The German Packaging Institute (“dvi – Deutsches Verpackungsinstitut e.V.”) has honored Syntegon Technology, formerly Bosch Packaging Technology, with the German Packaging Award in the category “Packaging Machines”: the compact TPU1000 form, fill and seal system convinced the jury with its wide range of possibilities for innovative, sustainable portion packs made of fiber-based material. The German Packaging Award 2020 underlines Syntegon’s focus on sustainable and intelligent technologies.
Every year, the German Packaging Institute dvi honors groundbreaking packaging ideas and machines in a contest that encompasses all industries and packaging materials. This year, one of the coveted prizes went to the TPU1000 paper forming machine from Syntegon. According to the jury, the form, fill and seal machine for paper-based packaging material paves the way for new, sustainable packaging solutions that meet the trends towards replacing petrochemical plastics and individualization. “The TPU offers brand owners with high demands on sustainability and aesthetics completely new packaging options for food, cosmetics and non-food products,” says Matthias Klauser, sustainability expert at Syntegon Technology. “We are therefore all the more pleased that the dvi recognizes our innovation and sustainability efforts.”
The module-based TPU1000 forms environmentally friendly “Shaped Paper Pods” with a filling volume of ten to 100 milliliters, which are suitable for single-portion packs and small-format products that are normally packaged in blisters. The material fed from the paper roll is formed into the desired shape at a speed of up to 15,000 packages per hour. This enables high quality packaging designs and embossing for a variety of products and filling techniques.
“In combination with BillerudKorsnäs’ 3D formable FibreForm® paper, the TPU1000 produces unique packaging with a special feel that meets both brand manufacturers’ needs for an individual look and feel and their sustainability efforts,” says Klauser. FibreForm® allows for up to ten times deeper embossing than regular paper. This results in unique 3D effects that differ from existing packaging solutions on the market. Various types of barrier layers can be applied to ensure the necessary protection of the respective product. The jury of the German Packaging Award praised the innovative material: “This highly stretchable paper allows wrinkle-free processing from a roll and a detailed reproduction of small embossing elements.”
Since 1963, the German Packaging Institute dvi has presented the German Packaging Award in several categories. The international competition takes place annually under the patronage of the Federal Minister of Economics and Energy. 2020, entries from Austria, Denmark, Finland, France, Germany, Great Britain, Italy, Spain, Switzerland, Turkey and Denmark were evaluated in a total of ten categories. The focus of this year’s competition was on the highly topical issues of sustainability and digitalization.
3D layouts underline line competence
SOMIC develops and produces sophisticated secondary and end-of-line packaging equipment. Its machines ensure that the goods of leading companies in the food, pet food, and pharmaceutical sectors are stackable, transportable, storable, and easy to handle at retail. Customers particularly appreciate the high level of line expertise: the company’s experts have a comprehensive understanding of how their machines can be integrated into production lines and spatial conditions.
The combination of performance and functional requirements, technical specifications and structural conditions is the essential factor in the quotation process. This not only results in the specifications of the machines – rather, the Group must also always find individual solutions for the plant layouts. Until now, these layout plans were implemented in a 2D drawing program as a plan view and then reproduced as a 3D layout in the Solidworks CAD system for the final order presentation to the customer – a time-consuming procedure that was prone to errors due to the multiple media discontinuities.
SOMIC turned to the Lino team to establish consistent, automated quotation processes that would lead to attractive order documents that were meaningful to everyone much more quickly. Their software Lino 3D layout for 3D layout planning and Tacton Design Automation for rule-based configuration are integrated into Solidworks – and ensure a quality leap there without media breaks: For example, all systems access a central data basis for machines and components. In this way, the set of rules prevents technically problematic variants, and modified models are automatically available to all future layouts.
In addition, Lino 3D layout reports immediately if dimensions do not match or structural collisions occur. SOMIC now clarifies whether plant layouts can be reliably implemented at a very early stage of the quotation process. In addition, Lino 3D layout significantly speeds up the layout planning process, because the employees insert objects into the layout using drag-and-drop – where they land directly at the correct interface thanks to snap technology.
As a result, they receive comprehensible layouts that illustrate all the necessary details from different perspectives. As an interactive presentation with realistic colors, surfaces and logos, they are a great asset for SOMIC when talking to customers.
New naturally colored capsules without e-number
The new portfolio of ACGcaps™ NTone includes multiple coloured capsules with no e-number. The aesthetically appealing colour solutions include Ocean Blue, Sunny Yellow, Desert Brown, Purple Pure Carrot, and Red Pure Radish. The colours used are safe and non-toxic, do not contain any artificial ingredients, and there is no change to product shelf life when compared to synthetic-coloured capsules. This new range creates the perfect opportunity for formulating clean label products.
“Consumer preference has shifted, and there is an increasing need for products with recognisable and simple ingredients. We anticipate real interest in these naturally coloured capsules, particularly for nutraceutical formulations, such as dietary supplements. Customers can fill them with powders, pellets, or granules.”
– Selwyn Noronha, CEO of ACG Capsules
The portfolio includes a range of capsules that are free of titanium dioxide and are available in different options for gelatin and HPMC range.
Selwyn Noronha further explains, “As part of our unwavering commitment towards product quality and safety, we have worked tirelessly to deliver a new capsule to meet consumer demands for clean products. We are determined to deliver products that are of superior quality while meeting consumers’ varying needs. ACGcaps™ TSafe and ACGcaps™ NTone are available in options that have been Halal, Kosher, Vegetarian society, non-GMO and preservative-free certified.”
High-performance, sustainable packaging solution
The Nature MultiPack from KHS uses easily detachable adhesive dots to join beverage containers into a stable pack instead of shrink film, thus saving up to 90 percent packaging material. The environmentally friendly packaging alternative is now also available for high-performance filling.
Originally developed for PET bottles, the Innopack Nature MultiPack packaging machine was initially designed for an output range of up to 45,000 bottles per hour plus 20 percent over output. However, it quickly became apparent that the sustainable concept of using adhesive dots instead of shrink film to join beverage containers into a pack that was stable for transport but easy for the consumer to break up was also of interest to the can segment. In close cooperation with the Carlsberg Group, the solution was successfully launched in several European countries under the name “Snap Pack” as a four-, six- and eight-pack for cans.
As cans are filled in the high-performance range with a capacity of more than 100,000 containers per hour, the Innopack Nature MultiPack was previously too slow. Setting up two machines in a line, as at Carlsberg, was therefore only an interim solution: firstly because of the double footprint – one machine is almost 25 meters long – and secondly because of the double investment costs.
In order to meet the requirements of the beverage industry in the best possible way, KHS is now also offering the Innopack Nature MultiPack for the high-performance range. It can process up to 108,000 containers per hour at over capacity, while the nominal capacity is up to 90,000 containers per hour. Depending on the format, the line outputs up to 450 four-packs per minute.
“The innovations already start with the conveying speed, which we’ve increased from 51 to 72 meters per second compared to the previous machine. In order not to have to double the speed – which would have meant a considerable amount of extra work – the pitch has been reduced in the separating module. In this way, more units run through the machine and we achieve our target performance range.”
– Dr. Matthias Caninenberg, Head of Nature MultiPack™ Technology at KHS