Greencore Group plc (‘Greencore’ or the ‘Group’), a leading UK manufacturer of convenience foods, is delighted to announce that, in partnership with the Co-op and Sainsbury’s, it will soon commence ‘test and learn’ trials of an all fibre plastic free recyclable sandwich skillet in stores across the UK.
The packaging, developed in conjunction with ProAmpac and believed to be the first of its type in the world, marks the culmination of 18 months of research and development by Greencore. The skillet will have a plastic-free window and be made entirely from paper-based material; crucially, due to the precise level of moisture resistance the skillet provides, it will see products have the exact same shelf life as if they were they packaged in a traditional skillet.
Data shows that consumers currently find it challenging to separate the plastic film from the packaging of a typical sandwich skillet, meaning that recycling rates are nowhere near as high as they could be. The new skillet’s all-paper construction will make the process much easier for consumers. Subject to successful trials, which commence in September 2021, and the proposition meeting all parties’ performance criteria, roll-out of the new packaging will begin later in the year. In time, Greencore expects to make these new packaging techniques available to the wider UK market.
Development of the fully-recyclable skillet sees Greencore deliver on one of the key commitments outlined in its 2020 Sustainability Report. The Sustainability Report also contains a range of pledges across the areas of sourcing, manufacturing, and community engagement. Further commitments include:
- All surplus product will be donated to local communities by 2022
- A deforestation-free supply chain by 2025
- All raw materials will be sustainably sourced by 2030
- Product development will be equally split between animal protein versus plant-rich alternatives by 2030.
It is estimated that some 600 million pre-packed sandwiches are consumed in the UK every year, or just over 1,100 every minute. Should the fully-recyclable skillet ultimately be adopted as industry best practice, the potential for significant reductions in plastic usage and in improved recycling rates is immense.
The DS Group is committed to the mission of Green enabling by Social, Structural and Economic transformation that will drive sustainability in its business. As a committed corporate citizen, the Group aims to create a closed loop system that minimizes the use of resources, creation of waste, pollution and carbon emission. The use of R PET in popular confectionery brand ‘Pulse’, the leader in hard boiled candy segment is a small step towards environment sustainability and circular economy. The PET Jar is made from a combination of virgin and recycled PET granules, which means that the waste from eco system is being reused into packaging and not burdening the planet. The company is also targeting Industrial ecology and blue economy by working towards reducing resource depletion and environmental pollution.
In last few decades the consumerism has increased at an exceptional pace and so has the quantum of waste that has led to an environment mayhem. The reuse of goods and waste utilization is negligent in the production-consumption cycle. Packaging is an unavoidable part of this development, as it protects, preserves, enhances, disperses information, acts as a marketing tool and allows for safe transportation. The packaging sector is a large user of the plastic and the increasing environmental pressure on the economic system requires a reconsideration of our economic paradigm. It is imperative that it consciously shifts its consumption preferences to recycled and reusable material. The world is heading towards an “ecological credit crunch” and is under severe ecological debt as we are over-utilising the natural resources without replenishing, and this crisis is far worse than all the financial and health crisis mankind has ever faced. This urges societies, corporates around the world to increase the efficiency of natural resources use and to reduce the overall environmental impact. Reusable, recycled packaging has been suggested as an option to significantly reduce environmental impacts.
Business objectives drive mold development.
At TricorBraun, our commercialization team’s first priority is to develop molds that are commercially viable for the duration of your product cycle. In other words, mold development takes into account the lifecycle of your package. In addition, the development timeline and cost can vary depending upon your projected annual volume and market strategy.
Once we understand your market strategy, we’ll factor in other build requirements as well—including manufacturing process and material requirements. From there, we’ll get to work in-house or identify the outside vendors best equipped to handle your mold development. We have a robust network of partners in North America, Asia, and South America. We aim to identify manufacturing partners with the appropriate qualifications, technical know-how, and equipment to build your mold.
TricorBraun’s unique value add: in-house mold building.
A rarity among packaging distributors, we offer in-house mold development and a production tooling shop. Because of this, we can control the timeline and build single or multi-cavity extrusion blow molds faster than most. Our onsite team includes experienced mold designers, tool path programmers, machinists, final assembly, and machine maintenance. Our customers appreciate the flexibility and speed to market that this value-add yields.
In fact, floor care industry leader Bona couldn’t say enough about our in-house team. “Our goal was to maintain and enhance the visual appeal of the products while also improve functionality and enhance the overall consumer experience,” said Susan Stern, Bona’s director of product management-retail. To achieve Bona’s business goals, we leveraged our in-house team to create four bottle molds. The Bona team opted to create prototypes first for the largest and smallest bottles, allowing them to make adjustments on the first two so that fewer modifications would be needed on the in-between-sized bottles. All four molds were built in-house at our Mold Development Center, which helped expedite the qualification process and bring the bottles to market. Bona’s Stern called TricorBraun’s engineering capacity “priceless” as the finished product produced bottles with comfortable grips and easy, no mess pours.
We sweat the details so you don’t have to.
From our design and engineering expertise to our mold shop, we have the experience and in-house capabilities to take you from concept to commercialization. Add in our extensive supply chain and best-in-class project management, and we’ve got your back every step of the way.
At TricorBraun, our customers don’t stay up at night because we do. We sweat the details, whether we’re designing your package, building your mold, or qualifying your package and getting it out the door. We support and oversee the entire process so you can have the confidence that you are partnering with a team committed to your success.
As the Trieste business explained, its latest series offers manufacturers a range of natural solutions to suit a variety of food and drink applications.
The Inspiring Fruits collection consists of essences, natural named flavours, and depictable flavours, including pear, sour cherry, peach, strawberry, raspberry, and blackcurrant.
As the essences are made using only high-quality raw materials, there are multiple labelling options for manufacturers, including clean-label, being displayed on-pack, and natural named flavours, which meet the new standard for organic-suitable flavours as set by the EU under regulation 2018/248.
With requests for provenance and transparency increasing, Synergy has also worked closely with suppliers to offer British provenance with the raspberry, strawberry and blackcurrant essences.
Drawing on over 130 years’ expertise of its Italian production site, Synergy’s proprietary process uses steam distillation to capture the aroma, or ‘essence’, of the raw material and preserve the authentic taste of natural fruits at their peak. The essences are suitable for a range of products, including beverages (juices, nectars, fruit waters, spirits, hard seltzers), dairy products (yogurts and ice creams), and desserts, whilst the natural flavour options offer further flexibility for manufacturers.
Using this approach, Synergy has been able to capture and enhance the best aromatic notes that are associated with each fruit. For example, in the sour cherry essence, this means efficiently extracting ‘dark’ aromatic compounds that are characteristic of the sweetness within a cherry’s flavour, and for the strawberry product, capturing the ‘jammy’ notes that are typical of ripened strawberries.
Eric Zabiolle, General Manager of Southern Europe, Synergy Flavours, commented: “Manufacturers are innovating and catering to demand from consumers for more natural
ingredients across food and beverage products. At Synergy, we use a blend of art, science and insight to capture and preserve the best of what nature has to offer, so that we can provide our customers with tailored solutions whilst keeping product labels as ‘clean’ and natural as possible.
By developing these essences, natural named flavours, and depictable flavours, we’re able to provide a true-to-nature range that offers authenticity and flexibility to meet the demands of today’s consumers. All of our solutions, including our wider Synergy Pure range, are easily tailored to meet specific taste challenges, and this is something we work on closely with our customers.”
The company’s plans were confirmed earlier this year, when it announced it would be restructuring some of its American sites, which also involved the closure of a further manufacturing facility based in Atlanta, Georgia, shifting production to other locations in the country.
As the business previously explained, the move – which the company explained to Confectionery Production impacting around 600 staff in New Jersey at its Nabisco site that had operated for decades, comes as the business seeks to re-focus its biscuit manufacturing to meet changing consumer demands.
A spokesperson for the US business stressed that it had offered a range of support measures for those affected by the move, through supporting them find other roles across the company, as well as in delivering career support for those who would be leaving the business.
Consequently, the company said it will re-purpose its US biscuit operations with owned-and-operated bakeries on the East Coast, Midwest and West Coast in Richmond, VA, Chicago/Naperville, IL, and Portland, OR. These owned-and operated sites will be further supported by US-based external manufacturing, which has been an important part of the company’s regional biscuit manufacturing network for many decades.
The company has previously stated it was considering closure of its New Jersey and Atlanta sites last November, as they were no long considered strategically significant locations. It acknowledged that both sites face significant operational challenges, including declining infrastructure and outdated production capabilities, which would have required significant investment to bring them to the modernised state.
“This was not an easy decision to make, but as we continue to strengthen our leadership in snacking and address changing consumer behaviours, we must focus on sites that are best positioned to meet our future needs,” said Glen Walter, Executive Vice President & President, North America on its original decision.
“We understand the impact this will have on our colleagues at these bakeries, many of whom have been
with our company for many years, and we will dedicate ourselves to working with the unions and our
employees to ensure that they will be cared for and supported through this transition.”
As part of the move, the Oreo manufacturing “Line of the Future” and Oreo cookie grind production currently in Fair Lawn will be moved to the company’s biscuit bakery in Richmond, VA.
Mondelēz International has a significant business presence in the United States, which is the largest market for the company globally, including its global headquarters in Chicago, Illinois and North American headquarters in East Hanover, New Jersey.
According to the company, its latest edition is ‘designed for all your extraterrestrial and earthly travels,’ featuring intergalactic, aluminium packaging, and is filled with the blue and purple candies you know and love from the brand, featuring Pineapple Passionfruit, Raspberry and Berry Punch.
“SKITTLES is always looking for ways to surprise fans, both earthlings and extraterrestrials, with shocking innovation,” said Fernando Rodrigues, Mars Wrigley Senior Brand Manager for Skittles. “We’re thrilled to bring better moments to fans by marking Skittles’ first trip to space with limited edition packs and look forward to pushing the boundaries of confectionery space exploration.”
As the company added, fans can follow Skittles for details on how they might be lucky enough to get their hands on the limited edition Zero-G packs later this summer.
Furthermore, as part of the brand’s expansion into extraterrestrial confections, the brand added that it is proud to make a donation to the Smithsonian’s National Air and Space Museum in support of inspiring the next generation of innovators and explorers.
AIPIA returns to the virtual stage for its two remaining Congresses for 2021. Both are carefully focused, covering the highly important and topical issues of Supply Chain Solutions (16th September) and the whole spectrum of Digitization: Connected Packaging & Sustainability (2nd November.) Each will address how these issues are impacting on current Smart Packaging development and use.
In November there will be an special emphasis on where Smart Packaging is making a positive contribution to more Sustainable solutions and contributing to reducing waste, better food safety and security, as well as improving ways to achieve a truly Circular Economy for plastics.
Both events already boast a strong line up of leading Smart Packaging product and service providers. These include Aptar CSP, Cambridge Design Partnership, Digimarc, Dimaco, Scantrust, Systech, Talkin’ Things, Tapwow, and Wiliott. Several other leading active and intelligent packaging technology providers are set to join shortly and a provisional agenda for September will be published on line soon. As usual this will be a ‘real time’ agenda and updated as speakers confirm.
Setting out the rationale for the two Congresses, Eef de Ferrante, managing director of AIPIA explained, “We consulted with our Advisory Board and other leading members who are developing or using the technologies and these topics came out as clear areas of primary interest. The pandemic has highlighted many ‘pain points’ in supply chain management, not least to do with distributing PPE and now vaccines. How to harness the full potential of Connected Packaging using digital solutions and making it work in a Sustainable environment is a challenge which many on both sides of the AIPIA community – developers and users – are keen to address. As usual with AIPIA, we aims to go beyond explaining the tech to understanding its impact and how best to apply it commercially.”
Real ‘use cases’ will be featured to illustrate how Smart Packaging is benefiting food, beverage, cosmetics and pharmaceutical markets already. They are an opportunity to listen to and learn from many of the leading exponents of Smart Packaging solutions, as well as network with them and Brand Owners in Discussion Rooms. AIPIA is using a ‘user friendly’ virtual meeting platforms to deliver value and an effective meeting environment for everyone.
While the Association looks forward to getting back to Person-to-Person in 2022 the pace of developments in Smart Packaging continues to accelerate continuously. So these two virtual opportunities for 2021 should not be missed!
Particularly soda and water bottles of all shapes and sizes. Scientists have been looking for ways to cut down on this waste and a study for Green Chemistryshows it may now be possible. Using genetically-modified bacteria, a team at Edinburgh University in Scotland, has been able to convert PET plastic waste into vanilla flavouring.
Previous studies have demonstrated that it is possible to break down PET into its basic subunit, known as terephthalic acid (TA). The researchers in Edinburgh discovered that E. coli bacteria can be “deployed” in order to convert TA into vanillin. Vanillin is the main component of extracted vanilla beans, and it’s responsible for vanilla’s signature taste and smell. It has a very similar chemical composition to TA, and so the engineered bacteria only needs to make minor changes to the number of hydrogens and oxygens that are bonded to the same carbon backbone.
The researchers mingled their E. coli with TA and kept them at room temperature for a day, in roughly the same conditions used for brewing beer. After process optimization, around 79% of the TA was converted to vanillin.The team believes it may be possible to increase this percentage. Also they believe that this vanillin would be fit for human consumption, but further tests are required.
Joanna Sadler, first author and BBSRC Discovery Fellow from the school of biological sciences, University of Edinburgh, said, “This is the first example of using a biological system to upcycle plastic waste into a valuable industrial chemical. It has very exciting implications for the circular economy.”
Stephen Wallace, also of the University of Edinburgh, added, “Our work challenges the perception of plastic being a problematic waste and instead demonstrates its use as a new carbon resource from which high value products can be made.”
One million PET bottles are sold every minute around the world, but just 14% are recycled. Currently the recycled ones have limited ‘second use’ opportunities, although much work is being done by the industry to ameliorate this situation. The plastics lose about 95% of their value after a single use, so the ability to upcycle into more lucrative materials could make this recycling process far more attractive and effective.
There is a shortage in supply of vanillin, which is found in a wide variety of food, cosmetic, pharmaceutical, cleaning, and herbicide products. In 2018, the global demand was about 40,000 tonnes and is expected to grow to 65,000 tonnes by 2025 which “far exceeds” the vanilla bean supply. About 85% of vanillin is currently synthesized from chemicals derived from fossil fuels – and this new experiment offers another way to do that, at a potentially viable level.
Company also will demonstrate its servo-driven HQ Series counting & dispensing machines, providing 100% accuracy for primary or secondary packaging of candy, confectionary and non-food products.
Building on consumer demand for sustainable ring carriers, the new WaveGrip cardboard carrier is lightweight, strong and easy to use, providing the same levels of pack retention as plastic. Each carrier weighs under 7g for a standard six-pack and is recyclable in all paper and board waste collection streams.
The white fully coated top side offers high quality printability in up to 10 colours, allowing brand messages and promotions to be easily included for enhanced shelf impact. In addition, the naturally brown reverse opens-up to offer a multitude of additional design possibilities and enable further direct communication with customers.
The new carrier style is available for both standard and sleek cans and unlike many competitive products, its patent pending design does not require folding and manipulation during application. This allows continuous running at high speeds, meeting both the performance and production needs of the latest beverage canning lines.
Applicators are competitively priced and range from simple, manual solutions to more integrated higher speed options. Planned developments also include the addition of an integrated advertising panel option for increased on shelf marketability.
Darryl Roadnight, Business Director at WaveGrip said: “Our new cardboard carrier meets the growing consumer demand for easy to recycle packaging and its unique design delivers both performance and sustainability that today’s brands are seeking.
“We are delighted to add this solution to the WaveGrip range and deliver even more choice in the effective, efficient and sustainable packing of beers and beverages around the world.”