PACKAGING INTELLIGENCE BRIEF

Packaging Trends 2010

Brand building, improving efficiency and reducing
costs are driving forces heading into 2010.

NOVEMBER 19, 2009

This report is brought to you with a sponsorship

from PMMI Member ProMach Inc.
About the Packaging
Intelligence Brief Series

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 Packaging Trends 2010
Brand building, improving efficiency and reducing costs are driving forces heading into 2010.
Countering the Recession
As they head into the new year, PACK EXPO attendees are
trying to counter recessionary forces of 2008 and 2009 by
focusing on building brands and improving productivity —
with twin goals of increasing sales and cutting costs.
In keeping with these goals, sustainability has evolved into
a mainstream commitment. Sustainable practices encour-
age sales by addressing consumers’ interest
in “greener” products, and by reducing
waste and conserving resources, they often
generate cost savings.
Other trends revealed at PACK EXPO Las Vegas
2009 included the increased adoption of digital
printing and safety enhancements.
Brand Building
Attention-grabbing packaging shapes, sizes, features and
materials increase shelf impact and product differentiation,
both of which help convince consumers to buy.
One new way to differentiate product is the Zip Box, a
hybrid carton/zippered pouch package from T.H.E.M.
(Marlton, NJ). The rectangular pack opens and recloses
easily, stacks better than a pouch and fits more
product per pallet than a canister.
Available in a variety of sizes, the Zip Box
fills like a standard carton on a modified car-
toner from Yeaman Machine Technologies, Inc.
The carton base and zipper-pouch top of the hybrid Zip
Box couples easy handling on the packaging line and in
distribution with convenient opening and reclosing for the
consumer.
PACKAGING TRENDS 2010 1
Pro Mach Inc. is proud to sponsor PMMI’s
report on Pack Expo Las Vegas 2009

Pro Mach, Cincinnati, Ohio, is a leading provider of integrated

packaging products and solutions for food, beverage, household
goods, pharmaceutical, and other diverse consumer and industrial
companies. Through three business units and related divisions,
Pro Mach provides equipment, training, installation, and parts in primary
packaging, end-of-line packaging, and identification and tracking.

For information on ProCustomer, our new customer

service initiative, visit www.ProCustomer.com.

Visit www.ProMachInc.com to learn about Pro Mach’s

divisions and packaging machinery solutions.

TM
(Elk Grove Village, Ill.). T.H.E.M. plans to sell printed blanks
as well as offer contract packaging services.

Another attention-grabbing concept, the ElastiTag hang tag

from Bedford Industries, Inc. (Worthington, Minn.) consists
of a single-ply or folded paper body attached to a flat,
stretchy loop. Available in a variety of tag and loop shapes
and sizes, the patented design carries brand, product and
country-of-origin information, point-of-purchase coupons,
inventory management data or a Universal Product Code.
Automating a process that is generally performed manual-
ly, application occurs on a machine from Graphic
The ElastiTag hang tag applicator handles bottles ranging from 12 ounces
Packaging’s Packaging Machinery Division (Crosby, Minn.). to 51 ounces.

The patented applicator rolls up to existing conveyors and

applies ElastiTag hang tags at speeds up to 450 per
minute.
Successful brand building also depends on quality control
measures that prevent flawed product from disappointing
the consumer. One way to prevent brand-damaging quali-
ty problems is via machine vision. To simplify integration of
complex inspection systems, CIVision, (Aurora, Ill.), has
launched the Pro Vision Series, a modular, do-it-yourself
system for contract packagers and original equipment
manufacturers.
“What was once acceptable, isn’t now,” warns Tom
McLean, president of CIVision. “Crooked, wrinkled labels
are unacceptable today if a brand owner wants to be
viewed as a good vendor. One bad label may prompt
retailers like Wal-Mart to reject the entire shipment.”
Capable of inspecting packs moving at up to 600 per
minute, the easily installed and operated system clamps to
the conveyor frame on a universal aluminum mounting
bracket and includes up to four cameras, a touch screen
operator interface, trigger assembly, strobe light, blow-off
reject mechanism, CIVCore vision software and an off-the
shelf, industrially hardened computer. Camera and lighting
height can be fixed or adjustable. Adjustments occur
manually via a hand wheel with a position readout or a slide
release with a guide ruler. They can also be fully
automated with servo drives.
The CIVision Pro Vision Series works with a variety of
cameras — monochromatic or color, low, medium or high
resolution. Options include stainless steel mounting brack-
et and NEMA 4X camera and electrical cabinet enclosures.
“The system is 100 percent a la carte, so integrators can

PACKAGING TRENDS 2010 3

P A C K A G I N G I N T E L L I G E N C E
pick and choose features,” reports McLean. “In fact,” he
says, “the system is so flexible, customers can supply their
own parts, if desired.”
In metal detection, the patent-pending Intellitrack XR signal
processing technology from Thermo Fisher Scientific
(Minneapolis, Minn.) eliminates product effect instead of
compensating for it. Now standard on the company’s Apex
metal detectors, the signal processor learns the conductive
and magnetic signatures of the product being inspected
and subtracts those signals from each reading. So, if a
product reads zero, it’s good. It’s especially well-suited for
discrete wet products such as cheese, bread, water and
baby wipes, which change over time and pose a challenge
for traditional phasing methods. Although products with
signals similar to ferrous or nonferrous metal or stainless
steel remain somewhat problematic, detection sensitivity
improves up to 40 percent.
End users also are becoming more familiar with x-ray
inspection technology, which can detect metal contami-
nants as well as a host of other problem materials like
bones and stones.
“They’re no longer asking why x-ray, but when,” reports
Rick Cash, marketing technology manager, Process
Instruments for Thermo Fisher Scientific, a supplier of
metal detectors, x-ray inspection systems and check-
weighers. “End users are realizing customers will not
tolerate low quality in food.”
4 PACKAGING TRENDS 2010
B R I E F
As a result, Cash predicts, “The x-ray market will be equal
or bigger than metal detection in a couple years.”
Productivity Improvement
On the productivity continuum, the need to minimize down-
time spurs demand for faster changeover and ease of use.
Tactics to achieve these goals include higher levels of
automation with increased adoption of servos, software
and robotics to speed changeover and reduce faults. The
need to cut downtime also is spurring interest in service
and support, automation of manual processes and hygien-
ic designs that require less time to clean.
Delkor’s servo-driven Trayfecta S Series carton/tray former features a
lower, more ergonomic blank magazine that is easier to replenish.
Delkor Systems, Inc. (Circle Pines, Minn.) has launched a
more flexible servo version of its Trayfecta carton/tray for-
mer. With servomotor drives controlling three axes of
motion (carton blank picking, carton transfer and forming
head action), each function occurs at its optimal rate. The
Trayfecta S Series not only runs 10 percent to 12 percent
faster, but also occupies less space, changes over without
tools in less than 10 minutes and handles a greater variety
of materials and shapes.
Flexibility is readily apparent on the high-speed FSU800
aseptic vertical form-fill-seal machine from Fres-Co
System USA, Inc. (Telford, Pa.). It handles a range of refrig-
erated and shelf-stable products from extended-shelf-life
dairy to high-acid aseptic or can be set up to simply hot fill.
The machine maintains overpressure in the form-fill-seal
area and sterilizes incoming film with ultraviolet light and
peracetic acid to ensure aseptic conditions. With a 22-inch
stroke, potential pouch sizes range from 1.69 ounces to
2.5 gallons with filling speeds from 17 pouches per minute
for the 2.5-gallon size to up to 30 pouches per minute for
the lower volumes. At the 2.5-gallon size, the form-fill-seal
process cuts packaging material costs to $0.25 to $0.30
per pouch versus $0.50 to $0.75 for a bag in box.
Modular construction of the ALS series of printer/applica-
tors from Avery Dennison, Printer Systems Division
(Framingham, Mass.) simplifies service and integration by
offering several mounting, loading and application options.
Built for heavy-duty use with a cast aluminum housing, the
ALS units feature a dynamic rewind and unwind to adjust
speed and torque for precise, repeatable label placement.
The ALS 306 manages labels up to 6 inches wide at
speeds up to 197 feet per minute. The ALS 309 handles
labels up to 9 inches wide at speeds up to 148 feet per
minute. A CompactFlash card slot makes it possible to
save, share and store configuration settings for several
packaging lines. Other standard connectivity options
include serial, Ethernet and USB ports. A ribbon-saver
function conserves material, cuts costs and decreases
downtime by reducing the frequency of ribbon changes.
Already viewed by many as the ultimate in flexibility, robot-
ic equipment is expanding functionality, ease of use and
setup with ultra-hygienic designs, vision capability and
advanced software.
A three-panel printer/applicator from Pro Mach’s ID
Technology (Fort Worth, Texas) thermal-transfer prints and
applies labels to up to three sides of a pallet, reducing the
number of applicators needed. Built on the same base as
the company’s other printer/applicators, the system fea-
tures a pivoting cam with a tamp-jet pad to apply labels to
leading, passing and trailing sides. A jet of air helps release
the label for tamp application on the fly or while the pallet
is stopped. The tamp-blow action helps ensure good con-
tact with the stretch wrap frequently used to unitize pallets.
Changeover takes only seven minutes on the HFP (Highly
Flexible Packer) from Focke & Co. (Whitsett, NC) because
With Focke’s two-robot HFP, case packing occupies only 81 square feet
(7.5 square meters) of floor space.
PACKAGING TRENDS 2010 5
P A C K A G I N G I N T E L L I G E N C E B R I E F

the only changes involve four indexing pockets, two quick-

release pusher plates and a conveyor guide rail adjust-
ment. When configured to pack at 15 cases per minute,
the dual-robot system orients cases to the product rather
than vice-versa, eliminates expensive product orientation
devices and minimizes product handling, making it partic-
ularly well suited for fragile products like potato chips.

The M-430iA robot from Fanuc Robotics America, Inc.

(Rochester Hills, Mich.) is the first robot certified by the U.S.
Department of Agriculture (USDA) to carry the USDA, AMS
Meat and Poultry Accepted Equipment logo, confirming it
meets or exceeds NSF/ANSI/3-A 14159-1 2002 specifica-
tions. Compatible with floor, ceiling or wall mounting and
designed for washdown conditions, the robot features pos-
itive air pressure inside the housing, a hollow arm to pre-

Delta robots such as the Adept Quattro s640HS feature a hygienic design
for washdown applications like meat and poultry plants.

vent contact with air hoses and electrical cables, dual seals
and windows at strategic locations so if a seal fails, mois-
ture will be visible. Specially designed surfaces and bolts
prevent accumulation of debris. The high-speed robot also
relies on food-grade grease, operates at 120 cycles per
minute with a 2.2-pound payload, 100 cycles per minute
with an 8.8-pound payload and may be equipped with
visual line tracking.

A growing number of robots, USDA certification is pending for the MPK robot, a similar-
including the MPK from Motoman,
withstand washdown conditions and ly equipped, washdown-compatible, IP67-rated unit from
meet USDA standards for handling
raw meat and poultry.

6 PACKAGING TRENDS 2010

Motoman (West Carrollton, Ohio). Available in 4.4- and 8.8-
pound payload models, the five-axis robot achieves speeds
in the neighborhood of 100 picks per minute.

Another washdown-compatible robot, designed to handle

raw meat and poultry, is a delta-style (parallel) unit from
Adept Technology Inc. (Pleasanton, Calif.). A new fixed plat-
form on the high-speed Adept Quattro s650HS allows it to
move heavier loads.

Enhanced software and vision capabilities are simplifying

and automating many robotic functions. Prewritten code
shrinks development time and costs by expediting
installation, startup and changeover. For example, with
Layer Tech software, from KUKA Robotics Corp. (Clinton
Township, Mich.) all the operator needs to do is input a few
parameters to set up a layer forming pattern. A similar pro-
gram for bag handling, BagTech, is expected to be avail-
able at the beginning of 2010.
A three-axis wrist gives the color-vision-equipped M-1iA delta robot a
wider range of motion than standard delta robots.
Fanuc’s iRVision 2D two-dimensional robot guidance tool
and a color camera make it possible for its six-axis M-1iA
delta robot to pick and place products by color without the
use of special sensors or custom fixtures. loads left on a film roll so operators can make a timely
switch. Based on the lean manufacturing concept, the
Since performance can’t be judged good or bad without system provides real-time performance data, such as
measurements, some machinery builders are adding mon- availability vs. output, stops due to machine blockage or
itoring and reporting capability to their control systems. For starvation, number of loads wrapped per shift, hour, day,
example, the visual management system on No Film Break week or month, number of loads per roll of film for last roll
stretch wrappers from Lantech.com (Louisville, Ky.) tracks and last 10 rolls, and status messages and alarms.
system performance and even counts down the number of

PACKAGING TRENDS 2010 7

P A C K A G I N G I N T E L L I G E N C E
Taking the measurement effort a step further, Lantech is
working to establish standards regarding load containment
or holding force and has begun to offer containment
workshops to help end users determine proper machine
settings, improve repeatability and reduce waste and
downtime due to the constant tweaking that occurs on
many packaging lines.
Support
Support has taken on new importance as packagers have
deferred new equipment purchases and/or reduced in-
house technical staff.
Many packaging machinery manufacturers are publicizing
existing programs or expanding service offerings. The six-
month-old Advantage Program at Dorner Manufacturing
Corp. (Hartland, Wisc.) includes a Get Fit introduction, Stay
Fit ongoing maintenance, replacement parts kits, same-
day shipment of parts and a 24-hour service line for mat-
top and belted conveyors.
“We also do maintenance and wear training,” reports John
Kuhnz, products marketing manager at Dorner.
A similar array of reactive, interactive and proactive support
services, including PMMI Certified Training and an invento-
ry of critical wear parts, is provided under the ProCustomer
initiative recently established at all 11 divisions of Pro
Mach (Cincinnati, Ohio). Its Web site dedicated to service,
ProCustomer.com, recently went live.
8 PACKAGING TRENDS 2010
B R I E F
After offering its InSite Services program to end users for
several years, Rockwell Automation (Milwaukee, Wisc.) has
extended the program to original equipment manufactur-
ers, who can sell it as part of their service packages.
Available on a subscription basis, the program monitors
equipment, expedites troubleshooting, signals it’s time for
preventive maintenance tasks, optimizes performance and
downloads updated information to the controller. It also can
maintain a history of the machine and database of support
information as well as organize data in standard or custom
formats to create reports or reveal trends.
At Filamatic (Baltimore, Md.) new one- and two-year serv-
ice agreements can be configured to include a complete
machinery and procedure assessment along with proactive
machine evaluations and tune-ups and operator training in
The operator interface on Standard-Knapp’s Tritium Multipacker features
easy-to-understand illustrations and color-coded alerts and moves the
most frequently used buttons below the touch screen to reduce wear and
tear.
troubleshooting and preventative maintenance. Plans
include a 10 percent discount on hourly service rates as
well as a 10 percent discount on parts purchased within 60
days of a service agreement visit. A newly formed three-
member service team makes on-site visits.
Other firms are simplifying the maintenance process itself.
For example, Walk-By-Maintenance™ on the new Tritium
Multipacker from Standard-Knapp (Portland, Conn.) makes
every moving part visible. As a result, mechanics spend
less time on diagnosis and assessment. It also makes it
easier to pre-stage parts in preparation for a maintenance
session. Other maintenance-friendly features on the shrink
wrapper include gull-wing guard doors, a slide-out film bed
and self-diagnostic sensors. A smart Operator Interface
relies on easy-to-understand illustrations and color-coded
alerts to present more performance data. In addition, com-
puter-aided fault recovery shortens Mean Time to Recover
and slashes downtime. An energy-efficient heat tunnel
and material-conserving wrapping technology address
sustainability needs.
Sustainability
Sustainable innovations fit well with brand owners’ lean
initiatives and fall primarily into five categories: utility
conservation, source reduction, recycled content, recycla-
bility and renewable materials.
Converting from the soap and water typically used to
prevent back pressure on bottling lines to Hartness DCL dry
conveyor lube from Hartness International (Greenville, SC)
saves an average of 250,000 gallons of water each year,
and lowers sewer and effluent treatment costs. Removing
water from the conveyor lubrication process also eliminates
wet, slippery floors; water-related damage to equipment
and packaging; the need for drip pans and associated
plumbing; and the time and expense involved with
cleaning regimens needed to discourage the microbial
growth associated with moist conditions. Classified by
USDA as an H1 lubricant (safe for incidental food contact),
the DCL formula consists of a Teflon-based lubricant in a
food-grade mineral oil carrier (medicinal white oil). An
automated pump/manifold distribution system applies 0.1
cubic centimeter of lube per nozzle to the conveyor every
15 minutes.
Like water conservation, saving energy is not only
sustainable, it’s cost effective. As a result, human/machine
interfaces on packaging machines are beginning to include
screens that show energy usage. Examples include the
Sustainability Measurement Option from Schneider
Packaging Equipment Co., Inc. (Brewerton, NY), which
dashboards parameters including kilowatts, voltage, cur-
rent and overall equipment effectiveness to help quantify
energy costs and carbon footprint.
Machines like the Bel 290 case sealer from Pro Mach’s
Wexxar Packaging Inc. division, (Delta, BC, Canada) take an
even more proactive approach. To reduce energy con-
sumption, a power save mode allows the system to hiber-
nate until it detects a case approaching. Schneider’s Model
HCP-10 case packer has similar capabilities. If no cases
PACKAGING TRENDS 2010 9
P A C K A G I N G I N T E L L I G E N C E
Wexxar’s Bel 290 case sealer reduces energy consumption by allowing
the system to hibernate until it detects a case approaching.
are arriving, conveyors stop, and the adhesive tank powers
down.
With motors and drives accounting for 68 percent of the
energy consumed in industrial settings, Bosch Rexroth
Corp., (Hoffman Estates, Ill.) takes a multifaceted approach
to energy conservation. Dubbed 4EE, it consists of energy-
efficient components, energy recovery, energy on demand
and energy-efficient design. On packaging machines, dig-
ital servo-amplifiers on motors eliminate the need for air
conditioning cabinets. A regenerative power supply cuts
electricity use up to 20 percent by capturing energy gen-
erated during braking and supplying it to other devices,
storing it in a buffer for the next cycle or feeding it into the
electricity supply grid.
There’s also more attention to optimizing the size of motors
and drives and replacing pneumatic actuation with electric,
10 PACKAGING TRENDS 2010
B R I E F
according to Rockwell Automation’s Leo F. Petrokonis,
business development manager – packaging industry.
A number of all-electric alternatives to pneumatic
machines have recently arrived on the market including the
Spec.e printer/applicator from Foxjet (St. Charles, Mo.),
and the Platinum E-Series tamp-on labeler from Diagraph
(St. Charles, Mo.) The latter costs about the same as its
pneumatic Platinum Series counterpart.
“The most important benefits are accuracy and repeatabil-
ity,” says Steve Dods, Diagraph’s labeling products man-
ager, about the all-electric unit. “There’s no decline in
cycle efficiency or starving for air [when other pneumatic
equipment is working].”
In addition, because a fan in the tamp pad holds the label
in place, there aren’t alignment issues or changeover
involved when switching from one label size to another. An
all-electric swing-arm model will join the Platinum E-Series
tamp-on and wipe-on labelers by the beginning of 2010.
Adhesive guns also are moving from pneumatic to electric.
“With smaller packages moving faster and smaller flaps to
seal, higher precision is required,” explains Rick Pallante,
marketing development manager, packaging for the
Adhesive Division of Nordson Corp. (Duluth, Ga.).
Another conservation measure, source reduction, light-
weights, downgauges, replaces or eliminates packaging
materials/components. Eliminating liner waste is the goal
Bosch Rexroth Corporation’s multi-faceted approach to energy conservation, 4EE, covers energy-efficient components and design, energy recovery and
energy on demand.
behind a pressure-sensitive label printer/applicator from
Arca Automation (Cherry Hill, NJ). The Bi-Fuel Linerless
Printer/Applicator handles linerless polypropylene or paper
labelstock and offers even greater waste reduction poten-
tial when switched to print linerless paper via a direct
thermal process that requires no thermal-transfer ribbon.
Capable of reproducing scannable barcodes, the system
relies on a Sato S8408 printhead customized for linerless
media and a pneumatic applicator, and its slightly higher
cost (about $25,000) is offset by material savings. A sec-
ond generation machine, scheduled to debut in 2010, will
be able to handle both linerless media and traditional liner-
equipped material.
Converting cut-and-stack labelers from open wheel adhesive
pots to closed extrusion systems from Nordson can cut hot
melt consumption 90 percent by eliminating waste and
reducing char. The closed system also cuts energy con-
sumption in half and minimizes downtime related to cleanup,
particularly of the drum, where adhesive tends to collect.
Addressing adhesive buildup another way is the hot-melt-
repellent Dura Motion finish on the Stay Clean Drum from
B&H Labeling (Ceres, Calif.). Available on all new B&H roll-
fed labelers and retrofitable on some older models, the
Stay Clean Drum lengthens the uptime intervals between
stops for cleaning to at least three hours and sometimes as
many as 12 hours.
“With standard drums, it’s not uncommon to stop the line
for cleaning as often as every 40 minutes,” notes Bob
Adamson, vice president, Sales & Marketing, B&H.
Eliminating hot melt entirely, the Roll-Adhesleeve roll-fed
labeler from PE Labelers USA (Cincinnati, Ohio), relies on a
label with pressure-sensitive adhesive on the leading and
PACKAGING TRENDS 2010 11
P A C K A G I N G I N T E L L I G E N C E
trailing edge. The drum cuts and applies shrink or
non-shrink film labels without stretching, enabling use of
monolayer film, usually polypropylene, as thin as 20
microns (0.0008 inch).
When hot melt is used, metallocene chemistries are
replacing ethylene vinyl acetate. Although the price differ-
ential between the two has shrunk, metallocenes remain
more expensive. That might be changing, says Joseph S.
Hetzer, research chemist at H.B. Fuller Co. (Vadnais
Heights, Minn.), the maker of Advantra hot melts
“People are starting to look at the total view and not just
the price per pound,” explains Hetzer. That big picture
includes a higher yield plus reduced waste since the met-
allocene hot melts contain no oxygen to cause charring.
More importantly to today’s sustainability-conscious end-
users: Metallocene hot melts separate more easily in the
recycling process.
Source reduction and recycling benefits are behind the
development of StreamOne extrusion-coated polyester lid-
stock from Rollprint Packaging Products, Inc. (Addison, Ill.).
Intended for use with polyethylene terephthalate (PET) or
polyethylene terephthalate glycol trays, the peelable poly-
ester lidstock replaces the mixed-polymer laminations or
coextruded films typically specified. This means the entire
pack (tray and lidstock) can be recycled in the #1 (PET)
recycling stream. With a thickness of 1 mil (254 microns),
the polyester film also represents a source reduction of
roughly 50 percent compared to commonly used 2- or 2.5-
12 PACKAGING TRENDS 2010
B R I E F
Applications for StreamOne extrusion-coated polyester lidstock include
gamma-sterilized medical devices, consumer goods like razors and frozen
foods.
mil (508- or 635 micron) laminations or coextrusions. Less
material also translates into a cost savings of more than 15
percent. “Eventually, we also want to offer PE and
polypropylene lidstocks so we can match any tray materi-
al,” says Dwane Hahn, sales manager – New Business
Development, Rollprint.
It should be noted that changing to the coated polyester
lidstock may require adjusting seal temperature. In addi-
tion, medical device suppliers will need to follow standard
IQ/OQ procedures to make the change, and Hahn recom-
mends food processors perform drop and puncture tests to
ensure satisfactory performance.
“The polyester is probably less puncture resistant and
more abrasion resistant,” he explains.
To overcome the variability inherent in recycled content
corrugated, the WF30 case former from Pro Mach’s
Wexxar features an enhanced Pin & Dome case opening
technology. An electromechanical (rather than pneumatic)
servo system from Festo Corp. (Hauppauge, NY) detects
the amount of resistance in the box score flap and sends
feedback to the controller to compensate for variations and
maintain consistent case forming speed at up to 30 cases
per minute.
Single-ply paper with 100 percent recycled content is con-
verted into cushioning by machines from Sealed Air (Saddle
Brook, NJ). The three-speed FasFil void-fill system shapes
the paper to impart protective properties. Designed to be
positioned over a conveyor, the machine features a shaft-
less cradle unwind, which not only eliminates the need for
core plugs, but also the core itself. When it’s time for
replenishment, drop-in paper roll loading eliminates the
need to walk around, crawl under or climb over the con-
veyor. To increase throughput, one motor operates both the
knife and clutch.
The PackTiger Hybrid paper system from Sealed Air shapes
single-ply 17-inch by 20-inch sheets into multi-ply pads
for void-fill. Flipping a switch changes density so pads can
serve as cushioning. Designed for pack stations rather than
conveyor applications, the system features a front-loading
paper tray and can connect as many individual sheets as
needed to create the desired length.
Digital Printing
With the advent of more sophisticated digital presses, the
use of digital printing is growing, especially for labels and
shorter runs. Since each impression is generated by the
Three unwind heights allow Sealed Air’s FasFil paper void-fill system to
match any conveyor height.
digital file, digital printers are particularly well-suited for
printing variable data, including unique codes.
“For runs under 20,000 the digital press is cheaper than
conventional printing,” states John Pitts, sales manager at
CSAT America LLC (Louisville, Colo.). Savings on runs
above 20,000 depend on ink usage and setup time.
Characteristic of today’s state-of-the-art digital presses,
CSAT’s ITS 600 four-color, drop-on-demand inkjet label
printer operates as a standalone unit or integrates with
labelers or converting equipment as well as vision-based
inspection systems. The model shown at PACK EXPO Las
Vegas 2009 featured a 9-inch web width with a 4-inch
print area. A model with a 15.75-inch print area is expect-
ed to debut in 2010.
The ITS 600 digital press prints any web-based material
(film, foil, paper), including die cut and preprinted stock,
destined for use as labels, shrink sleeves, stick packs or
PACKAGING TRENDS 2010 13
P A C K A G I N G I N T E L L I G E N C E
flow-wrapped packs. An edge guide and sensor ensure
precise positioning. Specially designed printheads are
housed in an enclosure and retract to the back of the
machine for a drip-free, 10-second purge and wipe
cleaning process. Automating cleaning eliminates operator
contact and extends printhead service life. Custom 1-liter
ink cartridges also help maximize uptime.
Four colors are standard, but six are available. A program
in the controller can estimate ink consumption based on a
study of the print file for the job. The software also pre-
pares the file for printing, virtually eliminating setup.
Ultraviolet-light-emitting diodes cure the ink with less heat
than other curing processes and no ozone emissions, so no
blowers are needed to dissipate heat or fumes.
Safety Enhancements
With internal risk assessment initiatives and new safety
standards, especially in Europe, some equipment builders
are adopting Category 3 safety circuits to provide redun-
dancy and fast reaction time.
One company that’s standardized on Category 3 safety
components, Columbia Okura LLC, (Vancouver, Wash.) has
built its FL2000 floor-level palletizer with dual-circuit inter-
locks and a discharge light curtain. A sliding tunnel on the
infeed provides additional protection and easy access.
“Our customers have asked for Category 3 safety circuits
as an option for several years,” reports Ted Yeigh, sales
director, Columbia Okura. “This year, we have standardized
on Category 3 circuits across our product line. The compo-
nents are more expensive but offer a greater level of
14 PACKAGING TRENDS 2010
B R I E F
Columbia Okura has standardized on Category 3 safety features for all its
machines including the FL2000 floor-level palletizer, which builds 10-case
patterns at a rate of 20 cases per minute and 15-case patterns at 25
cases per minute.
security.” Yeigh estimates Category 3 implementation
probably adds 6 percent to 8 percent to the cost of a
machine.
Bosch Rexroth builds safety functions into its drives and
controllers to reduce monitoring requirements, save on
certification costs, provide a reaction time of less than 2
microseconds and simplify integration. These capabilities
also help U.S. packaging machinery manufacturers build
machines to European requirements.
Safety is receiving more attention — in the United States
and outside the country. It plays a key role in the European
Union’s CE requirements, and it’s also part of today’s soci-
ety, with its greater levels of litigation and awareness of
injuries, and a higher-value labor force. Further, improved
safety practices tie in with the lean and sustainable initia-
tives that were so prevalent at PACK EXPO Las Vegas
2009. These trends and the others described in this report
will evolve throughout the coming year, and will be on dis-
play next fall at PACK EXPO International 2010.
About PMMI
PMMI is a trade association with more than 550 member companies that manufacture
packaging, processing and related converting machinery, commercially-available pack-
aging machinery components, containers and materials in the United States and
Canada. PMMI’s vision is to be the leading global resource for packaging, and its mis-
sion is to improve and promote members’ abilities to meet the needs of their customers.

PACK EXPO
PMMI organizes the PACK EXPO trade shows: PACK EXPO International, PACK EXPO Las
Vegas and EXPO PACK México, connecting packaging and processing equipment and
materials suppliers with their customers around the world.

Coming in 2010: EXPO PACK México in Mexico City, June 22–25, and PACK EXPO
International, Oct. 31–Nov. 3, at Chicago’s McCormick Place. PACK EXPO Las Vegas
returns to the Las Vegas Convention Center Sept. 26–28, 2011.

Packexpo.com
Packexpo.com is your connection to the packaging and processing supply chain — includ-
ing the exhibitors of PACK EXPO. Around the clock, and around the year. Use the site to
find the suppliers you need, any time, and enjoy the benefits of PACK EXPO all year long.

PMT Magazine
PMT Magazine is the industry’s only publication dedicated to professionals in packaging
operations, purchasing maintenance and training.

Learn more about PMMI and the PACK EXPO trade shows at PMMI.org and Packexpo.com.