“Sustainability: the New Manufacturing Imperative” | |||||||||||
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THE CONFERENCE AT PACK EXPO PROGRAM-AT-A-GLANCE | |||||||||||
Monday, October 15, 2007 | |||||||||||
UPGRADING OPERATIONS |
MATERIAL ADVANCES |
SUSTAINABILITY |
PROCESSING |
CONVERTING |
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8:30- |
Improving the Packaging Line from Throughput to Footprint |
Emerging Stand-Up Pouch and Other New Flexible Packaging Innovations from Japan |
Case Studies for Flexible Packaging Providing Improved Sustainability |
Hot Water for Sanitation |
Emerging Flexographic Plate Technologies |
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9:20- |
Improving Profitability of Packaging Operations Using Real-Time Performance Management Software |
Shapely Metal Containers: Passing Fad or Emerging Future? |
Sustainability as a Competitive Lever |
Use of PMO Mixproof Valve Technology to Increase Productivity in US Dairy Plants |
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10:10-10:50am |
KEYNOTE: | ||||||||||
COST SAVINGS |
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11:00- |
Technical Training Partnership: OEMs and End Users Working Together to Create Best Practices |
Knowing and Understanding the Hidden Costs in Your Packaging Operation |
Maximum Performance – Minimum Packaging |
Dannon Improves Efficiency Up to 40% Using High-Speed Video |
If the Horse You Are Riding Is Dead… |
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BRAND PROTECTION |
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11:50am- |
Key Rules to Get the Best Out of a Development Project |
Advances in Breathable Polymers |
Enhancing Sustainability Through Intelligent Packaging Design for Source Reduction |
Brand Protection in Packaging: Fighting Through the Noise |
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LUNCH |
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CONVERTING |
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1:30- |
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WEB COATING - Selecting the Correct Coater for Atmospheric Changes |
How to Automate and Secure the Printing Workflow Process |
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2:20- |
Predictive Maintenance: A New Tool for the Converting Industry |
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In order for the food, beverage and consumer packaged goods (CPG) industry to thrive, consumers in the U.S. and around the globe must be able to trust the brands they buy and the foods they eat. The United States has a tremendous track record when it comes to food safety, however, recent events have shaken consumer confidence in the safety, security and sustainability of the food supply. Working closely with policymakers and food and consumer products companies, GMA has developed a comprehensive program to help modernize our nation’s food safety net and bolster consumer confidence in CPG products and brands.
Description: Packaging companies are faced with a multitude of challenges when configuring and reconfiguring lines and plants, including the need for flexibility to accommodate the trend toward close coupling of machines to reduce footprint of systems and remove accumulation that buffers inefficiencies and adds complicated line controls. In addition, as plants increase the number of SKU’s, this need for flexibility and steady state, efficient throughput is increased. These challenges require a new breed of solution can in part be met with continuous flow technologies.
Description: This presentation will detail how using a Real-Time Performance Management platform can improve the profitability of packaging operations by increasing on-time quality product delivery; decreasing unplanned downtime; decreasing cost of lost production; decreasing labor cost per unit; decreasing cycle time; and increasing asset utilization.
Description: It’s time to let go of the adversarial vendor/end user relationships that often develop during capital projects. PMMI’s Technical Training Community of Practice is set up to identify and share effective training techniques and principles and implement them through training partnerships and joint initiatives. Registrants will get the first look at a Request for Proposal (RFP) template developed by the Community to facilitate communication between end users and manufacturers.
Description: When off-the-shelf won’t do and a development project is required, customers and suppliers become increasingly strained. Deadlines and budgets have to be met for products that often exist as a concept only. The presentation will highlight the key rules that need to be followed from both sides to make the concurrent development process a success. It is enriched with examples and lessons learned from past development projects and provides insight into the way machinery developers work. The critical phase of machinery ramp-up and lifelong functioning are covered as well.
Description: Now that single-serve stick packs from Japan are gaining traction in NA, you won’t want to be taken off guard by emerging innovations from this pouch-centric nation that could be the next to pop up on the domestic landscape. Learn about pouches that are as space-efficient as paperboard cartons and incorporate reclosure. Machinery options, fill speeds, relative economics and potential market segments where these and other new Japanese technologies could take hold will also be addressed. While the names of some of these innovations are strange (“SIP,” “EDGE STAND,” “PG TAPE”), few will complain if they result in advancing sustainability scorecards.
Description: The brand protection, sustainability and shelf impact of shaped metal containers will be detailed in this example-rich presentation, which will also cover the latest metal container shaping techniques, including segmented expansion, die expansion and hydraulic bladder expansion.
Description: This presentation will teach attendees how to identify and quantify the costs that contribute to the total cost of end-of-line packaging operations. An interactive CD-ROM tool, based on market data collected over 50 years, will be provided to each participant, allowing packagers to enter data specific to their operation. The tool will be loaded with industry averages against which the packager can compare their operational costs. The presenter will demonstrate the tool and walk through real-life industry examples. He will explain the mechanics behind how and why each expense bucket contributes costs to a packaging operation.
Description: According to a recent survey, consumers rank product freshness as a top concern and an important factor in maintaining brand loyalty. However, consumer trends toward convenient, minimally processed foods (such as fresh fish and cut fruit) make ensuring freshness more of a challenge for food processors and packaging converters, because these foods have more demanding requirements for high transmission of oxygen or water vapor. Technologies enabling packaging of foods with these more demanding requirements for breathability will be discussed.
Description: Sustainability has grown to be a top priority for many businesses. Many packaging producers struggle to understand how they can positively contribute to sustainability, especially given limitations of resources and stringent performance requirements they are being asked to meet. This presentation will provide an overview of sustainable packaging and will present numerous case studies illustrating the performance and sustainability advantages of various flexible packaging alternatives.
Description: Companies have a great opportunity to turn the pressure for sustainable packaging into profit. Not only can they make cost savings from energy/materials reduction programs, but also companies can use sustainability as a competitive lever to increase market share. Turning “green into gold” requires a true understanding of the commercial cost-benefit versus environmental impacts across the end-to-end supply chain, where packaging plays a crucial role. A true understanding of the “sweet spot” between consumer requirements, technical feasibility and commercial reality can lead to an increase in profit and improvement of our world.
Description: Alcoa Closure Systems International proposes to speak on the emerging trend of beverage manufacturers to reduce packaging cost by light-weighting PET bottle finishes that use “short height” closures. In addition to packaging cost savings, the changes can actually exceed current performance standards and are good for the environment, which also support corporate sustainability programs. Alcoa CSI will present case studies of recent beverage bottler conversion to “short height” closures for carbonated beverages. Historically, the global “short height” closure trend represents the first major closure redesign for carbonated beverages in the last 15 years. Information presented will include a conversion checklist to assess existing bottling lines, cost advantages of new PET bottle finishes and a description of capping system implications that must be considered.
Description:The best way to enhance sustainability is to reduce the amount of packaging used – to minimize the material used, we must optimize the “virtual vessel.” Consumer goods are distributed today on a platform that measures 40" x 48" and defines the footprint of a virtual vessel that is approximately 51" tall. This 57-cubic-foot virtual vessel has become the required unit of handling and distribution for most products. Most packages today are not developed to optimize their performance relative to this virtual vessel. Significant material savings are possible by doing intelligent package design for distribution concurrent with the design for protection, presentation and automation. This presentation explains both the impact of primary container geometry and secondary packaging design and material selection on overall material usage.
Description: Sanitation is a fact of life in food processing, and hot water for sanitation is one of the ten principles of sanitary design. This presentation covers the direct contact technology for heating water. The presentation will cover the basic theory of the direct contact technology, how it works and how it saves the food processor money. The presentation will cover a comparison between conventional-type hot water heating systems, such as steam boilers and heat exchangers, vs. the direct contact technology. It will also cover how the direct contact technology can save 40% in utility costs, operating costs and equipment costs.
Description: Traditionally, process piping systems in US dairy plants have been based on so-called manual swing- or flow-panel technology, as well as more automated double block-and-bleed systems. These systems have inherent disadvantages in terms of piping system cleanability and high product losses, as well as being “open” to the atmosphere, with the inherent chance of airborne bacteria contaminating the product. PMO-mixproof-valve-based systems are fully cleanable, minimize product losses, result in fully “closed” piping systems and can be prefabricated at the factory, thereby reducing site installation and start-up costs.
Description: The presentation will outline how Dannon was able to improve production efficiency using cutting-edge camera technology. Dannon states that “within the past 3 months, we have increased line efficiency from 45% to 85% and contribute much to the camera aiding them in troubleshooting. Sleever improvements have been most critical. Recently, we had a record run… we had been experiencing Sleever (supplied by Fuji) issues for several weeks; we even had to have people flown in from Europe, which was unsuccessful. With the camera, we solved this major issue in 30 minutes. I asked Fuji if they had a camera to solve these problems before delivering the equipment. The system paid for itself in less than a week. The Minster Plant is the 4th or 5th largest in the world.”
Description: Anti-counterfeiting and gray market diversion are hot topics in the packaging industry today, but what can YOU do about it? With so many different technologies and messages out there, how do you fight through the noise and find what is best for you? The Brand Protection Alliance was established to serve as a resource organization that will assist brand owners in designing, developing and implementing customized, secure solutions against consumer product counterfeiting and diversion. This presentation will help you get factual information about this topic and give you strategies of how to begin a brand protection plan and what technologies best fit in the packaging industry.
Description: Learn the typical coatings properties and the coaters used to apply the coatings for Atmospheric applications. The presenter will discuss why these coaters were selected and what their abilities are. He will help attendees understand the theory of operation, capabilities, and operational parameters of each coater. There are several possible combinations. The objective is to choose the right combination to cover all or most of your needs. To make this decision, several properties are evaluated for each formulation and coater selection. Coat weight, solids, density, viscosity, shear stability and a host of other criteria will all be addressed.
Over the last six decades, high vacuum roll-to-roll coaters have been designed for and successfully delivered to almost every region worldwide. The technology for creating higher barrier flexible packages has become a commodity. Therefore, in conjunction with the increasing demands for higher coating qualities and system productivity, system users are requesting continuous improvement of these parameters.
Description: Flexo trade shops, printers and converters are all looking for ways to improve operational efficiencies and reduce costs, while delivering the best possible product to the brand owners they serve. This presentation will introduce NEW options to deliver faster and improved color reproduction, while reducing the total cost of the flexo printed package. Through the adoption of a new, high-productivity digital flexo plate system-one that provides a remarkable step-change increase in print quality and has the potential to deliver the promise of offset-like print quality, process control and productivity. An overview of the technology, as well as print samples produced on a variety of substrates, will be included.
Description: Every flexographic printer should be educated on the alternative to mounting tape: Twinlock. Twinlock is a self-adhesive plate mounting sleeve that, after use, requires only a quick surface cleaning and, within 30 seconds, is ready to hold the next set of plates. Printers save time and money experiencing a quick ROI.
Description: In today’s competitive atmosphere, in an industry with overcapacity and small profit margins, manufacturers of folding cartons are coming to one simple fact. In order to be profitable, they must be either one or both of the following: be the low-cost producer (LCP) or a high value-added producer (HV-AP), or they will not survive. This discussion will address the following topics: why CP groups are sick of “me, too” bids; studies show companies who do not run efficient business for “commodity-type” cartons are not profitable and will either disappear or be acquired; companies who “run in the middle” (not LCP or HV-AP) are not profitable; companies who are LCP are profitable; companies who are HV-AP are profitable; and how to exploit today’s printing and converting technologies to fit in one or both groups. This seminar will be interesting, challenging and thought-provoking.
Description: Selecting and implementing an ERP/MIS system in a packaging environment is a large undertaking that can drive substantial benefits such as streamlining business operations, responding more rapidly to customer needs and providing immediate access to critical business information. In this informative session an ERP/MIS systems expert, with extensive experience in the packaging segment will provide an overview of ERP/MIS solutions for packaging. The benefits that can be achieved, and what to look for when considering a system, will also be covered.
Description: The latest trends and technological advancement in the field of automated proofreading will be explored, along with guidelines on how to automate and secure the printing workflow process. We realize that there is a battle with tight customer deadlines, cost-effectiveness and print perfection in this industry. Methods for automating and securing the entire workflow process can help companies save millions of dollars, increase productivity and protect themselves from major errors.
Predictive Maintenance: A New Tool for the Converting Industry
PANEL: Dr. L. Fenney, CEO, Sigmala Ltd; Mr. J. Round, Director, Sigmala Ltd; Dr. D. Brown, Reader, Institute of Industrial Research
MODERATOR: Ms. Yolanda Simonsis, Editor, Paper, Film & Foil Converter
Description: Downtime is the enemy in converting. New artificial intelligence methods have been developed at the Portsmouth Institute of Industrial Research which allow large amounts of machine data to be accurately processed in real-time. This allows true predictive diagnostic and predictive maintenance functions to be successfully implemented in converting machinery.