Packaging Design for Future Stark - BUERGO.FOL · Source: BASF. BUERGOFOL GmbH · Jahnstraße 10 ·...

Packaging Design

for FutureDr. Kurt Stark 2017/02/08

Contents

1. BUERGO.FOL

- Company / Applications / Markets

- Products

2. Packaging and Packaging materials

- History of Packaging

- What must Packaging achieve today?

- Why are flexible or semi flexible Packaging

materials especially sustainable?

3. Kinds of Packaging

- Consideration of advantages/disadvantages

- "Duo Hard" as a future solution, concerningsustainability and for best profit?

- Examples in Practice

4. The best and ideal Packaging for Future

- What is the ideal Packaging?

- Some thoughts and philosophy

1. BUERGO.FOL

www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg

COMPANY / BRIEF PROFILE

CORE COMPETENCY

UNIQUE SELLING POINT

SPECIALTY

SITES

EMPLOYEES

CERTIFICATIONS

40 years of experience in the co-extrusionof composite films

Development of film recipes to suit theapplication or customer request

High-barrier EVOH-based films,printed and unprinted, as well as rigid films

Siegenburg, Ingolstadt, Neutraubling

Around 300

DIN EN ISO 9001:2008,BRC/IoP Global Standard Version 5, ISO 50001

SIEGENBURG, Bavaria, GermanyHeadquartersFlexible films

INGOLSTADT, Bavaria, GermanyRigid foil factoryPilot Plant for thermoforming

NEUTRAUBLING, Bavaria, GermanyCentre of excellencePrinting and laminating

COMPANY / LOCATIONS

www.buergofol.de

• BLOWN-FILM EXTRUSION

- Capacity: > 15,000 tons per year

· 2 x 3 layer· 3 x 5 layer· 3 x 7 layer· 2 x 7 layer shrink-wrap film machines

• CAST FILM EXTRUSION (APET)

· Capacity > 25,000 tons per year· 3 machines

• Pilot Plant: Multivac R530 Thermoforming machine

COMPANY

TECHNOLOGY / EXTRUSION MACHINES

BUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg

www.buergofol.de

• FOODSTUFFS

• TECHNICAL APPLICATIONS

• MEDICAL PRODUCTS

• PET FOOD

• CHEMICAL INDUSTRY

• SPECIAL APPLICATIONS

APPLICATIONS / MARKETS


www.buergofol.de

• TUBULAR POUCHES, TOP FILMS AND BAGS• BUERGO.FLEX FLOW / TOP, BUERGO.BAG

• BOTTOM FILMS• BUERGO.FLEX BOTTOM

• TOP FILMS• BUERGO.FLEX TOP

• LAMINATES / RECLOSABLE• BUERGO.FLEX SPECIAL / BUERGO.RECLOSE

• RIGID FILMS / FOAMED RIGID FILMS• BUERGO.PET / BUERGO.PET EXPANDED

• SKIN FILMS• BUERGO.SKIN

• SHRINK FILMS• BUERGO.SHRINK

• SPECIALISED FILMS• BFCR

PRODUCTS



2. History of Packaging

Times are changing….

source: scienceblogs.de

…. und Packaging is changing!


source: www.svi-verpackung.ch

2. History of Packaging

Shopping basket before 1945: metal sheets, carton,paper, glass, wood are common packaging materials.

Shopping basket in 1994: material savingpackaging materials made from plastics are used.


2. What must Packaging achieve today?

ProtectionBarrier, best before date, UV, transport, protection against theft, against forgery, against migration

Transportstowage, manoeuvrability, stackability, tightness, stability

StorageSpace saving, convenient

GuaranteeUndamaged packaging, best before date, consumer protection

ServiceInformation, storage vessel

SalesConsumer must be attracted to buy

AdvertisingAttractivity at POS, brands

Additional functionsrecycling, disposal of waste, separation

Consumer friendlyOpening characteristics: peel,reclosable, safety peel, perforation

Processingthermoforming, sealable, tear resistant, printable, sterilization

SustainabilityMaterial saving, cheap, bio based,LCA data, Carbon Footprint


Why are flexible or semi flexible Packaging materials more sustainable as rigid containers?

Source: PlasticsEurope

- In Europe, more than 50 % of goods are packed withPlastic materials

- Plastics only have 16 % of the total weight of all Packaging materials used

- A huge amount of goods can be packed with a small amount of plastic materials

- Packaging becomes better and betterBetween 1997 and 2007 the weight of the total Packaging material decreased by 28 %!This saves 1,8 Mio tons weight per year!

- The protective function of modern packaging has the highest contribution for energy saving:On LCA data, the product has the highest share, whereas the packaging material has a negligibleshare of only a few percents.

2. Why are flexible or semi flexible Packaging mate rialsespecially sustainable?

Only 64 % product!

More than 96 % product!

Source: BASF


What modern packaging achieves:

Source: PlasticsEurope“Verpackung - bestens schützen mit immerweniger Materialeinsatz”, 2007

Replacement of plastic packaging with alternate materials would mean: Weight 4 times higher , energy consumption factor 1.5 higher, production costs 2 times higher !!

2. (Flexible) Packaging – Most sustainable!



Overview and percentage of different kinds of Packaging in the market

20Soft, thermoformed;

e.g. PA/PE, 200 µ

Soft,

e.g. PA/PE, 70 µ

a) Soft Packaging

5Soft Flowpack film

E.g. OPET/PE-EVOH-PE = 12/70

Soft Flowpack film

E.g. OPET/PE-EVOH-PE

e) Flowpack

f) DUO HARD

d) Skin

c) Shrink systems

b) MAP

Name

1-2Hard (semi rigid), thermoformedHard (semi rigid), thermoformed

3-4Hard (semi rigid): e.g. APET or APET/PE = 250/50. Thermoformed.

Soft skin film, e.g. 75 µ

15Shrink film softShrink film soft

55Hard, semi rigid: e.g. APET or APET/PE = 250/50. Thermoformed.

Soft,

e.g. OPET/PE = 12/50 µ

Appr. Percentage

BOTTOM FILMTOP FILM

Packaging Systems

(� „soft“ = flexible, E-Modulus low; appr. 50 bis 1000 MPa; � „hard“; „semi rigid“ = stiffer, E-Modulus > 1000 MPa.)


a) Soft Packaging

TOP or Lidding Films BOTTOM Films



a) Soft Packaging

- Mechanical stability poor

- No rigid system. Not stackable.

- Reclosable system hard to realize

- Poor manageability, poor convenience

Disadvantages

- (Common) Machines are already installed

- Because of flexibility easily thermoformed

- Relatively cheap Packaging system

- All kinds of goods can be packed

- Sterilizable, Pasteurizable

Advantages



b) MAP-Packaging (Modified Atmosphere Packaging): Hard (semi rigid) Bottom, soft Lidding Film

LIDDING / TOP Films BOTTOM FILMS

Thicknesses, e.g.APET / PE EP = 250/50 µAPET / PE = 250/50 µ

Thicknesses, e.g.OPET/PE = 12/50 µOPET/PE RC = 36/50 µ


Foamed APET

(EP: easy peelRC: Reclose)


- More material needed in comparison to onlysoft packaging system.

- Higher requirements for Packagingmachines: Pre-heating, Cutting, etc.

Disadvantages

- THE standard system (traditionally)

- Machines are already in use / installed

- Bottom film is rigid and stable: excellent

mechanical stability. Stackable.

- Good price-performance ratio

- All kinds of goods can be packed, also withreclose (RC).

- Convenience and handling are perfect (e.g.

opening characteristics)

Advantages


b) MAP-Packaging (Modified Atmosphere Packaging): Semi rigid Bottom, soft Lidding Film


c) Shrink systems (highly oriented films which maintain a memory effect)

Typical thickness: 70 µ


These systems have:

Options:


- Not common for small portions below 500 g

- Used for higher portions > 2 kg

- Reclose hard to realize

- Poor handling/convenience

Disadvantages

- Film directly/tightly touches packed goods

- High stability is resulting

- Excellent product presentation


- Film is robust, has ideal barrier properties

and is adjusted to the packed good

Advantages

c) Shrink systems



d) Skin

TOP Films BOTTOM Films

Typical thickness 90 µ


Thicknesses, e.g.APET / PE EP = 250/50 µAPET / PE = 250/50 µ

www.buergofol.de

- More material needed compared to y only soft systems (with a soft and flexible bottom film)

- Machines are not standard (investments might beneeded)

- Requimerements for packaging machines arehigher: Pre-heating, cutting, skinning process etc.

Dis-advantages

- Bottom film is very robust: excellent mechanicalstability. Stackable.

- Perfect product presentation (like with shrinksystems)

- Lidding film is directly and tightly touching thepacked good. No juices (e.g. from meat) aresqueezed out.


- Excellent handling and convenience (e.g.

opening characteristics)

Advantages

d) Skin


d) Skin



e) Flow-Pack (FP)

Typical thicknesses and structures:

OPET/FP = 12/50 µCPA/FP = 20/50 µOPA/FP = 15/50 µ



e) Flow-Pack

- Poor mechanical stability

- No solid/rigid system: not stackable

- Reclose hard to realize

- Poor handling/convenience

Disadvantages

- Machines are trivial and already in use

- Because of the softness of the filmsprocessing is very easy

- Only one film is needed to pack a product


- Vertical/horizontal filling with the product

Advantages



f) DUO HARD – HARD TOP FILM, HARD BOTTOM FILM � Thermoformed TOP FILM

BOTTOM FILM

e.g. APET/PE EP = 250/50 µ(always thermoformed)

TOP FILM

e.g. APET/PE EP = 200/50 µ(thermoformed; or not thermoformed)


I N N O V A T I O N


- Better layer adhesion and bond strength compared to common 2K adhesives

- Migration is reduced to a minimum

- Both the bottom film and the lidding film are hard and stable: highest mechanicalstability. Stackable. Space saving. All is very robust.

- Thermoforming: No problem on all common thermoforming machines for lidding and bottom film: Detailled structures can be easily realized.

- All kinds of goods can be packed. Established: cheese. Backlog demand: For meatand cold cuts

- Tightness (barrier) and a high life period of the packed product are guaranteed, beforefirst opening

- Excellent handling and convenience (opening characteristics)

Advantages

f) DUO HARD – HARD TOP FILM, HARD BOTTOM FILM

(both films can also be considered as „semi-rigid“)



- Packaging is very appealing and attractive

- Elegant Reclose system: The thermoformed lid fits perfectly into the thermoformedbottom film. The lidding film remains connected with the bottom film (kind of hinge)

- No smell because of the adhesive: This Reclose system works without adhesives.

- A very long best-before date can be maintained. Also, a long shelf-life is given, afterfirst opening of the package. No repacking in boxes etc. is needed. Product remainsfresh and tasteful for a very long time.

- Converting: Printing in best quality is possible. (Print mostly remains on plain surfaces.)

- Summary: Less packed goods rot, almost no product is cas t away/littered!

Advantages





- Higher price, of course, because more material is needed

- TOP Film: Film rolls are more difficult to handle, compared to a flexible film. As the lidfilm is thicker, a reduced roll length is the consequence.

- Thermoformed TOP film: Machine settings need to be adjusted.

- Printing is less effective, as the TOP film has a higher thickness (compared to thinoriented films like OPET, OPP and OPA).

Disadvantages





www.leerdammer.deBel Deutschland GmbH

Sauels frische Wurst GmbH Fleischwaren & Co. KG

Böklunder Wurstfabrikation GmbH & Co. KG

Fresh Box / Fresh PackServe Box: Servierbox

3. Kinds of Packaging – Examples in Practice

f) DUO HARD – HARD TOP FILM, HARD BOTTOM FILM – where can you find this?


H. Kemper GmbH & Co.KG, 49638 Nortrup

Fresh Box / Fresh PackServe Box: Servierbox

f) DUO HARD – HARD TOP FILM, HARD BOTTOM FILM – where can you find this?

3. Kinds of Packaging – Examples in Practice


Excursion: Reclose Systems

The TOP Film is perforated (usually Laser perforation) and covered with a label which has a barrier function. First opening leads to an adhesion of the perforated segment onto the label. As the label remains sticky on the areas without the perforated segment, the package can be easilyreclosed with the label.

Reseal-it

Similar to the booklet. A TOP FILM and a BOTTOM FILM are thermoformed and suit well witheach other, fit together and do the reclose of the packaging system. For reclose, the TOP orBOTTOM Film are simply and easily pressed together.

Topforming

DUO HARD

Lid and bottom film are thermoformed and made only by one film. Lid and bottom film suit well witheach other, fit together and do the reclose of the packaging system.

Booklet

With opening of a package, an adhesive layer is set free behind the sealing layer.

Reclose happens with pressing the free adhesive layer in lid or bottom film against

the corresponding top or bottom film.

The free adhesive layer which is generated in the opening process can be in the lid or the bottomfilm.

Reclose withadhesive layer

3. Kinds of Packaging – Focus on Reclose Systems


A tight sealed package has an adhesive tape, which is used after the first opening of thepackage to reclose the package. This is often used to pack coffee (coffeebeans).

Adhesive tape

On a packaging machine first the inner side of the packaging film is sealed against the outerside of this film with overlap. A both side adhesive tape is brought in.

After the first opening, the reclose is done using the both side adhesive tape.

Lap-seal

Inside the package are two strips which fit together.

Like a „zipper“, but with polymer strips.

Zip Reclose


Excursion: Reclose Systems


4. The best and ideal Packaging for Future

What influences the kind of Packaging?

PACKAGING

Kind ofthe packed

goods

logistics

MarketingProducer

Availability

Order Discounter,Trade(ProductGuide)

Best-beforedate

Amount tobe packed

MachinesTools

Print

Production

Storage

CustomerConvenience!

Price(material, Amount,thickness)


Choice of Packaging systems: Price (per square meter) and amount of the packed goods

100 g to 10 kg0,8 X0,4 Xa) Soft Packaging

100 g to 4 kg0,5 Xe) Flowpack

f) DUO HARD

d) Skin

c) Shrink Systems

b) MAP

REFERENCE BOTTOM

Name

100 g to 500 gX1,1 X

100 g to 2 kgXX

100 g to 12 kg0,8 X

100 g to 500 gPrice X – Reference!

(Bio: 3,5 X)

„normal“: 0,5 X

RC: 0,9 X

Amount/mass of packed goods

BOTTOM FILMTOP FILM

Packaging Systems (unprinted)

4. What is the ideal Packaging?

(� „soft“ = flexible, E-Modulus low; appr. 50 bis 1000 MPa; � „hard“ = stiffer, E-Modulus > 1000 MPa.)


Specialties have a higher price. Example Reclose Systems:

1,1 XPrice TOP FILM,

Duo Hard,

semi-rigid

0,9 XPrice TOP Film,

With RECLOSE

(RC)

0,5 XPrice TOP Film,

„Normal“

and flexible

XPrice BOTTOM film,

semi-rigid

4. What is the ideal Packaging?


4. Some Thoughts and Philosophy

The ideal Packaging? For which application and for which requirements?

This presentation first showed the requirements on modern Packaging system.

Plastic Packaging is the best. The different kinds of Plastic Packaging systems were shown.

The Advantages and the Disadvantages were discussed.

As a new Packaging System, „DUO HARD“ was focussed.

On the way to the best Packaging systems, different criteria are important.

THERE IS NO IDEAL PACKAGING SYSTEM (every system has some disadvantages).

BUT:

MOST OF THE PACKAGING SYSTEMS ARE ALMOST IDEAL!

BUERGOFOL GmbH

Jahnstraße 10-1493354 Siegenburg Germany

Fon +49 (0) 94 44 / 97 91-110Fax +49 (0) 94 44 / 97 91-55

[email protected]

[email protected]

CONTACT

Packaging Design for Future Stark - BUERGO.FOL · Source: BASF. BUERGOFOL GmbH · Jahnstraße 10 ·...

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