Safety in every detail

uppunique packpaper 02|13

Safety in every detail

the magazine for professionals

PlasticsPackagingTechnologyAssemblingDecorationTrendsLifestyle

Trust and reliability: Consumers embrace these attributes more than ever in these current times that are characterized by new values and lifestyles.

Ensuring safety is what all participants in a value chain want to achieve. Thus, Greiner Packaging International places great value on safety, in every detail and in all aspects of the company’s activity – and it always has. It starts with the selection of materials, encompasses legal requirements, and continues through to optimum quality assurance in the production process. As a result, our packaging solutions meet modern safety requirements at the highest possible level.

Günter Ausserwöger Head of Division Kavo

Greiner Packaging International

EditorialDear Readers,

06

1213

In the current edition of unique packpaper, you will gain valuable background knowledge on the subject of safety in the packaging branch, and also explore several new and innovative products that were implemented by Greiner Packaging International within the last few months.

I invite you to leaf through our magazine and read more!

Best regards,

Günter Ausserwöger,Head of Division KavoGreiner Packaging International

K3®

Efficient communication through packaging has a name: K3® 04

Safety in every detail Packaging needs safety 06–11

New freedom of design through thermoforming 12

14

04

A portable home for LEGO® creativity 13

The secret of the self-activating sealing ring 14

Company Information 03

2 unique packpaper 02|13

Casali Coconuts are Manner’s alcohol-free option to traditional Rum-Kokos.The “convenience” megatrend is conquering the confectionary marketplace. Greiner Packaging International has incorporated this development into the packaging of the new Casali Coconuts. The cup is reclosable, and holds 34 tasty, non-alcoholic “coconuts”. The comfortable enjoyment on the go is a fundamental component of the packaging concept, and it impresses with its simple handling: The new cup fits perfectly in your hand, and due to its unique shape it can be taken anywhere – in a car, for TV, on a picnic, or to work.

Coconut filling with a chocolate layerCasali Rum-Kokos are colloquially called “rum balls” and are already well known far beyond the Austrian border. The new Casali Coconuts are their non-alcoholic counterparts, and the making of the new chocolate balls is based

Packaging facts

Capacity: 160 grams / 34 pieces

Material: PP Decoration

Cup: Sleeving Lid: thermoformed from transparent PET foil, labeled

Technology: Thermoforming

Sweet coconuts from the “convenience” cup

on the configuration of real coconuts: A liquid coconut filling is covered by a layer of white chocolate with dessicated coconut, and the tasty milk chocolate shell is made with cocoa from Casali’s own roasted beans.

Packaging facts

Capacity: 250 grams Material: PS Decoration: Dry offset print Technology: Thermoforming

Turkish refreshment “Full Service” packaging for Ayran, “Made in Austria”

Upon their arrival, guests in the Turkish countryside are traditionally offered Ayran. This refreshing beverage is made of yogurt and can be refined in many different ways. The Upper Austrian private dairy, Seifried, that is based in Aspach, manufactures Ayran from organic milk. The product is distributed by a company in Tyrol, named Sunar KG, while Greiner Packaging International is responsible for the production of its thermoformed cups with stylish printing that is applied using dry offset technology.

302|13 unique packpaper 3

COMPANY INFORMATION

Owner, editor, publisher, and editorial office: Greiner Packaging GmbHGreiner Straße 70, 4550 Kremsmünster, Austriawww.greiner-gpi.comCourt of Reg.: Landesgericht Steyr, Chamber of Commerce Reg. No.: 176892k

Responsible for content: Kenneth BoldogPhotos: Greiner Packaging, 2013 Shutterstock Inc., Wolfgang Stadler, Clemens Pürstinger, Nik Fleischmann, Emmi, Brillux GmbH & Co.KG, AS Tukuma PiensCreation, concept, and artwork: Das Kommunikationshaus Bad Aussee, Austriawww.kommhaus.com Printer: Druckerei MittermüllerSubject to alterations, errors, and misprints.

K3® packaging is setting new benchmarks in the branch.

The successful plastics-cardboard combi-nation K3® was developed by Greiner Packaging International, and it plays a key role in the sectors of decoration and communication. Customers in particular value the ability to print on the cardboard sleeve inside and outside. This

feature offers a variety of unprecedented marketing opportunities. High-quality printing methods, such as offset printing, UV varnishing, embossing and aluminum lamination along with gold and silver print allow for sophisticated decoration variants. Practically anything is possible – Greiner Packaging International provides a high level of competence to its customers from concept to completed K3® packaging.

Best Practice Communication with K3®

Efficient communication through packaging has a name:

K3®: Plastics- cardboard combination

K3® is the original. The technology was invented and patented in Switzerland more than two decades ago, and the letter-and-number designation stands for its plastics-cardboard combination of materials. Interestingly, the Swiss location of Greiner Packaging International at Diepoldsau is the site where the development of K3® is being further advanced.

Stickers on the insideThe inside of the cardboard sleeve is alsoavailable for placing stickers.


Efficient communication through packaging has a name:

Look and feel: Pure luxury!

Elegant and straightforward design of utmost printing quality speaks upscale.

The play instinct stimulates the desire to buyWhen the yogurt packaging serves as a toy at the same time, it is twice as interesting to children.

K3®

Impressive embossing and paintAdditional painting and/or embossing enhance the eye-catching effect on the shelves.

Extra space for informational messagingThe inside of the cardboard sleeve offers additional space for product information.

Organic throughout! Including the feel of the packaging.Organic look combined with organic feel.

Fun and games on the inside

The inside of the cardboard sleeve is ideally suited to display printed children’s games.

Winning instantly on the inside!Instant-win codes are printed on the inside of the cardboard sleeve and trigger an additional purchase impulse.

502|13 unique packpaper

ISO 9001:2008

ISO 14001:2004

BRC/IoP

HACCP

FDA

CAC/RCP

Clean room: Class ISO 8 certified to EN ISO 14644-1

Various certifications for the automotive and toy industries

Greiner Packaging International has received a number of certifications.

Packaging from Greiner Packaging International

Safety in every detail

116

Customers of Greiner Packaging International can be assured of maximum safety – at all times, and even in times of crisis.Maintaining reliable supply is a decisive factor for customers in the packaging branch. It is of particular importance in times of crisis, when suddenly something unforeseen or unexpected happens. At these particular moments that one can never be completely prepared for, a company is extremely challenged.

Safety through resilienceRemaining clear-minded, staying calm and reacting as fast as lightning in an emergency; these attributes are essential when it comes to crunch time. Today, this “management

of the unexpected” is often called “resilience”. The term implies steadfastness, robustness and flexible structure, including the power of self-correction. During the last few years, Greiner Packaging International has established excellent prerequisites for resilience within the foundation of its international network. If worst comes to worst, one production site is capable of filling in for another – flexibly and quickly. Due to a sophisticated purchasing policy, the network has created the greatest possible amount of flexibility that allows for maximum independence from any lack of supply in raw materials markets.

A legal framework creates safetyApart from modern organizational structures, safety in the

packaging branch requires clearly defined rules. Many of them are covered by the existing laws and regulations, e.g., Regulation (EU) 10/2011 on plastics intended to come into contact with food. In addition, a series of directives and standards influence the operating principles in the packaging industry and in production. All of these legal and branch-specific frameworks contribute to a high level of safety.

The influence of consumers and filling companiesThe safety of the package is also influenced by additional criteria that are determined by consumers, filling companies and current trends. For end consumers, factors such as shelf life, reclosability, suitability for microwaves, stability, and reduced environmental footprint play an

important role. The basic aspects for the filling industry are temperature-resistance, sealability, ease of processing in plant facilities, and the criteria for the protection of foodstuff.

Trendsetter for BPA-free materialsIn addition, current social trends such as a heightened sensitivity toward environmental concerns and “taboo materials”, such as bisphenols, phthalates, etc., have an impact on safety issues in the packaging branch. A classic example of this is the discussion of health defects caused by Bisphenol A (BPA). In this regard, Greiner Packaging International has been taking a leading role in the processing of BPA-free materials for many years.

In-house safety programDuring the production process, risks occur that concern every packaging producer. Greiner Packaging International handles these risk factors through the implementation of professional safety measures and the use of an in-house safety program that is based on the Hazard Analysis and Critical Control Points (HACCP) system. This is an internationally renowned standard that improves the safety of foodstuff for consumers. Possible sources of error in the production chain are tested using risk analysis and issues are identified and corrected in a timely manner.

Reliable quality management and certificationsSafeguarding quality requires efficient management tools. Therefore, Greiner Packaging International uses a mix of tried-and-true and cutting-edge methods in the area of quality management, and they are incorporated into all aspects of the production chain. A particular focus is on the prevention and remediation of errors. Whether it is BRC/IoP in the hygiene sector, ISO 9000 for quality management, or ISO 14000 for environmental management, certifications and standards are important proof of qualification for establishing a fundamental basis of trusting cooperation. In its partnership with customers, Greiner Packaging integrates a number of certifications. The respective declarations of conformity provide legal certainty.

Closure safety is

the bottom line.

Systematic safety procedures – from development through production

Selection of materialsDuring the selection of materials for sampling and for the first test runs the material composition is carefully scrutinized; the appropriate approval of the materials is a prerequisite. Project journaling that includes risk assessmentRisk assessment in an integral aspect of the project journal in which development is documented. The risk assessment is used to verify Greiner standards as well as legal requirements. FMEA (Failure Mode and Effects Analysis)Through this method, potential product defects or errors in the manufacturing process can be identified and prevention implemented. SamplingBefore a customer approves a packaging project for production, a faultless sampling run is first demonstrated. Quality assurance

During production, various parameters are continuously tested to ensure they meet quality

assurance requirements.

What is resilience?

The Latin word “resilio” means “to rebound, spring back.” The term is taken from physics and materials science, and it designates the stable state of equilibrium in a system. Since the 1970s, it has been used in educational science. Today, a modern lifestyle has been named after it – the “lifestyle of resilience.” In addition, the expression is being used within the management sector.

The safe closure

Greiner Packaging International supports its customers with the development of suitable package closures. Technological demands and solutions are fully coordinated with the product and safety requirements.Best-practice examples: The reclosable sealing lid (thermoformed), whether

round or not-round, interests customers in particular in the delicatessen and gourmet markets. Maximum product safety at POS as well as convenience are the top priorities.

Through the use of injection molding, Greiner Packaging International manufactures tamper-evident closures with versatile opening properties in various designs.

The protection of children is a top priority. Therefore, in the pharmaceutical and household sectors, children’s safety closures are more sought after than ever.

Packaging requires safety

Productionguaranteed

Health guaranteedQuality guaranteed

BPA-free

From safe raw materials to smooth serial production and perfected quality management

8 97 unique packpaper 02|13 02|13 unique packpaper 10

New freedom of design through thermoformingGreiner Assistec and SOLARFOCUS are developing a boiler lining with visible added value.

“Our technical challenge was to thermoform from negative to positive, thereby achieving precise radii and edges,” reports Franz Dilly, Head of Division Greiner Assistec at Greiner Packaging, on the key issue of a project with SOLARFOCUS. For the Upper Austrian company, Greiner Assistec was the go-to company in terms of plastics technology for several reasons. Firstly, the geographical proximity is beneficial for cooperation, and secondly, the company is renowned and highly valued in this industry for its technological diversity.

The boiler as an eye-catcher and brand ambassadorThe new boiler insulation scores highly due to its low weight, particularly when compared to linings made of sheet metal. The specialized thick-gauge thermoforming technology used by Greiner Assistec offers freedom and diversity of design. Thus, the heating-system boiler as an object of utility is substantially improved, and for the customer it transforms a boiler room into a place that’s pleasing to the eye. Through these design-centric features, the manufacturers are capable of strengthening their brand message.

Using the power of the sunIn 1993, SOLARFOCUS was founded in Steyr as a sole proprietorship. Presently, the company is a developer, producer and systems provider of innovative solutions for the residential, light manufacturing and heavy industrial market sectors. “All sources of life come from the sun. And we develop the required technology” – this is the company motto. SOLARFOCUS utilizes the power of the sun – directly (using the latest solar technology) and indirectly (in the form of biomass). The company has received several awards, and has a network of distribution and service partners throughout Europe. Product exports are as high as 70%.

Tech-facts

Materials: ABS / PMMA Technology: Thick-gauge thermoforming Additional processes: welding, gluing and

attaching adhesive labels


Technical details

Material: PP Technology: Injection molding and assembly Special processes: reproducable dimensions (fit) with varied

coloring and shrinking behaviors using a single tool

tuning of assembly and injection molding processes for a perfect fit

flexibility in production and supply (seasonal variations)

Building upon the excellent reputation of the LEGO® bricks that are renowned worldwide, the Danish LEGO Group is continuously expanding its product lines. All of the company’s product development efforts focus on the promotion of children’s creativity by learning through playing. But LEGO Group also thinks of practical matters with its first suitcase-style packaging that also serves as a mobile storage solution for LEGO® bricks.

Universal talentLEGO® Suitcases combine multiple functions: They simplify the storage of LEGO® bricks and components, while compartments of varied and adjustable sizes provide for neat organization and of the bricks. Whether a child just pays a visit to a friend next door or the family leaves for a vacation. LEGO® Suitcases are the ideal solution for practical portability – and they can be creatively integrated into play.

On two continentsBased upon its network organization, Greiner Assistec contributed its strengths to the development and production of the new LEGO® Suitcases. All stages of the project (concept – product design – choice of materials – choice and implementation of suitable testing procedures – tool making – process qualification) were defined and carried out in close cooperation with LEGO Group. The project was centrally managed in Austria following LEGO Group Standards. Production is being carried out in the Czech Republic for the European market, and in Mexico for the American market.

A portable home for LEGO creativityStoring, organizing, playing, transporting:

The new versatile LEGO® Suitcases manufactured by Greiner Assistec for a multitude of uses.

Five key benefits of LEGO® Suitcases

Maximum product safety Overlapping edges and snap-locking hinges

Optimum presentation On the toy retailer’s shelves and at home – stable base, rounded design in the handle/holding the carton in place.

Permanent storage Compared to cardboard packaging, LEGO® Suitcases offer benefits such as the permanent organizing, long-term storage and portability of LEGO® bricks.

Easy operation The opening and closing process is easy and reliable and the Poka-Yoke system prevents wrong assembly.

Play experience LEGO® Suitcases can be integrated into play and enhance creativity.


This is how the self-activating sealing ring works

During the assembly process, the self-activating sealing ring is pressed through the tapered neck of the package, while the freshly injection-molded neck of the package is still hot. It does not come into contact with the self-activating sealing ring and it cools down and shrinks independently from this process. Upon opening, the conical sealing ring is pulled immediately into the smaller diameter of the package neck activating itself. Thus, an optimum sealing effect is achieved.

Tetra-Pak developed the “one-action-opening” screwtop for the beverage cartons of its Tetra Top line. What’s outstanding about the 38mm screwtop closure is its high degree of convenience: Packages can be easily opened with just one hand.

Emmi realized a need for improvementOperating the Tetra-Pak filling plants, Emmi – the Swiss dairy processing company renowned for its high standards of quality – came to realize the need for the improvement of Tetra-Pak in the area of product security. The drawback was in the production process: The neck of the package is injection molded and the closure needs to be secured immediately after injection molding, before the package neck cools down. Due to this

The secret behind the self-activating sealing ringDivision Kavo is optimizing Tetra-Pak’s “one-action-opening“ screwtop closure for the Swiss dairy, Emmi.

Optimized production process details

The self-activating sealing ring serves as a stabilizing element in the assembly process by supporting the neck of the packaging.

The number of improperly assembled closures has been minimized.

The number of rejects is significantly lower than the defined upper limit.

The rejects have clearly fallen below

one per million.

specific requirement, the tightness of the closure had not been optimal.

Functional and process-related benefitsDue to its long-standing and trusted partnership, Greiner Packaging International received the order from Emmi to further develop and improve the screwtop closure. The result is the introduction of an individually designed self-activating sealing ring, for which a patent has been filed. Günter Ausserwöger, Head of Division Kavo at Greiner Packaging International is pleased to say, “We deliberately focused on a specific design feature of the packaging. The new closure concept creates added value for our customers in terms of functionality as well as performance.“


Packaging facts

Capacity: 280ml Material: PP Technology:

Stretch blow molding

”We would like babies to drink from these bottles as naturally as they do from their mother’s breast.” This was the main goal during the development of the new anywayup® baby bottle, and Greiner Packaging International met this challenge for the British

baby products specialist, Haberman. The result is a bottle designed to hold 280 milliliters made from a stringently-tested, baby-proof material.

Distinctive stretch blow moldingFor the production of the baby bottles, stretch blow molding technology is used. In this context, it is particularly essential to integrate a special lip that supports

the design of the anti-colic system. As a result of this system, the backflow of milk is blocked, preventing air from getting into the milk, which is the main

reason for colic. The new anywayup® baby bottle is available from September 2013 in Great Britain, eastern Europe and Russia, with projects in Western Europe and China

both underway for 2014. Haberman, an established distributor in Great Britain, has recently concluded a reciprocal manufacturing and distribution agreement with the Polish company Canpol Babies.

Revolutionary paints and varnishesSturdy one-liter pot for Brillux

varnishes and dispersions. For this new technology, the German manufacturer of paints and colorants, Brillux, has custom-tailored the water-based paint, Hydro-PU-XSpray.

Pressure-proof and suitable for use in a mixerBrillux paints are individually nuanced and glazed and ready for processing. They are filled in screw-lid pots that hold one liter. The pot design allows for the quick change-over of paints – an excellent time-saving benefit. The pot with a screw-on lid was developed by Greiner Packaging International and resists an overpressure of 0.3 bar and a contact pressure of 2,500 Newtons – without denting or buckling. In addition, it is possible to process it in a mixer to provide for an efficient nuancing of the colors.

XVLP. The technology behind these four letters revolutionizes the painting of small and medium objects. XVLP is the acronym for eXtra Volume Low Pressure. This new modular spraying system is used for building coatings,

As natural as breast-feedingInnovative anywayup® baby bottle with anti-colic system – on the market starting in September 2013

Packaging facts

Capacity: 1 liter Material: HDPE Technology:

Extrusion blow molding

Decoration: All-around label

Lid: Screw-on


www.greiner-gpi.com

• Information – Communication – Networking• At the oft-requested meeting place, the packaging branch.• This year’s focus is on Point of Sale.

greiner packaging gmbh4550 kremsmünster, austria

tel.: +43 7583 7251-0www.greiner-gpi.com

POSInnovation DayNovember 21, 2013

Documents

Safety in every detail