Sorting technology plays a pivotal role in making recycling more effective than ever before. This blog will explore the various sorting technologies that are changing the face of waste recycling

Mechanical Sorting:

Mechanical sorting is the backbone of many recycling facilities and is also the most rudimentary form of adopted sorting technology. Here are the key components and methods:

1. Conveyor Belts: These transport waste materials for inspection and sorting.

2. Screens: Vibrating screens help segregate materials by size.

3. Air Classifiers: These use air currents to separate lighter materials from heavier ones.

Optical Sorting:

Optical sorting relies on advanced sensors and cameras to identify and separate materials based on multiple visual and compositional properties.

1. Color Recognition: Optical sorters can detect and sort materials by color.

2. Shape Recognition: They identify materials by their shapes, making them useful for irregularly shaped items.

3. Composition Analysis: Some machines analyze materials based on their chemical composition.

Sensors used for composition analysis include:

1. Infrared Sensors: Detect the infrared radiation emitted by different materials, allowing for sorting based on composition.

2. NIR Sensors (Near-Infrared): Sort materials by their unique NIR absorption patterns, aiding in the identification of plastics and other materials.

3. X-ray Sensors: Provide detailed information about an object's internal composition, ideal for sorting materials with varying densities.

A combination of these sensors can enable the system to distinguish between different materials based on their unique spectral signatures.

Magnetic Sorting:

Magnetic sorting is employed for separating metals from other materials:

1. Ferrous vs. Non-Ferrous: Magnets are used to separate ferrous metals from non-ferrous metals.

2. Eddy Current Separation: This technology uses rotating magnets to repel non-ferrous metals, creating separation.

Intelligent Sorting Systems:

Technological advancement has provisioned automated systems that integrate robotics and machine learning to improve sorting accuracy and efficiency while reducing operating costs.

In a world where environmental consciousness is becoming increasingly important, innovative solutions are emerging to tackle the issue of single-use plastics.

In 2020, Lucas Moreau and Colin Deblonde founded Dripl, a company determined to revolutionize the way we consume beverages while addressing the waste generated by conventional soft drinks. Let's explore the concept behind Dripl and how it aims to offer a more sustainable and environmentally friendly alternative to the status quo.

A Health-Conscious Shift

Dripl's core mission is to encourage a health-conscious shift away from traditional sodas and sugary drinks. The company recognizes the detrimental impact of these beverages on our health and the environment. To that end, they aim to propose a network of refill points that offer a refreshing alternative to carbonated drinks laden with artificial flavors, sweeteners and other chemical additives.

Aiding Companies in Sustainability Efforts

Dripl isn't just about promoting personal well-being; it's also deeply committed to corporate sustainability. Their refill points are strategically placed within offices and businesses, helping companies reduce waste and lower their carbon footprint.

Dripl challenges the conventional notion of soft drinks. It questions why we rely so heavily on plastic bottles and cans when the primary component of these beverages is, in fact, water. Trucks crisscross the world, transporting water-filled containers when readily available tap water is abundant. This practice seems questionable at best.

An Eco-Friendly Approach

Dripl’s vending machines are more than just your average soda dispenser. They chill, infuse flavor, and carbonate tap water to create a delightful and healthy alternative to traditional soft drinks. This innovative approach has already prevented more than 2.5 million disposable packages from entering circulation. By encouraging the use of refillable containers underpinned by a network of refill stations, Dripl has already prevented millions of disposable packages from ending up in landfills and oceans.

By 2030, Dripl aims to eliminate the need for and circulation of a staggering 1 billion plastic bottles and cans.

Solid Bleached Sulphate (SBS) and Folding Box Board (FBB) are popular choices of packaging material. In this blog, we'll explore the characteristics, uses, and considerations for each material to help you make an informed decision for your packaging needs.

Solid Bleached Sulphate (SBS)

Solid Bleached Sulphate, commonly referred to as SBS, is a premium paperboard product known for its exceptional quality and versatility. It's made primarily from wood pulp that undergoes a stringent bleaching process to achieve a bright white appearance. Here are some key characteristics and uses of SBS:

Brightness: SBS is exceptionally bright, with a smooth and glossy surface that enhances print quality. This makes it an ideal choice for packaging that requires high-end graphics and vibrant colors.

Strength: SBS offers excellent rigidity and durability, making it suitable for products that need robust packaging, such as cosmetics, electronics, and pharmaceuticals.

Printability: Its smooth surface allows for superior printability, making it a preferred choice for packaging that requires intricate designs and detailed information.

Barrier Properties: SBS can be coated or laminated to enhance its barrier properties, making it an excellent choice for packaging perishable items or those sensitive to moisture and light.

Folding Box Board (FBB)

Folding Box Board, or FBB, is another type of paperboard used in packaging. It's characterized by its layered construction, with multiple layers of pulp, often featuring a white clay-coated surface for improved printability and aesthetics. Here are some key aspects of FBB:

Print Quality: Similar to SBS, FBB offers good print quality, though it may not be as bright as SBS. It is suitable for packaging that requires high-quality graphics but doesn't necessarily demand the brightest white appearance.

Economical: FBB is often more cost-effective compared to SBS, making it a popular choice for businesses looking for a balance between quality and affordability.

Sustainability: Many FBB products are sourced from sustainable forestry practices, making it an eco-friendly choice for environmentally conscious brands.

It is often used for food and retail packaging and for promotional materials such as brochures, flyers and display boxes.

Both Solid Bleached Sulphate (SBS) and Folding Box Board (FBB) have their unique advantages and are suitable for different packaging applications. Carefully assess your specific needs and objectives to determine which material aligns best with your packaging requirements. Ultimately, the right choice will help enhance your product's presentation, protect its contents, and meet your budgetary and sustainability goals.

Chemical and mechanical pulping are two different processes used in the papermaking industry to convert raw wood materials into pulp, which is then used to produce paper and various paper products. Each process has its own characteristics, advantages, and disadvantages.

1. Mechanical Pulping:
Mechanical pulping involves physically breaking down the wood fibers using mechanical means like grinding and refining. There are two main types of mechanical pulping:
•    Stone Groundwood (SGW) Pulping: In this process, whole wood logs are pressed against rotating grindstones, which mechanically break down the wood fibers into pulp. The resulting pulp has relatively long fibers but also contains a significant amount of lignin (a natural polymer in wood that provides structural support).
•    Thermo-Mechanical Pulping (TMP): In TMP, wood chips are subjected to both mechanical refining and heat treatment. This softens the lignin and makes it easier to separate the fibers. The resulting pulp has shorter fibers than SGW pulp and lower lignin content.

Advantages of Mechanical Pulping:
•    High yield: Mechanical pulping processes tend to have higher pulp yields, meaning more pulp is produced from the same amount of wood.
•    Cost-effective: Mechanical pulping requires less chemical input, making it a cost-effective method.
•    Retains strength: Mechanical pulps retain more of the original strength of the wood fibers.

Disadvantages of Mechanical Pulping:
•    Higher lignin content: The resulting pulp has higher lignin content, which can lead to yellowing of paper over time and reduced paper longevity.
•    Energy-intensive: The mechanical pulping process requires a lot of energy, which can increase environmental impact.
•    Lower paper quality: Mechanical pulp fibers are shorter and have lower bonding properties, resulting in lower-quality paper compared to chemical pulp.

2. Chemical Pulping:
Chemical pulping involves using chemicals to dissolve or separate the lignin from the wood fibers. There are two main types of chemical pulping:

•    Kraft Pulping: This process uses a mixture of chemicals, primarily sodium hydroxide (NaOH) and sodium sulfide (Na2S), to break down lignin and separate the fibers. The resulting pulp is known as "kraft pulp" and is commonly used for a wide range of paper products.
•    Sulfite Pulping: In sulfite pulping, sulfurous acid or its salts are used to break down lignin. This process results in "sulfite pulp," which is often used for specialty papers.

Advantages of Chemical Pulping:
•    Higher paper quality: Chemical pulping produces higher-quality paper with better color, strength, and durability due to the removal of lignin. The lower lignin content results in less yellowing over time.
•    Versatility: The resulting pulp can be used for a wide range of paper products.

Disadvantages of Chemical Pulping:
•    Lower yield: Chemical pulping processes generally have lower pulp yields compared to mechanical pulping.
•    Higher chemical usage: Chemical pulping requires the use of chemicals like sodium hydroxide and sodium sulfide, which can have environmental implications.
•    Higher cost: Chemical pulping processes tend to be more expensive due to the costs associated with chemicals.

In practice, a combination of both mechanical and chemical pulping methods is often used to optimize the balance between yield, quality, and cost in paper production.
 

Packaged beverages are a mainstay of the fast-moving-consumers’-goods industry. They can offer a wide array of flavors and nutritional benefits in addition to simply quenching thirst. Ensuring that these beverages maintain their quality and safety over time is of utmost importance for both manufacturers and consumers.

Industrial beverage preservation techniques and the use of preservatives play a vital role in extending the shelf life and preserving the freshness of these products. In this blog, we will explore the various methods employed in the beverage industry for preservation and the common preservatives used to achieve these goals.

In addition to pasteurization, its variations and aseptic packaging, other methods of preservation can also be used to extend the shelf life and preserve the nutritional value of beverages.

1. Carbonation:
Carbonation, the process of dissolving carbon dioxide in beverages, is a preservation technique used for carbonated soft drinks and beers. The dissolved carbon dioxide acts as a natural preservative, creating an acidic environment that inhibits the growth of most microorganisms.

2. Drying
Drying is a traditional and effective method used to preserve various ingredients in the beverage industry. By removing the moisture from the ingredients, the growth of microorganisms, such as bacteria, yeasts, and molds, is hindered, thus extending the shelf life of the final product. There are different drying methods employed, each suitable for specific beverage ingredients.

• Sun drying:  involves placing the beverage ingredients under direct sunlight to remove moisture gradually. This method is widely used for drying fruits and herbs used in teas and herbal infusions. However, it may not be suitable for all climates or ingredients, as it relies on consistent sunny weather.
• Air Drying: Air drying relies on natural air circulation to remove moisture from the ingredients. It is commonly used for herbs, spices, and certain fruits. The process may take longer than other methods but helps retain the flavor and aroma of the ingredients.
• Freeze Drying: Freeze drying is a more advanced technique that involves freezing the ingredients and then reducing the surrounding pressure to sublimate the ice directly into vapor, leaving behind freeze-dried ingredients. This method preserves the cellular structure of the ingredients, resulting in better flavor retention. It is commonly used for coffee, fruits, and other delicate ingredients.
• Spray Drying: Spray drying is commonly used for beverage powders like instant coffee and milk powder. The ingredients are transformed into a fine mist and introduced into a hot air stream, rapidly evaporating the moisture and leaving behind dry particles.

3. Fermentation:

Fermentation is a natural preservation technique that has been used for centuries to create various alcoholic and non-alcoholic beverages. During fermentation, microorganisms, such as yeast and bacteria, convert sugars and starches in the beverage ingredients into alcohol, acids, or gases, creating an environment that inhibits the growth of harmful microorganisms. This process not only preserves the beverage but also imparts unique flavors and characteristics. Beer, wine, kombucha and kefir are all fermented beverages.

It is essential to control the fermentation conditions, as improper fermentation can lead to spoilage or undesirable flavors. With the right balance of ingredients and fermentation conditions, beverages can undergo a natural preservation process that enhances their overall quality and appeal.

Common Beverage Preservatives:

Preservatives are chemical compounds added to beverages to prevent microbial growth and spoilage, enhancing their shelf life. They can either be natural or synthetic. While some consumers may express concerns about their usage, regulatory bodies ensure that approved preservatives are safe when used within recommended limits. Here are some common beverage preservatives:

1. Benzoates: Sodium benzoate and potassium benzoate are effective against yeasts, molds, and bacteria, commonly used in fruit juices, carbonated beverages, and flavored water.
2. Sorbates: Potassium sorbate is a preservative effective against yeasts and molds, often used in fruit juices, wines, and some soft drinks.
3. Sulfites: Sulfur dioxide and sulfite compounds inhibit the growth of yeasts and bacteria, making them valuable for preserving wines, fruit juices, and ciders.
4. Ascorbic Acid (Vitamin C): Besides its nutritional benefits, ascorbic acid acts as an antioxidant and helps preserve the color and flavor of fruit juices and other beverages.
5. Citric Acid: Derived from citrus fruits, it helps maintain acidity and prevents microbial growth.
6. Rosemary Extract: Contains natural antioxidants that help prevent spoilage and maintain freshness.
7. Grape Seed Extract: Rich in polyphenols, it acts as an effective antioxidant and antimicrobial agent.
8. Green Tea Extract: Contains catechins, which have antimicrobial properties.
9. Cranberry Extract: Contains natural compounds that inhibit bacterial growth.

Industrial beverage preservation techniques and preservatives play a crucial role in ensuring that consumers can enjoy safe and high-quality beverages. Each method has its advantages, allowing manufacturers to choose the most suitable technique based on the specific product and desired shelf life. While preservatives are essential for extending the longevity of certain beverages, regulatory bodies carefully assess their safety to ensure they are used responsibly. By striking a balance between preservation and consumer health, the beverage industry can continue to deliver a wide range of refreshing and nourishing products to consumers around the world.

As key players of the industry continue to invest in the research and development of improved preservation techniques that do not compromise the quality and safety of food products, many processes emerge to be promising alternatives to the use of preservatives and additives. Processes that allow to better understand the food composition and aid the development of appropriate methods of shelf-life extension have also been studied and implemented. 
In this blog, we will detail two of the processes that have gained the trust of, both, manufacturers and consumers. 
Superchilling, also known as supercooling, is a process that involves lowering the temperature of a substance or product below its freezing point without actually allowing it to freeze. 
While freezing extends the shelf-life of food by slowing down the physical and biochemical reactions, it also leads to the formation of ice crystal which can result in irreversible damage to the cell structure and texture. Superchilling technology helps maintain the original freshness of the foodstuff without any freezing damage. 
The process typically involves cooling the product to temperatures slightly below the freezing point of water, often between -1 to -4 degrees Celsius (30 to 24 degrees Fahrenheit). This temperature range is chosen because it slows down the growth of microorganisms and enzymes that cause food spoilage.
To superchill a product, specialized equipment or techniques are used to rapidly cool it down. This can involve processes such as cryogenic cooling, where liquid nitrogen or carbon dioxide is used to achieve extremely low temperatures quickly. Other methods may include using specialized cooling systems that provide precise temperature control.
The process of superchilling allows the preservation of the quality, texture, and flavor of the product for an extended period. It can also reduce the growth of pathogens, thus enhancing food safety. 
It's worth noting that superchilling alone does not completely stop deterioration processes; it only slows them down. Proper storage conditions, such as maintaining the superchilled temperature and preventing temperature fluctuations, are crucial for maximizing the shelf-life extension.
Microbial profiling, also known as microbial analysis or microbiological profiling, is a process that involves identifying and analyzing the microorganisms present in a particular environment or on a specific product. It is used to understand the microbial composition, diversity, and activity, which can be crucial in determining the shelf life of a product and implementing strategies to extend it.
Microbial profiling typically involves collecting samples from the product or its surrounding environment and analyzing them using various techniques. These techniques can include culturing methods, DNA sequencing, polymerase chain reaction (PCR), metagenomics, or other molecular biology approaches. By studying the microbial profile, scientists can identify the types of microorganisms present, their abundance, and potentially their metabolic activities which allows for targeted intervention.
When it comes to extending shelf life, microbial profiling plays a significant role. By analyzing the microbial profile of a product, experts can identify the microorganisms responsible for spoilage. This knowledge allows for the development of targeted strategies to control or inhibit the growth of specific spoilage microorganisms, thus extending the product's shelf life.

Microbial profiling can also help identify potential pathogenic microorganisms that may pose health risks if present in the product. This information allows for appropriate measures to be implemented to enhance product safety.
Process optimization, both manufacturing and storage, and overall quality control are also applications of the study of the microbial profile of a sample. 
Analyses similar to microbial profiling provide valuable insights into biology of a product and enable an informed decision-making process. 
By using microbial profiling, manufacturers and producers can gain valuable insights into the microbial ecology of their products, enabling them to make informed decisions about processing, storage, and preservation techniques. It allows for targeted interventions to control spoilage and pathogens, thus extending the shelf life and maintaining the quality and safety of the product.
 

High-pressure processing (HPP), also known as high-pressure pasteurization, is a food preservation technique that uses elevated pressure to extend the shelf life of food products.

The process works by applying pressure evenly and uniformly throughout the food product. Pressure is transmitted through a liquid medium, usually water, which surrounds the food. The food is typically placed in a high-pressure chamber, where pressure is increased to the desired level for a predetermined period, typically a few minutes. The pressure is later released, and the food is removed from the chamber.

The packaged or sealed food product is subjected to high levels of hydrostatic pressure, typically between 300 and 600 megapascals (MPa) or 43,500 and 87,000 pounds per square inch (psi).

Food preservation techniques are devised to serve a threefold purpose – minimize microbial and enzymatic activity, ensure pack integrity, and extend shelf life.

Extending the shelf life can help curtail food wastage, which would help remove one-quarter of the total greenhouse gas emissions from the global food system. Preservation techniques, like HPP, play a part in ensuring customer confidence by the maintenance of clean labels without compromising product quality or safety.

The high pressure exerted during HPP has several effects on microorganisms, enzymes, and other components of the food:

1. Microbial inactivation: HPP effectively kills or inactivates most types of bacteria, yeasts, molds, and parasites that can spoil food or cause foodborne illnesses. It disrupts their cellular structure and enzymatic systems, rendering them unable to grow or cause spoilage.

2. Enzyme inactivation: Many enzymes responsible for food deterioration and quality degradation are sensitive to pressure. HPP can inactivate these enzymes, including those that cause browning, texture degradation, and off-flavors in food.

3. Extended shelf life: By controlling the microbial load and enzyme activity, HPP helps to extend the shelf life of food products. It can significantly slow down the natural deterioration processes, maintaining the freshness, quality, and nutritional value of the food for an extended period.

HPP is commonly applied to meat, poultry, seafood, fruits, vegetables, juices, soups, sauces, dips, ready-to-eat meals, and even certain dairy products. It is a non-thermal preservation method and so does not rely on high temperatures, which can negatively impact the sensory and nutritional qualities of the food. Instead, HPP allows food manufacturers to achieve microbial safety and quality preservation while minimizing the need for additives or excessive heat treatment

Proper storage conditions, such as refrigeration, are still necessary to maintain the safety and quality of HPP-treated products as the process does not make the food completely shelf-stable but rather, helps extend shelf life.

The retort process was developed in the mid-19th century, enabling the safe preservation of food in cans.
Building on the invention of tin cans and their functionality, a technique needed to be developed to preserve perishable goods in tinplate cans without damaging the soldered seams. Applying direct heat treatments was destructive to the integrity of the seal, leaving little room to explore advanced applications. Employing the method of soldering, itself, could lead to contamination and limited the usage of the cans for certain products.
To counteract this limitation, a process was developed that involved placing sealed cans in high-pressure steam vessels called retorts and subjecting them to heat treatment. The intense heat and pressure ensured that the contents of the cans were thoroughly sterilized, eliminating harmful bacteria and extending shelf life.

The development of the retort process led to large-scale commercial production of canned goods. It also led manufacturers to use cans made of thicker metal, which could withstand the pressure and heat of the process. To streamline the process further, continuous upgradation and improvements of the canning machinery and automated production lines were also observed.

Soon, retort pouches, which are flexible, lightweight and often more convenient, emerged as an alternative to rigid retort cans. These pouches are made of multi-layer laminated materials, including plastic films and aluminum foil.
After flexible packaging materials gained popularity as an alternative to rigid containers like cans and bottles in the early 1950s, agencies such as NASA and their big-budget research departments focused their resources and energies on the development of packaging materials, especially for space missions. This was due to the many advantages, such as lightweight, easy handling, and space efficiency, offered by flexible packaging.

In the 1960s, NASA sought packaging solutions that would be lightweight, compact, and capable of preserving food for a long period of time without refrigeration. The resulting innovation paved the way for the retort pouch.
In the 1970s, retort pouches were first commercialized in Japan by a packaging company called Toyo Seikan. Toyo Seikan introduced a pouch made of laminated films with excellent barrier properties to protect the contents from oxygen, moisture, and light. These packs also offered the benefits of quick heating and product visibility. 

Today, retort pouches are used for packaging various food items, including sauces, gravies, pet foods, baby foods, seafood, vegetables, and even beverages like coffee and juices. Innovations include features such as resealable zippers, spouts for pouring, tear notches for easy opening, and microwave-safe designs.
Retort packaging continues to evolve, with innovations in materials, opening mechanisms, and heat distribution techniques to ensure food safety and quality.
 

There are several sealing techniques used in packaging to ensure the integrity, safety, and freshness of various products. Following is the list of some of the different sealing techniques:

1. Heat Sealing: Heat sealing is one of the most widely used sealing methods. To heat seal a package, heat is applied to a thermoplastic material, such as polyethylene or polypropylene, to create a bond between two surfaces. Heat sealing can be achieved through equipment like heat sealers, impulse sealers, or continuous band sealers.

2. Adhesive Sealing: Adhesive sealing makes use of adhesive materials to bond two surfaces together. It typically requires applying a liquid or hot melt adhesive onto one surface and then pressing the two surfaces together to create a secure seal. Adhesive sealing is most commonly employed for flexible packaging materials like pouches or bags.

3. Induction Sealing: Induction sealing is used for sealing containers with foil or induction-sealing liners. An electromagnetic induction is used to heat a foil liner, which melts a polymer layer and creates an airtight seal when pressed against the container's rim. This method is often used for sealing bottles, jars, or other containers for products like pharmaceuticals, food, or beverages.

4. Ultrasonic Sealing: Ultrasonic sealing uses high-frequency ultrasonic vibrations to create frictional heat at the interface of two materials, causing them to melt and fuse together. This technique is also used to seal thermoplastic films or blister packs and is known for its speed and precision.

5. Vacuum Sealing: Vacuum sealing involves removing air from a package or container before sealing it. It requires a vacuum sealing machine that sucks out the air, creating a tight seal. Vacuum sealing is most often used for food packaging to extend the shelf life and maintain product freshness.

6. Pressure Sensitive Sealing: Pressure sensitive sealing relies on the use of pressure-sensitive adhesives (PSAs) that adhere to the surfaces upon applying pressure. This method is commonly seen in self-sealing bags or envelopes, where the adhesive is pre-applied to one surface, and pressure is applied to create a bond.

7. Zipper Sealing: Zipper seals simply interlock plastic zippers or tracks in a reversible format that allows for repeated opening and closing of the package. It is most effective for resealable bags or pouches, providing convenient access to the contents while maintaining freshness.

The choice of sealing method depends on factors such as the type of product, packaging material, required level of protection, and production requirements.

In the packaging industry, different methods of filling are employed in the packaging line based on the product and container type. Gravity filling and auger filling are two such methods.

USE CASES

Gravity filling, often employed in the beverage and pharmaceutical sectors, is used to fill containers with liquid products.

Auger filling is commonly used in industries that deal with powders, granules, and other dry or semi-dry materials.

PROCESS BREAKDOWN

The method of gravity filling relies on the force of gravity to fill the containers without the need for additional pressure or mechanical systems.

The liquid product is stored in a reservoir at an elevated height above the containers to be filled. The containers are positioned below the reservoir, and the filling process is initiated by opening a valve or a nozzle. Due to the force of gravity, the liquid flows from the elevated reservoir into the containers.

Auger filling involves the use of an auger, which is a helical-shaped screw, to dispense the product into containers.

The auger filling process can be divided into three steps – product dispensing, metering and filling. The dry or semi-dry material is stored in a hopper or reservoir above the filling machine. The auger, located at the bottom of the hopper, rotates to draw the product from the hopper and carry it towards the discharge point. As the auger rotates, it advances the product forward while also metering the amount of material being dispensed. The pitch and speed of the auger can be adjusted to control the volume or weight of the product dispensed. As the auger rotates, the material is transferred into the containers through a nozzle or tube.

ADVANTAGES

Gravity filling is a relatively simple and cost-effective method compared to more complex filling systems. It is suitable for a wide range of liquid products, including water, juices, soft drinks, oils, and pharmaceutical solutions. Gravity filling also tends to be gentle on the product, minimizing foaming or agitation during the filling process.

Auger filling machines can handle a wide range of products, including powders, granules, spices, coffee, chemicals, and more. The auger design and configuration can be adjusted based on the specific characteristics of the product being filled. Auger fillers are also known for their high precision and accuracy in dosing and filling. The speed and rotation of the auger can be precisely controlled to achieve consistent fill weights or volumes.

DISADVANTAGES

Gravity filling may not be suitable for certain types of products or containers. For example, highly viscous liquids or products with particulate matter may require specialized filling techniques. Additionally, containers with narrow openings or those that need precise filling levels may require more precise and controlled filling methods, such as pressure or volumetric filling systems.

Auger filling may not be suitable for all types of products. Materials that are extremely fine, abrasive, or prone to compacting may require specialized auger designs or alternative filling methods.

Sri Yukteshwar ji remarked: “So long as you breathe the free air of earth, you are under obligation to render grateful service”.

This is so true, and we tend to forget that we need to take care of Planet Earth to take care of ourselves and the future generation.
 
The UN’s focus this year is on the plastic pollution crisis. While plastic has become a vital part of everyday life, experts warn that its annual production could treble over current levels by 2060.
 
At the current recycling rate of 9% that would be a recipe for disaster. The only way out of this mess is to use less plastic and recycle more.
 
We see that sustainability is becoming the key topic of discussion globally and why not, After all it’s our environment and we have the responsibility to preserve it if we & our new generation would like to enjoy it. Now the point is what exactly is happening around sustainability is not clear though a lot is happening. So, this survey is to map the exact status of sustainability and then present it to our packaging community for the benefit of all.
 
So, in order to do so, we have some of the questions below that we would like you to respond to, please.
 
1.    What exactly is sustainability from your point of view?
2.    What are the gaps to fill in to be sustainable?
3.    Do you think enough steps are being taken from sustainability?
4.    What are the options available?
5.    Do you have something to offer around sustainability?
6.    From your point of view, what should be done?
7.    Do you have any sustainability solutions that you would like to market?
8.    Any other point?  
 
To get a better understanding, we have created a small survey and the link is Sustainability - Challenges, Choices, and Consequences Survey (surveymonkey.com)   
 
We look forward to your kind responses. The survey closes on 14th June 2023.    
 

Happy & joyful living!

Sandeep Kumar Goyal Founder & CEO
https://www.linkedin.com/in/packaging/

Form-fill-seal (FFS) is a packaging technique commonly used in the manufacturing industry to automate the process of creating and filling packages. It is a highly efficient method that integrates the forming of a package, filling it with a product, and sealing it, all in a continuous and automated production line.

The form-fill-seal process typically involves the following steps:

1. Forming: The packaging material, which is usually a roll of flexible film or a pre-made flat bag, is fed into the machine. The machine forms the packaging material into the desired shape, such as a pouch or a bag, by folding, heat sealing, or both.

2. Filling: Once the packaging material is formed, the product is dispensed into the formed package. This can be done through various methods, such as gravity filling, auger filling, or liquid pumps, depending on the nature of the product being packaged.

3. Sealing: After the product is filled, the machine seals the package. This is typically done by applying heat to the edges of the package, melting the film and creating a secure seal.

Form-fill-seal technology offers several advantages in packaging:

1. Efficiency: FFS machines are capable of high-speed production, offering significant productivity gains compared to manual or semi-automated packaging methods.

2. Cost-effective: By integrating multiple packaging processes into a single machine, FFS reduces labor costs and material waste.

3. Product protection: The automated process of FFS ensures consistent and reliable packaging, minimizing the risk of product damage or spoilage during handling, storage, and transportation.

4. Versatility: FFS machines can be adapted to accommodate various packaging sizes and formats, making them suitable for a wide range of products, including powders, granules, liquids, and solid items.

Form-fill-seal technology has undergone significant improvements over the years, driven by advancements in engineering, automation, and materials. Some of the notable improvements include:

1. Increased Speed and Efficiency

2. Enhanced Flexibility: Modern FFS machines can handle different types of packaging materials, including flexible films, laminates, and specialized barrier films.

3. Advanced Control Systems: Precise control over parameters such as temperature, pressure, and speed, ensure consistent and accurate packaging results.

Advanced sensors and vision systems can detect defects, verify package integrity, and ensure proper filling levels.

4. Improved Packaging Designs

5. Enhanced Safety and Hygiene

6. Integration with Other Technologies: FFS machines can be connected to upstream and downstream equipment, such as product feeders, labeling machines, and cartoners, to create a fully automated packaging line.

7. Sustainability Considerations: FFS technology has adapted to support eco-friendly practices, such as the use of recyclable materials, reduced packaging waste, and energy-efficient operations.

Form-fill-seal technology is widely used in industries such as food and beverage, pharmaceuticals, cosmetics, and household products, where it enables efficient and hygienic packaging processes while maintaining product quality and integrity.

This automated computer-operated technology itself is subject to constant development.

Blow-fill-seal (BFS) technology, a progression of FFS, is a form of advanced aseptic manufacturing that is available for filling liquid pharmaceuticals, including biologics. In BFS technology, too, the container is formed, filled, and sealed in one continuous, automated system.

ChatGPT took many industries by storm. Some welcomed it with open arms while many were hit by its ability to replace human jobs. Nonetheless, it has piqued the interest of thought leaders as well as pioneers; individuals and communities who want to explore this avenue in an attempt to impact technological development. 
At Packaging Connections, we ride the wave of change. We foresee a future of complete integration with AI and automization that facilitates innovation. 
To show support, for this blog, we asked ChatGPT what “the latest trends in the packaging industry” were.
Here’s what the AI bot had to say –
As of my knowledge cutoff in September 2021, some of the latest trends in the packaging industry are:

Sustainable packaging: With increasing consumer awareness about environmental issues, there has been a growing demand for eco-friendly packaging solutions. This has led to the development of biodegradable, compostable, and recyclable packaging materials.
Smart packaging: Smart packaging uses technology to enhance the functionality of packaging. For example, QR codes can be printed on packaging to provide information about the product, or sensors can be embedded in packaging to monitor temperature, humidity, or other environmental factors.
Minimalist packaging: Minimalist packaging focuses on simplicity and using less material to create packaging that is both functional and visually appealing. This trend is driven by consumers' desire for products that are easy to use and environmentally friendly.
Personalized packaging: Personalized packaging is a growing trend in the packaging industry. It involves customizing packaging to meet the specific needs and preferences of individual consumers. This can include customized labels, packaging designs, and even packaging materials.
Digital printing: Digital printing technology has made it easier and more cost-effective to produce high-quality, customized packaging. This has enabled brands to create packaging that is more visually appealing and engaging, as well as to print smaller runs of packaging more economically.
Anti-counterfeiting packaging: With the rise of e-commerce and global supply chains, counterfeiting has become a major problem in the packaging industry. Anti-counterfeiting packaging solutions, such as holograms, QR codes, and tamper-evident seals, are being developed to combat this issue.
It's important to note that the packaging industry is constantly evolving, and new trends may have emerged since my knowledge cutoff in September 2021.
 

An on-the-go, affordable, unbreakable option for the necessity of hydration, single-serve, plastic water bottles largely contribute to the epidemic that is plastic pollution. Around 60 million plastic bottles end up in landfills every single day, and Americans alone send more than 38 billion water bottles to landfills every year.
At the turn of the decade, many startups as well as established corporations part of the chemical-producing, packaging-manufacturing and FMCG industries focused their energies on developing alternatives to single-serve plastic bottles for the beverage sector. While intended to be single-serve, they also, in most cases, end up being single-use. 
In this blog, we will highlight a few of the innovations introduced by these organizations. 

1.    BOOMERANG BOTTLING SYSTEM
Exposed to a harrowing example of bottled water’s damaging environmental effects, the founder, Jason Dibble, introduced a bottling system for closed-loop environments to refill their own reusable, glass or aluminum water bottles on-site. The system rinses, filters (the water), fills, and caps Boomerang-supplied custom reusable bottles. Boomerang Bottling System, or BBS, eliminates the need to ship over long distances, ensures fresh water and provides branding and marketing opportunities. Compact and customizable, it runs at the touch of a button. 

This concept is a very fitting example of taking a simple solution and adapting it for the supply chain.

2.    Cove
Cove is another startup that recognized this mammoth of an issue. As they also recognized that people might resist any significant changes to a system of convenience, they introduced a water bottle option based on the natural material PHA (polyhydroxylalkanoate). PHA is bio-based, fully biodegradable and free from microplastics.

Cove excepts to achieve competitive pricing once they start manufacturing at scale. On December 1st, 2022, the startup launched the first of its product line in the Erewhon premium organic grocery chain in Los Angles.

Grass paper is a green alternative to the most obvious and commonplace material of choice for box packaging.

An FMCG, food and transportation staple, conventional paper and cardboard packaging has an adverse impact on the environment, especially when manufactured using virgin fibers. The production process is energy and water-intensive and dependent on the use of corrosive, toxic and polluting chemicals.

Even with the use of recycled wood fibers, a certain proportion of fresh fibers is required in production as recycling shortens the fibers and diminishes their properties.

Since cellulose is not infinitely recyclable and can usually survive a maximum of six cycles of the recycling process, sustainable alternatives to curb deforestation as well as the immense energy and water consumption are deeply researched and sought after.

Green paper has more ecological benefits than using recycled wood-pulp paper in the mix and is also, still, recyclable and compostable.

As opposed to using wood as a raw material, grass helps save on cost and reduces emmisions by eliminating the need for transportation over long distances; grass can usually be obtained from ecological, agricultural compensation areas near the paper mill itself. These agricultural areas need to be unfertilized.

GRASS PAPER PRODUCTION

Like recycled paper, grass paper is not hundred percent grass fiber either.  Its proportion in the final product can range from 10 to 60%.

The raw material is dried grass or hay which is first cleaned and then, mechanically shredded. Once the fibers are cut to a suitable length, they are pressed into grass pellets. These pellets are used to produce paper without the use of any chemicals.

While both wood and grass contain pulp, grass contains 75% less lignin and resin, making it easier to liberate the pulp content. The production process also releases a fifth of the carbon emissions and uses half the amount of raw material as compared to that of wood fibers. Water and energy consumption is also monumentally lower.

Grass for paper is not competition to cattle feed as meadows are mowed only twice a year and that too, very late in the year.

Grass paper is suitable for folding boxes, food packaging, brochures and labels and is also slightly green in color, hinting at its origin.

In 2014, Notpla made headlines worldwide with its seaweed packaging; packaging that is biodegradable, home-compostable, and disappears naturally. Some of it is even edible!

In 2023, Notpla was joined on the list of winners of the Tom Ford Plastic Innovation Prize for their biodegradable packaging solution by Maharashtra-based startup, ZeroCircle – another organization built on the back of seaweed. Placing second, it was the only company from India and Asia to win the award. The winners of the competition have been awarded a collective $1.2 million cash prize. All three winners of the prize use seaweed as their raw material.

The seed for ZeroCircle was planted when founder Neha Jain, a former employee of Google, was initially provoked by a documentary on seaweed and its various use cases that could help reduce waste. This stirred curiosity was accompanied by the recent awareness of an American woman’s change in lifestyle to become completely “zero-waste”. After developing an interest in climate change and associated sustainable measures, Neha attempted to find a replacement for land-based, food-source raw materials (such as potato starch) in the bio-based material category but first switched to a minimal carbon footprint lifestyle herself. 
“I began to comprehend the impossible economics of recycling, zero-waste was a circular pipe dream in an economy that was linear”, said Neha.
As Neha explored seaweed as a substitute, she launched ZeroCircle in 2020.
ZeroCircle has invented and developed an alternative to fossil fuel-based thin-film polybags using seaweed. As opposed to other bioplastics that are marketed as compostable when, in reality, they are only industrially compostable in a factory environment with high heat, energy and humidity, ZeroCircle’s product is truly home compostable. 
The hands-on team of ZeroCircle envisions a carbon neutral future. They believe seaweed’s regenerative capabilities when redesigned and reengineered can make the chemical, food, fashion and plastic industry sustainable and pollution free. They also believe that seaweed can revolutionize the food industry as a rich source of vitamin B-12.
Other plausible use cases of seaweed include:
1.    Reduction of methane emissions - when added to cow feed at less than two percent of the dry matter, seaweed completely knocks out methane production. This is because seaweed contains chemicals that reduce the microbes in the cows' stomachs that cause them to burp when they eat grass.

ZeroCircle claims that just 9% of the ocean surface needs to be afforested to remove 53 billion tons of carbon dioxide from the atmosphere each year which is 13 billion tons more than the annual global emission rate. This means that, in ten years, the hopeless acidification of oceans and the poisoning of the atmosphere can be reversed.
ZeroCircle has already rolled out their packaging solution which is food-safe, thermally stable and serves shelf life needs. The flexible film is plastic-free, non-GMO, zero-PLA, transparent, heat sealable and printable. It is also landfill safe, marine safe and herbivore friendly. 
ZeroCircle is also known for using existing infrastructure in terms of production lines and commercial production methods. Their business supports those fishing households who have been struggling with declining income due to unsustainable fishing practices, pollution and the warming seas and provides them with a secondary income source in the form of seaweed cultivation. Additionally, seaweed cultivation is a low-investment and near-shore activity and is commonly picked up by women. 
Furthermore, increased seaweed cultivation sequesters CO2 much more than land-based plants, cools the ocean and contributes to the production of 90% of the oxygen in the atmosphere. 
A pioneer in its field in the Indian market, ZeroCircle has boldly announced its arrival and demands change.

As of 2022, we produce approximately 400 million tons of plastic waste every year globally. Of this colossal amount, 40% is contributed by packaging.[1] It is also estimated that 17 to 20% of all plastic packaging is multilayer packaging.[2]

Multilayer packaging (MLP) materials cannot be recycled using traditional plastic recycling systems and technologies, like mechanical recycling, owing to the chemical incompatibility of the different layers.

MLP can have several thin sheets of materials like aluminum, plastic, and paper that are laminated together and are very difficult to separate. Still, MLP is a preferred material in the food industry, as it protects food products and hence giving it a longer shelf life.

An array of fast-moving consumer goods and products employ MLP as their preferred wrapping. These include shampoo sachets, biscuit packs, chocolate wraps and chips packets.

Since MLP is hard to recycle, it is either conventionally:

1. Used for Energy Recovery - A variety of processes, including incineration, combustion, gasification, pyrolization, anaerobic digestion and landfill gas recovery can be undertaken to generate heat, electricity or fuel (oil).
2. Used in Road Construction or Cement Kilns as AFR.

Most MLP is still landfilled.

To combat the issues presented by plastic pollution, technologically advanced methods of treatment of non-recyclable post -consumer packaging must be developed.

With the same mission statement, Ashaya launched WITHOUT.

Their process works on post-consumer metalized multi-layered plastic packaging (MLP) and focuses on material extraction to chemo-mechanically engineer, upcycle and re-polymerize enhanced r-polyolefins and rPETs.

WITHOUT is world’s first recycled sunglasses made from packets of chips.

The process can handle almost all types of contaminants and almost all types of plastic waste without significantly impacting final product. This includes not only metalized MLP, but also other types of plastics and flexible packaging including TetraPak, coloured PET bottles, polycotton textiles, hair, dust, tissue-paper and metalized paper plates.

Their long-term goal is to monetize waste to sustain impact.

Following the theme of last week’s blog, this week’s piece will use pictorial representations of AI-generated brands and parallelly examine commercial success to truly understand the impact of the design of a product once it hits the shelves.

While statistics alone should be enough to reveal what works and what doesn’t, what further analysis will help us define is the reliability of AI.

To first state what AI can and cannot do, let’s make the obvious assumption that while AI can make suggestions, it cannot conceive its own concept without a prompt. This indicates that any team reliant on AI for branding and design will still need to brainstorm and go back-and-forth on aesthetic, target audience, brand perception, etc.

AI effectively plays a role in streamlining the process – it reduces manhours, increases efficiency and will essentially never draw a blank! This allows design teams to generate endless number of samples and prototypes with minimum effort as input.

Following are a few cases in which established brands hopped on the bandwagon to create new-age looks for their products using AI.

1. Nutella

In an attempt to increase its sales, Nutella fed a database of patterns and colors to an algorithm of generative AI* which was quick to churn out 7 million variants in jar designs. These unique jars were sold all across Italy in 2017 and were claimed to be sold out within a month! Nutella Unica, as they called it, relied on the brand's highly recognizable lettering that allowed other elements of the design to be highly customized.

Nike

Nike has chosen a different route to drive up sales and create a unique brand identity using AI. It launched a new system that allowed customers to design their own sneakers in store. This campaign not only attracts and engages new customers but it also collects a huge amount of useful data that machine learning algorithms can use to design future products and deliver personalized recommendations.

Do we still question if AI is the future?

*Generative AI is a type of artificial intelligence technology that can produce various types of content, including text, imagery, audio and synthetic data.

While every corporate event attendee appreciates receiving a gift bag at the event’s culmination, many of those gift bags still contain single-use items or, worse, get thrown away immediately upon leaving. This happens not because the receiver wasn’t appreciative of what they got but because the business handing out the event favors didn’t put a lot of thought and effort into what goes into their giveaway. 

Organizations have to think thoroughly about their gift bags. These are, after all, a form of marketing paraphernalia. Suitable event gift bags can boost your brand name, image, and entity, while skimping on them can wreak havoc on your organization’s reputation to the public.

If you want to take a be ahead of your competition and be able to give away useful event gift bags, read through this savvy guide of what you should and shouldn’t do. 

Consider Eco-Friendly Packaging Options 

First on this list is the most impactful of all corporate gift bags dos. Individuals today are considering making eco-friendly decisions seriously. Companies stuck in giving out single-use corporate gifts must develop new choices like eco friendly packaging. Paper and eco bags are no-fail ideas. 

The whole premise here is that the gift bag has strong potential to be re-used even after they’ve reached home. When you think about it, this is a marketing advantage as well. For instance, every time your company’s eco bag gets used, the reach and attention your logo gets multiply. That’s still advertising, right there. 

With that, you’re hitting two birds with one stone. First, you’re acing your organization’s marketing strategies. Second, you’re striking the fancy of event-goers who prefer eco-friendly and reusable packaging.

See Yourself Using Your Gift Bags

Before you order bulk from your supplier for items to include in the corporate event gift bag, ask yourself whether you see yourself using those items. Remember, you must help the receivers see themselves using your gifts too. But this can never be possible if you don’t even give receivers something with solid functionality and practicality. 

It’s time to step out of the usual notepads, pens, and tumblers, although those are really useful as well. There are other categories of items other companies may not have thought of exploring yet, that event attendees will be glad to receive, like: 

• Child-friendly giveaway items, especially if you’re a brand that focuses on parenting and children’s products; 
• Electronics such as chargers, universal adapters, and power banks; 
• Sanitation items like a pack of tissue, wet wipes, or alcohol; 
• Medical products, like everyday, over-the-counter medications and vitamins; 
• Travel suppliers; and so on. 

The point of the list above is to encourage you to think outside the box. Make your corporate event gift bag stand out from the fifty other booths at the same conference by handing out unique yet impactful event giveaways.  

Always Plan Your Budget 

Like any other facet of launching marketing activities and hosting corporate events, considering finances is crucial. Always plan your budget. Once the guest list is confirmed, you can know how much to budget for each one. That way, you can have a close-to-reality estimate as to what your event gift bags’ budget is in total. 

There’s no need to go above and beyond your budget for corporate event gifts. Instead, it’s more about finding the best suppliers to enjoy a competitive price for bulk orders while maintaining the quality and usefulness of each item in your event gift bag. 

Include A Welcome Or Thank You Note 

Whatever items you decide to put in your corporate gift bag, don’t forget that having a welcome or thank you note is imperative. Your bag will never be complete without one, as it shows your whole intention for handing out the event gift bags in the first place: that you’re grateful for the recipient’s attendance. 

You could attach your organization's business card along with your welcome or thank you note. This is a strong call to action. Now, there will be higher hopes that calls and inquiries in your business increase because attendees have your contact information through the business cards you’ve placed in your gift bags. 

The Bottomline 

Giving out corporate event gift bags isn’t always necessary, but it’s a nice add-on at the end of every event. There’s no better way to make a striking impact than by handing out gift bags as the attendees are about to leave. This notion is, however, limited only as far as the gift bags are well-thought-out. With the suggestions above, now you’ll be able to take a new twist into your corporate gift bags.

We have delved into EPR – a system that holds manufacturers and producers accountable for either correctly disposing or recycling the waste introduced into the economy by them – now, we will break down a system that incentivizes consumers to dispose their waste appropriately.
Deposit Return Scheme, also known as Deposit Return System, Deposit Refund System, Bottle Bills or Take-Back System, is essentially a surcharge on product, typically contained in a plastic or glass bottle or metal can, that is reimbursed to the purchaser upon return of the empty packaging.
DRSs are introduced to reduce littering and increase recycling rates on the account of the supplementary systems and infrastructure put in place. These systems include abundant and accessible collection centres, establishing a well-connected network of recycling plants and units and collection centres as well as suitable technology required to monitor and track deposits. 
DRS can be viewed as an application of the polluter-pays principle and is most commonly implemented by legislation although independent, private bodies can also take the initiative. 
Deposit Return Systems, or their informal equivalents, were first introduced as early as the 1800s to minimize financial losses observed due to market expansion and thus diminishing returns of business assets such as glass and stoneware bottles. These events predate the induction of plastic and aluminum as mainstay materials of bottle packaging.
What first appeared to be a solution soon became the reason behind the reintroduction of deposit-return systems. In the 70s and 80s, businesses and brands were excited to no longer invest in and maintain beverage packaging throughout its lifecycle an asset. The popularity of single-use PET bottles and aluminum beverage cans grew as they would be lightweight, disposable, easier to handle and cost-efficient. 
The first step in the revamping of DRS to limit a newfound evil was the introduction of curbside recycling.
Ontario was the first in the world to implement curbside collection by the name of “blue box” collection. 
The Litter Act of 1970 in British Columbia, Canada also marked a world first by introducing a mandatory refund system for beer and soft drink cans and bottles: the world’s first government legislated deposit return system.
Over 50 jurisdictions worldwide have now implemented Deposit Return Schemes.