It's been a long strange Packaging trip!

It's been a long time since I wrote anything about packaging! The reason for this is last July, I was hired to work for the number 1 spirits company in the world: Diageo NA. My title is Graphics Commercialization Manager for New-to-World (NTW) Innovation. Originally, I was brought in as a consultant and later on was hired full time.

So far, I've been working on some premuim packaging for recent entries into the spirits world such as Rökk Vodka, Moon Mountain Vodka, Godiva Vodka and others. The experience with Diageo has been great so far as the company is filled with very bright people working towards a common goal: to be the best. I recommend if you are looking to work for a world class CPG Beverage/Spirits company, go to the Diageo Careers website and search for a position that suit your experience or just set up a profile.

The reason that I haven't been blogging is that I am worried that I will get flooded with requests. I just don't have the bandwidth nor am I a specifier of packaging components. If you are doing something really innovative in the packaging field though, send me a note. Please drink responsibly!!

US District Judge lifts Block on NY bottle deposit law

On August 13th Judge Deborah Batts (Southern District of New York) modified the preliminary injunction order granted on May 29th to the International Bottled Water Association and other plaintiffs that has been preventing the state of NY from implementing all provisions of the recently enacted bottle bill amendments. (NY BIll S59 & A159)

The expanded bottle bill would have required a nickel deposit on other beverages including bottled water, beer and would require beverage companies to forfeit 80% of unclaimed deposits according to the statement issued by NY Attorney General Andrew Coumo.

The bill was supposed to take effect on June 1, but was pushed back to April 2010 by U.S. District Judge Thomas Griesa.

However, Judge Batts ruled on Thursday August 13th that most provisions could take effect immediately which means that soda and beer companies will have to begin returning the bulk of unclaimed deposits to NY State. How much money are we talking about? According to Cuomo, the sum will be over $100 million in new revenue for the cash-strapped state.

Water companies, will have until October 22 to comply. Consumption of bottled water has risen to roughly 3.2 billion bottles according to Laura Haight, senior environmental associate for the New York Public Interest Research Group, the organization that has been fighting for this law.

The bigger issue and major sticking point for the law has been the labeling rule that would require NYS specific UPC codes for bottles sold locally in NY. Having to do so would effectively require distributors to have multiple inventories of beverages, those sold in NY and those sold in the other 49 states. The packaging and warehousing nightmare to comply with this law is staggering (to me) and when you add that many of the beverages sold in eastern NY Come from distribution centers in CT or even western Mass, the complication is enormous.

Each beverage would have to have a New York variety. So this would effectively double the packaging used for each flavor; labels, 4 or 6 packs, cans, 12 packs, variety packs, cases, etc. This includes costs to design, prepare, produce and ship packaging. Not only that, if you had a production run you would have to predict case sales by market and break down the line twice to change the packaging. (NY - Non-NY) then warehouse it.

I suggest a simpler solution where the UPC remains the same and the deposit language changes on the affected packaging. I would also suggest that first year, NY forgives the packaging changeover by letting beverage companies keep a percentage of the collected deposit money to recover costs. What do you think?

The latest on Bisphenol A

I've been following the BPA debate for awhile now and it looks like California is not going to place BPA on their list of hazardous substances. They are also not going to be warning consumers: (those without internet, I guess) Health Canada, however is studying the effects of BPA on babies focusing on the coatings used on metal lids used for glass baby food containers. According to the study the levels found were quite low, like an average level of .18 ng/gram. By the way, a nanogram is one billionth (10^-9) of a gram. France is looking to completely ban the chemical in consumer packaging. (There is a login to read the article)

The Boston Globe last Tuesday published a story warning parents to avoid bottles with BPA as posing a danger for children.

Meanwhile, just when you thought you were safe, BPA Free labels may not be true according to this story. I guess you can't believe anything that you read.

The FDA maintains that the chemical is safe. Studies are starting to vet out that food and beverage containers made of polycarbonate do not pose a health risk to humans.

Banning the chemical based on current studies would be a hardship for the packaging & food industries that use the chemical. Whole Foods Market has a BPA policy and is working towards limiting and removing the chemical where they are able.

So the debate continues and so does the confusion. Consumers are going to have to avoid buying processed & prepackaged food; It is nearly impossible to avoid this chemical in the market place.

Big News!! I'm the Cover Feature in Flexo Magazine!

This month I am extremely proud to announce that Flexo magazine not only published my article called: Press Approvals from the CPC Perspective they even put me on the cover of the July Issue. Flexo magazine is the Flexographic Technology Source and the official journal of the Flexographic Technical Association. They have been covering my career for a few years now since they did an article in Feb 2007 about me when I was still with Cadbury Schweppes Americas Beverages. Please let me know what you think of my article!

Packaging Sustainability at 2009 EastPack show

I attended the Eastpack show on June 9th - 11th in NYC again and if you have been following my blog, I go to these shows to collect various examples of sustainability initiatives that I see when walking the floor. Some of the claims that I see are dubious and some seem more rooted in science & good manufacturing practices. The simple fact is that at this point, most companies have at least some kind of sustainability statement. I have not been paid to endorse the companies below.

The EastPack show this year featured a Green Manufacturing Expo sponsored by Design World Magazine. The pamphlet handed out features about 130 attending suppliers that have "identified themselves as offering energy efficient and/or Sustainable products or services." on the floor these vendors were further identified by a placard that said they were "Green".

Since I don't have the time or ability to verify any of their claims, I will just leave you on your own here, if you decide to use them for their environmental claims, make sure you get them to back it up with documentation & proof.

The most interesting product I saw was an odd-looking material displayed by ecovative called Greensulate & Ecocradle which is an alternative to foams and plastic internal shipping material and is made with natural composts & inert fungus. It is really compostable and looks different. The only possible negative to me is that it felt a lot heavier than the synthetics it's replacing which may affect shipping costs.

AM Packaging Incorporated, a litho box printing & packaging company has added a new very efficient printing press called a Komori Corp. Lithrone S 40P 8 color plus coater. With integral Computer-to-plate (CTP) technology & one-step register set up is reduced ten-fold. How is this possible? the plates are processed right on the press for nearly perfect fit. I have seen this technology and it works. Furthermore, AM claims that the press has reduced noise, energy & chemical consumption. These are all good reasons to invest in the latest technology and the fact that AM has found a creative way to promote the new equipment sets an example of how to market new technologies. Also new presses have the benefit of printing higher quality packaging.

I have been watching Bedford Industries for a couple of years now and they make a great product. It's an elastic hang tag that's becoming quite popular called Elastitag. The thing that makes these tags great is that they have an elastic band at the top which means that the tag itself can be used to hold together the product and eliminate the packaging altogether. (Think about using them to hold & identify a bunch of brocccoli) It has a die cut elastic band at the top and can be die-cut in almost any configuration and the tag itself can be a coupon book. I'm starting to see them everywhere I shop.

CWS Contract Packaging is a certified organic service to the food, retail and pharma markets. They are a socially conscious not-for-profit 501(c)(3) entity who provides co-packing using a diversified blend of community & dev. disabled workforce. They also offer PLA, RPETG & RPET packaging solutions. You can debate the merits of the new plastic solutions, but I think it is important to utilize community services like CWS, located in Norwich, NY.

Tucker Printers, a network of offset, digital printing, packaging & fulfillment companies now owned by Consolidated Graphics, claims in their hand-out to be, Powered by Wind Energy, Rainforest Alliance Certified, a member of the Forrest Stewardship Council (FSC) and the hand-out was printed with soy based ink. While I applaud that they have taken a stand for sustainability, I think it is really important to go the extra distance in their sales material to qualify what goals they have set and achieved such as, 45% of our power comes from wind, etc. Tucker Printers is located in Henrietta, NY.

XelaPack in Saline, MI has a product that I think is the future for many packaged goods that you now see in rigid bottles & tubes. They produce and co-pack a line of stock & custom paper stand-up packages with tear-off tops. Starting out as simple sample packages for hotels & spa's, their product line and fill weight has grown to include pharmaceuticals, beverages, & powders. According to their literature, the amount of packaging reduction is stunning. Something in the range of 93% less plastic when compared to similar sized bottles & tubes. Shipping reduction is also huge. As an added bonus, the entire package can be decorated. If you have an innovative new product, consider this package.

Ekan Concepts Inc. in Ontario, makes a cool premium wooden display box manufactured out of high quality veneers with different laser-etched or labelled decoration possibilities. I'm not sure how sustainable they really are as a company, but their product is made from 100% wood.

CardPack, a leader in custom engineered carded packaging designs located in Solon, OH, was passing out a nice folder which contained environmental printing awards from PrintAction, the Packaging Assoc. of Canada, the paperboard packaging Council as well as reprints from Brand Packaging & Green Packaging Magazines. Two of their products are called ClubPack & SustainPak are alternatives to clam-shell packaging. You can read more on their website, but the thing that stands out to me is their combination run printing service which I have never seen before publicly offered. Simply stated, they gang up your low-volume print job with other companies jobs on the same press set-up in gang quantities.

The disadvantage of this kind of printing might be that you get the color you get, but with computer to plate technologies, it's probably not a problem. This has to be one of the biggest behind the scene material wasters. Setting up all of these jobs on the same sheet has to offer amazing savings as opposed to having each job run separately. This is something that any printer could do.

Finally, for reference, at the show, I met with some folks from the Toxics in Packaging Clearinghouse (TPCH ormerly CONEG) made up of different State Environmental Agencies who were passing out literature such as QA considerations for Toxics in Packaging and Toxics in Packaging Fact Sheet. These interesting (to me!) documents outline what different states are doing and going to do to regulate toxics in packaging. If you produce, make or buy packaging you must be well-read in this area. These are the people that set the bar in states that have packaging laws.

More News about Bisphenol A (BPA)

BPA was in the news again this week for a marketing campaign they were about to launch to better sell in this highly scrutinized chemical used in plastic bottle and aluminum can manufacture. (as part of an internal epoxy coating) This article from written by Beth Daley in the Boston Globe, outlines the problem in detail. Also This article in the Effect Measure Forum has several excellent links to get you up to speed on the issue.

According to these verified, leaked minutes, the industry met in Washington, DC on May 28th to discuss tactics to better sell the chemical to the public by, of all things, using a pregnant woman as a spokesperson instead of a scientist because, "A pregnant woman would be "the holy grail" to serve as a spokeswoman, the memo says. Attendees said they doubted they could find a scientist to serve as a spokesman for BPA."

Attending Companies were: Coca-Cola, Alcoa, Crown, North American Metal Packaging Alliance, Inc., Grocery Manufacturers Association (GMA), American Chemistry Council, and Del Monte.

From the LA Times, All eyes are going to be on California as they are going to have a state EPA hearing next month on the subject that will affect Prop 65 in which the Governor will have to publish a list annually of the chemicals known to cause cancer or reproductive toxicity.

My thoughts are this issue has been poorly handled by all involved there are clearly studies that support the removal of this chemical from packaging or food contact as much as possible. The industries involved, are working hard to come up with alternative chemicals, but they won't be easy or cheap. Should the chemical be banned? Yes, until the science supports it's use in the future.

I'm reminded by the applied ceramic label (ACL) - Lead decoration issue that came up several years ago in the glass industry or the more recent lead in toys policies. Can BPA be compared to the dangers of lead to children? No, the science doesn't support that but guess what, the public doesn't understand or care about that.

This is going to have a great impact on packaging in the short future if California, New York and Connecticut place bans on the chemical and this is what these companies fear the most. This egg-on-your-face memo has not helped the industry or the issue and is only going to accelerate the legislated removal.

ShelfImpact puts on successful Package Design Workshop in Tarrytown, NY

I had a chance on Wednesday to attend one of ShelfImpacts! Package design workshop given by Jim George, Editor-in-Chief and Jim Chrzan, Publisher of ShelfImpact Magazine which is an e-mag and print supplement to Packaging World Magazine.I have to give them high marks for giving an informative and entertaining seminar. 

The "Jims"  traded places often while talking about US trends that affect packaging, consumer buying habits, creating value and talked about key emerging trends. The audience was engaged with a couple of fun quizzes and we broke into smaller groups and got to suggest packaging strategies for a wine company and got to evaluate packages from around the world.  The full program is here.

There was also a larger discussion of sustainability and how it relates to packaging.

TricorBraun, a full service design/engineering & global sourcing company was the local sponsor and their representative, Don Forbes spoke of & showed a short video about their capabilities. 

All-in-all this event was worth my time & the $425 cost and I would highly recommend catching one of their presentations, there are only two dates left, June 17 in Chicago and October 21st in Cinncinnati. here is a link directly to their workshop. 

More detail on the Expanded New York Bottle Bill with important links

I've been doing a little more research and here is some more info. The bill was spearheaded by the New York Public Interest Research Group. There is news lately that the application of the rules will have to delay implementation which was slated for June 1, 2009. Why is this? First, according to the Returnable Container Act, all beverages under a gallon that are sold in NY will have to have a unique UPC code for the bottles to be recycled by Reverse Vending machines that are going to be required if you are a grocer with a store over 40,000 square feet.

Stores will also have to post a prominent sign with the "New York Bottle Bill of Rights"

The bigger issue is that the beverage companies will have to change all of their UPC's to make specific NY UPC codes and set up a distribution system that supports selling the unique NY SKU's. This is going to double the amount of packaging that will be required if you want to sell beverages: NY and non-NY. The labeling will have to include any secondary packaging or cases because the UPC GTIN affects the other units. So beverage companies will have to dual-inventory everything. The transition for these kinds of things takes about a year when you take into consideration art & label production, material, stock and then selling through existing product. 

The other thing that is vague is how will the consumer be able to tell if the beverage they are buying is approved for sale in NY. I am certain that this fact and the loss of 80% of the no collected refund money will cause some beverage companies to pull out of NY all together, but no one has made that move publicly. 

NY Passes expanded Bottle Bill

This has been coming for a long time and I applaud my home state for passing an expanded bottle bill in the 2009-10 budget that includes water bottles and will not only help the environment, but it will boost the economy by requiring that beverage companies return to the state 80%  of unclaimed bottle & can deposits to the state. This could add up to over $100 million in revenue for the state. 

A side issue will be more work for redeemers, designers and printers who will have to print new labels with updated graphics with the new refund copy. I am trying to find out what the labelling requirements will be & timing for packaging. My personal opinion is that the bill should be expanded further to include all packaging in other categories as well or be based soley on container material. Environmental Advocates of NY

Spectrophotometer is the word

Here is a press release that I just did for a packaging service that I am going to offer. I invested in an X-Rite spectrophotometer because it is the ultimate prepress gadget and also takes some of the subjectivity out of doing color matches. The companies that really care about color (like Coca Cola) use these when they go on press so I thought that smaller companies can benefit from the technology too. You just can't blindly use it, but to be able to tell the pressman that the ink in the press will never make the standard on the first color pull is huge in my opinion. Let me know what you think.


CARMEL, NY, March 17, 2009 – Barry Sanel, a respected printing and packaging solutions executive with over 20 years of industry experience, announces customer press approval services uniquely geared towards the Flexographic Industry using X-Rite’s new SpectroEye spectrophotometer color management tool.
Consumer product companies (CPCs), now more than ever, are looking for flexo printers to be able to match ink standards set by offset litho or rotogravure printing. Barry Sanel Packaging Advisors can now establish quickly and easily if a mixed or process color will ever match the standard at any density after the first press-pull.
By using X-Rites best-match feature, the color hue can be matched more closely to the standard across different processes and substrates; such as flexible package printing, paper or pressure sensitive label, preprint & direct print corrugate, metal & plastic closure and foil printing.

“This is a critical step when trying to achieve a consistent look across the many different kinds of packaging a brand may use,” Sanel noted.

Many times, the brand manager while on press is challenged by hitting color targets and has to labor through hours of press-pulls. The printer also suffers with lost productivity. This service removes subjectivity, cut hours out of the press approval process and provides high quality feedback to both the printer and the customer.

How this service works:
Barry Sanel Packaging Advisors will attend your first press run, with or without your customer present and validate the color on press until the closest match possible is made to the approved standard. A comprehensive report will be provided detailing each press-pull until the print standard is achieved. When requested, we can communicate the match in any colorimetry standard such as: CIE L*a*b*, E* CIELAB (delta-E) etc. . .

"In my years within the packaging industry, I have seen many print jobs go over budget or get delayed because of color matching trial and error. My service eliminates this guesswork.”

Barry Sanel Packaging Advisors is located in the New York City suburb of Carmel, NY. Contact Barry at 845-228-5556 or barry@barrysanel.com.

Top Ten Myths about Sustainability

Recently, Scientific American posted an interesting and well written article on the Top Ten Myths about Sustainability written by senior science writer Michael D. Lemonick.  

As people who create and sell packaging it is important to not sell our products as being "Sustainable" Which Mr. Lemonick points out at the beginning of the article,  "The word has devolved into a meaningless cliché, or it has real conceptual heft. “Green” (or, even worse, “going green”) falls squarely into the first category. But “sustainable,” which at first conjures up a similarly vague sense of environmental virtue, actually belongs in the second." 

The point to be made as it relates to packaging is that no amount of packaging reduction is going to save the environment or the earth as long as the goal is to increase sales. Packaging, at best, along with cars and energy can only continue to be made more efficient to a degree and as he points out is not an easy concept to wrap a consumers head around.

Lots to be Thankful for in 2008!

Since September, I have been on assignment, so I have been negligent on my blogging. It has been a busy and great first year for me and my business. In March of 2008 I had an idea that maybe I could bring to design firms and consumer goods companies, the packaging philosophies and strategies that I developed while working at Cadbury Schweppes Americas Beverages as a packaging manager and CCL label as an art director. 

I spent the year going on press all over the country and managing color for design firms by helping with paperboard cartons, six-packs & 12-packs, paper, foil labels and corrugate trays. I even went to an aluminum can company for a beer can approval. When their design managers couldn't attend the press run, they called me and I travelled on very short notice with my wife Ava acting as my travel agent. 

I attended five packaging shows including the Packaging Summit, Eastpack, InnobevUS, HBA, and the PackExpo in Chicago. I also had the opportunity to attend OI's glass university. At these shows and conferences, I had the opportunity to talk to hundreds of people, companies and learn about packaging trends while focusing on sustainability issues. I joined the IOPP and am working towards becoming a CPP. (certified packaging professional) The goal is to stay current on packaging trends, materials and ideas. 

Since September as mentioned above, I have had the privilege to help a major cosmetics company with an important packaging project. 

The key here is that in this tough economy, there is still room for an individual with experience to make a difference with companies through outsourcing. I would like to take a moment here to thank all of my former colleagues at CSAB, the SBA and the design firms who have either hired me or given me advice to help me get my start. I would also like to thank my family who has been supportive through the transition from employee to business owner.

2009 will be an exciting year for me as I continue to build and, I hope that everyone reading this message has a safe, healthy and happy new year!

All the best,

Barry

 

Sustainablity at the HBA show

Last week I visited the 2008 HBA Global Expo at the Jacob Javits Convention Center in NYC. As always, I am on the lookout for interesting sustainable packaging and concepts. This is one of the main shows for the Health & Beauty (Cosmetics) industries and a great show to go to if you are searching for innovation and trends. 

Since I usually work in the food & beverage industry, it was a nice change of pace to see what is happening and as is expected, many companies were talking about sustainability. Here is another list of companies that I thought stood out:

At the top of my list is Mirel plastics. Apparently, Mirel is a biobased, biodegradable, compostable, bioplastic produced from corn. Well, I had heard of "biodegragable plastic" before and was quite sceptical because, hey what will this plastic degade into? Little bits of plastic? What makes Mirel different is that since it is corn based, it fully biodegrades in a short period of time when exposed to soil or a compost. I'm not clear on the science behind this, but the person that I spoke with at the show explained that the material is grown from microbes that convert sugar from corn somehow. Heavy stuff. However, from their literature, this material could replace polyolefin & polystyrene plastic. Their facility is due to be in production in 2009 an I think you should at least take a look at them. If you want to get some of it for yourself, pick up a gift card from Target as it is made from Mirel.  

Next is Monadnock Paper Mills in Bennington NH. They are a paper mill that has made it their policy to promote environmental awareness and invest in research to determine innovative ways to reduce waste and efficiently use natural resources. They say on their website that their plant gets up to 25% of its power directly from a local hydro electric source. They print a really well researched pamphlet that they will send you called, A Field Guide to Eco-Friendly, Efficient and Effective Print, which contains at-a-glance printing and paper information about important issues being faced by this industry.

Parallel Products is an environmental services company and North America's leader in unsaleable destruction and recycling. They specialize in the destruction and recycling of full case and bulk beverages, alcohol, health and beauty and bulk streams and will take your packaging wastes and convert it to useful byproducts such as fuel-grade ethanol. This is a direct assault on the waste stream and I like the idea that companies are emerging that offer innovative, environmental ways to recycle. 

Disc Graphics in Hauppauge, NY, a company that makes paperboard and high-end mini-flute boxes, offers an exclusive paperboard stock that is produced from a mineral and uses no trees or chemical breaching to produce. They offer a variety of post consumer waste boxes, and print with linseed-oil based inks. They are also part of the Forest Stewardship Council which plants a tree for every one that they cut down. 

My old friends at CCL Tube are marketing a post-consumer resin (PCR) tube that can be made of up to 70% PCR. They claim a three-layered process that isolates the product from the PCR material. In this manner the product does not come into contact with the recycled material, which insures integrity as recycled plastic materials pose a problem with the potential for inclusions. 

Note again that these observations are my own and I have no stake in any of the companies above nor can I prove that the claims they make are true.

Glass, Plastic or Can? continued

As a former packaging manager of a large beverage company, when it came to beverages I always wondered which was more environmentally friendly. Much like the old "Paper or Plastic" argument at the grocery store, which is better or is anything actually better for the environment? This is not an easy question to answer. Last time I wrote about sourcing, this week I want to pick up where I left off with manufacturing. Some of this info I am going to simplify a little, this is not a class!!

Glass (Bottles) 

Once the raw materials are mixed in the furnace (at 2800°) the materials are thermally mixed by carefully regulating the temperature to create convection currents. The molten glass then flows down a forehearth where it is carefully cooled before entering a feeder where it is cut into "gobs" (industry term) and these fall into an individual section (IS) machine and then the mold cavities. Most glass is formed in two stages, stage one is the formation of the parison and stage two is where the parison is transferred to the final cavity mold for container formation. Video

Once molded, the new, red-hot bottles move down a conveyer through an external & internal tin spray coating treatment (hot end coating: which increases container strength and helps with labelling) to an Annealing lehr where the glass temperature is raised up again to about 1050° and then cooled slowly to reduce internal stress caused by uneven cooling during the forming process. After all that, the containers are sent through a cold-end coating and given a water based spray to give the bottles lubricity and minimize glass checking. (chipping when traveling down a production line). Bottles are then QC'ed and palletized for shipping to the bottler. Here is a great video of the process from the Discovery Channel.

Aluminum (Cans)

Coils of aluminum are delivered to can factories by truck or rail. On average a coil is 15,000 linear feet, thickness is about .0108" Width is determined by the the die setting. It is important to note here that most beverage cans are made up of three parts: the body, the end and the tab. All three of these components are made of Aluminum, but go through different forming machines. 

On can bodies: the aluminum coils are QC'ed and placed on mandrel "uncoilers" where the aluminum is fed through lubricators and then a "Cupper" this is a die forming machine that stamps cups out of the sheet. These cups are distributed by a conveyer system to can making machines called "bodymakers" which draw and iron the cups into cans by punching them at high mechanical pressure into ironing dies. The aluminum is drawn through these dies making them thinner and longer. The bottom of the can is also formed at this point. The rough can is then ejected using air and sent to a trimmer where the end is cut off to a precision length. These trimmed cans which are oil coated are then washed and rinsed. Next stop decorating, (which I will talk about in a future post) Decorated cans are then internally coated necked and flanged in tools that give the cans their familiar reduced neck. Here is another great video again, from the discovery channel. Another from Ball Corporation.

Retained-Tab end manufacturing is much simpler. Most can ends go through a ten step forming process with the first couple of stages being similar to the body process but instead of punching "cups", the forming press makes shell blanks that are then "Curled". These curled ends then have a sealing compound applied that will help form a tight seal when the can is filled and capped. The curled are then formed further with the familiar score for the dispensing opening. At this point the can ends also might have relevant state refund information embossed. At the same time, the tab is also formed on a different machine and the two components are married until the end is fully converted. Can ends are considered a commodity, and it is really a good idea to use can ends made by the same company as the body.

PET beverage bottles: (Single layer)

The raw material is delivered to the plant in bins or boxed pallets sorted by color. This material is melted at 5-6oo° and the material is fed into molds at high pressure to create a "preform" preform molds are very expensive. Preforms are precision molded to assure plastic distribution throughout the container. It is interesting to note that the threaded neck is in its final form at this stage.

The preform is then heated again to nearly its melting point and sent into a reheat stretch-blow molder where it stretched and molded into its final shape. Often, preforms are produced and shipped to the filling plants and the bottle is molded on-site to save in shipping costs. Video, again from the discovery channel. 

So who wins manufacturing? Well, after viewing the three video's and reading my description, you should be able to see that even post sourcing, glass and aluminum can manufacturing are heavy industries. The energy costs to run glass furnaces & lehr's & aluminum die forming equipment and extruders has to be higher than the energy to heat and mold plastic bottles. The PET resin industry reports 52% less energy to produce PET over other containers. I am not biased towards plastic but I am trying to report physically and in plain terms what it takes to produce these containers/materials. I have been in glass, can and PET factories and I can tell you from experience that PET factories are far simpler and cleaner places. If anyone disagrees with me on this point please let me know. 

Scorecard: Glass = 0, Aluminum = 0, PET = 2

Up next labeling.

Glass, Plastic or Can?

As a former packaging manager of a large beverage company, when it came to beverages I always wondered which was more environmentally friendly. Much like the old "Paper or Plastic" argument at the grocery store, which is better or is anything actually better for the environment? This is not an easy question to answer. Since looking into this issue, I have decided to break it up into several posts.

The Sustainable Packaging Coalition defines four life cycle phases of key importance to determining how earth-friendly a package is: sourcing, manufacture, use and end-of-life.

I am going to try to avoid statistics as much as possible. While some statistics are probably OK, in the format of a blog, at a minimum they will put you to sleep and at worst, they are tools used by people trying to prove a point. As someone once said, there are three kinds of lies; lies, damned lies and statistics!

Raw Sourcing:

Glass (Bottles)

Glass is made up primarily of SiO2 or silicon dioxide. Also known as silica most commonly found in nature as sand or quartz. Silica is the most abundant mineral in the Earth's crustand the second most abundant element. Silica occurs commonly in nature as sandstone, silica sand or quartzite. It is the starting material for the production of silicate glasses and ceramics. It can exist in an amorphous form (vitreous silica) or in a variety of crystalline forms. Often it will occur as a non-crystalline oxidation product on the surface of silicon or silicon compounds.

The production of glass dates to the Egypt, Mesopotamia & Roman empires. (Fifteenth century) Modern glass making dates back to the late 19th century; That is, glass made by machine. Simplified: glass is made up primarily of Sand (Silicone Oxide SiO2), Soda Ash, Limestone, Feldspar and minor ingredients: (Fining agents, decolorizers & colorizers) Glass is remarkable for its strength and being chemically inert. These ingredients are mixed together (Also known as fusion casting) in a large furnace that runs at about 2800°F.  Typical glass factory diagram. 

Aluminum (Cans)

The chief source of aluminum is bauxite ore is mined and refined into aluminum. Bauxite is combined with caustic soda, lime, and steam to produce a sodium aluminate liquor. Impurities are filtered or settled out of the liquor and alumina hydrate is precipitated out of the mixture. The alumina hydrate is calcined to remove moisture and drive off the bonded water.

The resulting alumina is ready for smelting into aluminum. Alumina is electrolytically reduced into molted aluminum. Aluminum's melting point is approximately 1221°F. This reaction occurs in Hall-Heroult reduction cells (called pots) where the bound oxygen in the alumina reacts with carbon electrodes to form carbon-dioxide gas and aluminum. Each ton of aluminum requires 0.4-.05 tons of carbon anodes. The resulting aluminum is formed into slab ingots that are up to 26 inches thick, 20 feet long, and weigh up to 20 tons each.

The aluminum is then rolled into sheets through the process of forming. The slab is heated in a furnace and rolled between powered rollers until the plate is approximately 1 inch thick. The plates are further reduced in finishing mills where they are hot rolled to a thickness of 0.25 - 0.4 inch. These sheets are rolled into large coils and graded for quality.

Aluminum is too reactive chemically to occur in nature as the free metal. Instead it is found combined in over 270 different minerals. Aluminum is also an abundant metal and the third most abundant after Silicone Oxide and makes up about 8% of the Earth's solid surface. Refined aluminum is remarkable for its ability to resist corrosion. 

Polyethylene terephthalate (PET) 

PET is a thermoplastic polymer resin of the polyester family. Wikipedia. The raw materials are petrochemicals: crude oil, natural gas and ethylene glycol. PET is hydroscopic, meaning that it naturally absorbs water and it must have this moisture removed as much as possible before molding or extruding. Once molded, PET has a high resistance to moisture and is very strong.

Crude oil is a naturally occurring flammable liquid found in rock formations consisting on a complex mixture of hydrocarbons plus other organic compounds. Therefore, PET is an organic compound. PET was invented by DuPont chemists in the 40's during a search to make new textiles. The PET soda bottle was patented in 1973 and a two-piece 2 liter bottle was first used by Coca Cola in 1975. 

PET raw materials are either extruded or injection molded and chopped into pellets. PET has a melting point of approximately 480°F.  The raw pellets are packed in large pallet sized boxes.

So who wins raws sourcing? Since glass and aluminum are minerals and must be mined using equipment and refined in furnaces using extremely high temperatures, I have to vote for PET here. Sure, PET is refined directly from petroleum byproducts, however the energy costs used in the formation do not begin to add up to the amount of energy used to keep the mining equipment and furnaces running 24 hours a day, seven days a week. Energy that comes from Petrochemicals.

Scorecard: Glass = 0, Aluminum = 0, PET = 1

Up next: manufacturing

Glass, Plastic or Can? Which package is most "Sustainable"

It's been a busy July with a bunch of press approvals so I haven't been blogging as much as I should be. I have been thinking about this subject for a long time and talking to a bunch of container companies lately. In the next couple of weeks I will attempt to qualify which container is the most "Earth Friendly" from manufacturing through consumer disposal & recycling. I am going to limit myself to comparing containers that hold 12oz of beverage: a glass beer bottle, a common aluminum soda can and a PET bottle. The decoration, secondary and tertiary packaging will be considered to as well as the cap.

The bigger problem in this country is the real lack of recycling, the packaging material is just not getting where it needs to go to be recycled and there is no infrastructure to handle the waste stream. Not sure yet if I would support a national recycling law or support new deposit requirements.

If you are involved with this issue, please feel free to send me some information or make a comment. Thanks - Barry

On Press Again

I was at a paperboard company last week, on press to approve a box re-run for a client. It was especially critical because the first run had been rejected due to gross color variation. Why was it rejected? Because someone at the printing company miss-handled the WIP and shipped set-up material to the client. (This printer uses "set-up" material to get their die-cutter in registration.) When the item went into production, the packaging looked terrible and the entire job was returned to the printer for credit. 

While the job itself was not especially challenging, there were some things working against us from the start. There was a warm red and two special blacks used on these three items. The warm red on the proof was a build using 100% process M & Y.

1. The tone of the warm red was off giving the proof a blue cast.

2. The special blacks were not well-defined by the client. The way they were separated was not the way I would have done it, but it was already on-press.

3. Two of the items were running on different presses at the same time. 

4. The paperboard stock on press was not from the same mill as the proof. In this case the surface texture was way different. 

I decided that as a strategy we would get one up and running first on the older press and then match the second item to it on the newer, better press. I had to determine that we were not going to run a "special" magenta. Running special colors in the process stations can create as many problems as it solves. This practice is not that uncommon such as swapping out cyan for pro-blue, but when playing in the reds this can throw off the whole balance of the job. Plus; there were some process elements on this job that would be affected.

It took seven pulls to get it acceptable once we determined that the red wasn't going to get any better and the mottling wasn't going away on the black due to stock. On the other press, we got the color into the OK zone on the second pull. The third item was a quick changeover with a reset of the ink densities. 

If you are a printer, make sure you have a system set up that prevents shipping sub-quality material to your customer. When I was at CCL Label many years ago, one of our new CS agents sent labels they literally took out of a dumpster to the buyer at Clairol. The next day we almost lost that account. If you can't avoid setting up on the actual job, then quarantine it or have a quality agent approve the material. This stuff might seem like 101 to you, but the folks on the line may not have their head in the game.

On the artwork side, I am not 100% clear that the design firm, the client and the printer were in alignment as to how these jobs were going to print. Having this alignment would be beneficial to everyone in order to manage expectations. 

Fortunately, our client was happy with the job and hopefully the printer will remember this experence on future runs. . .    Have you ever had similar issues?

InnoBev US Beverage Entrepreneur Forum

On Thursday June 19th I spent the day in NYC attending the most important beverage conference of the 2008 in my opinion. The forum, held at the Le Parker Meridien Hotel, attracted ~200 serious business executives from around the world. The conference was put on by Zenith International and BevNet in association with Beverage Spectrum and Beverage Innovation Magazines. The Forum was also sponsored by Wild Flavors, Inc.

Download the full schedule for the day here.

Highlights for me included Peter van Stolk, former CEO and founder of Jones Soda Company talking about effective on-line strategies and how to target your audience. Peter is now the CEO of the Tree Fort Group, a marketing consulting firm.

Greg Steltenpohl, founder of Odwalla Inc. talked about his struggles of marketing a fresh squeezed product (with a three-day shelf life!) during the formative years and showed us many pictures of "Hippies"(his words) bottling and distributing his products on the west coast. He now runs Adena World Beat Beverages.

After lunch there was an innovator panel made up of beverage industry entreprenuers;

Bill Sipper - Senior Partner of Cascadia Consulting Group LLC

Mike Weinstein - CEO of Inov8 LLC

Tom First - CEO of O Water

James S Tonkin of Tonkin Consulting (link please)

Dr. Erik DonHowe, VP of Wild Flavors, Inc.

Each member of the panel spent 5-10 minutes talking about their unique experience and then took questions from the audience.

One of the most interesting parts of the day was the "Dragons Den" where three beverage executives got to pitch their young brands to a panel made up of major industry distributors. The distributors then had a moment to comment on each pitch and give advice.

The beverage executives were: 

Dr. Dan Ratner of Cell-Nique

TJ McIntyre, Founder and President of Pixie Maté

Brad Winter, CEO of SoNu Beverages

The beverage panelists were: 

Lewis Hershkowitz - COO of Big Geyser Inc.

Ken Davis, CFO of the Davis Beverage Group (link requested) 

Gerry Martin, VP of Marketing for Polar Beverages

Tim Sperry, President of The Sperry Group (link requested)

The process was very insightful. I applaud the three passionate officers & founders who stood in front of 200 or so people and told their story. It took fortitude and I am sure we will all be hearing more from these brands.

Finally there were some marketing briefs given about emerging growth opportunities, consumer trends and steps for securing finance. There was also plenty of new and unusual beverages to sample. If you are at all involved with the beverage industry, it would be wise to attend the InnoBev US forum next year. Make sure you log into BevNet to find out when the next one is. 

The best part of the evening for me was right at the end during cocktail hour where I had a chance to meet and talk with some of the beverage inventors and creative people. I also had the unique opportunity to watch Dr. Tzohar make "Diamond Water" or carbonated water from diamonds. This patented process involves placing a small diamond that has been heated to 2000° with a small torch into a vial of liquid oxygen.

The diamond then glows like a bright light for a minute or two and then vaporizes into carbon dioxide. The resulting gas is vented into a container of water. The Dr. claims that the resulting beverage is safe to drink. Video. The evening ended with a toast and a glass of diamond water which is the appropriate way to end a beverage entrepreneur forum. . . 

OI Glass University

Last week I attended the three day Glass University given by OI in Perrysburg, Ohio. This class is given four times a year. If you are at all involved with the purchasing of or creation of glass packaging, I highly recommend this class. 

 The first two days are all classroom, and the third day are spent visiting their glass plant in Charlotte, MI.

I learned that glass in this country, is grossly under-recycled and according to OI, for every 10% of recycled glass that makes it back into the furnace, energy use drops 2-3%. This is important because the furnaces run at about 2800° 24 hours a day, seven days a week!

During the glass they reviewed new Product development, Sustainability issues, Raw Materials & Furnace Operations, the Forming Process, Surface treatments, strength, inspection and Handling requirements. Alot of materials for three days. 

Glass does certainly have weight, breakage and other issues, but the purity of glass and its unique ability to protect the product and not impart any flavors into the product can not be ignored. Also - Glass is still #1 in premium perception with consumers. I see glass coming back in a big way and the folks in Charlotte are very proud of their newly designed glass baby bottle in that will be hitting the market soon.

The only thing I would have liked is more time at the factory. They took us to the furnaces, allowed us to look inside (through a welding mask), then the glass forming machines and right down the line right to the end where they ship product. Here is a video from the Discovery Channel showing a quick overview of the glass making process. (Not sure if it is an OI location)

If you have any interest in attending the OI Glass school contact Karen.Harwood@us.o-i.com

Why Brand Managers shouldn't go on press. . .

In my 14 years working first as an art director for CCL label, and then as packaging manager for Snapple Beverage Group/Cadbury Schweppes Americas Beverages (now called Dr Pepper/Snapple Group) on brands such as Mistic, Nantucket Nectars, Mott's, Stewart's Root beer, Orangina and Yoo-hoo Chocolate Drink, I have found that most design firms need a helping hand once they get to the mechanical phase of artwork development.

Design firms bring a broad scope of creative talent and skills to the early and middle phases of design. This would include materials for focus groups, senior management sell-in and then finally into mechanical development, but not the actual mechanicals. Why is this the case? Because; the talent and artists are focused more on great design rather than packaging execution. Not only that, a “mechanical” means something different to a designer than to a printer.

Packaging, as we all know, consists of vastly different processes for the production of the various components: registered shrink sleeve, aluminum can and bottle, pressure sensitive and cut-and-stack label, closure, paperboard and direct or preprint corrugate development.

Each kind of packaging brings with it the baggage of the printing process it is tied to: traditional offset litho, dry offset, flexography, letterpress, narrow web screen printing, roto-gravure and even digital printing.

While the design firm can get the art 'finalized' by submitting the file with the high res files, the color builds are usually off or the die line might not be in the final development stages. The printer might need to deploy a special color build for a match because there may be less color stations available on the press than the job was specified with. 

Even the best design firms struggle with the ability to achieve color, traps and printing effects and this is compounded by the Brand Managers lack of printing experience and prepress. No one likes to get the call from the printer in the final stages of production that an effect can not be achieved or worse, that the press is down the results of which cause delays, scrapped material and at worst, a delayed launch-to-market.

One solution is to employ a central engraver to provided proofs and work directly with the printer and design firm to tie the two goals together. Alternatively the print vendor knows their equipment and they may have in-house prepress that can be utilized to get the job done.

Just make sure to always ask for your files back after the job is complete for future alterations. The communication between the design firm and the printers is critical to great design and great, uninterrupted production. The earlier this communication can happen the better for everyone. 

Have you ever experienced these issues with your packaging?