In order to meet the demand from the market for alternative packaging materials, the two companies Leipa Georg Leinfelder and Koehler Paper Group have developed in conjunction with Multivac a cardboard composite, which can be used for packing fresh food such as meat for example. This innovative solution based on paper fibre packaging material was presented at IFFA on the Multivacstand and run on a compact thermoforming packaging machine. The packs are designed in such a way, that the end user is able to separate the cardboard backing from the plastic barrier layer and then put it into the paper recycling.
Multilayer composite for skin packs
When developing this material, the challenge was to produce a cardboard composite with high barrier properties and a suitable sealing medium, which has the stiffness of a flat pre-cut card sheet but is also capable of being wound onto a roll, so that it can be run on a thermoforming packaging machine. The first results show that the Leipaflat multilayer composite is excellent at meeting all the requirements. This material can be used on a thermoforming packaging machine to produce skin packs, which not only package the product securely but also present it attractively to the consumer. As a strategic development partner in the board sector, Koehler provides Leipa with the material for manufacturing Leipaflat.
“Leipaflat is made of up to 90 percent renewable raw materials. Compared to the conventional packs used for these products, the features of this packaging material are its appearance and feel of a paper pack, and this contributes significantly to product differentiation in the chill cabinet,” explains Matthias Haux, Commercial Head of Flexible Packaging at Leipa. “This solution meets the high aspirations and demands of consumers, who are conscious of both quality and the environment. The cardboard offers not just the required stiffness, but it can also be run particularly well on thermoforming packaging machines thanks to its ease of winding on rolls. This solution can generally also be used on existing machines and dies. If requested, we are always willing to give customers advice on site about the optimum settings for their equipment.”
Danny Köppl, Product Manager for Films & Consumables at Multivac, adds: “This sustainable packaging solution, which was launched at FachPack 2018 and marketed under the Multivac PaperBoard range, has already received a very positive reception from professionals in the trade. Now we are receiving a large number of enquiries from the market, particularly against the background of the EU Plastics Strategy, and these are coming not only from Germany and Western Europe but also from many other regions such as Eastern Europe, North America and Oceania. We are currently carrying out a large number of sample productions for a wide range of customers.”
“We see great potential for this project, which has begun very successfully, and we are convinced that we can address the future of packaging in conjunction with our highly qualified partners, who embody the same collaborative ideas as we do,” says Dr. Markus Wildberger, Corporate Director of Technology at Koehler. “As part of our own ideas on sustainability, this project supports our aims of replacing plastics in packaging with paper-based materials, where it is sensible and practical to do so. This means that a product made from renewable raw materials is used, one for which closed-loop recycling has already been developed. We see in this and other collaborative projects the opportunity to develop and market further innovative solutions in the sector of flexible and rigid board packaging.” Dr. Wildberger also emphasizes that this could involve developments in the non-food as well as food sector.
“Based on today’s knowledge of the planned harmonisation of the EU regulations on plastic disposal, we assume that Leipaflat will lead to significant cost benefits in the context of the packaging fee for companies,” says Matthias Haux from Leipa. “And last but not least, the environment as well as consumers also benefit from this solution.”
The PaperBoard portfolio comprises a wide range of solutions for producing MAP and vacuum skin packs from paper fibre-based materials. In conjunction with leading manufacturers, the company has developed suitable packaging materials, which can be run on standard machines. By using different functional layers, it is possible to produce packs from paper fibre-based materials, which also meet the barrier requirements of the most sensitive products. The packs can be designed in such a way, that the end user is able to separate the cardboard backing from the plastic barrier layer and then put it into the paper recycling.
La Huerta Grows with Key Technology
New Vibratory Shakers
La Huerta, processors of frozen fruits and vegetables, added their third production line in 2016 and their fifth automated packaging line in September 2018. Looking for world-class performance, including superior sanitation and rugged reliability, they’ve turned to Key Technology many times along the way. Now, Key’s Iso-Flo vibratory shakers can be found on every processing and packaging line at La Huerta.
“Every year, the demand for food safety gets stricter, with higher standards for microbiology and sanitation and more requests for audits. In this environment, our relentless focus on quality sets us apart,” said Carlos Gutierrez, Plant Manager at La Huerta. “Our equipment from Key helps us achieve our high product quality objectives at the same time it increases our efficiencies by maximizing uptime and reducing labor.”
La Huerta installed Key’s Veg-Mix in 2006, followed by an Iso-Flo dewatering shaker and an Iso-Flo fines removal shaker the next year. Since then, they’ve installed two integrated packaging distribution systems that each feature several Iso-Flo Smooth-Cycle™ scale-feed conveyors with pneumatic slide gates and an Iso-Flo collection shaker. They added another dewatering shaker in 2016 and a bar-style size grader, also based on Key’s versatile Iso-Flo design, in 2018.
“The quality of Key’s equipment is far better than any competitive solution that we’ve used. As our other shakers reach the end of their life, we plan to replace them with Iso-Flo,” noted Luis Picazo, Project and Maintenance Manager at La Huerta. “Key customizes each of these shakers for our processes so they work perfectly, and they’re designed to be easy to clean and hygienic. The support we’ve received from Key has also been great. Whenever we have questions or need anything, they’re very responsive.”
Iso-Flo shakers have always been recognized for sanitation and reliability, and Key is continuously working to improve their designs with new features that exceed rising food safety standards. In addition to stainless steel construction, smooth beds and durable StrongArm spring arms that have helped define Key’s vibratory shakers over the years, La Huerta’s newer Iso-Flo shakers also feature 100 percent continuous welds, no-pinch slide gates, stainless steel motors, self-draining surfaces and the elimination of laminations, which can trap bacteria. Every element of every Key system is designed for performance and sanitation.
Featuring independent frame-mounted drives and spring arm assemblies, Iso-Flo shakers distribute energy equally to all parts of the shaker bed in a controlled natural-frequency operation. This operating principle minimizes the vibration that is transferred to structural support and the floor, which cuts the cost of installation, reduces energy use and offers quiet operation. Key’s contoured StrongArm spring arms, made with propriety composite material, offer an operational life that is up to twice the life of traditional, straight spring arms. The stainless steel Iso-Drive adds to Iso-Flo’s extreme dependability, reducing maintenance and improving performance and uptime.
“La Huerta has been in the ‘healthy food business’ since we were founded by Jose Arteaga Campos in 1957. Today, under the leadership of his son, Jose Arteaga Niepmann, we remain true to our original principles of respect, integrity, responsibility and teamwork while we evolve,” said Katrin Derntl, International Sales Manager at La Huerta. “After growing our sales volume on average 10 percent annually over the last five years, we’re producing more than 60,000 metric tons of finished product a year and exporting more than 40 percent to 11 countries, including the U.S., Canada and Japan, where customers have the highest quality standards. Our products go to market under our own brand and under private label customers’ brand names, as well. In Mexico, the La Huerta brand is by far the market leader in the frozen vegetable category with over 70% of market share in retail.”
La Huerta installed Key’s Veg-Mix on their packaging lines to produce bags of mixed fruits or vegetables. This system receives each product in a separate infeed hopper, then de-clusters, meters, mixes and conveys the mixed product to packaging. The hopper design minimizes product ‘sticking’ to eliminate the buildup of thawed product. A long-span frame and integrated Iso-Flo collection conveyors allow for minimal supports to the floor, which makes the system easy to install and easy to clean. The master override adjusts total line flow while maintaining preset mix ratios. Independent, ‘on-the-fly’ adjustment of the Cluster Breaker and Vari-Feeder enable quick, reliable change of product mix and metering. “Our Veg-Mix ensures the right amount of each product in the mix so we’re sure to stay within specifications,” explained Picazo.
The two Iso-Flo packaging distribution lines at La Huerta feature several Iso-Flo Smooth-Cycle shakers with no-pinch sliding gates. One distribution system feeds product to three multi-head weighers that each feed a VFFS machine. The other feeds semi-automated packaging stations. Designed specifically for feeding applications, Smooth Cycle conveyors include controls that manage the flow of the product on the shaker, speeding up and slowing down as needed, to eliminate the mechanical stop/start transients common in these applications.
Turning the first spadeful
New Center of Excellence for meat portioning
As part of an official celebration, the first spadeful of earth was turned today for the construction of a new factory at TVI Entwicklung und Produktion GmbH in Bruckmühl. A state-of-the-art complex covering around 9,000 square metres of available space will be built there, and it will include an office building and Customer Center as well as the production hall. Completion is planned for May 2020, and the total investment amounts to approx. 17.5 million euros.
TVI is the market leader in meat-portioning machines and complete portioning lines. The product portfolio includes solutions for tempering, pressing, portioning and automating, as well as grill stick winders and equipment for producing kebab skewers. Since January 2017 Multivac has held a majority share in the company – and with the construction of the new building it is now creating the ideal conditions for further sustainable growth.
A large number of guests took part in the celebrations at Bruckmühl, among them Richard Richter, Mayor of Bruckmühl, Alois Allgaier and Thomas Völkl, the two CEOs of TVI, as well as Multivac Directors, Guido Spix (CTO/COO) and Christian Traumann (CFO).
Continuing to expand the position in precision meat portioning
“The Portioning Machinery Business Unit is developing in a very satisfactory manner. By investing in the new factory, we are facilitating the expansion of our product portfolio and at the same time enabling TVI’s leading position in precision meat portioning to be consolidated,” explained Guido Spix, CTO and COO of Multivac. “The number of employees is due to increase from the current 120 to around 250 in the coming years.”
The new Center of Excellence for meat portioning will include a production hall of around 5,600 square metres for the Pre-fabrication and Assembly areas as well as the Logistics, Warehouse and Development departments. The new factory will use a deep-well system to ensure that the building is cooled by ground water.
In addition to this, there will be a three-storey office building with a total area of 1,920 square metres, in which a modern canteen, high-quality offices and a recreation room will be housed. “When designing the new facility with its state-of-the-art working environment as well as its various functional areas and meeting places, it was very important for us to create an environment for our staff, in which they feel at ease and can find all the requirements for their work,” explained Alois Allgaier, CEO of TVI.
A two-storey Customer Center covering an area of around 1,400 square metres, including several demonstration rooms and a Customer Lounge, rounds off the new complex. “This will enable us in future to offer our customers the ideal conditions for discussing and demonstrating our high-performance portioning solutions under real conditions,” said Thomas Völkl, CEO of TVI. “It will also be possible to carry out individual trials with customers’ own products, as well as testing the solutions for feasibility, output, return on investment, give-away and other critical factors.”
Greater flexibility and advanced performance
For its packaging and forming machines as well as grinding and cutting equipment, Gea developed different Toolings to make sure the machines always fulfill their demands. Whether it affects the shape, size, taste, quality, or safety and economic needs for the end product, Toolings bring the latest innovations and developments to meet all those new requirements. The main advantages are reduction in manufacturing costs, extended lifetime of new tools and greater flexibility to get new products to market as well as enlarging the product range. Toolings are quickly available with a minimum capital investment and a very short implementation time. At the upcoming IFFA trade fair in Frankfurt (Germany), the experts will inform about the wide range of Gea Toolings for its several food processing machines.
Precision engineered to match forming machines
With the original Gea FormPlates, customers can make every gram of their product count. OEM quality ensures minimized give-away and optimized shape, quality and portion weight of formed products. In addition to regular form plates, the company is also able to design customized ones and with that responding quickly to customers’ demands and seasonal trends. The FormPlate Creator is a unique free service that contains a huge variety of shapes that can be turned into a custom form plate. After receiving some details, including the machine type, choice of raw material, choice of plate material, average product weight, and proposed production volume, a PDF drawing of the form and form plate and a cost estimate is available within minutes. With this service from Gea, customers can turn their creative ideas into business realities and manufacture products with extra appeal.
Hand crafted for unmatched quality and lifetime
With Geas bag forming sets for SmartPackers customers can lower their operational costs. High tech composites used for Gea Shoulders ensure lower wear rates and up to 10 times longer life as compared to stainless steel shoulders. In addition, the shoulders can easily be repaired in case of damage. The new standard forming set is delivered as a fiberglass-reinforced version with an insert. This version is stronger than the conventional forming set and therefore ensures less wear, extra protection and longer operational life. An insert also makes it possible to produce both overlaps and tucked seams with one and the same shoulder. Finally, each forming set is equipped with a rigidized surface to ensure smooth running in a moist/wet environment. In short Gea Shoulders provide complete peace of mind with unique design, high tech composite materials, simpler maintenance, lower operational costs and increased reliability.
Perfection down to the smallest detail with knives for CutMasters
Gea TopCut is a self-contained knife head system for Gea CutMasters that combines high speed cutting with performance benefits in terms of handling, hygiene and product quality. It is available on all CutMaster bowl cutters and can be fitted as a field upgrade to existing machines. Designed to increase productivity and be more user-friendly, the patented TopCut knife system delivers consistent quality for a wide range of products. Fine emulsions are produced in combination with a removable sliding plate, while removing the plate enables coarser cuts to be produced without smearing. In addition, a range of universal and special knives is available for CutMasters.