An innovative manufacturing process for flexible packaging ... ... of flexible packaging industry,...

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Polimer presentation for AWRE 2015 - Melbourne, Australiaproduction of garbage bags with and without drawtape.
Polimer’s production cycle is based on a brand-new and highly advanced technology that
allows a radical filtration of recycled materials to obtain the highest quality output.
Since foundation 45 years ago, Polimer has been developing efficient, highly-effective and
economic product solutions that can match the highest international standards according to
the requirements of every single local market.
Annual production capacity is 130 million bags, to cater Italian domestic market, export to
European Union markets, and production under private label.
Mr. Renato Federici, founder and Managing Director of Polimer sas, developed an
innovative production process and filed patent application in Italy,
Executive Summary
The industrial application of the patented process allows to directly extrude the
granules obtained from the waste destined for incineration by eliminating the step of
re-granulation, a critical step in the standard process currently applied in the
industry
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of the patented process include:
Executive Summary
eliminating the step of re-granulation = greater energy savings
final scrap being regenerated and transformed into secondary
raw material
100% green product
The Polimer Advantage
Business goals The project has been conceived and developed by Mr. Renato
Federici, owner of Italy-based Polimer sas, based on his
consolidated multi-year experience in the manufacturing and
production of environmentally sustainable garbage bags
Mr. Renato Federici has filed patent application in Italy for an
industrial process that generates a 100% environmentally
sustainable “green” product by using raw materials from waste
destined to incineration
Depending to the type of raw materials being used, this patent
allows to modify the traditional production process by
eliminating the step of re-granulation of the polymer itself. This
allows substantial savings in terms of time, manpower, energy
consumption and CO2 emissions.
Federici is considering a potential business/financial partner
interested in investing in this innovative production process
Product launch and
Project overview
Purchase of raw materials in the form of granules resulting from
garbage bound to incinerators
heated and transformed into
cut and heat-sealed to create the bag
Retail sale
granules that would otherwise
quallitative features of the products
obtained from the processing of
virgin polymers, and to date the
patented process leads to products
in dark shades
being granulated again and resued
as raw material
process as raw material.
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The idea behind the Polimer advantage: Lifecycle of waste as used in the patented production process
Mr. Renato Federici, boasting over 40 years of experience in the field
of flexible packaging industry, today introduces a wide range of large
and small bags for the collection of waste, garbage and trash, with
and without handle, made of polyethylene from 100% recycled
material, and suitable for every waste colection solution.
Mr. Renato Federici is Founder and Managing Director of Polimer sas
(www.polimeritalia.com) , a company based nearby the city of
Cremona, in Northern Italy, that manufactures and produces the
following range of products:
refuse sacks, trash bags, and garbage bags made of polyethylene
derived entirely from recycled material
biodegradable and compostable bags, for which he has recently
obtained the European certification “Vincotte”, applicable for example
for the separate collection of organic waste in both home and
business environments
film sheets made of polyethylene and suitable for covering areas,
indoor and outdoor tables, and for a wide range of other applications
The professional competence and know-how developed by Mr.
Renato Federici allowed him to conceive, develop, and patent a
new industrial process that allows the processing of very low
quality raw material, by skipping a step in the production
process when using raw material derived from recycled waste.
Mr. Renato Federici: business profile The patent
Mr. Renato Federici: the entrepreneur behind this innovative idea
Mr. Renato Federici filed patent application in Italy on 16 Oct 2014
(#B02014A000564)
Patent is expected to be approved by October 2015 with a 20-year
validity until 16 Oct 2034
Polimer is located in Northern Italy, in the town of Sospiro, 10 kms/6.5
miles from the city of Cremona, and 107 kms/67 miles from Milan.
Federici Andrea 99,9%
Federici Renato 0,1%
Polimer began the process of technological
innovation for processing the granules derived from
recycled waste
Polimer s.a.s. at a snapshot Polimer s.a.s.: company timeline
Polimer s.a.s.: company shareholders
# plant locations: 1 (2,000 square meters)
# employees: 12
# of bagging machines: 2 (Hudson & Sharp 1300 and Coemter 1200)
Production capability, per year: 130 million bags
Production capability, per year, for bags using the patented innovative
process:
25 million bags produced on Coemter bagging machine
(for a drawtape bag, size cm. 70x110/45, thickness 10µ, 10 bags
per roll, roll weight 700 gr. = 2.5 million rolls x 10 bags/roll)
37.5 million bags produced on Hudson & Shart bagging machine
(for a drawtape bag, size cm. 55x65/30, thickness 15µ, 15 bags per
roll, roll weight 357 gr. = 2.5 million rolls x 15 bags/roll)
Polimer: the range of products
CATEGORY PRODUCTS FEATURES
TRASH BAGS FOR
PURPOSE
Bags with or without handles in an array of neutral, purple, yellow and blue
colors, all on a transparent basis
Suitable for recycling of paper, plastic, aluminum and glass
Available in different sizes, with practical handles, reinforced thikness, and liquid
tight
Protective covers made of transparent polyethylene, UV rays resistant, with a
thickness of 48 microns
Suitable for agriculture
Made of black polyetylene, low density and high thickness, size of 1.5x5 meters
(4 feet 11 1/16 inches x 16 feet 4 27/32 inches)
Suitable for agriculture
Transparent films for covering laundry, with a thickness of 60 microns
Fully waterproof and environmentally friendly
Multi-purpose film in transparent polyetylene, with thickness ranging from 25 to
35 microns, and different sizes
Trekking films with thickness of 50 microns, highly resistant, walkable, fully
waterproof and environmentally friendly
Table cover films, in white polyetylene, waterproof, 25 microns of thickness
suitable for protecting tables from dust, scratches, water, leaves and weathering
Polimer: the range of products
CATEGORY PRODUCTS FEATURES
HANDLES
Wide range in different sizes and customizable to suit any demand or request
Suitable for supermarkets, municipalities, restaurants, hospitality, medical and
hospitals, areas of well-being
Vincotte certified
Represents the widest range of products on the market (great variety of sizes,
thickness, and different colors)
Easy to close, easy to move
Range of vibrant colors, fragrance, and selection of thickness make this product
unique
Suitable for home and office
Wide range in black color, for general waste, with practical and robust yellow
handles scrolling
Suitable for home and office
Full availability of a moltitude of combinations of sizes and thickness
Suitable for home and office
Side reinforced welds, high grip and total impermeability against leakage
The patent the patent developed by Mr. Renato Federici has 2 areas of application
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The Patent, applied to the extruder for the production of
large and small bags, with handles or traditional,
introduces an effective innovation in the production
process stages:
from the waste destined for incineration, by
eliminating the step of re-granulation, a critical
step in the standard process currently applied in
the industry
COMPETITIVE ADVANTAGES
energy savings
into secondary raw material
finished product is 100% environmentally
sustainable = 100% green product
The Patent, applied to the extruder for the production of
large and small biodegradable and compostable bags,
introduces a strategic advantage at the level of the raw
material being used:
lower emission of CO2
excellent quality of the finished product
finished product is 100% environmentally
sustainable = 100% green product
it allows to replace the use of virgin raw material
with substitute raw material
CLASSIFICATION OF RAW MATERIALS USED FOR THE PRODUCTION OF BAGS
Raw Material
Cost per
D RIGENERATED FROM BAGS, REELS, PRINTED 0,56 Yes 0,4 0,96
E1 SCRAPS, WASHED (first choice) 0,85 No - 0,85
E2 SCRAPS, WASHED (second choice) 0,70 Yes 0,4 1,10
F WASTE DESTINED FOR INCINERATION 0,55 Yes 0,4 0,95
C O
LO R
[*]: total cost of raw material prior to the extrusion step
• Generally speaking the scraps, washed (first choice) do not require the phase of re-granulation, but in most cases by omitting
this step some processing problems may emerge that would generate extra costs
• Differentiated and refined garbage waste (destined for incineration) represents the raw material of more low quality and more
difficult to process, and for this reason often the second phase, or re-granulation, is not sufficient and it becomes necessary
to pass to the mixing step (blending with virgin polymers), generating a further increase in the cost of the raw material
• The patented process is able to directly extrude the raw material without havng to perform any prior step, and the
products so obtained are available for the segment of dark bags, with significant competitive economic and
environmental advantages
GARBAGE WASTE
DESTINED FOR
INNOVATIVE PRODUCTION PROCESS
STANDARD PRODUCTION PROCESS
Thanks to a forty years experience in the flexible packaging industry, and a deep understanding of the technical problems
associated with the use of recycled materials for the production of 100% environmentally friendly products, Mr. Renato Federici
has patented an innovative technological solution concerning the extursion step, a solution which allows the use of raw
matierials of lesser quality, and already pavailable in the market (garbage waste destined for incineration) thus eliminating the
step of re-granulation.
0,55
production Notes: prices in EUR per kg
[*] reported cost per kg for the purchase of granules from garbage waste destined for incineration
STANDARD
SOLUTION
PATENTED
SOLUTION
applied to the extruder for the production of bags with or without handles
exclusive extrusion of granules obtained from refined garbage waste destined for incineration
with the patented extrusion machinery, Mr. Renato Federici is able to directly extrude the
granules obtained from garbage waste that cannot be processed by standard extruders
currentlyused in the industry, and which should therefore be subject to a phase prior to re-
processing in order to be extruded
the patent allows the elimination of the phase of re-granulation, providing a huge energy saving
which is then reflected on a lower final production cost of the reel
the final product is of exceptional high quality and 100% made from raw materials resulting from
waste, and with the least possible consumption of energy
COMPETITIVE ADVANTAGES
INNOVATIVE PRODUCTION PROCESS (with different mix of raw materials)
The patented innovative solution developed by Mr. Renato Federici is also applicable to the productiion process of
biodegradable and compostable bags. Also in this case the technologically innovative solution concerns the extrusion phase that
allows the use of a virgin raw material replacement while minimizing the use of virgin material and thus achieving significant
competitive advantages.
3.25 *
[*] reported cost per kg for the purchase of virgin polymer
[**]: reported cost per kg resulting from the mix of virgin polymers and raw materials
STANDARD
SOLUTION
PATENTED
SOLUTION
applied to the extruder for the production of biodegradable and compostable bags
extrusion of a mixture composed of lesser percentage of virgin polymers and greater percentage of
alternative raw materials (eg. Calcium carbonate or talc)
the patented innovative process developed by Mr. Renato Federici, applied to the extruder for
the production of biodegradable and compostable bags, allows incurring in lower costs for
procurement of raw material as it reduces the use of the virgin polymer and to replace it with
alternative raw material
It also allows a more easy processing of raw materials
COMPETITIVE ADVANTAGES
increasing population drives the need for
trash bags for waste collection
Price flactuation caused due to trends in the
cost increase of raw materials of virgin type
(eg. Hdpe, lldpe, and ldpe).
SPREADING OF RECYCLED
recycling is creating a growing need for
multiple trash bags for the collection of
different types of waste
requires the purchase of dedicated products
Sharp increase in recent years
expected further growth in the
coming years
The patented solution developed by Mr. Renato Federici is not
subject to this price flactuation condition as it reduces to little or no
percentage the use of virgin polymer by substituting it with raw
materials resulting from garbage waste destined to incineration.
PERFORMANCE OF
DISTRIBUTION CHANNELS
channel
VOLUME
MTW Group
30 Cecil Street
#19-08 Prudential Tower
to schedule a meeting at AWRE 2015 in Melbourne, Australia,
please send an email to: mtw@marketingthatworks.us