The winners of the prestigious ‘Tube of the Year 2024 Award’ of the European Tube Manufacturers Association (etma) have been announced. The voting took place on 23 May 2024 at etma’s annual conference in Warsaw. A seven-member jury from among the member companies selected the best tubes in the categories aluminium, plastic, laminate, prototypes and sustainability. Time and again etma’s annual competition demonstrates the creativity, innovative strength and performance of the European tube industry. Beyond the borders of Europe, the award sets global standards for pioneering and sustainable packaging solutions of the highest quality.

Etma’s Secretary General, Gregor Spengler, was extremely satisfied with the quality and results of this year's award: ‘European tube manufacturers have once again demonstrated their strong innovative strength and creativity in this year's competition. This is demonstrated not least by the large number of tubes submitted for the competition in the prototypes category. I am particularly pleased about this, as I see it as an indicator of the wealth of ideas of our member companies, which is a guarantee for the future viability of tubes as a packaging material.’ 

This year's winner in the aluminium tube category was a Chanel tube produced by Tubex Aluminium Tubes. Building on the success of its popular Chance fragrances, Chanel has launched a limited-edition set of three Chance hand creams. The delicate, refreshing creams feature the familiar floral scents of Chance, Chance Eau Fraiche and Chance Eau Tendre. Each Tube is decorated in a soft pastel shade that matches its perfume counterpart and reflects the brand’s sophisticated style. The design is rounded off with a pearlescent finish and an elegant octagonal closure. The creams come in a sleek box containing all three scents. Besides their chic aesthetics, the tubes are also highly sustainable: Chanel chose the manufacturer´s Blue Tube Evo, which was the world’s first tube to be made of 100% recycled aluminium. The innovative material uses 95% PCR content, is infinitely recyclable and significantly reduces carbon emissions. For a brand built on the notion of timeless beauty, it made perfect sense to choose stylish, eco-friendly packaging designed to close the packaging-to-packaging loop.

The jury chose a tube from L'Occitane, produced by Albéa, as the winner in the laminate tube category. L'Occitane was founded in Provence in 1976 and its cosmetic products are made in the south of France using essential oils and natural ingredients, combining tradition and innovation. Today, the company has more than 3,000 points of sale in more than 90 countries. L’Occitane has collaborated with Albéa to revamp the packaging of its 30 ml iconic hand cream collection, starting with the shea butter version. The transition involved shifting from an Aluminium Barrier Laminate (ABL) tube to a Greenleaf tube, an APR-certified solution with a multilayer sleeve in HDPE, thereby replacing the former ABL tube. For the cap, L’Occitane turned to Albéa’s EcoTop technology featuring OctoTop, a 2-in-1 flip-top closure system with the iconic octagonal shape synonymous with L’Occitane, eliminating the need for a peel seal. 
 
By using the OctoTop opening system and Greenleaf sleeve, the number of materials was reduced from 5 to 2 and the components from 3 to 2. This consequently decreased the overall tube weight by 23% compared to the current one, while enabling the entire tube to be recyclable in existing recycling streams in France, Europe and the United States.

First place in the plastic tube category went to the Decathlon Active Solaire Sun SPF50 sunscreen tube from Albéa. Decathlon is a sports brand that wants to enable as many people as possible to enjoy sport. Founded in 1976 by seven friends near Lille, the concept was a revolution at the time: a retail space dedicated solely to sporting goods, from clothing to equipment, at affordable prices. Today, with over 100,000 ‘teammates’ in more than 1,700 stores and over 70 countries, the company offers sports equipment for over 80 sports. Decathlon has chosen Albéa to produce the tubes for its Active SolaireSun SPF50 sunscreen. The sports retailer has opted for a PCR Max tube which integrates 70% post-consumer recycled material (PCR) in the sleeve. This PCR sleeve is combined with the manufacturer‘s EcoFusion Top which represents a fusion of the head and cap for further weight reduction. The EcoFusion Top innovation is achieving an 80% weight reduction compared to a standard head and cap solution. The tube is monomaterial and ready for recycling in the HDPE recycling stream.

A tube from the Swiss manufacturer Hoffmann Neopac won in the prototype category. The innovative concept and its successful realisation convinced the jury. The company introduces the world’s smallest child-resistant tube, marking a breakthrough in compact and secure packaging. The high-barrier tube eliminates the need for additional blisters. It comes in diameter 10 mm with 0.30 wall thickness for 0.4 – 2 ml content. The cap is a two-part composition PE/POM, the child resistance is tested in accordance to US 16 CFR § 1700.20 and EU ISO 8317. Additionally, the tube can be fitted with a dropper insert for precise dosing. Decoration options are a coloured tube body, low-migration offset print and varnishing. Lightweight and ergonomically designed, this tube meets the needs of pharmaceutical, consumer and animal health sectors, produced under ISO 8 cleanroom conditions for highest cleanliness in Switzerland and in the US. The result is a standout primary packaging solution offering the highest level of protection, maintaining a professional look and strong brand identity.

Finally, the EcoLittle Top Tube was the winner in the Sustainability category. It is produced by Albéa for Clarins, a French company that is recognised as the number one for premium skincare in Europe and stands for responsible beauty with its innovative and natural products in around 150 countries. Clarins and Albéa have been collaborating on the EcoLittle Top system. The new flip-top closure, adapted to the sample format, responds to the triple CSR challenge of recyclability, weight reduction and the use of recycled materials. Aligned with the CSR commitments of both brands, EcoLittle Top reinvents Clarins samples. Clarins will be upgrading the range of sample tubes with EcoLittle Top, the latest addition to Albéa’s EcoTop range. Thanks to the removal of one component, the EcoLittle Top offers a 47% weight reduction on the complete tube. In line with Clarins’ and Albéa’s commitments to circular economy, the tube incorporates 45% recycled material, thanks to the manufacturer’s PCR Max range. The PCR PE solution combined with EcoLittle Top in HDPE is therefore monomaterial, making it recycable in HDPE streams. The incorporation of recycled plastic reduces the amount of virgin plastic used to produce the tubes.  

„Our globally recognised “Tube of the Year” competition is always an internationally renowned benchmark and trend indicator for current and future developments in the tube industry,” said etma Secretary General Gregor Spengler in his concluding remarks. „Unsurprisingly, sustainable and resource-efficient packaging solutions are still at the centre of the competition. 
 
In particular, improved recyclability, further material reductions and the increased use of recycled materials should be mentioned here. However, smaller tube formats are also in vogue, reflecting social developments such as rising mobility and the trend towards single households. And in view of all these aspects, the tube is increasingly proving to be the tailor-made and contemporary packaging of the future.“
 

Transaction marks new chapter in the future development of IBG, enabling the company to accelerate growth and enhance capabilities.

Paris, France – IBG (Innovative Beauty Group), a leading global beauty solutions provider, has been acquired by Fremman Capital, a prominent European private equity firm. The strategic acquisition begins a new chapter for IBG, as the company departs from its previous shareholder, Albéa Group. The transaction also marks a major milestone in the future development of IBG, enabling the company to accelerate its expansion and enhance its innovative capabilities across a range of market segments. 

Fremman Capital is known for its strategic investments in high-potential companies and its commitment to fostering growth and excellence. The firm’s focus on sustainability and innovation aligns closely with IBG’s core values and business practices.

Supported by Fremman, IBG will have the support and resources needed to flourish in the beauty and personal care market, opening new strategic opportunities. As before, IBG will continue to develop turnkey solutions for the beauty brands and retailers under the Orchard Custom Beauty brand, supported by the recent acquisition of Roberts Beauty. Additionally, it will continue to pursue the development of its innovative packaging solutions under its FASTEN Packaging brand while also continuing to develop its own brands in collaboration with retailers or celebrities. Each of these business lines will feature a strong focus on supporting IBG customers to reach their sustainability ambitions.

"IBG is a leader in the beauty industry with a strong track record of innovation and sustainable business practices," said Olivier de Vregille, Co-Founder at Fremman Capital. "We are excited to support IBG in its next phase of growth and to work together to drive further advancements in beauty and personal care offerings."

“We extend our utmost gratitude to Albéa Group for their support and collaboration over the years,” said Xavier Leclerc de Hauteclocque, CEO of Innovative Beauty Group. “In this next chapter, we look forward to a bright future with Fremman Capital, a partner that shares our values and passion for people and service.  As always, we remain dedicated to delivering exceptional beauty products and packaging solutions to our valued clients across the globe.”

IBG clients, partners and employees will experience no disruption in service during this transition. The company remains committed to maintaining the highest standards of quality, innovation and customer service that have been a cornerstone of its success.
 

Company’s Process Analytical Monitoring (PAM) Moisture Control 
system provides 100% inspection of food items, while offering 
production process optimization and intuitive operation.   

Northern District, Israel – Yoran Imaging, which develops and supplies thermal imaging systems to optimize filling and heat-sealing processes on packaging lines, will debut a system for inline moisture control and process optimization at Pack Expo, November 3-6 in Chicago. At Booth LU-8847, the company will offer live demonstrations of its new Process Analytical Monitoring (PAM) Moisture Control solution, which utilizes thermal imaging technology to provide 100% moisture monitoring, and continuously oversees the overall process to maintain defined moisture level boundaries. 

Yoran Imaging’s PAM Moisture Control system is a robust step up from two common methods of moisture control. For food brand owners utilizing moisture control inspection via sampling, Yoran’s inline, 100% monitoring system yields immediate and substantial upgrades to both inspection comprehensiveness and, by eliminating the need for inspection-related line slowdowns and stoppages, production output. For companies already using inline inspection via spectroscopy, PAM Moisture Control provides a significantly simpler system for operators, as well as enhanced process control that can virtually eliminate unscheduled line downtime.

Through a passive process that requires no direct product contact, the PAM Moisture Control system converts recognized moisture content into corresponding thermal images. The system then generates this information into useful moisture and process control data, helping operators keep the line within specified moisture contents while recognizing any desultory trends that, should they continue uncorrected, could bring the line out of spec.

The system’s elevated inline moisture and process control capabilities lean on sound science: water molecules vibrate vigorously when absorbing infrared light. This allows the thermal imaging-enabled system to determine a product’s moisture content with exceptional precision – and, from there, display these findings in a user-friendly HMI setup. As the PAM Moisture Control system continues inspecting each and every product, it also recognizes developing trends, indicating the need for preventative corrections that prevent small issues from becoming larger, line-stopping ones. 

In being among the first to utilize thermal imaging technology specifically for moisture control processes, Yoran Imaging aims to bring food industry customers a set of layered benefits. For starters, it eliminates outdated sampling and single-purpose spectroscopic sensors through cost-effective, comprehensive and contact-free inspection of each product, vastly decreasing the likelihood of defective products entering the market. 

At the same time, productivity also can be considerably increased, with user-friendly data alerting operators when preset quality or OEM parameters are degrading, providing guardrails and guideposts that minimize machine downtime through informed preemptive measures. Helpfully, the company’s systems also occupy a small footprint and are easily integrated into a wide range of production line configurations. 

About Yoran Imaging
Specializing in the food & beverage sector, Yoran Imaging utilizes cutting-edge thermal imaging technology to revolutionize the filling & heat-sealing process on packaging lines. Drawing upon more than two decades of thermal imaging inspection experience, the company’s solutions provide non-invasive, 100% in-line inspection combined with production-optimizing data collection and analysis. This real-time sealing data allows for enhanced predictive maintenance, reduced labor investments and minimized materials and product waste.

Yoran Imaging’s groundbreaking Process Analytical Monitoring system replaces inadequate manual sampling with comprehensive product inspection, provides unprecedented levels of packaging line insight, and preempts production failures before they occur. The result is dramatically heightened brand protection, smarter manufacturing processes, and a more efficient packaging operations.
 

With the growing need for sustainable alternatives in the packaging industry, bioplastics have emerged as a promising solution. As we strive to replace conventional, highly polluting plastics, it's essential to understand the benefits and limitations of bioplastics in packaging.

What Are Bioplastics in Packaging?

Bioplastics in packaging are often confused with biodegradable and bio-based plastics. To clarify:
- Bio-based plastics are derived from plant materials rather than oil. However, they are not necessarily biodegradable, compostable, or recyclable.
- Biodegradable plastics can decompose naturally and can be plant-based or petroleum-based.
- Compostable plastics are defined by ASTM International as plastics that degrade through biological processes during composting, leaving no toxic residue.1

It's crucial to note that all compostable materials are biodegradable, but not all biodegradable materials are compostable.

Composting Bioplastics in Packaging

Many bioplastics are marketed as compostable, but they often require industrial composting facilities with specific conditions, such as higher temperatures and specialized microorganisms. This makes them unsuitable for home composting.

Disposal of Compostable Bioplastics in Packaging

Disposing of compostable bioplastics correctly is vital:
- Recycling Bins: Compostable bioplastics can contaminate recyclable plastics.
- Compost Bins: Home compost bins are not suitable for industrially compostable bioplastics.
- Trash: Unfortunately, the only viable option for many is the trash.

The lack of widespread industrial composting facilities means that most compostable bioplastics still end up in landfills.

Benefits and Challenges of Bioplastics in Packaging

Bioplastics offer an alternative renewable source of production, reducing the reliance on fossil fuels and potentially lowering greenhouse gas emissions. However, the cultivation of plant sources for bioplastics involves high inputs of water, pesticides, and fertilizers, which can have environmental drawbacks.

The Future of Bioplastics in Packaging

The production and use of bioplastics involve multiple trade-offs. While they offer benefits over traditional plastics, their environmental impact depends on proper implementation and infrastructure. Improved technologies and advanced execution methods are necessary to maximize the benefits of bioplastics in packaging and minimize their drawbacks.

In conclusion, bioplastics in packaging present a potential solution to the plastic pollution problem, but they are not a perfect fix. The key lies in continued innovation and the development of infrastructure to support their proper disposal and composting.
 

Ever feel like you're wrestling giants? When it comes to bulk materials, that's exactly what it can feel like. From towering silos to overflowing bags, storing and packing these materials efficiently can be a challenge. However, there's nothing you should worry about. Here's your guide to optimizing bulk material storage and packing, turning those industrial titans into your loyal companions.

Know Your Bulk Materials

Before you explore various bulk storage buildings, make sure you understand the nature of bulk materials. These come in a vast array of shapes and sizes, from fine powders to chunky granules. Each type has unique characteristics that influence how you store and pack it. Below are some things to remember:

Flowability

How easily does the material move? Free-flowing materials like sand require less specialized storage than cohesive materials like sticky clays.

Degradation

Does the material deteriorate over time? Materials sensitive to light or moisture need specific storage environments.

Segregation

Does the material separate during handling? Materials with different particle sizes can segregate, impacting consistency.

By understanding these properties, you can choose the most appropriate storage and packing solutions.

Choose the Right Storage Solutions

Now that you've sized up your materials, it's time to pick the perfect storage containers. Here's a comprehensive rundown of popular options to match your needs:

Silos

These giants are ideal for large quantities of dry, free-flowing materials like grain or sand. Silos often come equipped with built-in loading and unloading mechanisms, making them efficient for large-scale operations. Consider investing in weatherproof silos for outdoor storage to protect your materials from the elements.

Hoppers

Similar to silos but smaller, hoppers are funnel-shaped containers that dispense materials through a controlled opening at the bottom. Perfect for metered dispensing of materials onto conveyor belts or into mixing stations. For some hopper applications, you might also consider installing agitators to prevent material bridging (clumping) within the hopper, ensuring a smooth flow during dispensing.

Totes and Drums

These versatile workhorses come in various sizes and materials (plastic, metal) to suit your needs. They're great for storing smaller quantities of bulk materials and offer easy stacking for maximizing storage space. Opt for nesting totes if you have limited space, as they can fit inside each other when empty, saving valuable storage for real estate. Lidded drums provide an extra layer of protection for moisture-sensitive materials or materials prone to spills.

Lightweight Maintenance Enclosures

While not strictly a storage container, a lightweight maintenance enclosure can be a valuable asset for protecting equipment and materials during maintenance or repairs. These portable structures are ideal for field use and provide a temporary work area shielded from the elements. They come in various sizes and can be easily assembled and disassembled for quick deployment.

Selecting the appropriate storage solutions will help you make the most of your available space and maintain material integrity.

Implement Essential Storage Solutions 

Once you've chosen your containers, it's time to create a storage strategy that protects your materials and keeps your operation running smoothly.

Pick the Storage Location Wisely

Consider the material's properties when choosing a storage location. For instance, keep moisture-sensitive materials like fertilizer indoors or in covered areas. Likewise, store materials prone to degradation by sunlight away from direct light. Ideally, your storage area should be dry, well-ventilated, and free from pests.

Labeling Like a Boss

Clear and consistent labeling is crucial. Include the material type, weight, date of storage, and any handling instructions. This saves time during retrieval and ensures everyone on the team knows exactly what they're dealing with. Consider using a color-coding system for different material types or hazard levels to add another layer of clarity to your labeling.

Stacking Smarts

Don't turn your storage area into a precarious leaning tower of containers. Follow weight restrictions and stack heavier containers on the bottom tiers. Utilize stacking aids for added stability, especially for bagged materials. Leave sufficient aisle space between stacks to allow for safe and efficient movement of equipment and personnel.

First In, First Out (FIFO)

Implement a FIFO (First In, First Out) system to prevent older materials from getting buried and expiring. This is especially important for perishable or time-sensitive bulk materials. Date labeling your containers becomes even more crucial with a FIFO system. Regularly rotate your stock to ensure the oldest materials are used first.

By following these storage solutions, you'll ensure your materials are well-organized, protected, and easily accessible when needed. This approach not only maximizes efficiency but also extends the lifespan of your materials.

Conclusion

With these steps in mind, you can transform your bulk material storage and packing from a chaotic scramble to a smooth and efficient operation. Remember, well-organized storage systems not only save you time and money but also minimizes the risk of damage and ensures your valuable materials reach their destination in top condition. So, take a deep breath, assess your materials, and start building your optimized bulk material storage empire!

Fully automated system producing unidose nasal spray devices
 for Naloxone, the life-saving opioid overdose drug.

Mount Vernon, NY – TurboFil Packaging Machines LLC, an equipment specialist dedicated solely to the design and development of liquid filling and assembly machines, is collaborating with Bridgewater, NJ-based Amneal Pharmaceuticals to develop an advanced automated assembly and vial filling machine for unidose liquid nasal devices. TurboFil’s state-of-the-art system will be utilized by Amneal to produce naloxone doses, the life-saving drug used to counteract opioid overdoses. 

Earlier this year, the U.S. Food and Drug Administration (FDA) approved the over-the-counter sale of naloxone hydrochloride nasal spray, USP, 4mg, which is the generic version of Narcan® and is used in the treatment of a known or suspected opioid overdose emergency. 

TurboFil’s system features advanced inspection capabilities to ensure each device performs its critical, time-sensitive mission. The machine's precise and flexible design includes state-of-the-art technology to meet or exceed required accuracy tolerances. The machine combines classical mechanics with modern technology to assemble these devices with precision. 

“We are excited to work with TurboFil on this project. Their advanced technology and expertise will help us advance our production capabilities and expand access to this crucial medication,” said Jiten Parikh, Senior Vice President of Operations for Amneal Pharmaceuticals. 

“Intranasal administration devices are among the fastest-growing forms of drug delivery, and we’re proud to work with Amneal in their mission to expand availability of a drug on the forefront of the urgent fight against opioid-related deaths,” said Deborah Smook, VP of Marketing & Business Development for TurboFil Packaging Machines LLC. 

About TurboFil Packaging Machines LLC 
TurboFil is an equipment specialist dedicated solely to the design and development of liquid filling and assembly machines for the pharmaceutical, medical device, health & beauty and chemical industries. Since its inception in 1999, the company has created novel, durable production solutions for some of the industry's most challenging applications, consistently setting new benchmarks for filling precision and operational simplicity. 

TurboFil's equipment portfolio features a broad range of standardized equipment, and the company also frequently collaborates with customers to develop, design and construct customized, built-to-spec machines. This versatility has made TurboFil a leader in supplying reliable, efficient and cost-effective filling and assembly systems that fit seamlessly into existing operations. For more information, visit www.TurboFil.com. 

About Amneal 
Amneal Pharmaceuticals, Inc. (Nasdaq: AMRX), headquartered in Bridgewater, NJ, is a global pharmaceuticals company. We make healthy possible through the development, manufacturing, and distribution of a diverse portfolio of over 280 pharmaceutical products, primarily within the United States. 

In its Generics segment, the Company is expanding across a broad range of complex product categories and therapeutic areas, including injectables and biosimilars. In its Specialty segment, Amneal has a growing portfolio of branded pharmaceuticals focused primarily on central nervous system and endocrine disorders, with a pipeline focused on unmet needs. Through its AvKARE segment, the Company is a distributor of pharmaceuticals and other products for the U.S. federal government, retail, and institutional markets. For more information, please visit www.amneal.com.
 

Ardagh Glass Packaging-Europe (AGP-Europe), an operating business of Ardagh Group, announced today that the glass bottles produced from its world first hybrid NextGen Furnace have reached a consistent 64% CO2 emissions reduction*, saving approximately 18,000 tonnes of CO2 since the start of 2024. 

Since starting commercial production in October 2023, the NextGen Furnace at AGP-Obernkirchen in Germany has been gradually ramping up direct electrical heating via electrodes, towards a goal of 80% electrical heating and 20% gas. To date in 2024, AGP-Europe has achieved an average rate of 60% electrical heating in the NextGen Furnace; progress achieved in part due to the support and expertise of furnace supplier SORG. 

The NextGen Furnace is funded through the BMWK** ‘Decarbonisation of Industry’ programme, which is managed by the KEI, and also from the ‘NextGeneration EU’ European Innovation Fund. 

It has pushed the boundaries of electric melting technology with commercial-scale output of up to 350 tonnes of amber glass, using up to 70% recycled glass cullet. 
 
Joris Goossens, R&D Project Manager, AGP-Europe commented: 
“Ramping up the electrical heating in the NextGen Furnace has not been an easy journey. In a conventional furnace, the combustion space is hotter than the glass, but in the NextGen Furnace, the glass gets hotter than the combustion space: the furnace is effectively upside down. We have been navigating uncharted territory.”

Sven-Roger Kahl, Manager of Furnace Operations, AGP-Europe added:
“The NextGen design, which features electrodes in the bottom of the furnace, has challenged traditional furnace operating rules. It has been like learning to drive again, but it has been worth the effort to reach our goal of low-carbon glass packaging.”

Many key customers, glass industry peers and suppliers have now visited the furnace to see it in action. Government officials have also been welcomed to Obernkirchen to discuss the need for electrical grid connection to roll-out the technology to other AGP facilities.

AGP-Europe intends to adopt hybrid and other sustainable melting technologies for furnace rebuilds from 2027 onwards, subject to access to the appropriate electrical infrastructure in the relevant markets. 

*Based on modelling
**Bundesministerium fur Wirtschaft und Klimaschutz (German Federal Ministry for Economic Affairs and Climate Action) and KEI: Klimaschutz in Energieintensiven Industrien (Competence Centre on Climate Change Mitigation in Energy-Intensive Industries) have provided a grant to qualifying energy-intensive industries in Germany.
 

Toronto, Canada - CANEI Corporation, a leader in recycled materials, is proud to announce its ranking on the Financial Times list of Americas' Fastest Growing Companies 2024. Securing the 184th position, CANEI has once again been recognized for its remarkable growth, showcasing its innovative approach in the recycled materials industry.

Founded in 2012, CANEI specializes in supplying high-quality recycled PET (rPET), PP (rPP), and PE (rPE), focusing on sustainability-conscious brands and manufacturers. The company's dedication to closing the plastics loop is evident in its specialization in food-grade recycled PET, catering to the increasing demand for sustainable solutions in the food packaging and bottle industries.

CANEI's global footprint and steadfast commitment to quality have set it apart, affirming its role as a trusted partner in the eco-friendly endeavors of businesses worldwide. The company's strategic focus on enhancing all aspects of its operations aligns with its mission to exceed the sustainability expectations of its partners, reinforcing its position as an indispensable ally in the green movement.

"CANEI is not only recognized for its significant growth but its pivotal role in waste management and recycling. We are proud to be among the few companies on this list driving change in recycling and sustainability, reflecting our dedication to making a meaningful environmental impact," said Alkarim Shamsy, Founder and CEO of CANEI. The company's dedication to innovation and excellence fuels its continued advancement in reducing plastic waste.

This award, presented by the Financial Times and Statista Inc., highlights the most innovative and successful companies in the Americas, based on their revenue growth. Announced on April 4, 2024, and featured on the Financial Times website, it showcases the top 500 companies achieving the highest annual revenue growth achieved between 2019 and 2022.

CANEI, with its dedication to sustainability and recycling, proudly stands among these leaders for another year. This recognition underscores its impactful business strategies and commitment to environmental stewardship, affirming CANEI's ongoing mission to lead in sustainable development and recycling innovations.

The installation of an Integrated Total Packaging Solution (iTPS) from Ishida Europe has given Maltese manufacturer Sunshine Snacks a huge boost in the speed and accuracy of its weighing and bagmaking operation. The flexibility of the new system has also enabled the company to introduce a new pack size for the airline market.

Part of Consolidated Biscuits, Sunshine Snacks manufactures a variety of crisps, popcorns and other snacks under its own brands (including “Crix”) and for private label.  As well as Malta, Sunshine Snacks exports to regions such as Europe, Africa and the Far East.

The need to replace an ageing packaging system led Sunshine Snacks in 2019 to search for a modern upgrade.  “While we didn’t have an Ishida weigher or bagmaker in our factory, we are familiar with the brand because we already had an Ishida checkweigher.  Also, our sister factories in Trinidad and Tobago have several Ishida multihead weighers in use,” said Robert Ellul, General Manager at Sunshine Snacks.

Ishida proposed the Inspira iTPS, which consists of two flagship Ishida machines in tandem: an Ishida RV series multihead weigher mounted over an Inspira rotary bagmaker, creating a streamlined system that increase speeds, minimise giveaway and eliminate issues such as product trapped in seals. 

The Inspira iTPS system was installed in June 2020 and the impact was immediate. 

Two extrusion lines – one for fried products, the other for baked snacks – feed into the weigher, which operates at 140 packs per minute, 9 hours per day, 5 days per week.  This speed exceeds what was possible with Sunshine Snacks’ previous solution. Indeed, sometimes operators were forced to slow down the extruders so as not to overburden packing capacity. Weighing accuracy has been increased by as much as 3.5 to 5 per cent depending on product, a massive improvement when calculated over time. 

“Our old weighing system either gave away too much, affecting profits, or too little, which meant more time was lost to rework.  We’d often had to slow down our previous solution to try and improve accuracy,” confirmed John Bartolo, Operations Manager at Sunshine Snacks.

“With the Ishida multihead weigher, the accuracy of the algorithm is astonishing. The machine calculates variables automatically and we’ve seen a significant improvement.”  

Accuracy is further improved because the faster throughout reduces the chance of snacks flavourings sticking to the weigher’s contact parts and affecting weight calculations. Similarly, the multihead weigher is better at detecting and removing product residue in the hoppers than the previous system used to be.

The Inspira bagmaker delivers great value too, including the reduction of film waste – an obvious cost and environmental benefit – and better seal integrity which maintains shelf life.  “The bagmaker is incredibly simple to use, with minimal set-up,” said Anton Bugeja, Plant Manager. “The operator presses a button on the touchscreen and automated features ensure that the film for the new bag size is fully aligned, saving time and reducing film waste close to zero.”

With 23 SKUs across its range, minimising downtime between product changeovers is critical. Since installing the Ishida iTPS, Sunshine Snacks has been impressed at the ease and simplicity with which changeovers can take place. 

“No tools are required and switching between SKUs via the control unit is fully automated,” said Paul Scicluna, Maintenance Production Manager.
Sunshine Snacks estimates that changeover time has halved. “It now takes no more than five minutes per changeover, whereas before it typically took more than 10 minutes,” continued Scicluna.  He added that cleaning regimes benefit from the hygienic machine design.

Several pack formats are used at the plant to suit size, product type and private label requirements.  After seeing the Inspira bagmaker in action, the company realised it could now introduce a new pack format – a 15g pack aimed at the airline market.  

“We expected to see benefits in speed and accuracy, but we hadn’t foreseen that these improvements would also lead to new commercial opportunities, only possible because of the decision to invest in the Ishida iTPS,” commented Robert Ellul.

In October 2022, Sunshine Snacks relocated to a larger and more modern factory, closer to the company’s sister factory, Devon Biscuits.  Moving the Ishida iTPS was a simple matter.  “The design made it easy to dismantle and reinstall,” confirmed Paul Scicluna. When support is needed from Ishida, the team at Sunshine Snacks contacts the technical team via WhatsApp and typically receives a reply within minutes.  

“Ishida Europe’s aftersales support is very impressive,” confirmed Robert Ellul. “Indeed, our company ethos is always to look at aftersales as well as performance when choosing a machine, so we were confident that Ishida would be as helpful as they’ve previously proven to be.”

Ellul concluded, “Using the Ishida iTPS has been an overwhelmingly positive experience.  As the system is so accurate and reliable, the team now spends less time firefighting and can concentrate on adding value to the business.  Plus, the speed and performance has given a real boost to our ability to offer only the best products to our customers.”

Ends

The customer:
 
Sunshine Snacks is part of Consolidated Biscuits, based in Malta since 1982, and affiliated to Associated Brands Industries Ltd (ABIL) based in the Caribbean.   Consolidated Biscuits manufactures snacks, biscuits and crackers from two factories, with Sunshine Snacks benefitting from a move to new state-of-the-art premises in 2022.

The company’s mission is to put customers and their needs first, and as such is a leading manufacturer in the biscuit and snack food market in Malta., Together with carefully selected distributors it competes on the global market successfully satisfying specific consumer requirements. 

Notes to editors:

Ishida is a world leader in the design, manufacture and installation of end-to-end weighing, packing and safety solutions for the food industry, helping manufacturers increase automation and compliance, reduce cost and downtime, increase operational efficiencies and brand protection, and maximise profits.  

With an installed global base well in excess of 100,000 industrial machines, covering a huge number of applications and end markets, the company is the undisputed world market leader for multihead weighers and one of the leading global suppliers of snack food bagmakers, graders, traysealers, X-ray inspection systems, checkweighers, leak detectors and Industry 5.0 solutions. 

This extensive product range, together with the company’s in-depth knowledge and experience of many food sectors, mean that Ishida is able to design and install complete turnkey solutions for products such as snacks and other dry foods, meat, poultry, fish, dairy, ready meals and fresh produce. 

The company’s vision is to play an enduring and indispensable role in the global food supply chain, ensuring food products are delivered and consumed safely, efficiently and sustainably.
 

Company’s TeknoVation Awards distinguish outstanding materials science achievements, with three inaugural recipients announced.

Holland, OH – TekniPlex, a globally integrated provider of innovative solutions through materials science and manufacturing technologies, has introduced a program to recognize standout performances in product design and development. Spanning both TekniPlex’s Healthcare and Consumer Products Divisions, the company’s TeknoVation Awards shine a spotlight on particularly innovative materials science solutions and the talented professionals who help create them.

“TekniPlex already has a lengthy list of intellectual properties, a testament to the invaluable individuals who contribute to our ever-expanding portfolio of products, solutions, capabilities, and assets,” said Oscar Martin, Senior Vice President, Global Innovation for TekniPlex. “Building upon these efforts to recognize exemplary performance, the TeknoVation Awards are designed to honor transformative ideas and the diligent work that goes into bringing them to market.” 

Following are the winners of the inaugural TeknoVation Awards.

First Place: Market-leading PVC-free Technology for Medical Tubing Applications
TekniPlex Healthcare is a leading provider of polyvinyl chloride (PVC) compounds and tubing for medical device applications. These tubes are commonly used in various medical procedures for transporting fluids into and out of the body, such as IV therapy and blood transfusions. However, global market dynamics and healthcare systems trends have resulted in the investigation and implementation of strategic initiatives for PVC-free patient environments. 

A decided medical market challenge has been a dearth of PVC material alternatives that match the functionality and cost-performance ratio of PVC, specifically its ability to easily bond to other materials and refrain from kinking in tubing applications. The advent of TekniPlex Healthcare’s PVC-free tubing solutions leveraged the division’s deep materials science expertise, process knowledge, and market understanding to meet a noted, well-defined need.

Second Place: High Melt Strength Foam Polypropylene Tray for Food Packaging Applications
TekniPlex Consumer Products (TPCP) is a leading provider of trays for the food packaging market. Conventionally comprised of foam polystyrene, the trays are designed to package and display a variety of protein food products at supermarkets. 

As headwinds against polystyrene continue to increase due to legislative, retailer, and consumer sentiment, the TPCP engineering team utilized materials science and foaming process knowledge to retrofit existing extrusion and thermoforming assets, producing foamed polypropylene. The innovation delivers a functional product alternative where foam polystyrene has been banned or otherwise phased out. 

Third Place: ProTecSeals IHS Recyclable Liner
TekniPlex Consumer Products is a leading provider of liner solutions protecting high-leverage food products. In a packaging component niche where sustainable innovation had been lacking, TekniPlex’s ProTecSeals® Recyclable IHS Liners represent a first-of-its-kind induction heat seal solution recyclable wherever paper recycling streams are available, and compatible with conventional induction heat sealing equipment. The patent-pending liners are suitable for a wide range of bottles and jars, making them ideal for packaging products such as vitamins, supplements, protein powders, peanut butter, and other non-reactive, non-acidic dry products.
 
Comprised of paper made from tree pulp, the ProTecSeals® liners are recyclable in the paper stream while providing the same protective properties as conventional induction seal liners – and without requiring investment in new heat sealing machinery or upgrades to legacy equipment. The liners offer moisture and oxygen barrier, leak resistance, contaminant prevention, and shelf-life extension equal to standard IHS liners, and tamper evidence features also can be incorporated. Printed recycling instructions can be supplemented or replaced with brand messaging, adding real estate for under-the-cap marketing opportunities.

About TekniPlex 
TekniPlex is a globally integrated company that provides innovative solutions through materials science and manufacturing technologies. A global leader in the healthcare and consumer products markets, TekniPlex provides medical device components and a multitude of materials science solutions that lead to a healthier and more sustainable world. Its solutions are found in some of the most well-known names in the healthcare, pharmaceutical, personal care, household, and food & beverage markets. 

Headquartered in Wayne, Pa., TekniPlex employs 7,000 team members throughout its operations in Belgium, Brazil, Canada, China, Colombia, Costa Rica, Germany, India, Italy, Mexico, Northern Ireland, and the United States. For more information visit www.tekni-plex.com
 

Company also will showcase AI-enhanced blister filling control, checkweighing equipment, and solutions for efficiency in track & trace compliance and line clearance procedures.

Travagliato, Italy, May 22, 2024 - Antares Vision Group, a leading player for traceability and visual inspection solutions, will present its latest technological developments for the life science sector at  ACHEMA, June 10-14 in Frankfurt, Germany. Among other solutions, at Stand B4, Hall 3.0 the company will debut its first automatic inspection machine for blow-fill-seal (BFS) cards. Providing 100% inspection, the VRI for BFS Cards can provide seamless quality assurance at speeds of up to 100 pieces per minute.

BFS containers are among the most prominent packaging type for pharmaceuticals; however, their inspection presents a set of unique challenges due to characteristics such as surface uniformity, complexity of shape, variable transparency and opacity, and small dimensions. Antares Vision Group’s BFS card machine performs cosmetic inspection, particles detection (reflecting & non-reflecting), fill level check (short wave infra-red) and tab OCR/OCV verification. When necessary, the unit can employ advanced algorithms capable of effectively detecting foreign particles in containers at low fill levels, which pose additional challenges given their aversion to spin-centric detection techniques.  

Leak Detection Capabilities

Also at ACHEMA, Antares Vision Group will emphasize its prowess in leak detection. For example, the company’s container closure integrity testing (CCIT) plays a critical role in maintaining the sterility and stability of sterile products, and is essential for preserving critical headspace gas conditions – including those common to freeze-dried products. The company’s solutions set in this niche includes Head-Space Gas Analysis (HSGA), a rapid, reliable, and non-destructive analytical method suitable for monitoring gas concentration and pressure measures in sealed containers. HSGA can be used to detect primary container leaks, or as a process analytical technology (PAT) to control facets of the upstream process (e.g. humidity excess). 

Antares Vision Group provides visual inspection, CCIT and combined VI & CCIT machines that are specially designed for small- to large-volume BFS containers, as well as solutions for other container types.

AI-enabled Solutions for Blister Filling Control

At ACHEMA, Antares Vision Group also will showcase a completely redesigned solution for  inspecting pharmaceutical blisters. Equipped with artificial intelligence features, the Blister Filling Control (BFC) module can be easily integrated into common blister production and sealing lines. The system’s features provide enhanced inspection of various oral solid dose products housed in blisters – including scenarios where low contrasts (such as white pills in white packaging) present inherent challenges. The BFC unit also facilitates and expedites new product recipe setup.

Weight Control

At ACHEMA, Antares Vision Group also will display its new range of checkweighers designed for maximized efficiency and seamless line integration. The machines perform accurate weight control at speeds up to 350 ppm, and feature a top-bottom gripping system with stabilization conveyor. The solution is fully compliant with 21 CFR Part 11, and can be equipped with various ejection systems as determined by product weight. 

Other solutions presented by Antares Vision Group at ACHEMA include:

•    Serialization and aggregation technology: Antares Vision Group’s proven modular solutions for managing track & trace compliance with seamless integration on any third-party equipment, as well as standalone modules covering Levels 1-4 hardware and software for EU-FMD, DSCSA and other regulatory requirements. 

•    Smart Clearance: A solution environment designed to automate the mandatory line clearance process through integrated cameras powered by artificial intelligence, toward the goal of improving plant efficiency and productivity.

•    Layout Inspection for stick packs: A system that verifies the correctness of printed information (including variable data or barcodes) designed for inline installation on stick pack filling machines. 

Antares Vision Group systems are part of DIAMIND, the integrated ecosystem of solutions connecting physical products with digital identities and operating at line, factory, warehouse, enterprise, and supply chain level to guarantee product quality and end-to-end traceability through integrated and cloud data management. 

Antares Vision Group

Antares Vision Group is an Italian multinational, listed on the STAR segment of Euronext and included in the Euronext Tech Leaders index, which is dedicated to leading tech companies with high growth potential. AV Group enables the digitalization of products and supply chains through traceability, inspection for quality control and integrated data management. It supports companies and institutions in ensuring. Through DIAMIND, the integrated ecosystem of solutions, the Group guarantees safety, quality, efficiency and sustainability of products (with inspection systems and 
machines) and end-to-end traceability across the supply chain (from raw materials to production, from distribution to the consumer, and vice versa), with integrated data management, boosted by artificial intelligence and able to be integrated with blockchains. AV Group operates in the Life Science sector (pharmaceutical products, biomedical devices and hospitals) and in the Fast-Moving Consumer Goods (FMCG) industry. It is the world leader in Track & Trace systems for 
pharmaceutical products, supplying major global manufacturers (over 50% of the top 20 multinationals) and numerous government authorities. AV Group recorded a turnover of Euro 223 million in 2022, operates in 60 countries, employs over 1,100 people, and boasts a network of over 40 international partners.
 

EcoCortec® is pleased to announce that it has closed another plastic recycling loop with the first delivery of plastic waste from its customer Jakob Schober GmbH (Waldorf, Germany) to Beli Manastir, Croatia. This signals the start of a new recycling partnership between EcoCortec® and Jakob Schober to recover plastic scrap and incorporate it back into quality finished goods. The initiative comes at a time when Europeans and the world are increasingly looking for ways to be more sustainable. It is a powerful example of how EcoCortec® is helping to make the “circular economy” a reality at the level of a direct customer-manufacturer relationship

Circular Economy Challenges
Talking about the circular economy is much easier than making it happen. According to the UN, 46% of plastic waste ends up in landfills, 22% ends up as litter, and less than 9% actually ends up recycled. Why is it so hard to capture and reuse this plastic waste? Among the challenges are collecting material after it has been sent around the world and finding a consistent supply of recycled content within strict cleanliness and quality requirements. These issues can make it difficult for manufacturers to turn used packaging into anything more than cheap garbage bags.

Overcoming Recycling Barriers

EcoCortec® does not let these barriers stop them from pursuing and implementing a circular economy in the VCI films market. First, EcoCortec® introduced VpCI®-126 PCR in early 2023. This version of Vapor phase Corrosion Inhibiting film contains 30% post-consumer recycled content (PCR) sourced from a recycled raw material supplier that follows strict quality standards. Eco-conscious customers like Jakob Schober intentionally order VpCI®-126 PCR to achieve a better environmental footprint.

Onsite Reprocessing Facility

EcoCortec® is able to go above and beyond simply producing film with PCR content, thanks to its onsite recycling facility, where EcoCortec® can reprocess both post-consumer and postindustrial scrap. Jakob Schober naturally ends up with much of the latter as it creates 3D bags from both VpCI®-126 PCR film and regular plastic film for their export packaging kits. Scrap builds up quickly, and in March 2024, Jakob Schober entered into an agreement with EcoCortec® to ship clean plastic scrap to the Beli Manastir plant for reprocessing. After further inspection at EcoCortec®, the scrap was re-granulated using state-of-the-art reprocessing equipment and tested in the lab before being used in VpCI® Film production. EcoCortec® does the same with used packaging from a local construction company and EcoCortec’s sister company CorteCros®, thus minimizing waste and expanding the use of PCR in finished goods beyond VpCI®-126 PCR film alone. The same truck that brought VpCI®-126 PCR to Schober was loaded with VpCI®-126 PCR scrap for transport to EcoCortec® 1,000 km away, resulting in additional fuel savings for a better carbon footprint as well as a circular economy.

Pursuing Recycling Goals

EcoCortec® is on the lookout for more recycling partners who will help them increase their volume of high quality recycled content in all VpCI® Films by sending their clean post-consumer plastic waste for recycling. This will create new channels for EcoCortec® and local businesses to fulfill European and international goals such as increasing the amount of high-quality closed loop recycling, making products that can be recycled in their original markets, and reaching 30% recycled content in plastics packaging by 2030.

Become Part of the Circular Economy

By not only making 30% PCR film but also receiving and reprocessing local waste materials into quality new material, EcoCortec® is well on its way to making these goals achievable for itself, customers, and local businesses. If you want to get involved in closing the loop on plastic recycling instead of just talking about the circular economy, contact EcoCortec®  today to learn more about VpCI®-126 PCR and our European recycling partnership opportunities.

As drivers spend increasingly longer hours on the road, the demand for solutions that enhance comfort and convenience within the vehicle has never been greater. Recognizing this need, KRAIBURG TPE, a leading global manufacturer of thermoplastic elastomers (TPEs), is proud to announce the launch of its latest TPE solution tailored for car window shade applications.

Redefined Driving Experience with Advanced TPE Materials
Introducing the THERMOLAST® K FG/SF/AP series, an innovative solution meticulously engineered to meet the stringent requirements of the automotive sector. https://www.kraiburg-tpe.com/en/automotive This cutting-edge material combines advanced features and regulatory compliance, making it an ideal choice for automotive interior components.

Enhanced Features for Unmatched Performance
The THERMOLAST® K https://www.kraiburg-tpe.com/en/thermolast-k FG/SF/AP series from KRAIBURG TPE offers a host of advantages designed to elevate the driving experience:
•    Low Density: Provides lightweight yet durable protection for vehicle interiors.
•    Adhesion to PP: Ensures seamless integration with existing vehicle components.
•    Controlled Emission and Odor: Maintains a clean and odor-free automotive interior environment.
•    Optimized Flow Properties: https://www.kraiburg-tpe.com/en/automotive-thumbwheel-flexible-tpe-solu… Facilitates ease of processing during manufacturing.
•    Surface Mapping: Enhances aesthetics and design flexibility.
•    Temperature Stability: Withstands temperatures up to 100°C, ensuring long-lasting performance.
•    Demolding: Simplifies production processes for efficient manufacturing.
•    Processing Method: Compatible with injection molding for streamlined production.
•    Color: Available in sleek black for seamless integration with vehicle interiors.

Ideal applications for the THERMOLAST® K FG/SF/AP series include handles, function and design elements, thumb wheels, soft touch surfaces, seals and automotive interior applications.
KRAIBURG TPE (www.kraiburg-tpe.com) is a global manufacturer of custom thermoplastic elastomers. KRAIBURG TPE was founded in 2001 as an independent business unit of the KRAIBURG Group and is now the industry's competence leader in the field of TPE compounds. The company's goal is to provide safe, reliable and sustainable products for customer applications. With more than 660 employees worldwide and production sites in Germany, the USA and Malaysia, the company offers a large product portfolio for applications in the automotive, industrial and consumer goods industries, as well as for the strictly regulated medical sector. The established THERMOLAST®, COPEC®, HIPEX® and For Tec E® product lines are processed by injection molding or extrusion and offer manufacturers numerous advantages not only in processing but also in product design. KRAIBURG TPE is characterized by its innovative strength, global customer orientation, customized product solutions and reliable service. The company is ISO 50001 certified at its headquarters in Germany and holds ISO 9001 and ISO 14001 certifications at all its sites worldwide.

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