TODAY'S brand owners must contend with shrinking margins, globalisation and shifts in consumer needs. Remaining profitable requires delivering innovative and value-added products and reducing environmental impact.
Attendees at PACK EXPO International 2010 (October 31-November 3; McCormick Place, Chicago) will see for themselves how they can use packaging to accomplish their objectives. And they will be especially interested in The Brand Zone, which debuts in Chicago this year. This special area will feature a variety of innovative containers and materials that brand managers can use to make products stand out on the shelf, enhance convenience and functionality and better satisfy sustainability-related requirements. As changes in containers and materials affect equipment, developments are often the result of a collaborative effort. "It makes sense to find a partner with similar goals and attributes," says Ron Puvak, director business development and marketing at Plastic Technologies, Inc. (PTI) (Booth # 5030). "We're very open to collaborative efforts. It not only brings complementary strengths together, but also shares the risk."
Pouch/folding carton hybrid Some of the newest packaging designs meet demands for both shelf impact and environmental attributes. The Zipbox™from T.H.E.M. is a good example. The pouch/folding carton hybrid combines the cube efficiency and stable, upright stance of a folding carton with the easy-open and -reclose and freshness-preserving features of a zippered pouch. "Sustainability has to be part of the conversation today," says Neil Kozarsky, president of T.H.E.M. (Booth # 4330).
On demo lines at T.H.E.M.'s headquarters, carton converting equipment from Yeaman Machine Technologies, Inc. (Booth # 4443) with zipper/material assembly applicators from Zip-Pak (Booth # 1902) seals zippered pouch material to carton blanks at up to 120 per minute today, with higher speeds anticipated on the next machines. Filling on the Yeaman occurs through the bottom of the carton. Its quick-change buckets and rails permit size changeover in less than one hour. For higher-volume needs, a carton converter, such as Malnove Packaging Systems Group, would install the Zip-Pak unit right after the folder/gluer. The process is compatible with a variety of materials including poly-coated paperboard and poly/foil/paperboard laminations for the carton and heat-sealable film with zippers for the pouch portion. "Phase one targets grocery and convenience store applications in the less than 5-pound range while club store packs of products like pet food or other dry products in the 8-10-pound range appear to be right around the bend," says Steve Belko, vice president at T.H.E.M., the primary inventor of the hybrid concept. In addition to standing out on the shelf, Zipbox also offers sustainability benefits. Since its rectangular or square shape fills gaps found between canister or pouch packs, at least 30 per cent more product fits on a pallet. "This means fewer trucks, fewer pallets, less fuel and a smaller carbon footprint," adds Mr Kozarsky. Although the Zipbox is likely to weigh more than an equivalent size pouch, this heavier tare weight may be offset by reductions in corrugated distribution packaging.
"We're still collecting data, but with some Zipbox designs it may be possible to reduce or even eliminate corrugated distribution packaging," he predicts.
Foamed PET Product differentiation is one goal of the oPTI™bottle foamed polyethylene terephthalate (PET) container from PTI. "Everyone is looking for uniqueness," notes Mr Puvak. Based on MuCell®microcellular foam injection moulding technology, the foamed bottles are made in a few basic steps: -Nitrogen is injected into the melt thr
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