Canadian Packaging September 2014

IN THIS ISSUE: CANADIAN CONVERTING • PRODUCT ID NOW • CORRUGATED PACKAGING

SEPTEMBER 2014 | $10www.canadianpackaging.com

TOAST OF THE TOWNStory on page 12

Packaging automation upgrade gets to the crust of the matter

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Whether you’re in need of a more cost-effective packaging option,

better speed-to-market capabilities or new innovative package designs,

Veritiv will help shape success for your business.

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IntelligentMotionTM

With its breakthrough design, the 9550 applies labels directly onto packs without the need for an applicator, while self-adjusting label placement accommodates varying line speeds, throughput and package sizes. Revolutionary Intelligent Motion™ technology targets zero unscheduled downtime as it precisely and automatically controls the entire system.

See the Videojet 9550 in action at PackExpo 2014 in Chicago.

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Download the Conair for Men AppLaunch the 3D Product AR Select the ‘display’ option

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Innovative Packaging and Retail Displays

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Custom design display

Conair and Add Ink teamed up to develop a virtual video display printed right onto an in-store display. Now customers can use their smart phones to directly engage with Conair’s new Even Cut display and watch the grooming tool in action. AR technology activates virtual video on the display or on the front panel of the product package.

To learn more about virtual video display technology, contact us. We’d love to hear from you.

• Replaces costly display-mounted LCD screens • Easy set-up - no power cords or batteries required• VVD is printed onto the display and/or product packaging;

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SEPTEMBER 2014 • CANADIAN PACKAGING WWW.CANADIANPACKAGING.COM • 3

UPFRONT

Packaging rarely gets the credit it deserves in the court of public opinion

for all the wonderful things it does to help people go about their daily lives in relative

comfort and safety. Taken for granted at best and scorned as a necessary evil at worst, packaging is the first thing to get the blame whenever consum-ers have a hard time opening a product package or the milk in the fridge turns sour just before this morning’s coffee.

And while most right-thinking people would agree that a world without modern consumer pa ckaging would be a pretty grim place, bashing packaging as a major contributor to some of the word’s gravest ecological and societal challenges seems to have become a brave new pastime among the mil-lennial generation empowered by social media and general disdain for anything pre-Internet in general as, well, just being so 20th Century, dear God!

But that’s no reason for the packaging industry to stop striving to develop better, more effective and more engaging packaging formats that will ultim-ately help change the public’s largely cynical take on its contribution to the greater societal good, despite a plethora of existing credible evidence to the con-trary. It would also do the industry well to take a more active role in educating the public on the multitude of practical benefits that a well-designed package inherently brings to their daily existence—especially when it comes to food packaging.

While enhancing product protection and shelf-life is the obvious no-brainer, there are many other reasons why, according to the industry’s conserv-ative estimates, the food product waste that this packaging prevents from taking place is at least 10 times greater than the waste it creates.

This mighty multiplier effect has profound sig-nificance for Canada and the U.S., with consumers in both countries estimated to throw away about 40 per cent of all the food produced there each year—translating into about $27 billion in Canada and some US$162 billion south of the border, or six million and 35 million tonnes respectively.

So how can packaging be used to cut that waste down in a meaningful way?

According to a recent position paper from AMERIPEN (American Institute for Packaging and the Environment), packaging can be effectively used to reduce this staggering mountain of food waste by:• Maintaining longer freshness, nutritional

value and safety. Rather than acting as mere oxygen barriers, “The latest packaging innova-tions even include technologies that prevent or reduce contaminants—increasing shelf-life and product safety, while maintaining nutritional value,” the study points out.

• Providing critical storage and usage infor-mation, thereby increasing the amount of food that is actually consumed, rather than thrown away due to spoilage.

• Delivering effective portion control. “Individually-wrapped chicken breasts, squeez-able yogurt tubes, and cheese sticks are much more than conveniences,” according to the study. “They ensure that the portions not eaten remain fresh and protected, ready for use at a later date [and] they help you from inadvertently serving to your family more than they can finish.”

• Providing more pre-cut and pre-washed food options. Bagged pre-cut carrots and celery, jarred sauerkraut and canned artichokes reduce waste by “delivering only the parts of these prod-ucts that can be eaten,” without all the stems, peels, husks and stalks that have to be disposed of. Instead, all these ‘edibles” can be composted by farmers and food processors before packaging to create natural fertilizer and soil condition right where they’re needed in the field.Says AMERIPEN’s executive director Donna

Dempsey: “To most people, the fact that pack-aging plays a very positive role in our efforts to reduce food waste is counterintuitive, as they usu-ally think about a package when it comes time to put it in the recycling or trash bin.

“What they don’t realize is how that little bit of packaging saves a significant amount of food, along with the related economic and environmental resources from being thrown away.”

One way or another, it’s time for everyone to start doing their part to help make that realization sink in where it really counts.

WASTE NOT WANT NOT 2.0

SEPTEMBER 2014VOLUME 67, NO. 9

SENIOR PUBLISHERStephen Dean • (416) 510-5198 [email protected]

EDITORGeorge Guidoni • (416) [email protected]

FEATURES EDITORAndrew Joseph • (416) 510-5228 [email protected]

ART DIRECTORSheila Wilson • (416) 442-5600 x3593

[email protected]

PRODUCTION MANAGERBarb Vowles • (416) 510-5103

[email protected]

CIRCULATION MANAGERAnita Madden • 442-5600 x3596

[email protected]

EDITORIAL DIRECTORLisa Wichmann • (416) 442-5600 [email protected]

EXECUTIVE PUBLISHERTim Dimopoulos • (416) 510-5100

[email protected]

BIG MAGAZINES LPVice-President of Canadian Publishing • Alex Papanou

President of Business Information Group • Bruce Creighton

HOW TO REACH US: Canadian Packaging, established 1947, is published monthly by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. 80 Valleybrook Drive, North York, ON, M3B 2S9; Tel: (416) 442-5600; Fax (416) 510-5140.

EDITORIAL AND ADVERTISING OFFICES: 80 Valleybrook Drive, North York, ON, M3B 2S9; Tel: (416) 442-5600; Fax (416) 510-5140.

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©Contents of this publication are protected by copyright and must not be reprinted in whole or in part without permission of the publisher.

DISCLAIMER: This publication is for informational purposes only. The content and “expert” advice presented are not intended as a substitute for informed professional engineering advice. You should not act on information contained in this publication without seeking specific advice from qualified engineering professionals. Canadian Packaging accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. Canadian Packaging receives unsolicited materials, (including letters to the editor, press releases, promotional items and images) from time to time. Ca-nadian Packaging, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort.

PRIVACY NOTICE: From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1-800-668-2374 Fax: 416-442-2191 Email: [email protected] Mail to: Privacy Office, 80 Valleybrook Drive, North York, ON M3B 2S9

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We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage for our publishing activities. Canadian Packaging is indexed in the Canadian Maga-zine Index by Micromedia Limited. Back copies are available in microform from Macromedia Ltd., 158 Pearl St., Toronto, ON M5H 1L3

COVER STORY12 TOAST OF THE TOWN By Andrew Joseph Innovative Quebec breadmaker making the most of its recent packaging automation

investment with optimized productivity and vastly improved line efficiencies.

Cover photography by Pierre Longtin

3 UPFRONT By George Guidoni4-5 NEWSPACK Packaging news roundup.6-7 FIRST GLANCE New packaging solutions and technologies.8 ECO-PACK NOW All about packaging sustainability.10 imPACt A monthly insight from PAC, Packaging Consortium.32 PEOPLE Career moves in the packaging world.33-34 NOTES & QUOTES Noteworthy industry briefs.35 EVENTS Upcoming industry functions.36 CHECKOUT By Paul Pethick Joe Public speaks out on packaging hits and misses.

FEATURES18 RAPID PROGRESS By Andrew Joseph A new printing press installation is

a powerful morale and performance booster for venerable Ontario folding-carton stalwart.

22 LIVING IN THE FAST LANE By Andrew Joseph A labeling system upgrade keeps leading

producer of household and automotive chemicals in pole market position.

28 FOUR WAYS TO PROSPER By Nick Griffin Ontario boxmaker scaling new heights of

productivity and production flexibility with a new state-of-the-art folder-gluer.

DEPARTMENTS & COLUMNS

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NEWSPACK

4 • WWW.CANADIANPACKAGING.COM CANADIAN PACKAGING • SEPTEMBER 2014

NEW WINE LABELS PAY A FITTING TRIBUTE TO FALLEN CANADIAN WAR HEROESWith the summer commemorations of 100-year anniversary of the start of World War I provid-ing a timely sobering reminder of the ultimate sacrifices by thousands of young Canadians who perished in the brutal four-year conf lict, Ontario-based Diamond Estates Wines & Spirits is keen to keep that sense of patriotic pride alive for years to come with the release of two new wines paying fitting homage to the country’s war-time efforts.

Launched last month across Ontario, Manitoba and Alberta, the 750-ml bottles of 1914 Honour white and 1914 Valour red varietals represent a somber departure for one of the province’s leading winemakers—operating several large wineries and vintners in the Niagara region—which is better-known for its celebrity-endorsed vintages such as Dan Aykroyd and NHL Alumni wine series.

“These new wines were developed specifically to recognize and celebrate the achievements of the generations who served and continue to serve in Canada’s military,” says Diamond Estates president and chief executive officer Murray Souter.

Paying a tribute to both the 100th anniversary of the Great War and the 150th Anniversary of Confederation—initiated by the historical 1864 Charlottetown Conference that paved the way to Canadian Confederation in 1867—both wines are

currently available in 750-ml glass bottles, sporting elegantly attractive labels designed by the Toronto-based graphics agency Brand Muller (pictures below) and in the nine-liter bag-in-box packaging formats for the foodservice industry.

Diamond Estates says it will donate 50 cents from the sale of each bottle sold through LCBO (Liquor Control Board of Ontario) and other

provincial liquor boards to the True Patriot Love Foundation, with the aim of raising $50,000 by the upcoming Remembrance Day celebrations on November 11, 2014.

Established in 1955, the not-for-profit organiza-tion funds a variety of programs in mental health, physical rehabilitation, family support and vet-eran transition that address the unique challenges related to the impact of military service.

“The LCBO has always been a great supporter of charitable causes and they were very receptive to helping us promote this effort and the many pro-motional activities leading up to Remembrance Day,” Souter states.

“We will be working tirelessly to get these wines into the hands of Canadians in every province.”

According to Diamond Estates brand marketing manager Peter Toms, the company plans to make both labels a permanent part of its product port-folio, rather than a one-off, limited-time release.

“This is a whole new brand that we are very proud of and that we feel has real staying power to it,” Toms told the Canadian Packaging magazine.

“We are confident that all Canadians who try it will appreciate it both for its message and its approachable taste profile that can be enjoyed at any occasion,” says Toms, noting that the company fully intends to extend the brand’s geographic reach nationwide.

Adds Diamond Estates vice-president of wine-making Tom Green: “The 1914 Honour is a refreshingly crisp white wine, while the 1914 Valour is a bold and mouth-filling red [and] either wine can be readily enjoyed either on their own or with food.”

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SEPTEMBER 2014 5

NEWSPACK

RECYCLING SCHEME A BIG GREEN PERK FOR OFFICE COFFEE-LOVERSWidely loved by consumers for their convenience, and just as widely reviled by environmentalists for their allegedly excessive carbon footprint, the sin-gle-serve coffee capsules—still commonly referred

to as K-Cups after their original inventor Keurig—have the cof-fee industry working furiously to develop a workable end-of-life solution to prevent these hard-to-recycle, multi-material mini-pods from ending up at landfills across North America in their mul-

tiple billions year after year.And while it may not quite be the

green silver bullet the coffee indus-try would love to see right now, a new pilot recycling initiative just launched by TerraCycle Canada and leading office supplies distribu-tor OfficeMax Grand & Toy is certainly a step in the right direction.

Under the program—for now limited to a trial run in southern Ontario—OfficeMax Grand & Toy will offer its customers one of three specially-designed recycling boxes to collect all the discarded K-Cup capsules at their offices and ship the filled boxes directly to TerraCycle.

Widely acknowledged as one of the world’s leading “upcyclers” of waste products, TerrCycle uses a proprietary process to separate all the K-Cup components (cup shells, lidding, filters, etc.) to make the leftover materials suitable for manu-facturing a broad range of useful new products—from plastic carry bags and pencil cases to park benches and outdoor garbage bins.

“At OfficeMax Grand & Toy, we believe that each and every person has a responsibility to do their part to better the natural environment that we all share,” says OfficeMax Grand & Toy’s sustainability man-ager Serguei Tchertok.

“In line with this philosophy, we embrace environmental responsibil-ity across every facet of our business, and we foster it through unique, pro-gressive programs such as this,” says Tchertok, adding that K-Cup Packs are one of the company’s most popu-lar coffee products.

“We launched this program based on the stakeholder feedback that we received from our associates, suppli-ers and customers, who have identi-fied waste and recycling as our most important sustainability issue,” he adds, pointing out that OfficeMax Grand & Toy, an affiliate of global office products provider Office Depot, Inc., is the first retailer in Canada to get involved in the recyc-ling of K-Cup capsules.

Resembling a compact-footprint filing cabinet in shape and size, the TerraCycle K-Cup Recycling System boxes are available in small, medium and

large sizes, with the final price of each option ($52.99, $96.99 and $136.99 respectively) also cov-ering the cost of a pre-paid shipping label to send the filled boxes directly to TerraCycle for processing.

(See full pricing and purchasing information atwww.officemaxcanada.com/terracycle)Says TerraCycle Canada’s general manager Nina

Purewal: “TerraCycle is thrilled that OfficeMax Grand & Toy has partnered with us to launch Canada’s first K-Cup Packs retailer recycling program.

“Their leadership in helping us eliminate waste speaks to their commitment to sustainability.

“We are excited to be able to offer a recycling solu-tion to this wastestream problem to Canadian con-sumers,” says Purewal, adding that a successful pilot project in southern Ontario would set stage for the program’s nationwide rollout.

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Sarong S.p.A., the worldwide leading manufacturuer of thermoforming fill and seal packaging machines, superior packaging materials and exceptional contract packaging, for food, pharmaceuticals and household products, has opened a new location in Mississauga, Ontario, Canada. Specializing in single dose packaging, Sarong recognizes the importance of expanding this concept throughout North America where unit dose serving in packaging is becoming the packaging solution of the future. For years, the single dose packaging concept has been the norm throughout Europe where family homes have smaller storage spaces that demand smaller packs for food and household products. On the other hand until recently, consumers in North America commanded large family size packaging for their favorite consumer products. Today the North American consumer is changing, demanding more sustainable packaging and less food wastage, therefore, vastly receptive to unit dose packaging solutions. For Sarong, expanding its locations to North America was a strategic move. Mr Alberto Bartoli, Vice President of Sales & Marketing with Sarong S.p.A.

explains, “It makes perfect sense for us to have a domestic location in North America servicing the Canadian and US market. We offer innovative packaging

solutions and can’t wait to demostrate our capabilities to small and large organizations in this region.”

In November 2014, for the first time, Sarong S.p.A. will be exhibiting at the Chicago Pack Expo show Nov 2-5 and will also be presenting on the innovation stage lecturing on thermoforming packaging for single dose.

Be sure to visit the Sarong S.p.A booth #1022 located in the

Pharma Expo section.

For more information please contact:Rachel Gualtieri [email protected]: 647-448-9124

Sarong North America Inc. Offices:2470 Stanfield Rd., Unit C,Mississauga, Ontario L4Y1S2Office: 905-272-3699

Sarong S.p.A. Italy Expands Offices to North America


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Flexlink_Sept14.indd 1 14-09-04 2:33 PM

CODE OF CONDUCTThe new model 1050 thermal inkjet printer from Markem-Imaje is designed to produce high-resolution serialized data and complex linear and 2D (two-dimensional) barcodes on fast-moving production lines in the food, beverage, pharma-ceutical and other industries, according to the company, while also excelling in case-coding applications in dusty, humid or corrosive environ-ments. Incorporating a high-precision, f lexible printhead capable of generating text, logos and

high density graphics up to two inches in height in 600-dpi (dots per inch) resolution on high-speed packaging lines, the 1050 is easy to main-tain because it features ink cartridges that com-bine the printhead and

ink—meaning no mov-ing parts—with the snap-in/out cartridges facili-tating uninterrupted operation. Well-suited for creating customized product promotional coding in short-run production, the 1050 thermal inkjet printer incorporates a user-friendly, seven-inch touchscreen interface with intuitive WYSIWYG programming, along with full compatibility with the company’s powerful CoLOS coding software for centralized network control of all the Markem-Imaje printers.Markem-Imaje 401

PRESSING THE ISSUEDesigned to offer label and packaging converters faster turnaround times through automated color management, a wider frame and new ink capabil-ities for expanded applications, the new rollfed HP Indigo series WS6000 digital printing press from Hewlett-Packard Development Company, L.P. is outfitted with a new inline spectropho-tometer utilizing closed-loop control to eliminate the need for manual color calibrations and adjust-ments—thereby reducing time spent preparing color profiles and PANTONE color matching

by up to 75 percent, according to the company. Boasting an expanded 320-mm frame width for higher press output, the new press also incorpor-ates an Enhanced Productivity Mode (EPM) option to enable label converters to produce up to 131 linear feet per minute in full color. Powered by Esko’s Packaging Workflow Suite 4.1 and the HP SmartStream Labels software, the WS6800 press also boasts proprietary ElectroInk Silver technology to enrich the labels’ appearance with a metallic look similar to UV f lexo silver inks, which can be used as a spot or base color on a range of label appli-cations, including paint, automotive, household chemicals, nutraceuticals and soft-drinks, with high-def resolution of up to 223 lines per inch.Hewlett-Packard Development Company, L.P. 402

HIP TO BE SQUAREThe new patented Square Bag f lexible packaging solution from Mondi Americas incorporates advanced packaging films with a variety of spouts, closures and handles to provide a reliable and effective alternative for pack-aging of liquid food, wine, laundry detergent, pet food, motor oil and other liquid products in up to 1.5-gal-lon volumes, as well as pow-ders and granular materials weighing up to 10 pounds. Easily adaptable to most common filling lines with-out specialized filling technology, the versatile Square Bag can be fitted with a spout, zipper, slider, and hook or loop openings, with label handles on different panels that can be constructed from up to three different materials.Mondi Americas 403

FIRST GLANCE

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http://www.flexlink.com


Sarong S.p.A., the worldwide leading manufacturuer of thermoforming fill and seal packaging machines, superior packaging materials and exceptional contract packaging, for food, pharmaceuticals and household products, has opened a new location in Mississauga, Ontario, Canada. Specializing in single dose packaging, Sarong recognizes the importance of expanding this concept throughout North America where unit dose serving in packaging is becoming the packaging solution of the future. For years, the single dose packaging concept has been the norm throughout Europe where family homes have smaller storage spaces that demand smaller packs for food and household products. On the other hand until recently, consumers in North America commanded large family size packaging for their favorite consumer products. Today the North American consumer is changing, demanding more sustainable packaging and less food wastage, therefore, vastly receptive to unit dose packaging solutions. For Sarong, expanding its locations to North America was a strategic move. Mr Alberto Bartoli, Vice President of Sales & Marketing with Sarong S.p.A.

explains, “It makes perfect sense for us to have a domestic location in North America servicing the Canadian and US market. We offer innovative packaging

solutions and can’t wait to demostrate our capabilities to small and large organizations in this region.”

In November 2014, for the first time, Sarong S.p.A. will be exhibiting at the Chicago Pack Expo show Nov 2-5 and will also be presenting on the innovation stage lecturing on thermoforming

packaging for single dose.

Be sure to visit the Sarong S.p.A booth #1022 located in the

Pharma Expo section.

For more information please contact:Rachel Gualtieri [email protected]: 647-448-9124

Sarong North America Inc. Offices:2470 Stanfield Rd., Unit C,Mississauga, Ontario L4Y1S2Office: 905-272-3699

Sarong S.p.A. Italy Expands Offices to North America

SEPTEMBER 2014 7

FIRST GLANCE

INTEGRAL BENEFITSThe new turnkey Integra 320 robotized blister line from Marchesini Group features a new machine pitch control system combined with high-speed carton opening and product insertion systems to reach output levels of up to 320 blisters and more than 260 cartons a minute. Boasting a small-foot-print design, the Integra 320 line smoothly inte-grates blister thermoforming and carton packaging

phases in a compact system utilizing a three-axes Robocombi robot with a sucker pick-up head that connects the two stations and minimizes size changeovers. Equipped with a servo-operated film unwinder that stops automatically when the material runs out, the line features an integrated forming material splicing table with automatic vacuum system that blocks the film in the correct position.Marchesini Group 404

MAXIMUM SAFETYDeveloped by Constantia Flexi-bles, the new Safemax container is a deep-drawn aluminum container for pharmaceutical devices—featur-ing innovative construction whereby aluminum is laminated to poly-

prolypene and then combined with a lidding foil to ensure optimal seal integrity and provide convenient peel-off lidding foil that is safe and easy for end-users to open, while pro-viding reliable, highly-hygienic pro-tection against moisture ingress for the medical devices inside.Constantia Flexibles 405

UPLIFTING FEATURESWith payload capacity of up to 50 kilograms, the new JumboFlex 50 vacuum tube lifter from J. Schmalz GmbH features a new operator han-dle with a redesigned button—along with larger soft-touch inserts on the control handle—that can be con-trolled with either one or two fingers by either right- or left-handed oper-ators. Employing an energy-saving electrical pump to generate optimal suction power and lifting speeds of up to one meter per second, the JumboFlex 50 lifter comes with a variety of dif-ferent quick-change suction pads to suit a broad range of demanding appli-cations: including the round suction pad for barrels and buckets; double

and quadruple suction pads that can be used for hand-ling wooden panels, metal sheets and other large

workpieces; and a sack gripper for safe and reliable transport of plastic and paper sacks.J. Schmalz GmbH 406

SOMETHING IN THE AIRStoropack’s newly upgraded line of AIRplus air cushioning now includes three new types of film to expand the application range of the company’s on-demand AirPlus machine—set up directly at the packing station—to offer a cost-effective alterna-tive to the use of conventional, pre-inf lated bubble

wrapping materials. Now available in both a standard width of 400-mm (Bubble 29b) and a larger width of 700-mm (Bubble 53b) for packing small items such as cell-phones or cosmetic products, the new protective packaging options also include the AIRplus Cushion material with 28 chambers per perforated section (Cushion 28b)—engineered for the wrapping of larger items such as laptops, as well as for the wrapping of individual products in a package where sensitive items inside need to be protected from damage by other packaged goods.Storopack North America 407

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http://www.sarong.it

Autumn holiday orders are the lifeblood of many smaller artisan bakeries specializing in creating memorable pumpkin, key-lime, apple, cherry, pecan and blueberry pies that often travel vast dis-tances to arrive just in time for special occasions in immaculate shape and condition.

This makes the delivery of such hand-crafted pies, cheesecakes and layer cakes a trickier pack-aging challenge than some may think—both in terms of product freshness and the environmental footprint.

But not too tricky for the Norfolk, Neb.-based Thermal Packaging Products, whose new Pie and Cake Shippers were designed specific-ally to offer online fine-food purveyors a clever and environmentally responsible way to protect temperature-sensitive pies and cakes during mail

order delivery to customers across the continent.According to the company, the cotton-en-

han ced insulating materials used in the Pie and Cake Shipper car-riers provide soft cushioning and thermal protec-tion for the pack-age contents via the use of special insulating cot-ton padding made from a select blend

of recycled f locked cotton fibers that provide ‘super-absorbent’ properties for effective contain-ment of undesirable condensation or accidental spills, while also incorporating a time-sensitive,

EPA-approved antimicrobial additive for cross-contamination prevention.

“This unique combination, when used with gel packs or other refrigerant, provides the superior thermal protection necessary for temperature control during shipments,” the company says.

The reversible two-part insulation liners also allow for frozen shipments utilizing dry ice film on one side, according to Thermal Packaging, or the perforated film for refrigerated shipments using frozen gel packs that often condensate dur-ing the thawing process.

The tiny perforations in the film allow for any spills or unwanted condensation from gel packs to be wicked away from the product and be absorbed into the insulation fibers, according to the company.

8 • SEPTEMBER 2014

INSULATED CARRIERS HIT THE GREEN PACKAGING SWEET SPOT

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File Name: 14SAC200A_G&T_PROC_ENG_CanadPack_v2 Client: CryovacDesc.: Grip & Tear Value Drivers (English) Canadian Packaging

Live: 7 in (w) x 10 in (h) Trim: 7.875 in (w) x 10.75 in (h)Bleed: 8.125 in (w) x 11 in (h)

Color: 4C ProcessBuilt @: 100%Printed @: 100%

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While the solid growth in recyc-ling rates for PET (polyethylene terephthalate) beverage containers is great news on the surface, things look less rosy when one considers that up to one-third of the collected bottles ultimately can’t be recycled as intended due to contamination from labeling materials and adhesives.

According to recycling indus-try sources, out of the 1.5 million pounds of PET collected across the U.S. for recycling in 2010, yield losses from contamina-tion traced to dir-ect printing, paper labels and standard pressure-sensitive labels ranged from 24.4 to 32,2 per-cent—amounting to a loss of over 40 million pounds of bottles.

With these numbers in mind, it’s hard to understate the promising potential of the CleanFlake port-folio of adhesives developed by the Glendale, Ca.-headquartered label-ing manufacturer Avery Dennison, which recently picked up the coveted Top Product of the Year honors in this year’s Environmental Leader Product & Project Awards competition.

In a nutshell, the patent-pending CleanFlake adhesives are specially-formulated to prompt them to lit-erally “switch off” when submerged in a recycling bath to enable labels to separate cleanly from the PET f lakes.

“Although these labels adhere firmly to PET containers during use, they detach readily in a conventional recycling facility and f loat to the surface of the bath, allowing clean PET f lakes to sink to the bottom for easier reclamation,” explains Don Nolan, president of Avery Dennison’s Materials Group business.

A FLAKY TAKE ON CLEAN PET

PACKAGING INNOVATION AT WORK

You can change over aDelkor Trayfecta® in the time

it takes to read this ad.

delkorsystems.com | 800-328-5558

Three minutes! That’s all it takes to change over a Delkor Trayfecta former – no tools required. It doesn’t matter whether you’re going from a lock-style paperboard carton to a glued corrugated case. The Trayfecta even handles shelf-ready applications such as Delkor’s new, patent-pending Cabrio Case®. Once the changeover is complete, you can immediately start high-quality production. With product-specific tooling, there is no need to make multiple adjustments that create

material waste. Trayfecta formers come in single- to four-headed units to meet the widest

range of line speed requirements. It’s no surprise that plant managers are calling it “the best and most versatile machine” in their packaging lines. Stop by our booth # S-3834 at Pack Expo International in Chicago or visit our website today to see how the Delkor Trayfecta former can help you meet today’s – and tomorrow’s − packaging challenges.

Cartons CasesTrays

®

PACK EXPOInternationalADVANCING

& PACKAGINGPROCESSING

November 2 - 5, 2014McCormick Place Chicago, IL, USA

Booth S-3834

SEE US ATStop by our booth # S-3834 to see our Trayfecta® former in action!

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PACKAGING INNOVATION AT WORK

You can change over aDelkor Trayfecta® in the time

it takes to read this ad.

delkorsystems.com | 800-328-5558

Three minutes! That’s all it takes to change over a Delkor Trayfecta former – no tools required. It doesn’t matter whether you’re going from a lock-style paperboard carton to a glued corrugated case. The Trayfecta even handles shelf-ready applications such as Delkor’s new, patent-pending Cabrio Case®. Once the changeover is complete, you can immediately start high-quality production. With product-specific tooling, there is no need to make multiple adjustments that create

material waste. Trayfecta formers come in single- to four-headed units to meet the widest

range of line speed requirements. It’s no surprise that plant managers are calling it “the best and most versatile machine” in their packaging lines. Stop by our booth # S-3834 at Pack Expo International in Chicago or visit our website today to see how the Delkor Trayfecta former can help you meet today’s – and tomorrow’s − packaging challenges.

Cartons CasesTrays

®

PACK EXPOInternationalADVANCING

& PACKAGINGPROCESSING

November 2 - 5, 2014McCormick Place Chicago, IL, USA

Booth S-3834

SEE US ATStop by our booth # S-3834 to see our Trayfecta® former in action!

Delkor-Canadian Packaging Sept 2014.indd 1 9/3/14 8:53 AM

p 08-09 cpac sept 2014 ECO p 08-09.indd 9 14-09-05 11:01 AM

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©2014 Rock-Tenn Shared Services, LLC. All rights reserved. ROCKTENN, the stylized R, and META are trademarks of Rock-Tenn Company and its subsidiaries and affiliates.

Visit us at PACK EXPO International, Booth #S-2122

RockTenn’s precision mandrel-forming technology forms cases around a fixed mandrel, minimizing case-skew and maximizing structural integrity, resulting in cases that outperform standard RSC’s

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COVER STORY


MOST DARING ADVENTUREQuebec bakery’s automation investment hits the packaging line efficiency sweet spot

ANDREW JOSEPH, FEATURES EDITOR PHOTOS BY PIERRE LONGTIN

No manufacturer of global renown has ever gotten to be that way without daring to set high goals for itself, and Kitchener,

Ont.-headquartered Dare Foods Limited is as fine a testament to the virtues of dreaming big and reaching high as any major Canadian food produ-cer out there—even after more than 120 years in the highly competitive baked-goods business.

Founded in 1892 by Charles Henry Doerr under the name of C.H. Doerr Company, the family-owned business that rose to iconic prominence as a manufac-turer of delicious, high-quality cookies is nowadays also a major North American player in the market segments for crackers, fine breads, candies and other baked goodies and treats that busy modern-day con-sumers can’t seem to get enough of—including the very popular line of snack-bread products produced at the company’s highly-automated, 140-employee breadmaking facility in Saint-Martin, Que.

One of six manufacturing plants operated by Dare Foods in North America—employing over 1,300 people in total—the Saint-Martin plant is home the company’s very popular line of Boulangerie Grissol brand portfolio purchased by Dare Foods in its 2001 acquisition of the cookie and fine breads business of the Montreal-based Culinar Inc.

Housing two baking lines and three packaging lines,

the busy plant turns out the full range of Boulangerie Grissol brand products, including the perennial best-seller Melba toast, Canapé, Bread Sticks and Baguette Bites, along with the recently-lunched new favorites such as Morning Thins, thin crispy slices of bakery-style loaves with seeds, fiber and fruit for on-the-go mornings; Sweet Thins, a sweet calorie-controlled snack; and Artisanal Baguettes, a line of premium-quality, oven-baked baguettes made under authentic recipes and using fresh natural ingredients like black olives, cinnamon and raisin, or cranberry and figs.

Lead Role“We are a leading Canadian fine bread manufac-turer,” says Saint-Martin maintenance manager Matthew Beauchamp, noting the company consid-ers itself to be one of the leading players in the fine bread market segment across North America, despite growing competition from both imports and private-label store brands.

“Increased competition is a reality for us,” Beauchamp told Canadian Packaging in a recent interview, “but we constantly strive to remain competitive by launching new and innovative products.

“We also look at our bottom line results with the realization that by constantly updating our manu-facturing equipment, we will not only improve our production line speed and efficiency, but will also reduce our manufacturing costs,” says Beauchamp,

citing four major facility expansions and innumer-able equipment upgrades taking place at the Saint-Martin factory since it first started producing the venerable Boulangerie Grissol products back in the 1940s under previous owners.

As the plant’s maintenance manager, it is Beauchamp’s job to ensure the plant’s production and packaging lines are always running up to snuff, which is no easy task for a plant “producing on three shifts a day, covering the entire week—with regularly scheduled sanitation—24-hours-a-day and seven-days-a-week.”

Despite the plant’s high-throughput rates and growing volumes, Beauchamp says the facility does not take any shortcuts that would in any way under-mine the final quality of the product manufactured at Saint-Martin.

“After fresh ingredients are mixed in batches to produce dough, we process it into various pans, and bake it in large ovens,” he relates. “After de-panning, the cooked loaves are placed onto large wheeled racks and are refrigerated for several days to ensure most of the humidity is removed.

“Removing it from the refrigerated section, we slice the now-dry bread, and further toast it on a processing line specific to the type of cut and pack-aging required,” Beauchamp expands.

“After packaging—either semi-automatically or fully-automatically—the packaged products are palletized and immediately placed into vans for

Dare Foods’ Saint-Martin facility maintenance manager Matthew Beauchamp holds semi-finished boxes constructed by the high-speed Delkor Trayfecta S4 1502 carton former.

p 12-17 cpac sept 2014 DARE cvr sty p 12-17.indd 12 14-09-05 2:27 PM



COVER STORY

shipment to our distribution center which will then ensure our products go to the proper destination.”

For a company that is often credited with rewrit-ing the book on cookie packaging in Canada, hav-ing borrowed a trick from coffee packaging and introducing the tin-tie strip to cookie packaging in 1954 to make it a new de facto cookie industry standard, the performance of packaging machinery and equipment at the Saint-Martin facility natur-ally get all the close scrutiny and attention it duly deserves, according to Beauchamp.

“When I became the maintenance manager for the Saint-Martin plant last year, I noticed early on that an existing carton former that was in use on one of our major line was not up to par,” he says.

“Relative to our needs, it was a poor design that featured overly complicated changeovers and adjustments that, quite frankly, caused us a lot of unnecessary downtime.

“Back in the summer of 2011, I was looking for a simple, robust, yet high-performance design with a high level of performance and efficiency, and I found one that offered all of that in one,” relates Beauchamp. “We found that at Delkor.”Delkor Systems, Inc., a St. Paul, Minnesota-

headquartered designer and manufacturer of pack-aging machinery, installed a brand-new Trayfecta S4 1502 model case, carton and tray former at the Saint-Martin facility.

According to Beauchamp, it was when he worked

for Dare’s engineering department that he first considered them for a project.

“I was impressed by the equipment that they offered, but unfortunately, that project fell through,” relates Beauchamp.

Delkor sales manager Fred Sowa says that for the latest project Dare Foods was looking for a new tray former, but that “the actual carton matrix they presented was a bit unique in that they had a large format that ran quite slow and that the other smaller formats required speeds up to 90 cartons per minute.”

Head StartAccording to Sowa, the Trayfecta S4 1502 was the best possible solution for Dare Foods, allowing it to utilize two heads for the higher rate, while only one head would be required for the slower rates, a f lexibility offered by the machine that is con-sidered to be unique in the business.

“We actually design and manufacture three other carton formers, with another having four heads allowing for forming speeds over 200 cartons per minute, but the 1502 matched so perfectly for this mix of size and rate required, that it was a no-brainer for us to recommend it to Dare Foods,” advises Sowa.

He adds that since Dare required a nominal rate of 78 with a surge rate of 90 cartons per minute for their fastest requirement.

Delkor was aware that the speed on these machines

is dictated by the carton size and style, “But on the 1502, we can mechanically operate at 60 cycles per minute so the machine is not being stressed.”

Key features of the Trayfecta S4 1502 include:• A tool-less changeover that takes three min-

utes per head thanks to three servo motors that actually do most of the work automatically;

• Fixed tooling sets that are simple to install, enabling instant startup on the first cycle for immediate formation of quality cartons, with less costly carton waste;

• Changeovers that are easy for operators of all skill levels, via an HMI (human-machine inter-face), that is very intuitive with easy-to-follow procedures;

• Provide a thorough training and support for independent operation by the plant.

• Ability to run three materials: paperboard, cor-rugated and microf lute materials with just a minor tooling change.

“You might note that Delkor seems to be a wee bit obsessed with the number three—but when we are talking about the Trayfecta series, it is by design, as it is a play on the word ‘trifecta’, bringing the power of three to the forming applications,” reveals Sowa.

“The Trayfecta can also run three different pack-age formats—cartons, cases and trays, and handles glued, locking and fold-over lock designs,” he expands.

Pre-printed box flats ready to be placed into the Trayfecta S4 1502 carton former, to be glued into shape with the Nordson ProBlue 7 hot-melt adhesive applicating system.

The Delkor Trayfecta system utilizes the Nordson ProBlue 7 hot-melt adhesive dispensing and applicating system for forming the paperboard cartons at high throughput speeds.

Flat paperboard sheets being pneumatically transferred inside the Delkor Trayfecta carton former to be glued and then assembled at high speeds.

A close-up of the Trayfecta carton forming machine shows cavities being formed in the cartons to make just the right amount of space for the packaged product.



COVER STORY

14 SEPTEMBER 2014

“Should you require it, it could form a paper-board carton on one lane, while at the same time form a corrugated case in the other lane,” states Sowa. “It’s just that impressive.”

To handle rough going at Dare Foods, the Trayfecta S4 1502 boasts a robust construction with fixture head slide guides that maintains a stroke tolerance within 0.008-inches for repeatable and close tolerance motion.

The Trayfecta S4 1502 utilizes a Rockwell Automation Allen-Bradley brand PanelView Plus 700 for easy operator interaction, and a ProBlue 7 hot-melt adhesive system to seal the car-tons, cases and trays, manufactured by Nordson Corporation.

Now using the Trayfecta S4 1502 for cartoning of the Melba toast products, and the new Sweet Thins and Morning Thins products, Beauchamp is quite happy with the whole project.

“Everything worked out very well,” he begins.

“The machine was up and running in no time, and it passed all the SAT (site acceptance test) and commissioning at a 99.5 per cent efficiency.

“We went from a two-hour change-over that took another two hours to fine-tune in production with our old machine, to a less than 10-minute changeover that generated perfect cartons in the first cycle after startup,” recalls Beauchamp.

Sowa concurs, noting that Delkor performed substantial testing prior to the customer’s factory acceptance test.

“Once their team arrived, we fol-lowed Dare’s extensive protocol to prove the machine,” says Sowa.

Beauchamp says he was also happy about the fairly simple training for Dare Foods’ operators.

“After only about 12 hours of training, a new operator could run and perform changeover with the Trayfecta within the required time,” Beauchamp says, noting that Delkor’s assembly technicians also serve as the installation service support.

“As such, when we do our extensive training with the customer in our facil-ity, and follow through at the installa-tion with the same technicians, we can provide a training service that is per-fectly in tune with people who are fam-iliar with not only the tray former, but also Dare’s requirements,” relates Sowa.

Other key equipment installed at the Saint-Martin facility include:• a Bosch Packaging Technology

robotic top-loading system;• a Markem-Imaje model 6064 ther-

mal inkjet coder;• a Loma Systems model IQ2 metal

detection system;• f lexible stand-up pouch packaging

machinery for the new Boulangerie Grissol Artisanal Baguettes products.

Beauchamp says he is convinced that the bakery will continue to move forward to be the best in the market segment.

Leading the food industry in processing and packaging solutions.

Reiser Canada1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611Reiser725 Dedham Street, Canton, MA 02021 • (781) 821-1290www.reiser.com/fabbrisausage2013

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Fabbri Automatic Stretch Wrappers produce highlyattractive packages that make your products lookfresh and “just packed”. Fabbri Stretch Wrappers usestretch film to package fresh sausage in preformed trays toprovide an in-store wrapped appearance. They employ four-way stretch technology to produce tight, over-the-flange,wrinkle-free packages with securely sealed bottoms and a superb case presentation. And here’s something you might find even more attractive: Fabbri Stretch Wrappers can help increase your profitability.Fabbri packaging is produced using low-cost packaging materials. And when you factor in its Best in Class low cost ofownership, the Fabbri Stretch Wrapper is your most economical and affordable packaging solution. Compact and robust servo-driven Fabbri packaging machines are built for speed, versatility and the highest levels ofproductivity. Fabbri Stretch Wrappers can handle a wide range of tray sizes with no changeovers, producing up to 62 packs perminute. All models feature a user-friendly full-size control panel for easy operation and maintenance. Test the Fabbri at ourReiser Customer Center and see for yourself how it can improve your packaging. Contact Reiser today.

Fabbri_2013Feb_MeatPkgAd_Sausage_CP_Layout 1 2/8/13 11:13 AM Page 1Formed cartons exit the Trayfecta S4 system via con-veyor to be filled with product.

It’s mId-range, but way above average

EXPERTFOLD 170 / 230 / 300 / 350

www.bobst.com

274.6375x403.225

As a mid-volume corrugated box manufacturer, you need equipment that sets and runs quickly, gives you great box quality, and can be adapted to future changes in your markets.

Right in the middle of the BOBST range is the new EXPERTFOLD, a specialty folder gluer which gives you exactly that.

Available in four widths and three configurations, EXPERTFOLD has been specifically designed with mid-volume production in mind, whatever your markets.

EXPERTFOLD : The right tool for the job.

The Markem-Imaje 6064 thermal ink coder and the Loma IQ2 metal detection system pair up for optimal product coding and quality assurance.

continues on page 16


http://www.reiser.com/fabbrisausage

It’s mId-range, but way above average

EXPERTFOLD 170 / 230 / 300 / 350

www.bobst.com

274.6375x403.225

As a mid-volume corrugated box manufacturer, you need equipment that sets and runs quickly, gives you great box quality, and can be adapted to future changes in your markets.

Right in the middle of the BOBST range is the new EXPERTFOLD, a specialty folder gluer which gives you exactly that.

Available in four widths and three configurations, EXPERTFOLD has been specifically designed with mid-volume production in mind, whatever your markets.

EXPERTFOLD : The right tool for the job.


http://www.bobst.com

COVER STORY


Machine operator using the Allan-Bradley PanelView Plus 700 terminal to monitor and control operations of the Delkor Trayfecta S4 model 1502 carton former.

Dare Foods employs a robotic top-loading system to execute gentle and efficient place-ment of packs of Melba toast in the outer boxes.

CANPACK-MicrositeSept-14.pdf 1 8/29/2014 9:39:03 AM

DARE FOODS TIME-LINEThe humble start to the Dare Foods empire began when Doerr began mak-ing and selling hand-made cookies at his own grocery store located in Berlin, Ont.—a predominantly German community now known as Kitchener, about an hours drive west of Toronto.

By the time World War I had ended, the company a locally well-known and fairly successful cookie and candy business.

Unfortunately, Doerr’s son Webourne and daughter-in-law Irene both died of the Spanish Flu of 1918, but he carried on by running the business and raising his infant grandson, Carl.

By 1933, Carl began working at the family business and took over at the age of 24 when Charles passed away in 1941.

After the factory burned down in 1943, the business-savvy Carl bravely proceeded to rebuild and modernize the factory, and change his family name.

Perhaps because his family name was of Germanic-origin, and Canada was at war with Germany, Carl surmised that a name change might be good for business, proceeding to change both his surname and company name to Dare, and soon after starting to ship product to all regions of Canada.

Not content with just producing food products, the company also took an active role in its food packaging. In 1954, Dare Foods took a coffee pack-aging concept and introduced cookie packaging to the tin tie-strip. The new format allowed consumers to reseal the bag to better maintain the product’s freshness, ultimately becoming the de facto standard of cookie packaging in Canada.

By 1956 the company had penetrated into the lucrative U.S. market, and in 1983 introduced the popular Breton cracker line, which became a bestseller in both Canada and the U.S.

Other key expansions include: • The construction in 1989 of a fully-automated soft-candy manufacturing

plant in Milton, Ont., bringing the European style RealFruit Gummies to North America;

• The building of a cracker bakery on a 33-acre Greenfield site in Spartanburg, S.C., which helped Dare become more of a major presence in the North American market;

• A 1999 acquisition of the 134-year-old Bremmer Biscuit Company of Denver, Co. adding Bremmer Wafers to its line-up;

• A 2001 acquisition of the cookie and fine breads business of Culinar Inc., adding the BearPaws, Whippet, Wagon Wheels and Viva Puffs brands, as well as the classic Melba toast, Canapé and Bread Sticks products, sold under the Boulangerie Grissol brand name;• Being chosen by the Girl Guides of Canada as the exclusive supplier of

their cookies in 2002;• In 2003 it became one of the first companies in North America to turn

all its facilities peanut-free in response to public concerns over nut-based allergies. Manufactured in Canada and the U.S., Dare Foods has a wide range of

cookies, crackers, fine breads and RealFruit candy all of which are available throughout North America and in more than 30 other countries around the world.

continued from page 14




COVER STORY

An SEW-Eurodrive motor powers the conveyor line leading cartons to the product handling robotic station, where the wrapped products are placed inside cartons formed by the Trayfecta S4 model 1502 system.

For More Information:

Delkor Systems, Inc., 460

Rockwell Automation 461

Nordson Canada, Limited 462

Bosch Packaging Technology 463

Markem-Imaje Inc. 464

Loma Systems (Canada) Inc. 465

Sonoco Products Company 466

SEW-Eurodrive 467

CANPACK-MicrositeSept-14.pdf 1 8/29/2014 9:39:03 AM

DARING ADVENTUREcontinued from page 14

“We will continue to improve our line effi-ciency and performance for our existing products to maintain our strong market position, involv-ing integrating new technologies and workplace practices,” sums up Beauchamp. “We will also continue to be a leader in innovation by launching new and delicious products that fit well with our core business and values.”

As for Dare Foods’ continued commitment to proactive capital investment, Beauchamp pro-claims: “It’s a credit to the Dare family, and their foresight, for empowering the company to not merely be viable financially, but to be a successful business now and for the long-term future.”


CANADIAN CONVERTING


Employing about 70 people, Inger soll Paper Box producing a multitude of straight-line boxes such as reverse tuck, straight tuck and universal bottom; automatic bottoms also known as ‘crashlock’; four- and six-corner boxes; and blister cards.

“We also offer services like CAD (computer-aided design), printing, embossing, folding and die-cutting,” says Skinner, citing the com-pany’s wide-range of customers involved in the food, healthcare, pharmaceutical and automotive industries.

This past spring, the company made a serious declaration of intent with the announcement that it had just completed the installation of a brand new KBA Rapida 106 7+L ALV2 seven-color, 41-inch fully-automatic printing press, said to be the first press of its kind to be installed in North America.

“It was a multimillion-dollar purchase,” Skinner points out.

“And we are confident that over the next three years it will pay for itself, thanks to the KBA’s labor-saving properties, its speed, and quality of its print.”

Skinner says that in addition to making everyone in the boxmaking industry take notice, the new press installation not only benefited its customers, also had a great positive impact on the staff morale by demonstrating the management’s commitment to ensure a successful future.

ing legacy, but she is confident that a series of well-executed major capital investments carried out by the company in recent years perfectly positions it to keep thriving a very competitive and hotly con-tested marketplace.

“While a rush order in 1922 is the same as a rush order in 2014, we have always sought to imple-ment the latest technologies here at Ingersoll Paper Box to ensure our customers receive the best qual-ity product,” says Skinner, who initially joined the family business in 1994 as part of the sales, market-ing and management teams.

It has only been in recent years where she has taken over leadership of the company and played a key role to the recent growth and upgrades at Ingersoll Paper Box.

“Our own efforts at continuous improvement, as well as customer requirements, have helped build this company over the decades, and I am sure that it will continue to drive our future as well.”

TOP SUPPORTThis corporate culture of continuous improve-ment has been well supported over the years under the leadership of her father David Skinner, she relates, who made many keen purchases and capital upgrades that have kept the company viable and profitable, while continuously investing in new machinery to remain highly competitive.

RAPID PROGRESSNew printing press propels Ontario boxmaker to the next level of technical prowess

ANDREW JOSEPH, FEATURES EDITOR PHOTOS BY COLE GARSIDE

Most people may think that a box is just a box just a box, but most people out there do not make their living in the

modern boxmaking business—like the venerable family-owned folding-carton converter Ingersoll Paper Box Co. Limited, where quality has been a well-entrenched part of the working vocabulary for over 90 years.

Started up in 1922 by Robert Skinner to make ice cream-cones, Ingersoll Paper Box has happily been toiling away as a local, but successful player in the production of paperboard packaging and folding car-tons for local CPG (consumer packaged goods) and industrial customers across southwestern Ontario.

“Because the cones we made needed boxes for protective packaging, we decided to go into the paper and paperboard business ourselves,” Ingersoll Paper Box president Sarah Skinner told Canadian Packaging during a recent visit to the company’s remarkably tidy, 85,000-square-foot facility built atop the original site’s f loor in Ingersoll, Ont., about a two-hour drive southwest of Toronto.

As the great-granddaughter of the company’s founder, Skinner readily acknowledges the burden of carrying on a very long and proud manufactur-

In May 2014, Ingersoll Paper Box president Sarah Skinner purchased the first Koenig & Bauer Group KBA Rapida 106 seven-color press in Canada.

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As the oldest press manufacturing company in the world, German-based press Koenig & Bauer Group (KBA) custom-builds each press to customer specifications to ensure they get the machine best-suited for their unique processes and their customers.

Accordingly, this particular The KBA Rapida 106 —a seven-color printing press featuring a coater and UV (ultraviolet) dryer—was completely custom-built for Ingersoll Paper Box’s exact needs and application requirements.

Some of the special options on Ingersoll’s new press include a kit just for packaging printers, nonstop operation for longer runs, inline quality measuring systems and special fast cleaning system which are perfect for running spot colors and special coatings.

Being able to measure density, spectrally, LAB values (to define absolute colors), dot gain and other key variables makes it a perfect fit for the boxmaker’s high expectations of product quality.

Says KBA North America, Inc.’s vice-presi-dent of marketing and product management Eric Frank: “In my opinion, it gives Ingersoll Paper Box a unique advantage in the marketplace—it is exactly what they need today and in the future in terms of press speed, number of printing units and automation.

“It certainly enables Ingersoll Paper Box to be able to address the packaging needs of customers in today’s market place,” Frank states.

“This is a tremendous example of how a cus-tomer’s future needs can be analyzed and then be manufactured as press specified, designed and built to address a certain need.”

BUILT FOR SPEEDThe KBA Rapida 106 boats speed rates of 18,000 sheets per hour—or a blistering five sheets a second—which Frank says actually exceeds the customer’s current requirements.

“The print quality on the press is the best for dif-ficult forms that have heavy solids, fine screens and forms that tend to ghost.

The ink train is very reactive so this reduces waste and ensures consistent color during the run,” mentions Frank.

The new inf lux of automation brought by the KBA Rapida 106 has enabled Ingersoll to have extremely short make-ready times, as the press essentially utilizes a one-button set up system, not

to mention presets, fast-washing cleaning systems, and a host of simultaneous processes.

That one-button set-up system is done via the Rapida 106’s ErgoTronic console, whereby an ergo-nomic touchscreen provides easy access for the press operator to manipulate all press functions.

As well, KBA added a very large visual screen of its own manufacture, so that operators can easily see what is going on in the Rapida 106.

The screen also features what KBA calls a live-image QualiTronic ColorControl—an inline color measuring system to ensure print integrity is main-tained throughout the print run.

BETTER VIEWThe QualiTronic ColorControl utilizes a camera vis-ual system that is integrated directly into the press using LED illumination to allow the operator to check in-time ink density measurements in control strips, which can be positioned at either the front or center of the paperboard sheet.

When the printing starts, the control strips are scanned directly in the press, and the measured solid densities are presented on the screen in a live graphic display. These measurements are used as a basis for fast, dynamic inline color correction.

After the measuring system is set up, all meas-uring patches are scanned on every printed sheet, right up until reaching maximum production speed.

The first setting corrections are realized immedi-ately after the job start—with a control cycle meas-uring every single sheet and then adjusting every 10th sheet to ensure a perfect print run.

At the other end of the Rapida 106 lie the feeder and infeeder sections, which, along with every-thing else on the press, made a big impression on Skinner.

“We purchased the optional automatic skid/pallet changer with light curtains,” says Skinner. “While it doesn’t save us any time, it does actually save on worker ergonomics, meaning we have healthier employees.”

After the blanks on pallets are placed within the DriveTronic feeder that is controlled via four servo-motors, the continuous, stepless pile lifting of the blanks into the press is performed smoothly thanks to automatic: speed compensation; format setting; pile side-edge alignment; pile-height sens-

ing and skew-sheet correction at the feeder head; and anti-static sheet loosening via air separation.Electronic sheet deceleration ensures opti-

mum sheet arrival speed is achieved at the front lays of the infeed section.

“The swing infeed accelerates the sheet smoothly in towards the feed drum, while the DriveTronic Infeed provides motorized remote adjustment for the com-plete infeed system,” explains Frank.

Other main features on the Rapida 106 printing press include:• Patented KBA DriveTronic SIS (sensoric infeed

system) that electronically controls the lateral sheet alignment;

• Patented Venturi system to provides smooth sheet infeed;

• Ultrasonic double-sheet detector; • Optical skew-sheet sensors; • Optical front lay sensors with electropneumatic

overshoot blocking;• Manual non-stop system with individual rods for

The KBA live-image QualiTronic ColorControl wall screen provides the Rapida 106 press operators with a visual inline color measuring system to ensure print integrity is maintained throughout the run. Photos by Andrew Joseph.

With maximum throughput of 18,000 sheets per hour, the KBA Rapida 106 seven-color printing press with a coater and UV dryer was custom-built to Ingersoll Paper Box’s exact specifications.

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uninterrupted production during pile changes; • Fully-automatic non-stop system with sensor-

monitoring rake for logistics operation;• Job Access software program for automatic job

pre-setting; • Remote register setting; • The LogoTronic professional management system

that not only provides prepress setting, order management, but can also provide graphic rep-resentation of the production process as well as management of all quality reports;

• Double-size impression cylinders and transfer systems on the printing unit for reliable sheet travel, regardless of substrate;

• Continuous gear-train for smooth running and high precision;

• Corrosion-free cylinder surface finish;

• Universal gripping system for maximum hold-ing force. “It really is an amazing press—so much so that

days after our open house event celebrating the Rapida 106 at Ingersoll Paper Box, we had cus-tomers knocking on our door to do business with us, and more continue to follow,” Skinner recalls.

A few months before the KBA press was installed at Ingersoll Paper Box, the converter purchased a new platesetter system, the model Avalon N8-22 and Elantrix 125 SX, from Agfa Graphics.

“We used to purchase plates externally until six months ago,” says Skinner, “and then we’d have to store them.

“But now we no longer have to store plates and we have total control over the plate manufactur-ing—not to mention the time we save by doing it ourselves—plates which we use on the KBA Rapida 106.”

In May of 2011, Skinner made a significant pur-chase from BOBST, installing a new BOBST EXPERTFOLD 110 A-2 high-speed folder-gluer that Skinner says replaced some older antiquated equipment, while significantly increasing through-put capacity.

To better optimize the EXPERTFOLD 110 A-2’s performance, Ingersoll Paper Box purchased a BOBST Handypack GT semi-automatic collec-tion table for collecting and packing cartons, along with a VCX Gluing and Quality Assurance glue system option from Valco Melton—ensuring optimal quality control for the glue patterns and application of the Resicol X-697 Blue adhesives supplied by Halltech Inc.

Even three years later, Skinner is still quite excited about the EXPERTFOLD’s unique capabilities,


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notably the BOBST AccuBraille application system that can add Braille to the on-package information to be read by visually-challenged customers.

The Braille messaging on the cartons is created when a metal band with raised nodules is added to the EXPERTFOLD to apply pressure to the metal band as each paperboard carton passes by.

After each carton has the Braille messaging applied, a Valco Melton CaptorT system verifies the information, using high-speed CCD (charged-coupled device) camera technology and custom lighting to produce over 10,000 images per second of the carton area.

THE RIGHT IMAGEThe image analysis algorithms and system software evaluates the image instantly, identifying defects like faulty cartons, incorrect Braille messaging, or improper adhesive application.

Valco Melton’s OT-120 control package touch-screen data entry system uses simple pictograms and market-specific program symbols for fast set-up and changeover on the EXPERTFOLD machine.

The BOBST EXPERTFOLD folder-gluer util-izes a Schneider Electric power and control panel, Baumüller servomotors, and Festo pneu-matic components.

Other key equipment at the Ingersoll plant includes: • a BOBST HandyPack Alpina 110 folder-gluer;

• two BOBST SP 102-SE die-cutters;• a BOBST SP102-E Autoplatine automatic f lat-

bed die-cutter;• two manroland 700 printing presses;• four 3M-Matic case-sealing systems from 3M;• a Phoenix Innotech stretchwrapper;• a Marsh PatrionPlus large-character inkjet print-

ers from Videojet Technologies Inc.;• a Mx12 ink formulation and dispensing system

manufactured by GFI Innovations, Inc. and maintained by Sun Chemical via Sun’s GFI ink dispensing program, with Ingersoll being the first sheetfed printer to sign up to the program.

• the MK420Q MINI high-speed/precision carton inspection system from Masterwork Graphic Equipment which uses four high-resolution CCD cameras for the detection of defects down to 0.2x0.2-mm at speeds of 80,000 units per hour.“There’s that old adage that ‘sometimes you have

to spend money to make money’, and that’s true to a certain extent,” Skinner ref lects.

“I think it’s imperative that when money is being spent, it should be well-spent on things that will not only improve the quality of life for the employ-ees, but also enable the company as a whole to create something that separates us from the com-petition,” she asserts.

“I think that our recent capital expenditures have really done that for us,” Skinner concludes. “Now we have to use our forward momentum to ensure a successful future.”

Ingersoll Paper Box Co. Limited 468KBA North America Inc. 469Agfa Graphics 470BOBST 471Valco Melton 472Halltech Inc. 473Schneider Electric 474Baumüller Nürnberg GmbH 475Festo Inc. 476Manroland Canada Inc. 477 3M Canada Company 478Phoenix Innotech Inc. 479Videojet Technologies Inc. 480GFI Innovations, Inc. 481Sun Chemical Corporation 482Masterwork Graphic Equipment 483


Ingersoll Paper Box president Sarah Skinner (left) chats with employees amongst rows of completed print jobs.

The EXPERTFOLD 110 A-2 high-speed folder-gluer manufactured by BOBST utilizes the unique AccuBraille application system to apply the Braille language codes onto the paperboard packaging.

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the household, automotive and paint sundry chem-ical business,” Recochem’s Consumer Division, central region plant manager Larry Funnell told Canadian Packaging during a recent visit to the company’s 170,000-square-foot, state-of-the-art facility located in Milton, Ont., about 40 minutes drive west of Toronto.

“I’d bet that most people in Canada have at least one of our products in their home.”

The licensed brands made by Recochem are: • Armor All care for cars;• Liquid-PlumR for drain clogs; • Poly-Care hardwood and laminate f loor cleaner; • Preston and STP antifreeze/coolant for vehicles;• Rain-X windshield wiper liquid; • Varsol paint thinner; • Windex glass cleaner.Along with the licensed brands, which make up about 35 per cent of its core business, about 25 per cent of its production is for its own brand of prod-ucts called Turbo Power washer f luid.

The brands seven products include: Windshield Washer –35°C; Windshield Washer –40°C; Premium Washer Fluid and De-Icer –45°C; Bug Wash; Bio-Green Ethanol-based Windshield Washer; Windshield Washer Concentrate; and All Season Windshield Washer.

The remainder of Recochem’s production com-prises third-party manufacturing for Walmart, Esso, Petro Canada, Husky and Canadian Tire.

“We produce around 500 different SKUs (stock-keeping units) here at the Milton facility,” Funnell relates. “Each one is a different recipe, of course, and we can create an individual product recipe for any customer that request it.”

Funnell continues: “Our plant’s blowmolding capabilities for different sizes, along with our in-house graphic design and regulations team are added ways in which Recochem will work with a customer to not only design your packaging, but to also ensure that all regulatory compliances are followed.

ANDREW JOSEPH, FEATURES EDITOR PHOTOS BY COLE GARSIDE

For every car, truck and motorcycle traveling the busy Canadian roads and highways, there are multitudes of different products available

in the marketplace to ensure their optimal per-formance on a daily basis, just as there is a strong possibility that many of those essential auto-care products were manufactured by Canada’s remark-ably successful specialty chemicals producer Recochem Inc.

Founded over 60 years ago in Montreal, Recochem is a chemical manufacturer of house-hold products and automotive f luids, featuring a global recognition for quality products and out-standing customer service.

When the Austrian-born Joseph Kuchar and family emigrated from Czechoslovakia to Montreal, he quickly embraced the Canadian immigrant dream of a better life, and formed Record Chemical Co. Inc. with his wife.

He later shortened the company moniker to Recochem, which initially became involved in the export of bulk chemicals to Europe and South America, as well as to a fast-growing Chinese market.

Over the following six decades, the Kuchar family and its long-serving team members built the company into a well-respected multinational producer and packager of specialty chemicals.

Via its Consumer Division (Americas), Recochem produces, formulates, contract packages and wholesale distributes household chemicals and automotive f luids from five Canadian locations,

including Saint John, N.B., Montreal, Toronto, Edmonton and Vancouver.

The company’s most famous sought-after prod-uct at one time was naphthalene—more commonly known as mothballs—and while it still processes and packages the pungent product for its custom-ers, it’s no longer the chief revenue generator.

“Nowadays, our Canadian consumer division, supplemented with U.S. contract packaging allian-ces, has helped us successfully grow our business in

LIVING IN THE FAST LANEThriving manufacturer of automotive fluids and household chemicals fine-tunes its production capabilities with new cutting-edge, high-throughput labeling technologies

Weber Marking Systems Canada specialist Fred Moore (left) and Recochem Consumer Division central region plant manager Larry Funnell in front of the Model 5300 label printer-applicator system manufactured by Weber.

One of the workhorses on the main packaging line at Recochem’s Milton facility is the new Model 5300 label printer-applicator system purchased from Weber Marking Systems Canada, capable of reaching speeds up to 50 boxes per minute.

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Funnell says that when it moved into the Milton plant five years ago, Recochem upgraded each of its five blowmolding machines, adding that the plan is to “hopefully expand” in that area of pro-duction soon.

“At our Milton facility here, we do all the one-, four- and 10-liter containers, as well as the 1,000-liter totes, 215-gallon drums and also full loads for tanker trucks for certain customers,” Funnell says.

Cool RunningsThe Milton facility currently houses five liquid-filling lines, two powder-filling lines and has some manual filling capacities.

Its main production line, aptly named Line No. 1, boasts a capacity of filling, capping and label-ing some 650,000 liters of liquid product every 24 hours, according to Funnell.

Further downstream, Recochem places a product label onto each carton by its label printer-applicator supplied by Weber Marking Systems Canada.

“Fairly recently, we had a customer request for scanable bar codes, and although we had some great help from Atlantic Packaging who supply us with the corrugated, the customer said they needed us to provide a high-speed capacity of up to 50 boxes per minute with great print quality,” explains Funnell.

“Although we already had excellent printers capable of doing one or the other, we needed to upgrade if we wanted to do business with them.”

Recochem looked at three different companies, but selected Weber owing to what Funnell says was

“the best price, along with them giving us the con-fidence level to achieve our requisite speed levels.”

All in all, Funnell and Recochem were suffi-ciently impressed with the label print-and-apply technology of the Weber system, purchasing and installing eight machines in March of 2014 at its Milton and Montreal facilities—seven Weber model 4300 units, and one model 5300 system.

Weber labeling systems specialist Fred Moore says Recochem purchased five units for the Milton plant:• One 5300 with a stand and alarm light system

used on the Milton No. 1 Line; • Three model 4300 units with a stand and alarm

light system;• One 4300 systems with an integrated conveyor,

stand and alarm light system;• All units equipped with print engines manufac-tured by Zebra Technologies.The three Weber units in Montreal are: • Three 4300’s with a stand and alarm light sys-

tem, featuring 12-inch stroke and variable stroke sensors;

• Fitted with wireless Zebra print engines.

The Weber 5300 Label Printer-Applicator utilizes easy-to-use computer software, simpli-fying product changeover, and real-time alterations or adjustments to label data.

“All of the sites across Canada produce their own HDPE (High-density polyethylene petrol-eum-based) plastic bottles in a number of sizes, including our proprietary multi-layer co-extruded solvent bottles,” adds Funnell.

“We offer liquid-filled containers from as small as 50-ml bottles all the way up to tanker trucks and train cars.”

Funnell notes that all Recochem sites are highly-automated with a plethora of machinery, including blowmolders, filling lines, palletizers and robotic case-packers, which allows it to provide 24-hour operation and a rapid response to any client requests, while maintaining its nationwide ISO standards of product quality.

“When we moved into this facility in 2009, we essentially doubled the size in total land space, manufacturing capacity, inventory storage area and office space, and expanded to where we now have about 104 employees,” Funnell relates.

While Recochem certainly needed more space to increase its production thanks to the popularity of its products, Funnell was adamant the company would also take an even more stringent look at safety requirements, noting that the manufacture of chemicals can indeed present a hazardous work-ing environment.

“We spent about $750,000 on safety features here at the Milton facility,” notes Funnell, add-ing it fully follows CSA (Canadian Standards Association) standards, and all PSR (Pre-start Health and Safety) requirements.

The filling room, as expected, is highly-venti-lated, and is continuously automatically monitored for LEL (lower explosive level) possibility.

“Recochem is extremely serious about the volatility of its products and for the safety of our employees, as such when the LEL monitors reach the 10 per cent level, an alarm will go off, and we will monitor the situation to see where the prob-lem is,” Funnell relates.

“Should it reach 30 per cent, we immediately shut the equipment down.”

In the event of the worst-case scenario, the facil-ity can utilize an advanced multiple high-=capacity sprinkler system consisting of water, foam and ESFR.

All in all, the plant is doing a very healthy busi-ness, as it also makes its own bottles, fills and labels them and ships them out seven-days-a-week, 24-hours-a-day.

Using air-blow tamp configuration where the label is blown onto the carton, the model 4300 label printer-applicator from Weber normally runs at a rate of 25 labels per minute.

Supplied by agent Alex E. Jones & Associates, a model 28V09 filling and capping system from Pacific Packaging Machinery filling four-liter plastic containers with windshield washer fluid at Recochem’s Milton facility.




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The Columbia Machine HL6000 series high-level palletizer manufactured by Columbia Machine easily loads over 60 cases of product per minute onto the signature blue wood CHEP pallets.

Says Moore, “The speed of these Weber units is variable, depending on how fast the customer wants to run it.

“While the 5300 can print up to 50 labels per minute at 203-dpi (dots per inch), the 4300s are all capable of printing at a rate of 25 labels per minute.”

Funnell points out that the model 4300 is a low-speed label printer-applicator system, which the Milton facility only tends to run at a com-fortable rate of eight to 10 boxes per minute.

“We generally run the Weber model 5300 at around 35 to 40 cases per minute, but for that one client who wants it, we can easily hit its target speed of 50 units per minute,” Funnel relates.

The Weber model 5300 label printer-applicator is also very versatile—offering customers a wide range of high-quality print engines with an equally wide range of optional print resolutions and label dispensing rates.

Significantly, Weber has now made it available with an upgradeable RFID (radio frequency identification) print encoding ability, though Recochem did not purchase that option.

“With the 5300 we can print and apply labels with barcodes onto a wide range of surfaces, such as the plastic containers, corrugated cases,

or even on the various formats of pal-lets, if we chose to,” says Funnell, add-ing the adhesive labels can be applied in a variety of manner: top, bottom, sides, and even across corners for what-ever happens to provide best scanning performance.

Other formidable examples of the 5300’s versatility include the myr-iad number of ways it can be config-ured depending on the user’s labeling requirements: tamp-blow; air-blow; direct-tamp; swing-tamp; corner-wrap; dual label; and electric tamp-blow.

All of the label printer-applicator purchased by Recochem employ the air-blow method, whereby the label is blown onto the product from a fixed distance—without utilizing a pneu-matic cylinder.

“The 4300 models generally have a three- to eight-inch stroke length, while the 5300 in Milton has a one-inch stroke,” explains Moore. “The shorter the stroke, the quicker the label application.”

Moore says that rather than having to purchase a whole new label application system, a user only needs to purchase a new tamping tech. “The reconfig-uration can address any future print-and-apply labeling requirements, a modularity that saves money.”

Other value-added features of the 5300 system include a microprocessor controller and downloadable firmware capabilities, plenty of different inputs/outputs, and a robust construction to withstand harsh industrial environs.

Standard features include a remote locatable controller connected via a 15-foot cable, which allows the oper-ator more convenience when mon-itoring the label printer-applicator’s workf low, such as label application, pad sensor settings, alert lights, or the status of the label roll or printer ribbon.

Moreover, companies like Recochem are able to easily monitor the full oper-ational status and configuration of the 5300 unit, by simply logging into a Web page unique to each individual 5300 system.

The unit also features an intelligent computer-controlled unwind and


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SEPTEMBER 2014 25

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rewind function that ensures the labels match the ribbon supply at the same rate, thereby avoiding the double downtime possibility for changeover.

“Also helpful to us, owing to the different-sized products and the different all-round products we place through Line No. 1, is the fact we can easily store our printing require-ments in the 5300’s memory, making it very easy for the operator to select the requisite job from the applica-tor rather than having to download it from the computer,” Funnell relates.

Funnels adds that while he is extremely pleased at how well the Weber printer-application units are working at both facilities, he says he was equally impressed by how quickly Recochem was able to take possession of the systems.

“It really was a quick turnaround, and I think it surprised all of us here at Recochem,” recalls Funnell.

Another key piece of technology utilized at Recochem, is the HL6000 series high-level palletizer designed and manufactured by Columbia Machine, Inc. which is capable of palletizing 60 or more cases per minute while providing a tight, square and stable load.

Says Funnell: “We installed the Columbia HL6000 in 2009 and we have been very happy with it from the outset.

“Although we have had a few normal wear and tear issues, in the past five years we have had nothing out of line.”

The Columbia HL6000 palletizer comes standard with such controls as the Rockwell International’s Allen-Bradley Compact Logix PLC (program-mable logic controller), a PanelView Plus 600 Color touchscreen interface and Columbia’s own Project Manager software, all of which help make it easy to control and care for.

Funnell says that the folks at Columbia Machine continue to be very easy to work with whenever called upon, and the fact that they are very knowledgeable and offer reason-ably priced parts is a bonus.

“One day when we did have an issue, it was quickly resolved as they were able to help us troubleshoot the HL6000 over the telephone, as well as by con-necting into the PLC,” Funnell relates.

After palletizing by the HL6000 is completed, the product is conveyed to an overhead stretchwrapper manufac-tured by MJ Malais/Wulftec.

A Baldor motor helps ensure smooth-running operations for conveyor lines at the Milton plant.

A Foxjet inkjet printer supplied by Harlund Industries ap-plies large-character product codes to the cartons.

Other equipment and suppliers utilized by Recochem at its Milton facility include: • Hitachi PB and Foxjet inkjet printers supplied

by agent Harlund Industries Ltd.; • Aesus bottle sleever;• Italian-made Comag SLC-300 over-the-top sleever

utilizing an SEW-Eurodrive motor and Siemens Simantic touch panel for user programmability;

• Sleeves from Pro-Pals Industries; • Pacific Packaging Machinery Inc.’s 28V09

filler and capper supplied via the agent Alex E. Jones & Associates featuring an Allen-Bradley PanelView Plus 1000 touchscreen interface;

• Pearson Packaging Systems’s case erector and filling system;

• Hartness International Inc. Model 835 case-packer, also supplied by Alex E. Jones & Associates;

• Several Nordson ProBlue 10 hot-melt adhesive applicating systems to seal the cases;

• Corrugated cartons from Atlantic Packaging Products;

• Various Baldor motors to power the conveyor lines;


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• CHEP-supplied pallets for national and inter-national transport of product.Funnell says that the recent capital expenditure

moves by Recochem are indeed a great sign for the company’s long-term future, showing that workplace safety is deemed as important as being profitable.

He adds that the company is also aware of its environmental responsibilities locally, and has gone to great lengths when designing the facility to ensure that when it comes to its water usage, it actually recycles and reuses it.

“Nothing is ever dumped down the drains,

because we have a closed drain system in place,” he states.

Summing up, Funnell recalls that when Recochem first moved into the Milton facility, and that despite the production f low working smoothly, it still took about a year-and-a-half for the stress level to leave the building. Notably, none of that stress came back with the introduction of the Weber label equipment, he points out.

“I think there’s still a learning curve for the operators on these machines—as we continue to experiment with ways to make our unique situa-tion even more efficient—but so far, the Weber

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A Model 835 case-packer manufactured by Hartness International was purchased by Recochem from Canadian agents Alex E. Jones & Associates.

machines have been working very well for us and I know everyone involved is quite happy with its performances,” he concludes.

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intrigued, but due to other commitments at the time, they had to wait to put the plan in action.

“So they offered me a position as a trouble-shooter—going between their plants and coming up with solutions for the various issues they were facing.

“Unfortunately, I found myself spending most of my time sitting around waiting for the phone to ring so I could go somewhere to solve a problem,” Gerrity continues. “After three weeks I went back to my new employers and, even though they had

ago, Gerrity initially took a job operating an over-head crane at a corrugated box plant, “Because I needed a job, any job,” he explains.

“Very quickly I learned how to operate their corrugator,” Gerrity recalls, “so that when their existing corrugator supervisor was about to go on holidays, the company asked me if I could operate it during his absence and I said, ‘Sure, nothing to it.’

“It was a brand new, 96-inch Langston, a beauti-ful machine, and I was put in charge of the nine people it took to operate it,” he recounts.

“While I was running it I doubled the super-visor’s production output and cut down on scrap, so when the regular supervisor came back the boss told him that he didn’t know what to do with him because of the improvements made in his absence.

“They allowed him to work under me as second operator,” Gerrity relates, “and he was grateful for that and worked for me for the next four years.”

Gerrity then took on a job as a corrugated fore-man with another company where he would spend the next 16 years, during which he rose to become a vice-president and general manager.

“When I left there I approached a large inte-grated company with a plant that has now become known as a sheet feeder,” he recounts. “They were

FOUR WAYS TO PROSPERBoxmaker’s customer service and technical excellence keep it on solid growth path

BY NICK GRIFFIN PHOTOS BY COLE GARSIDE

Behind every successful company lies a set of core principles that have helped guide that company to its current market prominence

and renown—whatever the industry.For Gerrity Corrugated Paper Products,

Ltd. of Concord, Ont., those basic tenets can be boiled down to four core competencies: remark-ably quick turnaround times; innovative software management of every aspect of their business; con-tinual reinvestment in the latest finishing equip-ment; and, above all else, hard work.

Along with his sons Blaine and Scott, com-pany founder and chief executive officer Thomas Gerrity operates a classic, single-location ‘medium- to large-sized sheet plant’ to serve a customer base he deftly describes as, “Broad to the point of doing everything for everybody.

“If it is made of corrugated, we can do it,” says Gerrity, a high-energy 82-year-old who still per-sonally oversees the entire plant f loor operation with the youthful drive and enthusiasm of some-one half his age.

Upon first arriving to Canada more than 60 years Head operator Danny Buttigieg monitors EXPERTFOLD’s performance at the machine’s touchscreen control panel.

Gerrity Corrugated Paper Products founder and chief executive officer Tom Gerrity proudly poses with the brand new, state-of-the-art EXPERTFOLD 230 A-4 folder-gluer, manufactured by BOBST, recently installed at the company’s boxmaking facility in Concord, Ont.

p 28-31 cpac sept 2014 Gerrity-Bobst p 28-31.indd 28 14-09-05 2:40 PM



increased the pay, I told them that it simply wasn’t working out.

“I couldn’t stand doing nothing: I hated it, I needed to work.”

Having just celebrated his 45th birthday, Gerrity decided to take the big plunge and start up his own business.

As he recalls, “With nothing more than a slitter and a band-saw I got from my brother, I leased a vacant 9,000-square-foot building, we got sheets into the place, and with my wife sitting at a desk in the office and me in the plant, we soon started getting our first orders.

“As I would feed the sheets through the slitter my wife would catch them on the other end, after which I would strap them up, load up the truck and deliver the job.

“That’s how we started—making just pads, dividers, and in some cases using the band-saw to cut off the corners for cutout wraps,” says Gerrity, relating that the f ledgling startup managed to turn a profit in only its third month of operation.

After finishing school about six months later, the couple’s older son Blaine happily joined the growing family business.

“We had him get a haircut and a new suit and sent him out selling,” he recalls. “He quickly built up a good deal of business: Within a few months he was selling $50,000 worth of pads.

“Everybody at the time said we were stupid and couldn’t possibly do what we said we could—buying full sheets from a corrugator in different cutoff lengths and different grades of board.

“Then we’d get calls from area sheet plants asking for orders as small as 50 pieces of one grade of board. They’d ask, ‘When can we get them?’, and we’d answer, ‘When do you want them? Send your truck over and they’ll be cut and ready.’”

After about two years Gerrity con-cluded that despite the volumes increasing month after month, the family business had to try something different.

“We couldn’t get enough business

SEPTEMBER 2014 29

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The STREAMPACK batch collector installed at the end of EXPERTFOLD line.

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this way to keep growing in a meaningful way, so we added a simple die-cutter so we could make cartons, while adding more people both in the office and the plant,” he relates. “The former plant manager from my early employer came to work for

us and when Scott, our younger son, left school, he also came on full-time.”

As Scott Gerrity recalls, “Even when I was in school I was working in the plant 35 to 40 hours a week, which frequently included weekends.

“One weekend when we needed extra help I persuaded some friends to come in and help out in exchange for a case of beer,” he chuckles, revealing solid people skills and work ethic that spans generations.

According to Tom Gerrity, the first major new piece of equip-ment to arrive to the plant was an S&S partition slotter, soon joined by a die press.

“One day Blaine came in with an order for 30,000 taped boxes and we knew we couldn’t do that by hand, so we made our own taper,” he recounts.

“Those days we got away with a lot of things that would be unimaginable today,” he chuckles. “So much of our work is based on the premise of immediate turn-around, that we would do whatever it took to achieve it.”

Adds plant manager Scott Gerrity: “Even today, we take orders for our slitter jobs that we have out the door the very same day.

“We really pride ourselves on our turn-around, whereby 50 to

60 per cent of all our business is booked today and shipped tomorrow.”

This consistent ability to complete even the most demanding jobs within a day or two of receiving them has clearly payed off for the family business in a big way—enabling it to take on many last-minute projects that few other plants have the capabilities to execute.

On some of the simpler orders, according to Tom Gerrity, jobs are completed in less than two hours from receiving the order.

Nowadays this core competence is greatly enhanced with the ever-growing array of state-of-the-art production machinery assembled at the Concord facility over the years.

“We have everything and then some,” Gerrity enthuses. “We duplicate our processes because it’s our business to always be on time.

“For example, we have eight similar machines in a row so that machines are always waiting for the work—not the other way around,” he explains.

“We even have complete redundancy with our baler system, so that if one baler breaks down, we simply hit the switch and the parallel baler comes online.”

Scott Gerrity says the extremely f luid day-to-day nature of the business makes this f lexibility a priceless core competency for the company.

“It is second nature for us to switch quickly from one type of product to another,” he states. “One day the folder-gluers are running every minute of our two shifts, while most of the die-cutters and flexos sit idle.

“The next day it can be the exact opposite.”Today the Gerrity plant also boasts specialized

expertise in inline specialty folding and gluing, which is especially beneficial when dealing with the smaller, very narrow and hard-to-handle boxes, as well as those with multiple gluing points.

This has been enabled in large part by the recent purchase of a state-of-the-art EXPERTFOLD 230 A-4 folder-gluer with a STREAMPACK semi-automatic batch collector from global con-verting machinery manufacturer BOBST.

“Since we purchased the EXPERTFOLD, the difference that it has made for our plant has been extraordinary.

“It has brought a lot of business our way,” states Tom Gerrity, saying the new equipment has attracted a lot of work bypassed by other boxmakers who either can’t or don’t want to get involved in small-run production.

“They want the really big orders, but because they don’t want to turn anything down from a customer, they send those orders through us,” he explains, adding that installing major new pieces of equipment is a regular occurrence at the plant.

“Every year we add to or upgrade one major machine, and this year it was upgrading from an older BOBST Domino folder-gluer to their EXPERTFOLD 230 A-4 with a batch collector,” he says, adding the Domino machine is now used primarily to run the larger, less complicated boxes.

“The other folder-gluer doesn’t have the finesse of the EXPERTFOLD, which can glue six points at one time,” Gerrity states. “There’s also a big dif-ference in speed.

“Instead of 2,000 boxes per hour on our older machine, running that same box on the EXPERTFOLD makes 6,000 boxes per hour a reasonable target.

“That’s triple the production, sometimes even more,” Gerrity enthuses, while lavishing praise on the quality, reliability and high performance capabilities of BOBST machinery.

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“My youngest son Scott went around and looked at everything out there and determined that this EXPERTFOLD folder-gluer was exactly the machine that we wanted,” he relates.

“Moreover, the semi-automatic STREAMPACK batch collector at the end of the line adds a high degree of f lexibility with its ability to be adjusted to collect all the types of boxes that the line can produce.

“The EXPERTFOLD costs a little more than the other machines we looked at, but its capabil-ities far exceeded the others,” says Gerrity, adding any difference in the machines was quickly offset by its productivity levels and the quality of final product.

“In addition, BOBST had a guy in here for more than two weeks, showing our lead operator all of the things that the machine can do that we never even knew about,” Gerrity states. “They’ve also been coming back and showing us more ways the machine can be configured to make any num-ber of products.”

To complement its manufactur-ing prowess, the company has also developed solid in-house expertise in the development of software used to operate its box plant, with many advanced features and functions not available on vendor-offered software.

According to Blaine Gerrity, “We started by getting a real computer whiz-kid named Darren Ramsay to program and develop the software.

“The original computer system started with a single module, but today our system is fully mature with every-thing from purchasing, docket con-trol, pricing/estimating, scheduling, order tracking, shipping and invoi-cing, as well as account management.

“In recent years we’ve extended the system, giving our customers online pricing and ordering, job tracking and other features.

“Customers can know down to the minute when a job has been shipped,” he states, noting that Gerrity’s soft-ware has also been sold to many of the company’s locally competing plants.

This software proficiency helps the Concord plant to maintain a large inventory of stock sheets of virtually every type and quality of corrugated, as well as all full corrugator widths by vari-ous cutoff lengths—including specialty sheets like two-sided oyster and E-f lute.

“Tell me who else you can ask for a thousand boxes by tomorrow mor-ning and have them delivered,” Tom Gerrity points out. “The customer can order 20,000 boxes, and because we already have the stock on the f loor, we can run them right away.

“We also keep track of all the cutoff leftovers from a job in a computer pro-gram, utilizing them for small orders.

“This way we don’t waste any material,” he states, pointing out that the plant often has well over 100 different cutoff sizes in stock at any one time.

In conclusion, Gerrity sums up the business as not just highly cus-

tomer-centric, but also well-planned and expertly managed.

“We get orders today and some of them are to be shipped this afternoon,” he says. “Most are for

SEPTEMBER 2014 31

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An inline MOSCA strapping machine (left) makes the compressed bundles of corrugated boxes coming off the STREAMPACK batch collector ready for shipment.

tomorrow, and very few will be for the day after, but the point is that people like to order from us because they know we can ship it to them in timely fashion.

“That’s the biggest single growing trend I see in the modern corrugated business—the JIT ( just-in-time) inventory and Kanban scheduling systems. They enable us to hold finished products for cus-tomers so they’re available immediately and in the quantities they want.

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Bottling line equipment supplier Krones Inc. of Franklin, Wis., has appointed Hector Takahashi as regional sales manager for the U.S. northeast-ern and mid-Atlantic region, with responsibilities for sales development and support in the states of West Virginia, Virginia, North Carolina, South Carolina and Maryland.

Cincinnati, Ohio-head quar ter ed automated material handling systems manufacturer and integra-tor Intelligrated has appointed Mario Rodriguez as general direc-tor of the com-pany’s Mexican operations—to be based in Mexico City—and Carlos Vega as senior sales manager for

its western regional operations, working out of Roseville, Ca.

Japanese-based industrial con-trol and electronics manufacturing group OMRON Cor poration has appointed Nigel Blakeway as chief executive officer of the company’s Omron Auto mation and Safety business for the Americas region, headquartered in Hoffman Estates, Ill.

The board of Naperville, Ill.-headquartered World Packaging Organisation (WPO) has unani-mously elected Thomas Schneider to serve a second term as the group’s president for 2015-2017.

Lincolnshire, Ill.-headquartered industrial and consumer electron-

ics manufacturing group Honeywell has appointed Sach Sankpal as presi-dent of Honeywell Safety Products, a division of the com-pany’s Honeywell

Automation and Control Solutions life safety business.

Plastics process-ing equipment group Graham Engi neering of York, Pa., has ap pointed Robert Deitrick as vice-presi-dent of global sales.

Israeli-head quar ter ed industri al vision systems manufacturer Ad van

c ed Vision Technology (AVT) Ltd. has appointed Windell McGill as president of the Americas region, to be based at the com-pany’s regional offices in Atlanta, Ga.

Electric motors and drives manufacturer Baldor Elec tric Company of Fort Smith, Ark., has appointed Greg Hewitt as engineering manager for mounted bearings, and Galen Burdeshaw as power transmission components engineering manager—respon-sible for the company’s Dodge and Maska brands of power transmis-sion product lines—with both to be based at the company’s design and production facilities in Greenville, S.C.

Branding and package design services provider SGK, Inc. of Des Plaines, Ill., has appointed Andrew Flynn as vice-president of brand strategy.

32 SEPTEMBER 2014

The Toronto-headquartered Food Industry Association of Canada has selected Marc Guay, president of leading snack-food manufacturer PepsiCo Foods Canada, and Louise Wendling, country manager for Club Store retailer Costco, as recipients of the organization’s 2014 Golden Pencil Award honors in recognition of their professional contributions to the Canadian food industry.

The Canadian Plastics Industry Association (CPIA), Mississauga, Ont.-headquartered national trade organization for the plastic industry’s processors, material suppliers, equipment manufacturers and brand-owners, has appointed Aiñe Curran as director general for issues.

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Australian food packaging systems group TNA Australia Pty Ltd. (tna) has completed the acqui-sition of FOODesign Machinery & Systems, Wilsonville, Ore.-based manufacturer of fryers, ovens, seasoning and coating machines, bulk hand-

ling conveyors, and other cooking and baking equipment for the meat, poultry, seafood, bakery, con fectionery and snack-food industry applications. “This move underlines our commitment to servicing our cus-

tomers’ growing needs for f lexible and efficient turnkey solutions,” says tna managing director

FOODesign president Joseph Mistretta (left) and tna chief executive officer Alf Taylor shake hands on the deal.

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David Favret has joined Harpak-ULMA as Product Manager for the ULMA TFS Thermoform line. David is

a seasoned industry veteran who has spent the last two years as Product Sales Manager of Tray Sealing Systems for Ross Industries. Prior to that he held a progressive series of positions over a 25 year career with GEA Convenience Food Technologies, most recently as Product Sales Manager of Packaging. David is a resident of the town of Sandwich on Cape Cod and is based out of Harpak-ULMA’s Taunton office.

Dave Favret Appointed TFS Product Manager

Diana Duryea, Marketing Manager

Harpak-ULMA Packaging, LLC175 John Quincy Adams RoadTaunton, MA 02780

www.harpak-ulma.com

Ph: (800) 813-6644Fax: (508) 884-2501Cell: (781)690-3141

APPOINTMENT

In his new role, Vin will pursue his long-time passion for

providing cutting edge packaging solutions to the medical and industrial market segments in North America. Vin will be working closely with the Harpak-ULMA sales team to support customers in the non-food and specifically medical packaging segments for packaging and automation solutions. Vin has been with the company since 1981 in the role of Product Manager for packaging and has extensive experience in the area of medical packaging.

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Vin Faherty Appointed National Sales - Medical/Industrial

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Michael Green. “The acquisition gives tna access to all the necessary skills, networks, market knowledge and relationships to provide customers with a new choice in processing equipment—from fryers and feed systems through to packaging and controls—so that we can add value to our customers’ entire line and achieve significant economies of scale.”

German protective packaging products and equipment group Storopack has completed the acquisition of CleanPak Products, Tampa, Fla.-based supplier of loose-fill materials and other protective packaging products such as bubble wrapping, bubble-lined mailers and rolled foam (see picture) to continue the company’s strategic expansion in the Florida and other U.S. mar-kets. Earlier this years, Storopack acquired a majority interest in two other Florida-based com-panies—Action Corrugated Supply LLC and Specialty Converting LLC—which have since been merged into a new corporate entity called Action Specialty Packaging LLC. Operating manufacturing facilities in Tampa and Opa-Loka, Action Specialty provides a comprehensive range

of protective packaging products such as single-face corrugated and paper rolls, along with cor-rugated boxes, bubble wrap and bubble-lined mailers. “The partnership will enable Storopack to even better serve its distributors and customers in key business areas and to further develop business opportunities in the Florida market and beyond,” says Daniel Wachter, president of Storopack North America in Cincinnati, Ohio.

Belcamp, Md.-based Independent Can Company has picked up the coveted Grand Award in the annual awards competition of the International Metal Decorators Association (IMDA)—held a few weeks ago in Chicago —for the superior print quality of the Natura Tapered Pet Can specialty metal package (see picture) produced for Natura Pet Products, Inc. of Santa Clara, Ca. Selected from over 180 entries submitted by companies around the world. This year’s award marks the third time in the past eight years that Independent Can has won IMDA’s Best of Show honors—as selected by an impartial panel of global graphic arts professionals on the basis of the quality of printing, the degree of difficulty, the appearance of coating finishes, regis-tration and technical expertise.


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NOTES & QUOTES

34 SEPTEMBER 2014

14-09-04 4:44 PM

Industrial automation technologies group Yaskawa America, Inc. has announced the opening of a new facility in Queretaro, Mexico, to serve the local operations of the company’s Yaskawa Motoman division, a leading manufac-

turer of industrial robotics headquar-tered in Dayton, Ohio. Currently employing six full-time staff, the new 5,000-square-facil-ity (see picture)—the

company’s third in Mexico—is intended to be primarily used for sales, training, parts warehous-ing and robot demonstrations. “With the recent growth of our customer base in the region, we knew that we needed to expand our support team and have a more local presence,” says Yaskawa

Motoman’s vice-president of customer satisfaction Doug Schenher. “We will now be able to provide more local training, service and parts fulfillment, and we also have ample, high-bay shop f loor space available for robot demonstrations to show poten-tial customers and local integrators.”

Philadelphia, Pa.-headquartered Packaging Coordinators, Inc. (PCI) says it has com-pleted the expansion of its packaging facilities in Rockford, Ill. —one of its three U.S.-based manu-facturing operations—to accommodate continued growth in the company’s contract packaging ser-vices for the pharmaceutical and healthcare indus-tries. According to PCI, the 20,000-square-foot expansion has enabled the plant to acquire new secondary and tertiary packaging capabilities such as cartoning, overwrapping, heat-seal carding and compliance-prompting packaging, as well as sup-

porting packaging for biotech delivery forms such as secondary packaging for injectable vials, syrin-ges, devices and transdermal products. “The facili-ties expansion we have undertaken in Rockford is the latest in a series of investments we have made to enable continued growth and at the same time continue to provide our customers the extraordin-ary service they have come to expect from us,” states PCI president and chief executive officer Bill Mitchell. “We are committed to providing an unparalleled customer experience with our clinical and commercial services, which require world class facilities, and we are very excited about what these investments bring to our expanding business and our ability to support our clients.”

Leading Finnish meat packaging products group ViskoTeepak has completed the acquisition of Vista International Packaging, LLC, Kenosha, Wis.-

based food packaging supplier to the U.S. meat and poultry industries, as well as the exclusive U.S. distributor of fiberous casings—widely used in the production of dry and semi-dry sausages—manu-factured by ViskoTeepak. “This is a win-win for everybody because it creates an opportunity for ViskoTeepak to enhance a strong supply base of fibrous, tubular plastic and cellulose products here in the U.S., while Vista becomes an integral part of a global organization with access to world-class research and develop-ment and support services,” says Vista’s vice-president of sales and marketing Ron Ramsey. “This will significantly strengthen our competitive position by improving upon our ability to offer the most innovative and effective casings solutions in the market,” says Ramsey, adding that the actual converting of ViskoTeepak’s fibrous casings—along with the Wienie-Pak range of cellulose casings (hot dogs and frankfurters) and the Nova brand tubular plastic casings (deli meats and specialty dairy prod-ucts)—for the U.S. market will remain at Vista’s existing Kenosha manufactur-ing facility.

TimBar Packaging & Display, Hanover, Pa.-based manufacturer of corrugated containers, retail-packaging and POP (point-of-purchase) dis-plays, has completed the acquisition of Hanover Packaging, also of Hanover, for an undisclosed amount. “Hanover Packaging has built an outstanding repu-tation for service and quality over its 89 years in business,” says TimBar presi-dent and chief executive officer Matt Heleva. “This purchase provides us with an immediate and exciting growth opportunity based on the ability to bet-ter service our customers and markets by expanding our retail packaging offering to include folding cartons, rigid boxes and plastic boxes, while also providing the opportunity for Hanover Packaging’s customers to consolidate vendors and purchase a fully-integrated merchandis-ing solution from TimBar that includes displays, fulfillment and retail pack-aging—all from one source.”



http://www.kba.com

SEPTEMBER 2014 35

Sept. 28 – Oct. 1Chicago: CPP EXPO 2014, converting and package printing expo by H.A. Bruno LLC. Concurrently with Graph Expo. Both at McCormick Place. To register, go to: www.cppexpo.com

Sept. 30 – Oct. 2Toronto: A Day in the Life Symposium, sustain-able packaging conference by PAC, Packaging Consortium. At Steam Whistle Brewery (Sept. 30 and Oct. 1) and Real Sports Bar & Grill (Oct. 2). Contact PAC at (416) 490-7860; via email pack-info@pac/ca, or visit the website at:www.pac.ca

Oct. 7-10Tokyo, Japan: Tokyo Pack 2014, packaging tech-nologies exhibition by Japan Packaging Institute. At Tokyo Big Sight. To register, go to:www.tokyo-pack.jp/en

Oct. 14-15Princeton, N.J.: Barrier Pharma Packaging 2014, global conference on barrier packaging for pharmaceut-icals and biologics by Applied Market Information LLC. At Hyatt Regency Hotel. To register, go to:www.amiplastics-na.com

Oct. 14-16Cologne, Germany: Multilayer Packaging Films 2014, international conference on packaging technology, materials and markets by Applied Market Information Ltd. (AMI) At Maritim Hotel. To register, go to:www.amiplastics.com/events/

Oct. 19-22Myrtle Beach, S.C.: FlexPackCon 2014, f lexible packaging conference by the Society of Professional Engineers (SPE). At Marriott Grand Dunes. Contact Sue Wojnicki of SPE at (203) 740-5420, or via email [email protected]

Oct. 20-22Tokyo, Japan: COSME Tech 2014, international exhibition for cosmetic ingredients, machinery and pack-aging by Reed Exhibitions Japan Ltd. Concurrently with the COSME Tokyo 2014 cosmetic products exhibition. Both at Tokyo Big Sight. To register, go to: www.cosmetokyo.jp

Nov. 2-5Chicago: PACK EXPO International 2014, pack aging technologies and materials exhibition and conference by PMMI-The Association for Packaging and Processing Technologies. Con-currently with Pharma Expo pro-cessing and packaging conference and trade show and the AIPA World Congress by the Active and Intelligent Packaging Industry Association. All at the McCormick Place fair-grounds. To register, please go to: www.packexpo.com

Nov. 4-6Cologne, Germany: Polymer Foam 2014, inter-national conference on thermoplastic, thermo-set and physical foam processing technology by Applied Market Information Ltd. (AMI) At Maritim Hotel. To register, go to:www.amiplastics.com/events/

Nov. 10-14Jacksonville, Fla.: AME International Excellence Inside, annual conference by the Association for Manufacturing Excellence (AME). At Hyatt Regency Jacksonville. Contact Jodi Talley at (224) 387-3367; or go to: www.ame.org

Nov. 12Brampton, Ont.: Paper Fact & Fic tion, confer-ence by PPEC (Paper and Paperboard Packaging Environmental Council). Contact Catherine

Ashworth of PPEC at (905) 458-0087, via email [email protected], or go to:www.ppec-paper.com

Nov. 17-20France: Emballage, international packaging exhib-ition by Comexposium. Concurrently with the Manutention material handling exhibition. Both at Paris Nord Villepinte. To register, go to:www.all4pack.com

Nov. 19-20Montreal: PACKEX Montreal, packaging technol-ogies exhibition by UBM Canon. Concurrently with Expoplast, Design & Manufacturing Montreal, Automation Technology Expo (ATX) Montreal, and Powders & Bulk Solids exhibitions. All at Palais des congrès de Montréal. To register, go to: wwwe.UBMCanonEvents.com/Montreal

Just a Few Reasons to Attend:Explore an exhibit hall fi lled with top suppliers, advanced technologies, and new products and services

Engage in educational sessions tackling critical concepts

Hear from industry insiders, watch live product teardowns, and more at the NEW Tech Theater

Trigger fresh ideas, identify new options, and expand your network

EXPOSITION: November 19–20, 2014Palais des congrès de Montréal | Montreal, Canada

Get Your Badge Today!

PACKEXmontreal.com/cp

“I was able to make unexpected discoveries, fi nd new suppliers, get inspired, make networking connections and learn many things to apply back at the offi ce.”—Jean Francois Durette, President, Oculo-Plastik Inc.

Optimize Your Packaging

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p 35 cpac sept 2014 Events p 35.indd 35 14-09-05 11:21 AM

http://www.cppexpo.com

http://www.pac.ca

http://www.tokyo-pack.jp/en

http://www.amiplastics-na.com

http://www.amiplastics.com/events/


http://www.cosmetokyo.jp

http://www.packexpo.com

http://www.amiplastics.com/events/

http://www.ame.org


http://www.ppec-paper.com

http://www.all4pack.com

http://www.ubmcanonevents.com/montreal

http://www.packexmontreal.com/cp

One look at the aver-age North American kitchen quickly

reveals that we, as a culture, are obsessed with culinary contraptions. Whether you

need it cracked, cut, mashed or crushed, the likes of Pampered Chef or Kitchen Stuff Plus have you covered with an ever-growing array of gizmos—in at least eight designer colors of your choice. Having been long fascinated by the so-called ‘time savers’ like chocolate fountains, bread-makers and Slap Chops—albeit on other people’s counter-tops—I used to take special pride in my relatively gadget-free lifestyle, having gotten through life this far without even a microwave oven. But you could say my life has taken on a sparkling quality since

I picked up a home beverage car-bonation system—made by Israeli-based SodaStream International Ltd.—that turns ordinary old tap water into an extraordinar-ily refreshing club soda filled with sizzling sparkling bubbles to make each sip a reinvigorating beverage experience. For those with a sweet tooth, there are plenty of f lavored

syrups available—including cola, lemon-lime and my own favorite Dr. Pete (a less-than-subtle fac-simile of Dr Pepper)—to make your own fizzy favorites that could give national brands a good run for their money in a blind taste. The whole system consists of just three main components—a canister of CO2

to generate the bubbles, a novel carbona-tion delivery system and a bottle full of H

2O—that

are all ready to go with a simple push of the but-ton. If there is a ‘catch,’ it’s the fact that you need to use the patented SodaStream bottle, whose nice, large mouth enables a super-tight connection to the CO

2 delivery system to form the necessary seal.

While the starter kit I bought came with a one-

liter bottle, I ended up purchasing an auxiliary set of two BPA-free 500-ml bottles for their extra port-ability. The add-on set includes one green and one red SodaStream bottle—featuring branded cartoon characters intended to appeal to both the child and the inner child—with both container lids boasting spectacular hermetic sealing performance to keep the contents effervescent for days at a time.

While extolling the virtues of my soda epiphany at work, an office colleague turned the discussion to the ongoing revival of mixology: the age-old art (and mad science?) of preparing mixed alco-holic drinks. For those quick to dismiss mixology as glorified bartending, the error of this line of thought is self-evident when you ask them to serve up something as advanced as sweet basil soda syrups or candy cap mushroom infused bourbons, which requires good understanding and apprecition of botanical bitters. As a relative newbie to these dark arts, I started out with a 100-ml bottle of Toronto’s very own Bar 40 Bitters Sour—an infusion derived from various herbs and spices steeped in high-proof alcohol. As one of four gustatory Bar 40 Bitters f lavors that also include Sweet, Salt and Umami, the Sour is a perfect match for my penchant for whiskey sours—blended with my own soda, of course. Measuring only 100-ml, what these aromatic bitters may lack in stature is amply com-pensated by the intense f lavor that actually requires the use of a lid dropper—something right out of a 1940s apothecary—to achieve precise measure-ment and dispensation for the intended end result. This extra bit of faux alchemy makes the entire experience of mixing a fancy old-school cocktail a much more visceral and inspired bit of mischief all around, which is precisely the point.

I’m not sure how former U.S. president Ronald Reagan’s favorite candy treat came around to mak-ing a move into the kitchen gadgetry market, but

suffice it to say that my recent purchase of the Jelly Belly Ice Shaver snow-cone maker—manufactured by the California based Jelly Belly Candy Company—has more than earned its keep during some of this past summer’s more hot-and-

humid days. Boasting its own accessory line of Jelly Belly-branded snow-cone Cups & Straws—clev-erly packed inside a see-through paper-plastic box bursting with fun candy colors—this is one utensil that’s guaranteed to bring any summertime party or barvbeque’s to life with its nostalgic throwback look and a joyful visual presence.

If making your own brain-freezing slushies is not your cup of tea, you’ll find a little more mature sense of joy in the new Mike’s Hard Lemonade Frozen f lavored malt beverages marketed by Canada’s own pre-mixed cocktails pioneer Marc Anthony Group Inc. of Vancouver. Proudly standing out on the liquor-store shelf in 296-ml f lexible stand-up pouches adorned with vibrant colors set against a black background, this adult treat packs a perfect mix of chills and thrills once it’s taken from the freezer’s icy cold and squeezed into your favorite glass to serve up a tasty, ice-cold refreshment that would make many a bartender feel as proud as punch.

Paul Pethick is a technical writer and editor living in Toronto.

CHECKOUT PAUL PETHICK


A TOAST TO SPARKLING PACKAGING MOMENTS

ADVERTISERS’ INDEX Page

ABB Robotics 26Atlantic Packaging Products Ltd 2Balluff 21BOBST Packaging Technology 15CHEP 30Columbia Machine 20Delkor Systems, Inc. 9Emerson Industrial Automation IBCFesto 24Flexlink, A Company of Coesia Group 6Fortress Technology Inc. 29Harlund Industries Ltd. 4Harpack-UMLA Packaging, LLC 33KBA North America 34Multivac Canada Inc. 25PMMI Packaging Machinery Manufacturers Institute 27Packaging Technologies Inc. 20RockTenn Automated Packaging Systems 11Robert Reiser & Co. Inc 14Sarong Machinery & Packaging Materials 6, 7Schneider Electric 5Sealed Air Food Care 8SEW-Eurodrive Co. of Canada 17, 33Thermo Scientific 32UBM Canon 35Unisource Canada IFCVC999 Packaging 4, 36Videojet Technologies Canada 1Weber Marking Systems Canada 31WeighPack Systems Inc. OBC

FREE SEPTEMBER 2014PRODUCT INFORMATIONCIRCLE THE R.S. NO. THAT MATCHES THE NUMBER ON THE ADVERTISEMENT OR ARTICLE OF INTEREST.FAX THIS BACK TO US AT (416) 510-5140

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BEYOND THE CUTTING EDGE

· POUCHES · SHRINK BAGS · THERMOFORMING FILM · TRAY LIDDING FILM · SKIN FILM ·· POUCHES · SHRINK BAGS · THERMOFORMING FILM · TRAY LIDDING FILM · SKIN FILM ·

[email protected] • 877-435-4555

Print ITBag IT Form ITWrap ITSeal IT

Shrink ITPreserve IT

Sell ITXtraPlast.com

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Reducing water usage is an important goal for the Beverage Industry around the world. Eliminating water and lubrication from conveyor systems is a proven method of achieving this goal!

Contact System Plast at 866-765-8744

PowerTransmissionSolutions.com/Beverage

What Happens HappensWhen We Don’t Conserve

The Earth’s Resources?

System Plast is a trademark of Emerson Electric Co. or one of its affi liated companies.©2014 Emerson Power Transmission Corp., All Rights Reserved. MCAD14001E | Form 9873E©2014 Emerson Power Transmission Corp., All Rights Reserved. MCAD14001E | Form 9873E

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Visit us at Pack Expo2014 in ChicagoBooth #N6132

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STAND-UP POUCHES HAVE TAKEN OVER

CASE PACKINGAutomatic accumulation loading and sealing for

a variety of pack patterns.

PALLETIZINGUse the Z.Zag to

automatically pick and place cases onto a pallet.

[email protected] 1.514.422.0808 [email protected] 1.305.622.4070

CASE ERECTINGThe Boxxer T-12 is one of the most economical and compact erectors

on the market.

STAND-UP BAGGING The Swifty Bagger is

engineered to open, fill, and seal a wide variety of

pre-made bags.

POWDER FILLING The Star Auger is

designed to weigh/fill powders, granules, spices, and more.

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place on pallets.

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http://www.weighpack.com

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Documents

Canadian Packaging September 2014