, Wuxi
Sunmart Science and Technology
Co. Ltd., was just finishing the
injection molds, with plans to start
tube production shortly thereafter.
Double the pleasure
Product formulation, filling, labeling
and final packaging operations will be
done in the U.S. at a contract filler.
Balm Chicky Inc. was close to deciding
which one of two finalists at press time.
But the production process will likely
be the same:
• Empty PP tubes will be inserted face
up in a titanium holding tray (most
probably custom made).
• Te liquid balm, formulated in
100kg kettles, will be poured over
the tray to flood the tubes.
• Once the product sets (dries),
excess balm will be scraped off and
Retro label graphics play off the adult film genre theme from the 1970s. Labels will be sourced by the contract filler.
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25 www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011
returned to the kettle.
• Tubes will then be flipped over, and
Te Friend End filled the same way.
• Double-filled tubes will be
capped (both ends), then labeled,
overwrapped and packed 24 or 30
to a case.
Schwalb explains why they decided
to package the tubes singly and
simply: “We thought about having
an external box as with other prestige
products, but both of us are conscious
of the impact Balm Chicky has to
our environment and didn’t want to
generate additional waste through
excess packaging. Also, since Te
Friend End feature is such a profound
marketing tool, we didn’t want to
enclose and hide the concept in a box.”
Looking the part
If Balm Chicky Balm Balm
rolls off your tongue like a melody
from a campy porno film, that’s no
mistake. Te founders characterize
the company and its branded lip
balm as one of “playful sexiness.”
A post on the company’s Facebook
page even teases, “Te Friend End
ENCOURAGES you to put a finger
in our bottom!”
Te brand’s sexy ’70s vibe comes
through the retro label graphics
(by Portland-based freelance artist
and graphic designer Ann Storer)
and tongue-in-cheek flavor names:
Juicy Melons (cantaloupe), Sticky
Bunny (cinnamon/caramel), Huge
Cucumber (cucumber/mint), Sweet
Baby Ginger (ginger), Hot Chocolate
Love (chocolate), Wild Mountain
Honey (honey/orange), Papa
Cherry (cherry), Rosie Pomegranate
(pomegranate), Tantric Tease (chai
masala) and All Naturals (unflavored).
Tere’s even a ménage à trois in
the making. “About six months after
the launch of our brand Balm Chicky
Balm Balm,” Moskow tells us, “Balm
Chicky Inc. plans to roll out vintage
tins with a threesome of flavors, to
enhance your lip soothing enjoyment,
as well as lip stain, lip gloss, body
balms, scrubs and more.”
License to kill
No joke: April 1, 2011, is the target
launch date for Balm Chicky Balm
Balm. It will be sold for a suggested
retail price of $7 per tube in prestige
cosmetic stores, kiosks and upscale
boutiques in Portland, OR, to start,
with hopes to distribute across the
country as soon as possible. Teir
plan is to make Te Friend End a
household name for everyday balm
users or for anyone who is concerned
about personal hygiene and keeping
their own balm end sanitary.
Additionally, Balm Chicky Inc. is
actively seeking an exclusive licensee
for Te Friend End, and is open to
other licensing options “if the fit is
right,” Moskow says. Te concept
could easily be used with other
products, too, such as medicated
brands and ski/surf/sport products.
“We really want to let other
companies know that Te Friend End
technology is a sure-fire way to bring
attention and increased sales to your
brand,” Schwalb says. “Differentiation
is the name of the game in the
cosmetics world and it’s not often that
a package feature is not only different,
but also serves an important function.”
View additional exclusive photos
online at www.packagingdigest.com.
Balm Chicky Inc., 720/475-0979. www.balmchicky.com
McCaskey Design and Development, 503/313-9217. www.jeffmccaskey.com
Ann Storer, 503/270-9282.
Wuxi Sunmart Science and Technology Co. Ltd., +86 510-82733182.
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26 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com

Brand owners know that extending their brand
in new directions can provide the impetus for
growth and, ideally, profit. But they also know that
if not executed properly their brands can lose the
connection to the consumer.
Years ago, Coca-Cola Co. was faced with an
important challenge: Transitioning their iconic
brand from a glass to plastic bottle. Tis was an
important step for Coca-Cola from both strategic
and environmental perspectives. Arguably the
most important component of the change was
whether or not consumers would accept the new
bottle as something that was true to the Coke
brand. Te look, the feel, the weight all required
consideration to ensure consistency of the brand
Te Coke bottle is as much a part of the brand
as the Coke script in the logo and required intense
scrutiny because the plastic bottle affected filling,
distribution and the overall brand experience. A
few years later, Heinz faced the same challenge
with an iconic bottle of their own. Te process
of extending your brand into multiple packaging
formats can be challenging. Let’s explore the top
three considerations:
1. Brand equity
Brand equity is the
No. 1 consideration
when introducing
your brand in multiple
formats. Te exercise of
exploring formats that fit
your strategy will force
an in-depth analysis of
the components that
truly encompass your
brand. Remember, your
brand is the sum of
its parts, not any one
individual component.
Brand owners must ask
themselves the tough
questions: “If we change this component (print
process, substrate, color, size), will it still feel like
my brand?”
Brand owners need to understand their
brand’s equity before ensuring it is consistently
communicated across all touchpoints. Color and
shape are the easiest targets when assessing brand
equity but it’s important to recognize all the
individual elements of your brand to
dissect it. Once you have dissected
your brand, you will have a good
understanding of what can and can’t change. Tis
will allow you to enhance specific elements without
alienating consumers.
Te debacles widely publicized around design
changes to Tropicana and the GAP logo are
examples of what not to do.
2. Brand experience
When consumers decide to part with their
money and purchase your brand what kind of
experience are they going to have? Does the
new packaging format provide an opportunity
to enhance the brand experience? Tese are the
types of questions that should be considered when
extending your brand.
Moving to a new format should have some built-
in value-added benefits to the consumer. Perhaps
it’s more convenient, faster to make or easier to
dispense. Whatever the benefit is, make sure it is
consistent with and, if possible, enhances your
brand’s experience.
And make sure there actually is a benefit to
the consumer and not just to your organization.
Sometimes the lure to extend your brand is
simply because it reduces your costs in some way
or streamlines distribution. Tis has nothing to
When extending a brand to NEW OR ADDITIONAL
PACKAGING FORMATS, consider these three factors.
When moving from glass (left) to plastic
(right), Coca-Cola Co. worked hard to
make sure that the new packaging
lived up to the consumer’s brand
Coke used its advertising to tell consumers about the glass-to-plastic packaging switch.
27 www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011
do with the consumer and you are
putting your overall brand at risk.
In fact brand owners must consider
whether their brand is strong enough
to be stretched to new formats. If
your brand is not performing well
in the market, it is unlikely that
extending it to new formats will
improve its position.
3. Brand consistency
Tis is the most diffi cult
consideration to execute because
it typically involves many moving
parts. Manufacturing, print processes,
substrate/materials all need to be
considered when moving the brand
to new formats. Hopefully, you’ve
already completed the exercise of
understanding your brand’s equity
and know how to deliver the brand
experience, but how do you plan
to make it all come together? Te
manufacturing component alone
usually requires new suppliers, new
print processes, new substrates.
All of these elements are new
territory for your brand and are
critical to its success. While PMS
colors are supposed to be consistent,
there are still fluctuations in color
hue when printing across multiple
substrates. But the consumer doesn’t
know or care about all of your hard
work in the background. Tey are
only exposed to your brand at the
point of purchase. Tey care, and will
notice, if the brand they know and
love has changed in some way.
Timing is important because
introducing a new variant to your
packaging will require support from
marketing and advertising budgets.
In addition, it is always helpful to
engage consumers to validate your
brand strategy. Tey will probably tell
you something about your brand you
didn’t know or consider.
Understanding your brand’s
unique characteristics will assist you
in determining which visual direction
to take and, assuming the new
packaging format offers consumers
something new or better, you can
position yourself for success. Tere’s
no question that when executed
effectively, extending your brand
to multiple formats can have an
extremely positive impact on profit.
Just make sure you understand your
brand as well as your consumers do.
John Miziolek is an owner of Reset
Branding, a Toronto-based branding
agency. For more information, visit
Even Coke’s most recent plastic bottle
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shape from the earlier glass container.
The process of
extending your
brand into multiple
packaging formats
can be challenging.
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28 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com


Lisa McTigue Pierce, Editor
Once you’ve got a winner, it’s hard to follow up
with a good sequel. Keeping the kicks the third
time around takes real ingenuity.
When designing the packaging for its Book of
Shadows III, California beauty brand Urban Decay
knew it had to up the ante for its popular annual
eye shadow collection.
Tasked with the project, product development
director Amy Zunzunegui at Urban Decay says,
“We feel like every year we need to make it more
interesting and more appealing to the customer so
we shine versus our competitors. We’d seen LED
lights in other things, like cards. We’re always trying
to take things that have never been done before in
packaging and apply it to our package.”
BOS III incorporates seven LEDs in a pop-up
box design of a New York City evening cityscape.
“New York City is very Urban Decay-ish,” explains
Zunzunegui. “Even though we’re not from New
York, it’s kind of a quintessential Urban Decay city
and feels very much like our brand. We thought the
lights in the skyline would be great.”
Urban Decay worked closely with its supplier
HCT Packaging on the concept, design and
implementation of this package. Nick Gardner,
evp for HCT, says, “Having created the two
previous Book of Shadows, as well as the hugely
successful Alice in Wonderland pop-up palette, we
wanted to take the concept to another level and
create something with Urban Decay that really
stood out from the crowd. New York City is a
fantastic place, full of atmosphere and character
which is what we wanted to capture in this third
book of shadows.”
Inspired by the glimmering lights and iconic
landmarks of New York City, the elaborate BOS
III pop up shows hand-illustrated depictions of
the city that never sleeps—from skyscrapers such
as the Empire State building to landmarks like the
Statue of Liberty and Central Park—set against a
backdrop of a star-filled night sky.
A ribbon pull-out drawer holds 16 shades (seven
of which are exclusive to this palette), plus two
colors of Glide-On eye pencils and a 3.7ml travel
size eye-shadow Primer Potion. Tis melting pot
of color, with its unique package, is positioned as a
collector’s item.
Artful functionality
Starting with the idea that they wanted to
use LEDs somehow for BOS III, Zunzunegui
talks about designing the NYC theme around the
functionality of the lights. “It took a long time to
flush the artwork out, to go back and forth with
‘Yes, this side is right, it isn’t right. Let’s tweak this.
Let’s make the sky look this way, the girl look this
way. We need to make the taxicab move over to the
left because it’s blocking this skyscraper.’ Tere was
a lot of back and forth,” Zunzunegui remembers.
“Once we got our artwork, then we had to figure
out the positioning of the lights. ‘Tis light can’t
go in this building because it’s not thick enough
to hold the wire up the back. Or it can’t go here
because it’s too close to the border. We need more
A built-in battery in the lid powers the
pack’s seven LEDs, a number selected to make a
maximum impression at an affordable cost. Two
of the lights are positioned in buildings printed on
the inside of the lid. Te other five are incorporated
into pop-ups.
HCT had worked with LEDs before, but only
by applying them directly onto the pieces. Tis
design needed to be a bit more sophisticated.
Gardner explains, “LEDs have a tendency,
because they’re so bright, to visually look not very
appealing. When you open them, they’re like ‘ooh,’
this horrible set of lights, like a being blinded by a
car. It’s diffi cult to control the voltage.”
He continues, “So what we did with this was,
all the LEDs are covered. Te back section of
the lid is covered with a mylar sheet that acts as
a light shade, if you will. Te other LEDs on the
pop ups are either placed at the back or inside the
buildings so the buildings look as though they’re
illuminated. But it’s not a light that would be
unnatural, like stuck on them. It’s in them, so
when you look at them, the buildings are lit from
the inside.”
When asked about the impact on recycling
or disposal of the package, Gardner says, “We
obviously cannot speak for how the end customer
would dispose of these but in truth it would be
hard to remove the batteries to allow them to
be placed into a clean recycling stream. We are
not making strong claims for the environmental
friendliness of this packaging unlike some of
the other UD products we make such as ‘Te
sustainable shadow box’ that is made from bamboo
and recycled greyboard.”
To keep customers coming back for more, URBAN DECAY LIGHTS UP A
NEW YORK CITY POP-UP CITYSCAPE for its Book of Shadows III eye-shadow
collection through a marriage of package design and function.
A first for cosmetics
packaging, seven
LEDs—positioned in
buildings and on the
bridge—light up Urban
Decay’s latest Book of
Shadows collection.
Urban Decay’s Holiday
2010 Book of Shadows III
launched in October 2010. By being
the first palette to incorporate LEDs
with a pop-up cityscape, it one-upped the
company’s Book of Shadows I from Holiday 2008 (left),
which was the first pop-up design. Book of Shadows II
from Holiday 2009 (right) departed from the
pop-up format to feature a photo
album-style of Urban
Decay images most
popular with customers.
The lid opened to reveal a
trap door where the photo
album was housed.
on earlier
d th
pop-up form
29 www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011
Making it work
Once the design details were worked
out, HCT set about bringing the
package to life. Te main structure
of the box is made from die-cut
greyboard, a staple in HCT’s inventory.
Te recycled paperboard, pressed
into sheets in different thicknesses, is
stacked, glued and cut to create the
shell of the box and the drawer.
Te box is outer wrapped with art
paper—128 grams per square meter
thick—offset printed in four-color
process, embossed and UV coated. Te
pop-ups are offset printed in four-color
process on white cardstock and die-
cut. Total weight of an empty package
(minus the product pots) is 400 grams.
Magnets in the box and the top
corners of the lid provide a secure
closure. An activation switch and timer
for the LEDs is in the lid. When lifted,
the lights come on by themselves. Tey
turn off automatically, too, after about
a minute. Te standard battery provides
between 5,000 to 6,000 activations.
Te entire package was hand
assembled at a licensed factory in
southern China, which used about
500 people on the line to fill the
order for 400,000 packages. Each
“book” took about five to six minutes
to make. “Te main challenge was
the sheer complexity of the piece,”
Gardner says. “Te large amount of
handwork in the assembly, the placing
of the lights and ensuring that the
pop ups and lights all functioned well
lead to very long production times.”
Assembled packages were sent to
plants in the U.S. and the Dominican
Republic for filling by contract
manufacturer Oxygen Development.
Te company formulates the eye
shadows based on Urban Decay’s
recipes, opens the drawer, drops in the
products and closes the drawer. Each
palette is then packed into a clear
folding carton, made of virgin PET,
with an insert card that shows all the
product colors. Both carton and card
are sourced and supplied by HCT.
Crazy for quality
BOS III retails for $54 and is sold
at Macy’s, Sephora and ULTA stores
and online at macys.com, sephora.
com, ulta.com, beauty.com and
Eye shadow is an important market
at Urban Decay. “Our customers
are crazy for the eye shadows,”
Zunzunegui says, as they represent
a higher percentage of business
compared to competitors, who
typically sell more lip products.
BOS III has been so well-received
that Urban Decay has ordered a
second production run. Part of its
draw is that, like other UD palettes,
it contains seven shades not available
elsewhere. Tat exclusivity—plus the
variety of the collection—appeal to
the brand’s fans, those experimental
Millennials and selective Gen Xers
in the 18 to 35 age range with the
discretionary income to be able to
afford UD’s quality shadows.
It’s overall satisfaction, Zunzunegui
contends, that keeps them coming
back for more. “We’ve set a trend with
our customers that they’ve come to
expect new and innovative things with
our packaging. But it always has to
function and echo our brand image as
well,” she says. “So we’re always looking
for different treatments, different ways
to do things, different stuff to put in
the palettes. Tat being said, we take
great pride in the fact that we have
high-quality makeup. If you don’t have
good cosmetics behind the scenes, then
you can sell one palette, but no one’s
going to buy another one.”
0 More information is available:
HCT Packaging, 310/260-7680.
Oxygen Development LLC, 954/480-2675.
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30 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com

Jack Mans, Plant Operations Editor
Black Bear Bottling Group LLC, Oak Creek, WI,
specializes in contract packing carbonated beverages.
Te plant has a glass line running 6.3 oz to 1 qt
bottles, a plastic line running 10 oz to 3L and a
B-I-B operation. Customers include Wit Beverage
Co., Goose Island sodas and Deerfield Traders, which
produces products for Walgreens. An interesting
element of Black Bear is that almost of all of its
equipment is bought used. “Contract packaging of
carbonated beverages is a very cost-sensitive business,
so it makes sense for us to buy used equipment when
it meets our needs and is available,” says Black Bear
president and co-owner Peter Caruso.
“Te key is to find a source for the used equipment
that you can trust and that has the knowledge and
resources to find the equipment you need,” he adds.
“For us, that source has been Howard Buckner
at SMB Machinery Systems. Almost all of the
equipment I have in my plant has come from Howard.
I tell him what I need and he finds it for me.”
SMB has a 120,000 sq-ft facility outside of
Atlanta, GA, where it maintains an inventory
of used equipment, but if it doesn’t have the
required item in inventory, it will conduct a search.
SMB rebuilds equipment as required, although
this isn’t always necessary, says Caruso. “Te
equipment Howard finds us is generally in excellent
condition,” he says. SMB also has electrical and
controls divisions that did work for Black Bear.
Tey built new UL-approved control cabinets and
designed line controls so that upstream equipment
will shut down automatically if bottles back up on
the conveyors, and an operator can start all of the
equipment on the line from a single cabinet. Most
of the equipment at Black Bear uses Rockwell
Automation controls. Black Bear Equipment in
the plant was installed by Pieper Electric.
Running Jelly Belly blueberry drink
During PD’s visit, Black Bear was running Jelly
Belly blueberry gourmet soda in 12-oz glass bottles
at a speed of 200 bottles/min for Wit Beverage Co.
(WBC). “Black Bear has been running products
for us for the past five years, and we have been
very satisfied,” says Paul Kassis, co-founder of
WBC. “Quality is a major requirement for us in
selecting a contract packer, and Black Bear has done
a great job. Teir
SQF certification is
a big factor because
it assures that the
highest levels of
quality are being
achieved and certified
by an independent
third party. Relationships are also very important
to us, and Pete Caruso has been outstanding to
work with. Black Bear has done an excellent job of
accommodating our requirements.”
Black Bear receives all of its bottles, which are
supplied by Anchor Glass Container Corp. and
O-I, in bulk stacked pallets. Tus, the first step
in the glass packaging line is a bottle depalletizer.
In this operation, the bottles are swept off onto a
bulk take-away conveyor on the top level and are
conveyed by an Ambec lowerator conveyor from
FleetwoodGoldcoWyard to the floor level.
Te bottles travel to a bottle rinser that picks
up the individual bottles with rubber grippers,
inverts them for a water rinse and then sets them
back upright on the outlet conveyor. Te bottles
then enter a separate room where a monobloc unit
Contract packing
carbonated beverages
Based on what could be termed “sustainable economics,” BLACK BEAR BOTTLING GROUP
Bottles enter a separate room where a monobloc unit
with 40 filling heads and 10 capping heads fills and caps
Bottles are lifted for filling and then travel to the capper.
Rotary labeler has two labeling heads that apply p-s wraparound or front and back labels. As bottles leave the labeler,
an inkjet prints date and lot codes on their shoulders.
31 www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011
with 40 filling heads and 10 screw capping heads
fills and caps them. (Te depalletizer, rinser and
filler/capper were built by companies that are no
longer in business, so those manufacturer’s names
are not included.) Bottles are metered onto the
pressure filler by a star wheel that places them onto
individual spring-loaded bottle pedestals.
As the machine rotates, each pedestal raises the
bottle up against a seal on the bottom of the gravity-
fill valve. As the pedestal lifts the bottle, it pushes
open a valve and filling commences. Te filling cycle
is set so that the product reaches the bottom of the
valve sleeve as the filler rotation brings the bottle near
the machine-discharge starwheel. Te bottle pedestal
descends, allowing the fill valve to close, and the
bottles travel into the discharge starwheel.
Te bottles then enter the capper starwheel and
are delivered to the rotating capper. Caps travel
down a chute from the hopper and are placed on
the bottles, after which chucks tighten the caps
as the capper rotates. When the magnetic clutch
reaches the set torque, it slips and the chuck system
disengages. Black Bear also has a capper for crown
caps that it uses when running those products.
Black Bear has a newer, faster monobloc 40 fill
head, eight capping head unit on order to upgrade
its operation.
Monobloc filler/capper
Te bottles are filled at 38 deg F, so after leaving
the filling/capping room, they enter a bulk heating
tunnel where hot water warms them to about 65
deg F to eliminate any condensation on the bottles
that would affect the labeling operation.
Te bottles are then single filed and enter a
Kosme model Top II AD 12-head labeler from
Krones Inc. that applies p-s labels, which are
supplied by Orion Labels LLC. Te labeler is the
only new piece of equipment on the line.
Te unit is equipped with two labeling
stations that can apply individual front
and back labels or wrap-around labels. At
each station, a roll of labels is mounted
horizontally and the web is pulled through
a series of rollers to a point where the label
is applied to the bottle.
A feedscrew meters the bottles into the
labeler’s infeed starwheel, which, transfers
the containers to individual plates on the
continuously revolving bottle table. As the
bottle table rotates, the bottle plates also
rotate until the bottle is properly situated to
receive the first label. After this is applied, the bottle
plates continue to rotate so the bottle is positioned
to receive the second label exactly opposite the first
label. Te labeled containers then travel through a
discharge starwheel onto the discharge conveyor.
As the bottles leave the labeler, an Excel inkjet
printer from Videojet Technologies Inc. prints
date and lot codes on their shoulders. Te bottles
are then conveyed to a Hartness Intl Inc. Model
825 case packer. Black Bear packs the bottles into
four- or six-pack carriers, and the carriers and
shipping cases are erected ahead of the Hartness
unit by a machine from SWF Companies. Tis
erector incorporates a Melton hot melt unit from
Valco Melton that applies glue to the flaps. Glue is
supplied by Henkel Corp. Black Bear has two of
these units to keep up with production.
During PD’s visit, Black Bear was packing the
Jelly Belly bottles into four-pack carriers. Te
carriers are conveyed from the SWF machines to
a packer from Pearson Packaging Systems that
places six carriers into a case (four six-pack carriers
into a case when the plant is running those). Black
Continued on page 32
Black Bear Bottling Group LLC has become certified under the Safe Quality Food (SQF) Level 2000 food safety
standard that specifies the quality management system requirements necessary to identify food safety and quality
risks as well as validate and monitor the control measures. The SQF Institute is a division of the Food Marketing
Institute (FMI), which was established to manage the SQF food safety and quality certification program. The SQF
Program is an internationally recognized comprehensive food safety and quality management system to cover the
entire food chain. The program is made up of two codes (standards), the SQF 1000 Code for the primary production
sector and the SQF 2000 Code for the food manufacturing and service sectors. The SQF 2000 Quality Code is
a HACCP-based food safety and quality risk management system covering all food chain stakeholders. It covers
the identification of food safety and quality risks, and the validation and monitoring of control measures. These
international standards are designed to be used by any business in the food supply chain operating in domestic or
global markets, from primary producers to manufacturers, and those who offer services to the food industry.
Black Bear Bottling Group achieves Safe
Quality Food (SQF) Level 2000 certification
Case packer drops 24 bottles at a time into four-or six-pack
carriers, depending on what product the plant is running.
32 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com
packer. Te cases are then conveyed
through a SWF top gluer equipped
with a Melton hot melt unit.
Te cases travel past a Label-Aire
Inc. print and apply unit that is
equipped with a Sato America Inc.
printer. Te printer prints a p-s label and
an arm swings out and applies it to the
shipping case. Te line is also equipped
with an Arpac Group shrink wrapper
that is used when it is running trays. Te
cases are conveyed to a VonGal Corp.
palletizer, and Black Bear has a Lantech
stretch wrapper on order.
“I do business on the basis of
relationships,” says Caruso. “Our
suppliers are great, which takes a lot
of the pressure off of our operations.
Bear also runs trays on this line so it
has a Padlocker (now part of SWF)
tray former that it uses when it is
putting bottles onto trays.
Te cases containing the carriers
are conveyed to the Hartness case
packer, where they enter on a low-
level conveyor. Bottles enter the
machine single file on top and then
are separated into four lanes for
loading. When the correct number of
bottles have accumulated, the empty
case is lifted and the bottles drop into
the case. A Marsh inkjet unit from
Videojet prints the product flavor on
the sides of the cases as they exit the
Carriers and case flaps are sealed with hot-melt glue. Shipping cases are conveyed to a high-level machine for palletizing.
Anchor Glass Container Corp,
Arpac Group, 847/678-9034.
630/759-6800. www.fgwa.com
Hartness Intl Inc.,
800/845-8791. www.hartness.com
Henkel Corp., 866/443-6535.
Krones Inc., 414/409-4000.
Label-Aire, Inc., 714/441-0700.
Lantech, 800/866-0322.
O-I, 567/336-5000. www.o-i.com
Orion Labels LLC, 920/833-1173.
Pearson Packaging Systems,
800/732-7766. www.pearsonpkg.com
Pieper Electric, 414/462-7700.
Rockwell Automation, 414/382-2000.
Sato America Inc., 704/644-1650.
SMB Machinery Systems LLC,
770/704-2000. www.smbsales.com
Valco Melton, 513/874-6550.
SWF Cos., 559/638-8484.
Videojet Technologies Inc.,
800/843-3610. www.videojet.com
VonGal Corp., 334/261-2700.
0 More information is available:
printing with
pride in the U.S.A.
Henkel Corporation
10 Finderne Avenue
Bridgewater, NJ 08807
Henkel is the leader of adhesive and coatings technology
worldwide. Henkel Creates Advantage through a broad
range of high-performance products and process solutions that
drive operational optimization for you and your customers.
To learn how Henkel can Create Advantage
for you, and to receive more information,
visit: henkeladhesivesna.com/creatingadvantage21A.
Except as otherwise noted, all marks used are trademarks and/or registered
trademarks of Henkel and/or its affiliates in the U.S. and elsewhere.
®= registered in the U.S. Patent and Trademark Office. ©Henkel Corporation,
2011. All rights reserved. 6979 (1/11)







Total Process Solutions
Our Resources
Your Success
34 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com


A state-of-the-art, fully automated packaging system at Nestlé
Nespresso’s coffee plant in Lecco, Italy runs 1,260 coffee capsules/min.
Te Nestlé Nespresso SA Co., one of the fastest
growing operating units of the Nestlé Group, has
faced an unprecedented increase in customer demand
for its portioned coffees in induividual serving
capsules. Te company, headquartered in Losanna,
Switzerland, pioneered the concept of portioned
high quality Grand Cru coffees for use at home, as
well as at out-of-home locations, such as high-end
restaurants, hotels and cafés, premium event caterers,
customer care and luxury retail businesses.
In the past several years, the customer demand
for its products has been well above the company’s
sustained annual compound growth rate of more
than 30 percent. While presenting a great competitive
advantage, the customer demand has also required
Nestlé Nespresso to double its packaing productivity.
Troughout its growth, Nestlé Nespresso’s key
priority has been to not only meet the customer
demand, but also maintain a high quality standard for
its products and processes. Integrity of its production
process was thus regarded as critically important and
could not be compromised in delivering the project.
Packaging line upgrade
Nestlé Nespresso turned to Cama Group, a maker
of high technology secondary packaging systems
and machinery based in Lecco in Northern Italy,
to upgrade its existing packaging line and allow the
company to meet the expanding customer demand.
Cama’s outstanding packaging knowledge, combined
with a unique machine range and robotic loading
units, made it a logical choice for the project.
Cama has grown steadily over recent years. Te
company’s turnover has increased from 13.5 million
Euros in 2002 to approximately 43 million Euros
in 2010. In part, this success is due to a strong and
developing relationship with Nestlé over the past 20
years. Te group’s previous experience in working
with Nestlé to produce packaging for small cone-
shaped ice-creams products, greatly influenced Cama’s
approach to the Nespresso project and instilled
confidence in Nestlé Nespresso that Cama can deliver.
CAMA worked with Rockwell Automation
to deliver the project. Te two organizations have
worked together across a number of projects, so
their collaboration on the Nestlé Nespresso project
represented a logical continuation of a successful
relationship. In addition, Nestlé uses Rockwell
Automation for all of its automation needs, which
increased confidence in the ability of all parties
involved in the project.
Doubling the capacity of the Nespresso packaging
line required Cama to create a robotic wrapping
machine with a dedicated feeding system uniquely
designed to meet Nespresso needs. Te project was
intended to set a prototype for all future Nespresso
facilities, placing extra pressure on the importance of
its success. Te key challenge was to help increase the
safe handling of small cups at varying high speeds.
Tight deadlines
“We were under a lot of pressure to deliver this
project swiftly and successfully in order to meet
the rapidly growing demand for our
product,” says Enrico Induni, corporate
engineering manager, Nestlé Nespresso. “Te
‘devil’s triangle’ of maintaining quality standards,
while delivering on a tight deadline and on budget,
is always a struggle. In this case, however, Cama
approached the project ‘the Italian way,’ that is
without any fuss and promptly resolving any issues.
Te project was delivered within budget and on
Cama has been developing robotic packaging
systems since 1988, enabling it to offer a wide range
of dedicated package loading units equipped with
two or four-axis robots. Tese units are designed to
meet different packaging requirements for a variety
of products, such as flow-wraps, bags, thermoformed
packs and cartons.
Te Nespresso automatic line, that was built by
Cama, is a state-of-the-art, fully automated packaging
system that consists of a robotic loading system, a
side-loading cartoning machine and a wrapping
machine. Te line runs 1,260 capsules/min. Te
loading system is a two-axis robot with picking heads
designed and tailored by Cama to meet Nespresso’s
specific requirements. Te side-loading cartoning
machine places the coffee cups in sleeves containing
up to 10 items per sleeve. Each sleeve is sealed and
codified by a laser after being filled. Te wrap-around
machine then loads the sleeves into the shipping
cases, which contain 20 sleeves. A pallet system picks
up the cases and takes them to the outbound line. All
the production data is transmitted via Ethernet to a
central data collection system.
Cama utilized a range of Rockwell Automation
solutions in building the Nespresso packaging
line, including Allen-Bradley ControlLogix and
CompactLogix programmable automation controllers
(PACs), FactoryTalk View software, PanelView
HMI solutions and a Kinetix integrated motion
solution, featuring Allen-Bradley servomotors and
drives. Te Rockwell RSLogix 5000 programming
software package used in the Nespresso line includes
standard program modules for motors, valves,
alarms and analog I/O scaling as well as standard
program modules for PID loops, programs and
tasks structures, I/O mapping configuration, process
control sequence examples and safety/process
interlocks structures.
Te Rockwell Automation team in Switzerland
worked with Cama on this project because the Nestlé
System doubles
coffee production
The automated packaging
system consists of a robotic
loading system, a side-loading
cartoning machine and a
wrapping machine.
35 www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011
Nespresso plant is located there.
“It is a great advantage to work
with companies such as Rockwell
Automation and Cama, who can
draw on their subsidiaries in various
countries,” says Induni. “For a global
company such as Nestlé, this is a
key competitive advantage, ensuring
that the project can receive prompt
and effi cient support regardless of its
geographical location.”
Cama held a week-long workshop
for Nestlé Nespresso technicians at
its plant in Lecco to familiarize them
with the technological specifications
of the machines. Cama continued
to provide training on the Nestlé
Nespresso production floor to allow
its technicians to learn how to use the
Close coordination
When suppliers team up to deliver a
product to a customer, communication
and information sharing often
becomes a challenge, as companies
may sometimes be willing to reveal
only partial information about their
equipment and knowledge relevant
to the project. As a result, teams,
without full knowledge of each other’s
competencies, may not understand
how to fully leverage each other’s
equipment and expertise.
Te coordination between the
Rockwell Automation and Cama
teams was effi cient and seamless.
“Major multinational manufacturers
are standardizing with Rockwell
Automation’s equipment, because it
is hugely innovative, easy to use and
performs impeccably,” says Giovanni
Anzani, project manager for the
Nestlé Nespresso and CAMA Group.
“In addition, our teams had a good
knowledge of each other’s equipment
and worked really well together.”
Te project took only eight months
to complete from start to finish—a
very short timeframe for delivery of
such a complex project. “Under such
circumstances, strong commitment
of resources and will is required from
both the supplier and the customer to
help ensure the success of the project,”
says Nespresso’s Induni. “I am happy
to report that Cama and Rockwell
Automation were able to work together
and meet all objectives of the project.”
Since the completion of the first
production line, Cama has delivered
18 additional lines and more are being
ordered by Nestlé Nespresso. “Our
partnership with Rockwell Automation
on the Nestlé Nespresso project was a
fantastic one, resulting in a complete
success story for the customer,” says
Cama’s Anzani. “Our relationship with
Nestlé Nespresso continues, as is our
dedication to the partnership with
Rockwell Automation.”
Cama USA Inc., 201/940-7230.
Rockwell Automation, 414/382-2000.
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36 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com
Collaborative effort by packaging technology companies creates packages
that BETTER PROTECT WINES from potential environmental damage.
Research shows boxed wine sales are strong and
future growth prospects look promising. In the
U.S. alone, sales of 3-L boxes of wine have grown
at double-digit rates year-after-year since 2003 and
total U.S. consumption from the box, including
both 3- and 5-L formats, is more than 20 percent
by volume (source: AC Nielsen Scantrack Data).
Tis momentum among consumers and retailers
alike comes as no surprise, given the environmental,
cost and taste benefits of boxed wines. Unfilled
bags in bag-in-box (B-I-B) wine packaging require
up to 88 percent less storage space than bottles,
making them much more economical to warehouse
and ship. Boxed wines also are lighter than
bottled wines, less prone to breakage and easier to
Perhaps most importantly, B-I-B packaging
minimizes the product oxidation that occurs when
conventional bottles are opened. B-I-B wine can
stay fresh for as long as six weeks after opening
versus two to three days for bottled wine.
As a worldwide supplier of bags for the wine
industry with manufacturing locations on five
continents, Scholle Packaging’s products are sold in
more than 60 countries and include flexible films,
fitments and caps, bags and filling equipment
for the food, beverage and industrial
To keep the company at the
forefront of bringing flexible
packaging technology
and trends to life,
Scholle has
resources in the
areas of research and
development and packaging
innovation. So when it decided to
place the ethylene vinyl acetate (EVA)
based film, it had been using in its B-I-B
packaging for wine with a new and improved film,
Scholle needed a supplier with the capabilities and
knowledge to formulate a distinct product that
would meet its customers’ needs with breakthrough
technology for the B-I-B wine industry. As a global
company, Scholle also needed uniformity of resins
across geographies.
Bagging material improvements
With 14 manufacturing locations for PE in four
continents, the Dow Chemical Co. was the perfect
fit. Additionally, the companies could hit the
ground running as Dow as a long-time materials
supplier for Scholle.
“Dow is Scholle Packaging’s No. 1 supplier
because they really understand the flexible
packaging industry and have a tremendous product
portfolio,” David Bellmore, manager of global
product development, Scholle Packaging, remarks.
“Teir multi-source capability [for PE] both in
North America and other continents enhance
the security of supply that our customers value
Anand Sundaresan, senior North American
market manager, food and specialty packaging
at Dow adds: “As the largest PE producer in the
world, we knew we could develop a resin with
our strong polymer and material science expertise.
Collaboration really adds value by getting it right
the first-time, accelerating the speed to market and
helping our customers rapidly achieve success in the
marketplace. Effective collaboration was really
the key to successful innovation in
this case.”
of the new
film it sought to
develop: 1) Te new
film needed to have
improved strength for
better puncture and flex-crack
resistance which is crucial for
maintaining package integrity to
prevent leakage; 2) It should allow
for faster sealability; and 3) It must
deliver improved organoleptic
properties for freshness, taste
and odor.
Tis last requirement
was especially important to
Scholle, as it looked to appeal
to higher-end and more
specialty wine producers.
Dow listened to Scholle’s specifications to
identify a variety of ideas to match Scholle’s vision.
Te materials supplier then produced various
films in its fabrication facility, and then presented
important findings and suggestions to Scholle for
Te result of the collaboration was Scholle
FlexiTech, a single-layer, PE, non-barrier film that
offers strong seals and robust package performance.
Dow’s in-house reseach and development group
designed a resin for Scholle based on Dow’s catalyst,
process and product know-how that met Scholle’s
key requirements and requests.
Te new film, which serves as the wine contact
layer in B-I-B packaging, offers durability and flex
crack resistance. Additionally, FlexiTech allows
for consistent sealability which ensures the high-
quality of Scholle’s bags. It also helps to provide
optimal taste and odor properties of the wine.
“Te B-I-B wine industry is an important
market for Scholle—one in which we routinely
have seen double-digit growth year-after-year,” says
Bellmore. “Te distinct material that Dow created
with Scholle’s vision and guidance enabled us to
meet the needs of wine manufacturers and vintners
looking to capitalize on the benefits of B-I-B
packaging without compromising the quality of
their product.”
Tapping innovations for dispensing
Scholle says its innovation and leadership in the
boxed wine marketplace does not end with films
alone. Te company designs and sells dispensing
taps, too. Chief among its fitments is FlexTap, an
ergonomically-designed spigot that offers push
button dispensing of low-viscosity liquids and
features easy-on, automatic-off functionality and
flow rate control. Unlike standard closures found
on conventional bottles and rigid packaging
containers that allow product-degrading oxygen
Bringing innovation
to bag-in-box
Sales of 3-L
boxes of wine have
grown at double-digit rates
since 2003, and total U.S. boxed
wine consumption, including 3- and 5-L formats, has
grown more than 20 percent by volume.
Unfilled bags require
up to 88 percent
less storage space
than bottles, making
them much more
economical to
warehouse and ship.
37 www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011
to enter the container each time the
cap is removed, FlexTap’s positive
flow design blocks oxygen from
entering the package, preserving and
prolonging the product’s life. Equally
important, FlexTap is easy to use.
FlexTap’s applicability extends
beyond the wine industry to also
include the water, health drink and
juice markets where consumers
appreciate its easy-to-use, stay fresh
design. With FlexTap, Scholle also
saw an opportunity to meet a need in
the edible oil packaging marketplace,
particularly among consumers and
food-service operators using cooking
oils. Tis was because the tap enables
easy, clean dispensing of oils.
Prior to launching into the
edible oil market, Scholle’s Global
Technology Laboratory conducted a
series of pre-commercialization tests
to ensure a smooth transition into the
edible oil market. Tis early testing
revealed a challenge: Over time, the
edible oils would begin to migrate
through the soft push-button of the
To overcome this potential
problem, Scholle again collaborated
with Dow. “Dow offers nearly every
product in the polyolefin industry
and has a variety of grades to select
from, so we knew they would be
able to help us find a material that
offered the density we needed to help
eliminate oil migration from the tap
without sacrificing ease of use,” says
In another very collaborative
process, Scholle defined the modulus
properties of the existing push-
button and the level of flexibility that
it sought to keep. Dow presented
Scholle with samples from its
product portfolio, and together they
helped identify the grade that had
the right density and melt index to
meet Scholle’s needs. Scholle then
conducted injection molding trials
and lab testing.
“What we found was that using
denser materials made the button
harder to push but provided a better
barrier,” Bellmore recalls. “Ultimately,
Dow and Scholle together identified
the sweet spot that presented the
right density with effective oil barrier
“Dow has continually proven its
value to Scholle beyond that of resin
supplier,” Bellmore adds. “Tey work
hard to understand their customers’
business challenges and bring back
novel ideas that help drive business
“Collaborative innovation
between Scholle and Dow is
continually driving innovation in
the B-I-B packaging industry and
identifying opportunities to meet
the unique needs of its customers
with opportunities that are desirable,
economically competitive and
sustainable. Tis constant innovation
can be seen in our ever-expanding
Dowlex, Elite and Attaneportfolio,”
says Sundaresan.
Bellmore notes that investments
in research and development have
enabled Dow to innovate across
market segments to create packaging
solutions for applications from wine
to edible oils.
About this article’s authors:
Rachael Hopkins is the value chain
manager for packaging sustainability
at The Dow Chemical Co. Dowlex, Elite,
and Attane are trademarks of The Dow
Chemical Co.
Katie Scarpelli is the global
marketing communications manager,
wine & spirits.
Diane Chewning is the global
marketing communications manager,
food and beverage for Scholle
Taps with positive flow design block
oxygen from entering the package, which
can prolong product life.
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38 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com

Dinnerware distributor, Ten Strawberry Street, uses interlocking packing
materials to ABSORB SHOCK AND PREVENT SHIFTING of its ceramic
and glass products during shipment.
Linda Casey, Senior Editor
Meeting product protection needs when
distribution streams vary from pallets sent via
dedicated truck systems to case shipments delivered
by package delivery services can be a challenge for
packaged goods companies, especially as consumers
and retailer-customers are increasingly voicing
concerns about over-packaging.
Tis was the challenge facing Ten Strawberry
Street, Denver, CO, which imports its dinnerware,
glassware and flatware from factories around the globe,
including manufacturers in Sri Lanka, Bangladesh,
China, Tailand, Poland, Germany and Belgium, and
repackages them for retailer-customers. In addition
to repackaging product for shipment to retailers’
distribution centers in secured pallets, Ten Strawberry
Street sends product by the case via UPS and FedEx.
Pyramids form nests inside shippers
When the distributor started having problems
with its shipments to Walmart, it quickly took
the retailer’s advice to re-examine its packaging.
“Ten Strawberry Street had some pretty serious
damage issues and they were actually referred to
us through one of their customers,” recalls Jeff
Boothman, president of FoldedPak LLC, a supplier
of protective, paper-based, packaging material that
forms structures specifically engineered to absorb
energy and provide clean unpacking experiences
without large warehouse space requirements.
When Ten Strawberry Street first looked at the
product, which is sold as a flat material web called
ExpandOS—short for expand on site, the packaging
solution was fairly new to the market. “I was
a bit of guinea pig,” Zachary Zucker, COO
of Ten Strawberry Street, comments.
Te distributor was presented with a proof-
of-concept that was nearly a literal interpretation
of the pyramid’s nesting capabilities. “ExpandOS
sent me a raw egg in a package from New York
to Denver, and the egg showed up in one piece,”
Zucker exclaims. “We’ve been using it pretty much
exclusively for the last two years.”
A sustainable manufacturing process
Not only does the packaging’s functionality harken
back to nature’s own fragile container—the nest—
ExpandOS is made from eco-conscious material
using an effi cient manufacturing process. “ExpandOS
is made from 100 percent post-industrial waste,”
Boothman says. “It’s essentially a waste stream from
the industrial process that creates beverage cartons. It’s
first-quality material that’s just as good as what they’re
actually making beverage cartons out of.”
When the beverage carton company cuts the
cartons out of the web, it doesn’t use the entire
width of the web. Te remaining material typically
would be repulped to be used as pre-consumer
recycled fiber. Te ExpandOS material enables
use of the scrap material without repulping, thus
eliminating the carbon footprint associated with the
repulping process.
FoldedPak says that each 1,000 lbs of post-
industrial waste ExpandOS averts from the
repulping process saves 888 lb of CO
, which is the
equivalent of taking 3.9 cars off the road for a week.
Flat-out productivity booster
Additionally, ExpandOS is sold as a web of folded
material, with a small physical footprint and no core
to dispose of. Tis web is die-cut so an Expander
machine can create pyramid-shaped packing material
with 38 “fingers” designed to cling together using all
three sides of the pyramid.
“ExpandOS expands at a 25:1 ratio,” says
Boothman. “You don’t have to have a thousand cubic
ft of storage space right next to the pack-out line. You
can have a pallet of our paper, which is maybe 4 feet
tall, and make 1,000 cubic feet of protective fill.”
Tis lets Ten Strawberry Street keep its pack-out
process compact, which currently is a primarily
manual endeavor. For example, its dinnerware orders
are manually pulled and staged. Each set arrives at
the plant in primary packaging, so workers need only
to cushion these packages for transport. To this aim,
worker will manually erect each case, place 1 in. of
ExpandOS at the bottom, set the primary package
in the shipper, and flow ExpandOS over and around
the primary packaging before manually taping the
case closed. Product pallets are built manually, then
wrapped by stretchwrapper supplied by Orion
Packaging LLC.
Branded for the future
In addition to leveraging EspandOS’ protective
properties, Ten Strawberry Street has started to
take advantage of the marketing benefits of printed
ExpandOS triangles versus the plain triangles it
has been using. Tis is part of an ongoing brand
awareness campaign for the distributor, which isn’t
shy about expanding business offerings. “When
we [Zucker’s family] bought the company out of
bankruptcy, it had one SKU,” Zucker explains. “Over
the last 15 years, we’ve been able to grow the line
and diversify ourselves in a few different markets.”
Te strategy seems paying off: Ten Strawberry Street
opened its first retail store in 2010.
Packed for
safe travels
Packaging material is
dispensed below, around
and on top of a case of
small ceramic plates,
which otherwise
would be prone
to breakage.
An employee wraps a small pallet of product for
FoldedPak LLC., 866/909-6266.
Orion Packaging LLC, a div. of Pro Mach,
800/333-6556. www.orionpackaging.com
0 More information is available:
An operator loads the expanding machine with a web of
flat, die-cut material.
www.packagingdigest.com PACKAGING DIGEST FEBRUARY 2011 39
engineers’ outlook
One question often asked during an interview
is: “Where do you see yourself in five years?”
Your response probably had something to do
with advancement, increased responsibility or
management. But do you also recall being asked
how you plan to get there?
I’d wager few of you were asked that, but
it’s critical to your career that you give serious
consideration to and reflect on creating a strategy to
get there. Tat’s not to say that outside influences
won’t impede or hinder your plan, or that your
strategy will work all the time. But—as this is an
important aspect of addressing most challenging
issues—it’s better to have a plan in place from
which you can deviate, than to have no plan at all.
Over the years I’ve had the opportunity to hold
in-depth discussions with packaging executives
about the traits and characteristics they look for
in their employees that they believe make them
attractive for advancement. Tese include:
1. Personable—be pleasant to be around and easy
to work with. Be likable.
2. Demonstrate a passion for your work. It’s been
said, “If you love what you do, you never work
a day in your life.”
3. Fit into the organization’s culture. Embody
similar goals and values.
4. Be punctual. Arrive at work a little earlier than
expected and leave a little later.
5. Remain focused on achieving short-term goals
while working towards long-term strategic
6. Be well-organized. Tat includes having an
organized offi ce and desk, as well as knowing
how to organize
a project.
7. Be a team player.
Don’t always
seek credit for
everything you do. Never make the mistake
of thinking you will look good by making
someone else look bad. Be the person your peers
look up to.
8. Seek responsibility and take responsibility for
your actions.
9. Be honest and candid. Lies will come back to
bite you—hard.
10. Learn the art of public speaking. Make as
many presentations as you can. Volunteer for
assignments, keeping yourself visible.
11. Dress a little better than the norm, regardless of
“dress-down” days.
12. Learn how to write well. Remember that
spell-check does not correct grammar, usage or
alternative spelling.
13. Learn how to listen.
14. Learn how to sell, whether it be the company,
the company’s products or your ideas to
someone else.
15. Learn how to negotiate.
16. Don’t make excuses.
17. Keep your boss and management informed.
Anticipate and address problems before they
arise. Avoid crises by planning effectively.
18. Develop a strong network.
19. Find a mentor and, if possible, become a
20. “Act as if.” When you act as if you are the
person you want to become, people will
perceive your capability and that you are ready
to be in that advanced position.
Rick Pascal, a senior
partner at Adept
Packaging, is a certified
personnel consultant with
more than 25 years of
experience in packaging.
Adept Packaging is an
international packaging
engineering company
headquartered in the U.S. For more information,
visit www.adeptpkg.com
Engineers should create a strategy
that will advance their careers
For information on attending or exhibiting please visit us online.
North America’s Automation & Assembly
Resource for Advanced Manufacturing
Faster. Better. Cheaper.
February 8–10, 2011
Anaheim Convention Center
Anaheim, CA
June 7–9, 2011
Jacob K. Javits Convention Center
New Yerk, NY
5eptember 20-22, 2011
ßena|d £. 5tephens Cenvent|en Center
Rosemont (Adjacent to O’Hare Airport), IL
June 21–23, 2011
1erente Cengress Centre
1erente, 0ntar|e
March 14–15, 2012
Fort Worth Convention Center
Fert Werth, 1exas
IN 2012!
March 16–17, 2011
Orange County Convention Center
Orlando, FL
New Lecat|en!
Event will rotate back to Charlotte
for the 2012 edition.
Induction Sealing
Tried, tested, true...it’s what we do.
Flexible - Versatile - Reliable - Portable
40 FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com
Here’s what readers of packagingdigest.com are saying:
Talk back!
cookie trays, expecting to save 150 tons of paperboard.
I question the appropriateness of showing two
cracked football helmets on the package, consider-
ing all the attention being paid in the media to the
danger of brain damage, neck injury or paralysis
by using one’s helmet as a battering ram against
another player. Just ain’t funny.
Richard Salcer on “Carrot packaging uses humor to
appeal to football fans”
This competition seems odd considering Cereplast’s
portfolio of petroleum-based hybrids.
Steven Prindle on “Contest seeks best ‘bioplastics’ symbol”
Italian wine
sports white
leather case
American designer Denise Focil and
Italian wine maker Distilleria Bottega
create luxury and stylish packaging for
Amarone Bottega, Il vino Prêt-á-porter
wine. The bottle features a white leather
label and is nestled in a white leather
case embellished with debossed black
lettering, which is intended to remind
consumers of a vintage suitcase, and
enriched with metal studs.
Kraft Singles packaging
delivers discount for
Disney shows
Kraft Foods partners with Feld
Entertainment Inc. on a new marketing
campaign for Disney On Ice.
Consumers can redeem any Kraft
Singles package wrapper for a pair
of half-price tickets to any of fve
Disney On Ice shows playing across
the U.S., including Disney-Pixar’s
“Toy Story 3.” To promote this campaign,
Kraft has introduced specially marked packaging.
Four Loko XXX Limited Edition:
Rotating favors but not UPCs
To facilitate easy distribution and sale, Chicago-based
alcoholic beverage company Phusion Projects uses
one UPC code on all new favors of Four Loko
XXX Limited Edition drinks. New product will rotate
favors every four months, allowing distributors and
retailers to provide a variety of exciting favors to
customers on an ongoing basis.
Ralph Lauren fragrances debut
in high-performance pumps
L’Oreal expands the company’s Ralph Lauren
Fragrances brand with the worldwide launch of the
Big Pony Collection for men. The fragrances are
packaged in crimpless, high-performance pumps.
The packaging is supplied pre-assembled with the
pump for easy ftting, which the manufacturer says
can increase flling productivity as much as 40
percent. In addition, it has no rubber gasket, which can affect the fragrance.
Nutrition Facts to appear on meat, poultry
Under a new USDA rule, meat and poultry will feature nutrition facts panels
either on their labels (ground or chopped) or available for consumers at the
point-of-purchase (whole, raw cuts).
Girl Scouts trim cookie packaging
The organization has switched from paperboard cartons to a flm overwrap for its Thanks-A-Lot
Outstanding way to reduce carbon footprint,
waste, cost, freight and all! It would be interesting
to compare total cost to market for current paper-
board, recycled board and the new flm. What
resins for flm could be used that are more green?
Eda Englund Murphy on “Girl Scouts trim cookie
Get these bonus features at
11444 W. Olympic Blvd, Los Angeles, CA 90064 Attn: Lawrence Nokes
215/944-9832 • Email: lawrence.nokes@ubm.com • Fax: (303) 265-5286
Machinery & Materials
Contract Packaging
Contract Packaging
marketplace info showcase
We are a spice manufacturer, distributor,
contract packer and blender of all types of
spices. Our specialty is curry powder, meat
seasoning, jerk seasoning among many
other spice blends. Simply Jamaican will be
a new label that we will be putting out on the
market and would like to have exposure for
distributors to handle for us. We currently do
contract labeling/packaging for many other
Oriental Packing Co., Inc.
Tel: 305-235-1829 Toll Free: 1800-809-9793
E-mail: dll41212@aol.com
World Encoders, Inc. Hoffman Estates, IL 60169
formerly Koyo Encoder, Inc. Toll Free: 1-800-903-9093
The World Encoders!
Proven Reliability for over 53 years. Super-Durability & Absolute Dependability.
Distributors Wanted!
Online Shopping
Compare Pricing S.R.P. (List Price) Basis
World Encoders Dynapar BEI EPC
Modular Size 12 $ 47.00 E5/E2 $164.00 M15 $ N/A $ N/A
Size 15-Shaft (Std.) $132.00 TRDA-2E $349.00 E14 $ N/A $184.00 15S-1024
Size 20-Shaft (Std.) $205.00 TRDA-20N $384.00 H23 $305.00 H20D $336.00 702-1024R
Size 25-Shaft (Std.) $235.00 TRDA-25N $493.00 HA625 $515.00 H25D $361.00 725N-1024R
Size 15-Hollow (Std.) $120.00 TRDA-VA $230.00 F14/F18 $ N/A $201.00 15H-2500
Qube 2.25" $120.00 RS $238.00 21/22 $ N/A $190.00 711
Size 35-Hollow-Hub 1" $360.00 HS31 $473.00 HS35 $655.00 HS35 $358.00 25T
NEMA4 IP66 w/Cover w/Metal Body w/Metal Body w/Metal Body w/Plastic Body
Brand Encoders
Value &Technology
Linear Fully Enclosed
Modular / Kit
Wheeled & Qube
Small Wheeled
Heavy-duty HS31 Hollow
Incredible Features and Super-Low Prices!
Small Size 20 MPG
Handwheel & Pendants
Vertical Case Elevator
The new Alliance Case Elevator will take your pack-
age to new heights! The Case Elevators carry cartons
or cases with two parallel flighted chains driven by
dual brake motors. The brake motors stop the chain/
flights to wait for cartons at the pick up area.
Interpak, LLC
Interpak introduces the new Somic 424 case packer.
Capable of producing Shelf Ready Tray, Tray with
Hood, and Full Wrap Around cases on a single
machine. Fully servo driven, low ergonomic single
level product flow, tool-less changeover, and wide
format range.
Vari-Straight Topload Tri-Seal Carton Closer
The Vari-Straight is a straight-line closer for tri-seal
cartons that takes Kliklok-Woodman’s revolutionary
variable pitch technology to a higher level. To provide
a controlled carton turn without a change in direction,
the unique turning bed features “pop-up” turning bars
that capture the cartons and guide them through a 90°
turn and into the charlotte closing section. The inher-
ent slip and timing issues associated with conventional
“lugless” carton closers are eliminated. KWMarketing@
KliklokWoodman.com or at (770) 981-5200, or visit our
website at www.klikwoowoodman.com.
FEBRUARY 2011 PACKAGING DIGEST www.packagingdigest.com 42
Patricia Spinner
Senior Group Publisher
Steve Everly
Associate Publisher
Canada (eastern), Europe
Russell Thibeault
781-255-2053 Fax: 877-735-6707
Steve Slakis
630/990-7429 Fax: 630/990-8894
Canada (western)
Laurence Nokes
China | Sylvia Xiao
Japan | Masayuki Harihara
Taiwan | Robert Yu
Mary Williams
Marketing Services Manager
630/990-2371 Fax: 630/990-8894
Sales and Marketing Offices
sales staff ad index
Page number Page number
A-B-C Packaging Machine Corporation.....31
Automation Direct ...........................................................3
CAMA USA............................................................................22
Clippard Instrument Laboratory Inc. ...........13
CTM Labeling Systems .............................................12
Domino Amjet ...................................................................43
Fogg Filler............................................................................37
Heat and Control Inc. .................................................25
Henkel Corp. ......................................................................33
Hitachi America Ltd. ......................................................2
ICE USA ...................................................................................15
ID Technology, Div of Pro Mach........................24
Innovia Films ....................................................................17
INX International Ink Co. ........................................21
James Alexander Corp. ...........................................35
Klockner Pentaplast ...................................................11
McDowell Label ..............................................................32
Optima Machinery Corp. . ......................................37
Overnight Labels Inc. ....................................................6
O-I ...............................................................................................29
PakTech ..................................................................................27
Pillar Technologies ......................................................39
Primera .....................................................................................9
Quick Label Systems ....................................................5
Sealed Air Corp. ................................................................7
Sharp Packaging Systems ....................................44
Sleeve Seal ............................................................................6
The RB Dwyer Group ..................................................19
U.S. Tsubaki Inc. ............................................................14
Weighpack Systems ...................................................10
Kraton Performance Polymers
Inc. promotes G. Scott Lee to vp of
Paperboard Packaging Council
welcomes Metro Packaging &
Imaging Inc.
as a principal
member and
ACTEGA Kelstar
and Marquip
as associate
Piab USA Inc.
names Edwin
(J.R.) Reeser as
area sales manager for a newly formed
Midwest sales region.
Celplast Metallized Products hires
Marissa DesRochers as a product
development &
process engineer.
Magnetics Co.
hires Marvin
Angleton as
technical services
and quality; Tom
Andrews as metal
detection service
Ted Curran
as operations
manager; and
Ryan Van Horn
and Jessica
as design
programmers to
its Flexible Die
Dorner Mfg. COO Rich Ryan is
elected to the Packaging Machinery
Manufacturers Institute (PMMI) board
of directors.
Henkel Corp. names Joseph DeBiase
as senior vp of its North American
general industry business
Packaging Corp. of America names
Charles J. (Jack) Carter as vp,
LMI Packaging Solutions Inc. hires
Gary Morrison as national account
sales manager and JP Moran and
Rosa Wright-Orozco as inside sales
Barry-Wehmiller appoints Tom
Patterson, general partner at
investment frm Madrone Capital
Partners, to its board of directors.
H.B. Fuller hires Michael Olejnik as
business development manager.
Alcoa names Keith Walton as vp,
government affairs.
Palziv North America, a subsidiary
of Palziv LTD, announces the U.S.
manufacturing facility in Louisburg, NC,
to be fully operational in less than 75
Körber Group buys Seidenader
Maschinenbau GmbH.
Mid Oaks Investments LLC buys
Plastic Packaging Technologies LLC.
Sealed Air
Corp. acquires
Pro Mach
Inc. acquires
Shuttleworth Inc.
Plastics Inc.
BWay Holding Co. acquires Phoenix
Container Inc.
Danaher Corp. aquires EskoArtwork
for $470 million.
Island Acquisitions S.à r.l. buys
European rigid
plastic consumer
goods packaging
acquires Penn
Bottle and
Supply Co.
appoints Eco Ventures as exclusive
distributor for Brazil.
The Sterling Group acquires Saxco Intl.
ABB Robotics signs Kleenline of
Newburyport, MA, as a system
Group Aktiengesellschaft (GEA)
acquires Convenience Food
Systems (CFS).
Optima Group acquires Metall +
Plastic GmbH.
Automation Tooling Systems Inc.
buys Assembly & Test Worldwide Inc.’s
U.S.-based and German automation
and test systems businesses.
FANUC Robotics America sells
its 100,000th robot in North and
South America to Schneider
Rich Ryan
Dorner Mfg.
Michael Olejnik
H.B. Fuller
Joseph DeBiase
Henkel Corp.
Tom Patterson
Marvin Angleton
Bunting Magnetics
PACKAGING DIGEST® (ISSN 0030-9117) is published monthly, with a special issue in summer, by UBM Canon, 11444 W. Olympic Blvd., Los Angeles, CA 90064-1549; 310/445-4200; FAX 310/445-4299. Periodicals postage paid at Los Angeles, California, and
at additional mailing offices. SUBSCRIPTIONS – Free to qualifed subscribers as defned on the subscription card. Rates for non-qualifed subscriptions, including all issues: 1 yr. $150, 2 yrs. $250, 3 yrs. $300. Except for special issues where price changes
are indicated, single copies are available for $10 USA and $15 foreign. For telephone inquiries regarding subscriptions, call 763/746-2792. CHANGE OF ADDRESS – Notices should be sent promptly to P.O. Box 47461, Plymouth, MN 55447. Please provide old
mailing labels as well as new address. Allow two months for change. EDITORIAL CONTRIBUTIONS – Unsolicited manuscripts should be submitted via e-mail to john.kalkowski@ubm.com. Copy will receive every reasonable care; however, the publishers assume
no responsibility for safety of artwork, photographs, or manuscripts. NOTICE – Every precaution is taken to ensure accuracy of content; however, the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any
opinion expressed herein. POSTMASTER – Send address changes to PACKAGING DIGEST, P.O. Box 47461, Plymouth, MN 55447. Canada Post: Publications Mail Agreement 40612608. Return undeliverable Canadian addresses to: BlueChip International,
P.O. Box 25542, London, ON N6C 6B2. Printed in U.S.A. Copyright 2011 by UBM Canon. All rights reserved. Reproduction in whole or part without written permission is prohibited.
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Domlno. Do more. www.oomlno-na.com
www.sharppackaging.com • 800-634-6359
Stand Out In The Crowd
Sharp Packaging Systems is a nationwide, innovative manufacturer of quality, flexible packaging solutions, including
film, bags and packaging machinery systems. Sharp Packaging serves the electronics, pharmaceutical, mail order,
select produce, medical components, hobby/craft, automotive and hardware industries; among others. Sharp is
growing into one of the most respected manufacturers of pre-opened bags on a roll, poly film and packaging
machinery in North America. Our commitment to quality, innovation and integrity keeps customers coming back.
Through distributor partners Sharp Packaging Systems is able to provide advantages through JIT shipments and
service. Shorr Packaging features some of the most talented packaging professionals in the industry. Their Sales
and Customer Care Representatives, Equipment Specialists, Service Technicians, Packaging Designers, Packaging
Engineers, and Process Engineers are all highly skilled and possess a wealth of hands-on experience. Shorr finds
ways to improve products, pricing, ergonomics, design, sustainability, and procurement. We identify opportunities to
take cost out of packaging and put value in.
Where Custom
is Flexible
© 2010 Sharp Packaging. All rights reserved.
Visit Shorr Packaging website at www.shorr.com or call 630-978-1000

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