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http://www.packaging-technology.com/contractors/inspecting/aztech/press2.html Thu, 08 May 2008 16:45:25 GMT http://www.packaging-technology.com/contractors/inspecting/aztech/press2.html Aztech Secures Order from Prestigious European Ready Meal Manufacturer Aztech Engineering Solutions have recently secured an order for two FLEXICHECK Inline Leak Testing Machines. The order follows detailed discussions and demonstrations with a well known European food manufacturer, who until now, were unable to source a 100% non destructive test for their packs, despite lengthy searches. The two FLEXICHECK Inline machines will test every pack coming from the production lines, and each will be capable of testing 150 packs per minute. Any leaking packs will be rejected for repacking, and sound packs will be returned to the production lines. Our test method has the following benefits: Non-Destructive - Leaking packs are rejected automatically for re-packing, and sound packs are returned to the production area, without the need for re-packing, as the contents have not been contaminated in any way. This greatly reduces costs in terms of eliminating re-work and wastage. Our test method can detect micro leaks quickly, irrespective of gas and internal pressure We can test a full range of packaging types from vacuum sealed packs; liquid filled packs and modified atmosphere packs No consumables needed Non-subjective testing therefore removing human error Provides management information for continual improvement Our FLEXICHECK range includes offline testing, random sampling Testing and Inline Testing. These recent orders add to our continued success in the field of leak detection. To date we have supplied leak detection machines to a wide range of industries, including ready meal manufacturers, health food producers, pharmaceutical companies and contract packers. http://www.packaging-technology.com/contractors/graphics/adam-software/press1.html Fri, 25 Apr 2008 16:08:26 GMT http://www.packaging-technology.com/contractors/graphics/adam-software/press1.html Independent Research Firm Says ADAM Meets High-End Media Production Needs ADAM Software is said to offer an interesting DAM product with several differentiators ADAM Software has an interesting DAM offer towards the high end of the market. Under the name of ADAM, a full suite of DAM-based products are released based on the latest .NET technology of Microsoft. With its modular approach, ADAM underlines that it doesn't believe in a 'one size fits all' approach in the DAM-industry. ADAM Software believes an open architecture, a documented API and a variety of functional modules are the best way to respond to the variety of business needs described in the latest research paper of Forrester. Forrester analyses in its paper relevant DAM players worldwide and describes ADAM as: "a European alternative with differentiators." Furthermore “Belgium-based ADAM offers a DAM product with several interesting differentiators, namely, its stated commitment to a highly documented, open architecture and integration with native product catalog management." ADAM Software has focused in the recent years on the top end segment of the market and serves customers such as Lego Systems, Microsoft, Philips Medical, InBev, EIDOS and many other top brands on a global level. With its new release of ADAM 4.X, ADAM Software has enjoyed growing attention of world players and top brands. Pieter Casneuf, Executive Partner of ADAM software says: "It is an incredible reward that our company and product is named in a research document of Forrester. We will continue to deliver to our customers world class software, allowing them to organize, control and optimize marketing processes. We are committed to our customers and will continue to listen to them for the features and modules to bring in the near future." Since the release of the 4.X version, ADAM Software has increasingly won attention in the market for digital asset management and marketing optimization. After the launch of 4.0 in July 2007, version 4.1 & 4.2 were brought in production, to allow our customers to take full advantage of the .NET platform. ADAM will continue to deliver new features to the market in short product cycles, and is set for the launch of 4.3 in early June. ADAM will continue to focus on its customers and the diversity of their DAM environments, providing a powerful, and flexible platform to the marketing and IT-departments of brand owners & agencies. http://www.packaging-technology.com/contractors/containers/smurfit-kappa/press1.html Fri, 25 Apr 2008 14:06:47 GMT http://www.packaging-technology.com/contractors/containers/smurfit-kappa/press1.html Gold Rush for Smurfit Kappa at EFTA Print Awards Smurfit Kappa UK scooped a major medals haul at this year's prestigious EFTA (European Flexographic Technical Association) print awards, including the Best in Show award. The company, a leading provider of paper based packaging and print, won a total of ten awards, including five golds, and the judge's top award for the 'biOrb' - a stylish home aquarium, manufactured by Reef One. The awards, held at the Royal Armouries in Leeds, recognise the highest achievements in flexographic printing throughout the UK and across Europe. Smurfit Kappa UK's medal tally featured gold awards from several well-known drinks brands, including Cutty Sark Blended Scotch Whisky (Post Print category); Irish drinks brand The Knot (Coated Screen category); Chivas Regal Blended Scotch Whisky (Coated Process category) and William Lawson's Scotch Whisky. The company also carried off awards for the Lloyd Grossman food brand, and for Cross and Blackwell's Branston Relish. Smurfit Kappa dominated the Overseas Print Awards category too - taking no less than three awards. Adrian Bird, Sales & Marketing Director from Smurfit Kappa UK said: "It's very gratifying to have our work acknowledged by EFTA. We work extremely hard with brand owners to come up with print solutions that are innovative, functional and have great stand-out appeal. "The judging process for the EFTA awards is particularly rigorous, examining everything from technical excellence and production methods to environmental issues. Winning these awards really underlines our expertise in the printing sector." Bernard Catterall, chairman of EFTA UK said: "There is little doubt that producing to the standard to win one of these awards requires skill and a lot of technical know-how. An EFTA award is the benchmark in flexographic printing." Neil Walton, Operations Manager from Reef One, manufacturers of the biOrb aquarium, which took the Best in Show award said: "The biOrb is a stylish product which gives a modern twist to a traditional fish bowl. We needed a print solution that would capture the visual appeal of the biOrb, and Smurfit Kappa more than delivered. Sharp print, authentic colour and tone and great technical execution ensured that the packaging served as a great advert for the product." Smurfit Kappa offers a comprehensive range of print processes for use with corrugated cardboard including Flexo Post Print, Preprint, Screen, Digital, Litho-Lamination and Direct Litho. The company's national team of print experts works with clients to ensure the most effective combination of print process and substrates are selected to create innovative and striking designs. http://www.packaging-technology.com/contractors/closures/bericap/press20.html Wed, 23 Apr 2008 14:54:07 GMT http://www.packaging-technology.com/contractors/closures/bericap/press20.html ECOLAB Healthcare Europe As the world leader in premium commercial cleaning and sanitizing, ECOLAB has grown to US$5 billion in global sales. In more than 160 countries, businesses rely on more than 23,000 associates worldwide to keep their operations clean and sanitary. In late 2007, ECOLAB Healthcare Europe, selected BERICAP's closure SK 50/21 FB with PE liner for its product Sekusept® PLUS, a leader product for manual instrument reprocessing (e.g. for surgical instruments and flexible endoscopes in hospitals and the healthcare sector). Sekusept PLUS is both from a chemical formulation as well as a packaging design point of view a genuine innovative product. One of the determining factors for ECOLAB's closure choice has been BERICAP's slit tamper evidence band, a solution protecting very well against counterfeiting. http://www.packaging-technology.com/contractors/materials/ubcfilmsplc/press16.html Fri, 18 Apr 2008 09:19:33 GMT http://www.packaging-technology.com/contractors/materials/ubcfilmsplc/press16.html Innovative Cereal Pack Uses Natureflex™ Film Innovia Films' biodegradable, compostable NatureFlex™ film is being used as part of the packaging for a leading British cereal producer's organic range. Jordans has adopted new bags for the recent relaunch of its organic muesli and granola cereal. The innovative packs have been developed and manufactured by Alcan Packaging following three years of extensive research and development. The packaging is made utilising two different certified compostable films - with a structure of one layer of Innovia Film's NatureFlex NE30 film laminated to Novamont's Mater-Bi. The bio-based films, along with the inks and adhesives used in the conversion process have been certified DIN EN 13432 by Dincertco, a European standard for compostable and biodegradable packaging. These packs will break down naturally in six to twelve weeks. "The development of this breakthrough pack is the result of close collaboration between Innovia Films and all the companies involved in the process to respond to an identified customer need. This new laminate structure used in the first ever fully certified compostable pack, not only extends the applications that NatureFlex can be used for, but also highlights the versatility of this sustainable, cellulose based film," says Andy Sweetman, Innovia Films' Market Development Manager - Sustainable Technologies. Sweetman adds: "The unique bag design has enabled Jordans to align their packaging message with the spirit of their product marketing, by providing caring consumers with a biodegradable, naturally-based packaging material." http://www.packaging-technology.com/contractors/materials/ubcfilmsplc/press15.html Thu, 17 Apr 2008 12:22:28 GMT http://www.packaging-technology.com/contractors/materials/ubcfilmsplc/press15.html Chocolate Goji Treats Packaged in Sustainable Film Innovia Films' biodegradable packaging material, NatureFlex™, is helping a raw snack food company - Superfood Snacks - to fulfill its ideal for natural eco-friendly sustainable bags to package their first product, Chocolate Goji Treats. They are a synergistically balanced fusion of some of the world's most nutritious ancient superfoods and speciality ingredients, including goji berries, raw cacao, maca root and sundried vanilla bean. Superfood Snacks will also use its signature NatureFlex design for two new flavors to be launched later this month. Superfood Snacks uses a range of pure, raw and organic fair-trade ingredients in all their flavors of raw chocolate Superfood truffles, which not only provide superior nutritional benefits, but also an out of this world guilt-free tasty treat. Adam Collins, founder of Superfood Snacks says: "Superfood Snacks felt that this special organic raw product needed packaging that was in alignment with the integrity of the company's visions. One that was natural, sustainable and biodegradable was our goal. We invested extensive time and effort in developing this optimum pack and NatureFlex has fulfilled all our objectives. We are now considered the pioneers in sustainable printed packaging for food." The bags have been created to ensure the product remains in perfect condition and are made from metallised NatureFlex(TM) laminated to high gloss transparent NatureFlex film. This creates the final structure to encase the original raw chocolate Superfood energising snack. NatureFlex NM is a unique cellulose-based film, manufactured from renewable wood pulp and metallised in-house. It is the only metallised biodegradable film suitable for home composting because the level of metal is so small - less than 0.02% - which slows the film's degradation by a matter of days but does not interfere with its biodegradability in any other way. Modified coatings ensure excellent metal lay-down and adhesion providing a very high moisture barrier with a transmission rate of less than 10 g/m/day (30°C, 90% RH). It is this high barrier that ensures the Chocolate Goji Treats and future flavours remain in premium condition. NatureFlex has good dimensional stability, inherent anti-static properties, is resistant to oils and greases while providing a good barrier to gases and aromas. The film has a high level of ink receptivity and can be printed using solvent based, water based or UV inks. In addition, the films controlled slip properties ensure easier conversion. All NatureFlex films are cellulose based, derived from renewable wood pulp and are certified to meet both the European EN13432 and American ASTM D6400 standards for compostable packaging. The wood-pulp is sourced from managed plantations from referenced suppliers operating Good Forestry principals (FSC or equivalent). NatureFlex(TM) films typically have a renewable biobased content of some 95% by weight of material. "NatureFlex films offer many advantages," says Malcolm Cohn, Innovia Films' Market Manager, Americas and adds that: "They are not only biodegradable and compostable for those packer processors keen to use sustainable packaging but also have a technical performance second to none. Congratulations to Adam Collins of Superfood Snacks for his vision, passion and drive to align his packaging message with the spirit of his product marketing, by providing caring consumers with a biodegradable, naturally-based packaging material." http://www.packaging-technology.com/contractors/materials/mondi/press8.html Wed, 16 Apr 2008 14:27:38 GMT http://www.packaging-technology.com/contractors/materials/mondi/press8.html Mondi Consumer Flexibles: Innovation as Key to Success In 2006 Mondi opened its R&D Centre in Korneuburg, Austria, which has two laboratories and pilot production lines with digital printing equipment. The R&D Centre has extensive know-how in various extrusion processes, offset, flexo, rotogravure and digital printing, lacquering, glue and adhesive lamination, slitting and laser perforation, and bag and pouch production with various functional add-ons. The materials it focuses on include biodegradable polymers, transparent barrier materials, paper and polymer membranes. The R&D Centre's approach is to team up with customers and equipment producers at an early stage of product development to design innovative solutions that often pre-empt market needs. For example, ROFIN Laser Micro visits the R&D Centre regularly to help identify promising solutions, improve laser performance and streamline methods for integrating lasers into production processes. Examples of applications include: MAP (MODIFIED ATMOSPHERE PACKAGING) In MAP, laser perforation helps regulate air ventilation and humidity to increase the shelf-life of fresh or refrigerated food products. New laser perforation technologies are opening up new possibilities for selective creation of micro-holes in packaging. Micro-perforated films adapt to the product's respiration rate and adjust oxygen levels to create the ideal atmosphere inside the bag. Fresh salads were among the first products to which this technology was applied. The technology has now advanced to allow the packaging to control the flow of certain gases, e.g. in the ripening of cheese. Mondi Consumer Flexibles has the necessary in-depth knowledge of the processes involved, e.g. the size, number and positioning of the minute holes based on the contents and packaging in question. NEOSTEAM MAP NeoSteam is a microwave packaging developed by Mondi Consumer Flexibles for frozen or refrigerated food in pouches, bags or trays. It features a valve integrated into high barrier films which regulates pressure inside the package, allowing healthy preparation that retains flavour and vitamins. After launching NeoSteam, Mondi went on to combine the valve solution with MAP sealing films. The resulting NeoSteam MAP packaging prolongs the shelf life of refrigerated products in pouches (FFS bags) or trays (e.g. meat, seafood, fruit, vegetables, pasta, and ready-to-serve meals). NeoSteam and MAP both require laser perforation of varying diameters. The challenge was to find the best solution based on cost and performance. Mondi assessed the oxygen and water vapour permeability of packaging films for different contents. Having determined ways to optimize the size, amount and positioning of perforation holes for MAP and NeoSteam, Mondi R&D focused on ensuring high delivery rates in the manufacturing process. EASY-OPENING Convenience foods require easy preparation and handling, easy opening without scissors or a knife, and reliable resealing. Easy-opening involves selective weakening of the mechanically supporting layer without affecting other functionalities. Mechanical scribing or punching methods are simple but are unable to differentiate between the individual layers. The challenge for laser perforation was to find a dependable method which acts selectively on the different layers. Laser structuring with CO2 lasers provides a novel solution. ONGOING INNOVATION At Mondi Consumer Flexibles, every success story is the preface to the next: The Mondi R&D Centre is already working on tomorrow's packaging for even more convenient and economical packaging, and constantly endeavours to pre-empt market trends and producers' requirements. New materials, enhanced processing technologies such as laser perforation, and novel add-on features such as top sliders reflect the Mondi philosophy of delivering solutions for your success. http://www.packaging-technology.com/contractors/materials/mondi/press7.html Wed, 16 Apr 2008 14:15:52 GMT http://www.packaging-technology.com/contractors/materials/mondi/press7.html Mondi Consumer Flexibles: In-Depth Know-How in Laser Perforation Food and pet food are accurate indicators of changing lifestyles in the developed world. Convenience but also environmental aspects such as biodegradability and avoidance of excess packaging are high on the agenda. Key challenges include intelligent protection during shipping and storage, management of ripening, and ease of preparation and handling. In a highly competitive market, all these features must be combined with cost-effectiveness and attractive brand presentation. TINY HOLES Laser technology offers novel solutions to some of these issues. Tiny perforations, invisible to the naked eye, enhance the properties of stand-up pouches, plastic bags, and lidded trays for pet food, convenience food, fruit and vegetables, and medical products. Laser perforations can enhance shelf life, make packaging easier to open, and improve ease of preparation for foods. Mondi Consumer Flexibles has all the necessary know-how and specialised equipment for such applications. LASER PERFORATION: HOW IT'S DONE A perforation pattern is generated either via special polygon mirrors (for high-volume production) or via fixed optics with synchronous pulse triggering. Up to 16 lines can be placed in parallel on a single web. In a given line, up to 50 holes/cm can be made, to allow ventilation and ease of tearing. Typical hole sizes in films without an aluminium layer range from 60 to 400 μm. Aluminium-coated films require greater laser power and thermal input. In polymer film perforating, laser technology competes with needle technologies and flame perforating. Its advantage over those technologies is that the holes are smaller and also crack-proof thanks to the micro-melted edge. LASER STRUCTURING Almost all packaging films are multi-layer structures, i.e. several films on top of each other, each having a thickness of several micrometers. Each layer has a different function: PET is used as carrier web, PE for sealing and tear-proof qualities, PP for vapour impermeability, aluminium for general light hermetic sealing, and paper for stiffness. Most of the polymer materials used in the packaging industry, e.g. PET, PS or OPA, absorb a laser beam very efficiently at the typical wavelength of 10.6 micrometres. The result is local heating, resulting in complete ablation of the polymer layer in the small scribing area. Aluminium layers act as perfect mirrors for all wavelengths of a CO2 laser at low laser power, i.e. they neither absorb nor transmit the beam. The desired scribing structures can be achieved on most packaging materials provided the wavelength is right and the scribing is applied from the correct side. Under the microscope, materials like PE and PET are inhomogeneous: depending on the manufacturing process, films of the same material and thickness may have different qualities. Just as with multi-coloured imprints, a reliable high-quality laser process must take this into account, and it is for precisely this level of quality that Mondi Consumer Flexibles has built a reputation. http://www.packaging-technology.com/contractors/materials/mondi/press9.html Wed, 16 Apr 2008 14:05:07 GMT http://www.packaging-technology.com/contractors/materials/mondi/press9.html Sustainable Packaging for Sustainable Customer Value: Mondi Presents Biodegradable Packaging Solutions Sustainability is an absolute necessity for the leading businesses of today. Mondi has made a public commitment to integrating sustainable development into its business model. This includes the concept of product responsibility, which starts with the raw materials and ends with the downstream effects of the products. Mondi is one of the pioneering companies that attach strategic relevance to bioplastics and are therefore taking a lead role in the development of sustainable packaging. At the 'Bioplastics in Packaging' exhibition at the Interpack 2008, Mondi presents its unique portfolio of innovative biodegradable packaging solutions under the brand name Sustainex. Although bioplastics go back to the very beginnings of the modern plastics industry, their use as a flexible packaging material as we know it today is not only relatively new but also very promising. There is no generally accepted definition of bioplastics; basically they are a family of polymers with various major differences in properties. The industry association European Bioplastics, in line with other associations, considers there to be two separate classes within bioplastics: Plastics based on renewable resources: products do not necessarily have to be biodegradable or compostable Biodegradable polymers, which meet all the scientifically recognised standards for biodegradability and compostability of plastics and plastic products (the relevant European standard is EN 13432): products do not necessarily have to be based on renewable materials Usually, a high percentage of renewable resources is used in both classes in polymer production. At present, production of bioplastics is already dominated by renewable raw materials such as starch, vegetable oils and cellulose. "Product innovations with sustainable customer value have always been top priority for Mondi. This applies especially to bioplastics, which are currently used for numerous innovative developments in sustainable packaging," states Dr Peter Prader, project coordinator within the Mondi Innovation programme. Under the brand name Sustainex, Mondi Consumer Flexibles presents an innovative and novel blown film for Form-Fill-and-Seal (FFS) applications. This bioplastics film from Mondi is made from biopolymers based on vegetable oils. It has excellent print properties, workability, and mechanical properties such as strength, impact, and tear-resistance. The goal in developing this film was to ensure customers do not have to compromise, as it can be used universally on various FFS bag-making machines. Sustainex features include its double-sided heat sealability, allowing overlapping (Lap-Seal) as well as fin-shaped (Fin-Seal) longitudinal welds, and the fact that it can be used on production machinery with permanently heated sealing tools. Sustainex bioplastics packaging film has the similar visual and haptic characteristics as comparable standard plastic film. Therefore there are numerous potential applications; initial trials are currently in progress at leading frozen foods producers. Following extensive development work, Mondi Coating and Release is now able to offer sustainable extrusion-coated and laminated packaging materials that use biopolymers - also under the brand name Sustainex. During the extrusion coating process, the biopolymer melt is applied as a functional coating to a carrier substrate such as paper. In extrusion laminating, the biopolymer melt is used as a "glue" to combine substrates. Both technologies require the polymer to have high thermal stability and melt resistance, which biopolymers do not inherently possess. Mondi engineers have found a technique that allows using biopolymers in the extrusion-coating and lamination process. Sustainex combines the material properties of paper or board with those of biopolymers. It is a versatile biodegradable and sustainable packaging material thanks to its excellent sealability, gas and grease barrier, and thermal resistance. Dr Jurgen Betz, head of product development at Mondi Coating Zeltweg, sees enormous potential and numerous applications for Sustainex, dry food and fast food, milk and dairy, single-use paper cups and bowls, and hygiene products. http://www.packaging-technology.com/contractors/materials/mondi/press10.html Wed, 16 Apr 2008 13:59:28 GMT http://www.packaging-technology.com/contractors/materials/mondi/press10.html Mondi Consumer Flexibles Sets New Standard of Convenience in Pet Food Packaging Top slider offers consumers a new level of convenience and boosts brand value In the competitive pet food segment, packaging adds value not just by protecting the product: an eye-catching look boosts brand recognition and plays an important part in the purchasing decision, while easy-opening features are good for customer loyalty. Mondi Consumer Flexibles is a leader in developing new features for pet food packaging in conjunction with customers and specialist partners. Our portfolio of tried and tested pouches and bags is complemented by a wide range of add-on features. The latest convenience solution is the Slide-Rite reclosable system, a top slider developed by Pactiv which is integrated into Mondi Consumer Flexibles' proven Single Lip bag. Mondi Consumer Flexibles is the first company to introduce this unique combination of 'S'-Slider and Single Lip bag to the market. ATTRACTIVE SINGLE LIP BAG Pet owners want to serve small portions that stay fresh and appetizing, from easy-to-handle larger units. In the premium pet food segment, packages should open easily without additional tools and reseal reliably to keep odours inside the bag. Mondi Consumer Flexibles' Single Lip bag is convenient and attractive, featuring an innovative design for the emptying area that also enhances presentation at the POS. The bag top's hopper-like design allows emptying with just one hand, and the sealing design allows complete emptying. Mondi successfully delivers premium-brand looks in conjunction with an economical packaging process and, if needed, will be happy to assess customers' machinery to ensure optimum runnability. SLIDE-RITE CLOSURE SYSTEM: A FIRST IN EUROPE The Slide-Rite closure system, developed by Pactiv, is a smooth, reliable, easy-to-use closure system ensuring quick access to the contents. The product stays fresh inside its original, branded bag, and the slider's size is ideal for young as well as senior pet owners and for people with reduced dexterity. The new 'S'-Slider system, combined with enhanced end stops, offers extra reliability thanks to improved retention of the slider. It also provides additional marketing options, as the colours of the new end stops can be varied. HIGH-VISIBILITY BRANDING For premium pet food producers, Slide-Rite adds value thanks to the slider's high visibility. "This unique solution is a competitive advantage for our customers, as it encourages brand loyalty," says Stéphane Soudais, product segment manager at Mondi for reclosable bags. "Combined with the excellent printability of our bags, we deliver an attractive, sophisticated packaging solution - not just for the pet food market." This innovative solution for reclosable bags is one example of Mondi Consumer Flexibles' solution-oriented approach. Following the opening of our R&D Centre in 2006, the team is well prepared to tackle tricky packaging assignments, including optimisations and newly developed solutions. http://www.packaging-technology.com/contractors/machinery/loveshaw/press1.html Tue, 15 Apr 2008 16:42:58 GMT http://www.packaging-technology.com/contractors/machinery/loveshaw/press1.html Loveshaw Expands Service Team Orion Packaging Systems (UK) Ltd, the Hereford based pallet wrapping manufacturer has ceased trading A lot of people have been left wondering how they are going to get their Orion equipment serviced Orion and Loveshaw always had a friendly rivalry. They had similar customers, collaborated on some projects and had been competitors on others. Both have supplied significant amounts of end-of-line packaging machinery, semi-automatic turntable pallet wrappers in particular. "Given the similarity in the customer base and in some of our products," said Kevin Green the Loveshaw general manger. "When I became aware of the situation, we decided to take on Oliver Williams from Orion. He is an extremely well qualified engineer. Like the rest of our packaging machinery range, we will provide a full break-down, call out and planned maintenance program to those ex-Orion customers impacted by this. Unlike others who may offer a similar service, we will also provide a full range of spares and consumables. This will be supported and backed up with our normal warranty." He added: "Oliver has hit the ground running. We have already had Orion customers approach us to review their service requirements. Who better to do so than someone with more than ten yrs of experience with Orion, someone that has been involved in the design, service and manufacture of the entire Orion packaging machinery range? I am extremely please that he has decided to join us. We offer Orion customers an unrivalled assurance that they will still be able to obtain quality service and break-down cover, from someone that knows the range inside out." http://www.packaging-technology.com/contractors/conveyor_systems/flexlink/press27.html Fri, 11 Apr 2008 18:14:23 GMT http://www.packaging-technology.com/contractors/conveyor_systems/flexlink/press27.html FlexLink Shows Efficiency at Interpack 2008 At Interpack, FlexLink will show how to meet today's requirements in production and packaging lines with the new X85 conveyor system and distributed line control. Increased capacity and line uptime The speed of filling and packaging machines increase year by year and a high speed today is an ordinary speed tomorrow. FlexLink have developed the new X85 conveyor to allow high speed applications up to 120m/min. Meeting the demand to minimize planned and unplanned production stops, thus maximizing the MTBF (Mean Time Between Failures), the X85 conveyor is designed in detail to achieve a high uptime. Systematic testing and design engineering has resulted in noise level being reduced by more than half. Benefits of distributed line control Through a dynamic control of the speed, a production line can be balanced in an easy, efficient way, safeguarding a pull through the line and avoiding unnecessary accumulation. The speed goes seamlessly up and down balancing the product flow between up- and downstream machines. Soft starts and stops and gentle transfers between products and handling equipments is a key to a high yield in production and packaging lines. By seamless control of the conveyor speed, products are handled gently, with maintained stability, but still at high line capacity. In addition, it contributes to fewer disturbances in the line. The power consumption in today's conveyor systems can be reduced significantly when running the system only according to the need of the downstream machine or process. This means that idle running systems belong to history. Speed controlled equipment is one of the major energy saving potentials of today. FlexLink is a leading production logistics supplier - providing material and information flow management solutions to assembly and manufacturing industries. Based in Göteborg, Sweden, FlexLink has 675 employees, operates 28 sales units and is represented in 60 countries. In 2007, group turnover was MSEK 1,346. http://www.packaging-technology.com/contractors/converting/krelus/press2.html Thu, 10 Apr 2008 13:53:40 GMT http://www.packaging-technology.com/contractors/converting/krelus/press2.html New Homepage from KRELUS-Switzerland Please visit the new KRELUS homepage with five application movies! The leaflets are downloadable in five languages - German, French, English, Italian and Spanish. KRELUS - the energy saving IR-system. http://www.packaging-technology.com/contractors/atzlisting/2056_36804/press1.html Wed, 09 Apr 2008 17:47:38 GMT http://www.packaging-technology.com/contractors/atzlisting/2056_36804/press1.html Covert Security at Zero Production Cost: Another AlpVision Premiere at the Sixth Annual Pharma Packaging and Labelling Event During the Pharma Packaging and Labelling event (March 26-27, Amsterdam), AlpVision demonstrates for the first time in public its best performing covert security feature. What is more, it is produced at zero production cost! This new solution incorporates a marked improvement over AlpVision's already widely deployed Cryptoglyph covert feature in being applied to the transparent varnish layer of the packaging or of the labelling. AlpVision, the leading supplier of digital imaging solutions for brand protection and document security, already protecting over a billion branded products worldwide, has transformed desire into reality: the application of a feature providing a very high level of covert security for packaging and labelling at zero production cost. No special ink, no taggants, no extra security features: just a pattern of micro holes invisible to the naked eye, generated in the varnish layer within standard printing processes (rotogravure, flexography, offset). The covert security feature is produced without any change in the production process and without alteration of the production speed. The topping on the cake is that the process even saves a small percentage of the varnish ink compared to the printing of the same packaging or labelling without the covert protection. The detection of the covert marking is performed by an ordinary office scanner or a PDA camera phone. The latter can also detect the presence or absence of the invisible marking when loaded with standalone software. The capture of just part of the packaging is enough to produce a 'genuine-or-fake' verdict literally in hand in a few seconds. This security check can be performed anywhere as it does not require a fixed data network connection. The image can also be further analysed to identify the SKU attached to a genuine product and thereby uncover a possible grey market diversion. AlpVision covert security solutions for packaging, labelling and value documents are real breakthroughs compared to traditional security features. Through use of only consumer electronic devices for product authentication, the AlpVision anti-counterfeiting solutions can be made available to end-consumers, if such demand arises. AlpVision supplies licenses for the complete range of tools necessary for management of a global policy to combat counterfeiting and identify grey markets. These solutions are managed directly by the branded product manufacturer. They meet the requirements of the US health authorities with respect to pharmaceutical products (FDA 21 CFR part 11 ERES and FDA Revitalization Act S.1082). http://www.packaging-technology.com/contractors/machinery/covenegidiosncdipage/press3.html Mon, 07 Apr 2008 16:43:52 GMT http://www.packaging-technology.com/contractors/machinery/covenegidiosncdipage/press3.html Coven Egidio to Display at Beauty World Coven Egidio S.n.c. will participate to Beauty World trade show in Dubai, UAE. The company will showcase for the first time the new manual perfume filling machine model MD 07. This is the second year of participation to the growing show in Dubai, where Coven has a wide customer base and an agency with company NOORANI through their office located in Sharjah, UAE. The booth location is Hall 1 Booth 015. Dates are May 18th-20th 2008 http://www.packaging-technology.com/contractors/graphics/huber-group Wed, 30 Apr 2008 00:00:00 GMT http://www.packaging-technology.com/contractors/graphics/huber-group Huber Group The Huber Group is a leading global player in the offset and packaging inks sectors. Its scope of performance includes the manufacture and marketing of printing inks, overprinting varnishes and coatings, fount concentrates and printing auxiliaries for the commercial, packaging, news printing and security printing sectors. Core-filler compounds for telecommunications cables, toner for laser printers and copiers and special engineering services for systems engineering and component manufacture round off the company's range of products and services. Further services offered by the Huber Group include basic and advanced training courses as well as consulting on Good Manufacturing Practice (GMP). MGA INKS FOR GMP-COMPLIANT PACKAGING PRINTING The need to protect the consumer demands that packages do not in any way contaminate the food packaged inside them. The sheet-fed offset inks commonly used today to print food packaging made of folding boxboard fulfil this demand only to a limited degree. The Huber Group's MGA series is the world's first low-migration and low-odour ink system for producing food-friendly food packaging. MGA inks, coatings and fount concentrates are organoleptically neutral and only contain substances that are not capable of migration. THE MGA SYSTEM – LOW MIGRATION AND LOW ODOUR INKS MGA-CORONA® inks: Are low-migration, low-odour and low-swelling inks Contain vehicles based on renewable raw materials Dry purely through setting on absorbent substrates, such as folding boxboard, and must be coated inline with MGA-AcrylaC® emulsion coating Contain pigments that meet the requirements of EU Resolution AP (89)1/EC Are available as a Pantone® and CRS mixing system Constitute a system that has been granted a European patent (European Patent No. 0 886 671) Advantages for you: In many cases, it is possible to do without additional functional barriers such as coating the inner side of inner bags The folding box is used as primary packaging, i.e. as single-material packaging Folding boxes printed with MGA-Corona inks and coated inline with MGA-Acrylac emulsion coating are deemed safe packaging in terms of foodstuff regulations If you use MGA, your food packaging already meets the specifications of the "Ink Resolution" adopted by the Council of Europe in September 2005 Contact: Josef Sutter. PRINTING INKS FOR CIGARETTE PACKETS The inks used on a cigarette packet make the brand unique and maximise brand attractiveness with the target group. As a global partner for printing inks, the Huber Group offers a massive range of inks for all printing processes including CORONA-GA, low-odour inks for sheet-fed offset, GECKO, solvent-based inks for gravure and flexo, ACRYLAC, water-based emulsion coatings for gravure, offset and flexo, and MGA, low-odour, low-migration inks for sheet-fed offset. Contact: Franz Mußner. THE HUBER GROUP'S PRODUCTS FOR ALL PACKAGING PRODUCTION PROCESSES AT A GLANCE: Packaging printing in the sheet-fed offset process: RAPIDA – the fast sheet-fed offset process inks RAPIDA – the high-gloss sheet-fed offset process inks RESISTA – the rub-resistant sheet-fed offset process inks Speciality inks for printing on films and metallised surfaces: CORONA®-Label 5080 CORONA -GA 5015 – low-odour - the special process ink series for printing the outside of packaging for foodstuffs and other organoleptically sensitive package contents Special process ink series for polyolefin films: MGA-CORONA 5045 – migration and low-odour special inks for printing the outside of packaging for foodstuffs and other organoleptically sensitive package contents CORONA -HGA 5028 – low-hexanal - organoleptic characteristics for food, semi-luxury foods and tobacco packaging CORONA -TGA 5025 – the oxidative-drying special process series for organoleptically neutral print products HICOS® – the high-intensity, fast sheet-fed offset process series for the enhanced colour space RAPID-A-MORE – the fast and glossy sheet-fed offset process series GECKO – the solvent-based ink system for gravure and flexo http://www.packaging-technology.com/contractors/machinery/optima Wed, 23 Apr 2008 00:00:00 GMT http://www.packaging-technology.com/contractors/machinery/optima Optima Optima Packaging Group designs and produces automatic machines for the packaging of pharmaceuticals, paper hygiene, healthcare, medical, food, confectionery, detergents, cosmetics, powders and liquids. Optima is a globally-acting manufacturer of filling and packaging machines. We develop highly specialised and flexible technical solutions optimally adapted for your products. As part of the Optima packaging group we have a strong commitment to a worldwide service operation ‐ underlined by the fact that we have our own subsidiaries in the USA, Mexico, Brazil, UK and Japan. POWDER FILLING SYSTEMS AND SOLUTIONS The Optima group offer a wide range of products for the pharmaceutical, food, beverage and confectionery industries, including complete lines for powdered drinks, antibiotics and detergents. The powder / granular division produces filling systems with volumetric, weighing, or gravimetric principles. Products range from single-head machinery to multi-station units with up to 40 heads for the instant-coffee industry. Linear solutions for filling soft and hard pods, tea bags, and cups have been developed to fulfil the latest market requirements. Very high outputs from a relatively small layout can be achieved. INOVA ‐ SYRINGE AND VIAL FILLING AND CLOSING SYSTEMS Specialising in the pharmaceutical sterile requirements, we manufacture syringe and vial filling and closing solutions, including washing and sterilisation systems, suitable for clean room or fully-isolated environments. KUGLER ‐ COSMETIC FILLING AND CLOSURE SOLUTIONS We also supply standard cosmetic filling applications, and have experience with all types of closure systems. We can offer small inline filling and closing solutions for cosmetic, pharmaceutical, or ‐ in some instances ‐ food requirements. PACKAGING MACHINES FOR THE PAPER HYGIENE INDUSTRY Optima, and our sister company, Amotek, are also market leaders in packaging of soft disposable products such as diapers, tissue paper, sanitary products, wet wipes, nurse pads, and cotton wool. Our machinery range can feed, stack, count, and compress prior to placing into a bag. We offer a range from semi-automatic to high speed fully-automatic and servo-assisted machines. MEDICON ‐ MEDICAL AND HEALTHCARE PACKAGING AND CONVERTING SOLUTIONS Medicon provides complete solutions for the medical and healthcare markets with converting and packaging solutions. Medicon has an excellent reputation as a specialist in manufacturing and packaging nursing pads, products for wound treatment or surgical dressings. OPTIMA SOFTCAN A packaging dream come true, with the easy peel-off SoftCan. Neither a can or a bag, SoftCan is a new generation of multilayer flexible packaging that is simply revolutionary. The food industry, in particular, is intensively seeking new solutions and possibilities to differentiate their products. Q BAG VERTICAL-CARTONING SOLUTIONS We also provide vertical-cartoning solutions for dry products such as food, detergents, and pet foods, as well as soft can machinery for the Huhtamaki Cyclero™ with respect to dry products. PPS HORIZONTAL CARTONERS In addition, we supply horizontal cartoners for the cosmetic and hygiene markets. http://www.packaging-technology.com/contractors/closures/bericap Thu, 17 Apr 2008 00:00:00 GMT http://www.packaging-technology.com/contractors/closures/bericap Bericap The Bericap Group is one of the world's leading closure manufacturers of plastic closures. Bericap produces closures for the metal, plastic and carton container industries to an annual volume of around 45 billion pieces. Please contact us to find the perfect closure for your container. With 18 factories in 17 countries across the world, on-going projects in several countries of Asia and Middle East, and a network of licensees and partners, Bericap can offer a truly global service to supply similar products made according to the same quality and service standards to its global customers. With four central R&D centres in France, Germany, Spain and Turkey, two mould shops in Hungary and Poland, and several satellite R&D offices in its main operations, Bericap is particularly committed to development and innovation in plastic closures for its customers. Bericap's services and key competences include: Product development Neck and orifice design Mould making Technical assistance for capping technology Chemical compatibility of closures and products UN approval for hazardous products Tamper evident systems IHS systems Child resistant closures Gas barrier closings Oxygen scavenging Carbonation and pressure retention Venting Aseptic closures Hotfill in PET CAPS AND CLOSURES FOR EVERY CONTAINER Bericap can find the closure solution for virtually any container. We manufacture closures for carbonated soft drinks, still mineral water, HOD and water bottles from 5-litres to 10-litres, beer bottles, juices, energy drinks, edible oils, sauces and dressings, milk, pharma, chemical and agro-chemical products. Whether in metal, plastic or carton containers, our closures are used for coldfill, cold aseptic fill and hotfill applications. CLOSURES FOR CARBONATED SOFT DRINK (CSD) PET BOTTLES Bericap provide a vast array of closures for carbonated soft drinks containers, from 28mm, 35mm and 38mm: 28mm single start, non-refillable 28mm two start 28mm glass 35mm single start 38mm single start Liners range from standard EVA liners to barrier and barrier and scavenger liners. "Eau de Perrier" has chosen the state of the art Bericap Double Seal plastic closure for their low and high carbonated waters. The Bericap Double Seal has been specifically designed to be consumer friendly, highly secure for the users and with the highest CO2 retention performances, beyond all one-piece plastic closures on the market. This product is widely used by soft drink manufacturers. The Bericap DoubleSeal is the first one piece closure which ensures exceptional water-tightness and CO2 retention for highly carbonated beverages, even at high temperature peaks that may occur during transport. It performs as good as, or better than, a two-piece lined closure and the double seal feature enables to get these performances even on damaged PET neck finishes. GAS BARRIER, OXYGEN SCAVENGING CLOSURES FOR BEER BOTTLES Bericap has produced screw caps with gas barrier and oxygen-scavenging properties since 1999. These screw caps are in use by well-known brands like Bitburger, Heineken, Holsten and Kronenbourg. These brands successfully use these caps on PET bottles from various PET bottle producers. NON-DRIP, WIDEMOUTH AND FLIP-TOP CLOSURES Bericap produce a variety of non-drip closures with hinge-lid caps, screw caps, long-skirt pourers or overlapping caps. Each cap is suited to the specific viscosity of the product: from long-skirt pourers for low viscosity products such as vinegar, to hinge-lid caps for medium to high viscosity products such as dressings. Tear-off bands and membranes are included as tamper evident systems. Fitments are also available for flexible packaging. Widemouth caps for high viscosity sauces and condiments are suitable of glass and plastic jars with a neck finish of up to 80mm. The caps can be printed or embossed and lined with EPE, IHS or PVDC. CLOSURES AND DISPENSERS FOR CHEMICAL PRODUCTS Bericap has a large range of closures for chemicals, agrochemicals and motor oil; Bericap also supply and develop plastic components for metal cans and plastic containers. Bericap's R&D is highly dedicated to find solutions to customer specific requirements. The specialised R&D group has experience with regulated packages for hazardous products and can handle chemical compatibility issues. http://www.packaging-technology.com/projects/mullinscheese/ Thu, 08 May 2008 00:00:00 GMT http://www.packaging-technology.com/projects/mullinscheese/ Mullins Cheese, Mullins Cheese is one of the best-known cheese makers in Wisconsin in the US. The cheese facility is located in the town of Knowlton, around four miles south of Mosinee near Interstate 39. The company has been producing quality cheese since 1970 and the plant has expanded several times since, although it remains on the same site. "The latest addition to the technology at the Mullins plant is a new automatic bagging system." The company uses the latest technology to produce 40lb blocks of Cheddar, Colby Cheese, Monterey Jack Cheese, Jacko (marble) Cheese and wheels of Parmesan Cheese. The factory has a retail shop at the plant selling over 50 kinds of cheese but the majority of the 40lb block production goes to cheese processor's cut and wrap operations for repackaging into smaller retail blocks under various brand names for supermarket chains. The plant also sells to food service companies. The company has 80 customers across the US. The latest addition to the technology at the plant is a new automatic bagging system for cheese blocks that cuts down significantly on manual handling, saves labour on manual packing at the plant and produces much less waste. Mullins also has a second plant at Marshallville that produces the same range of cheese in 640lb blocks for food processing companies. The company uses over 1.1 million pounds of milk per day, which is obtained under contract from 900 farms across Wisconsin. CHEESE BAGGER In August 2007 the company invested in new packing technology and introduced six new cheese block handling, orientation and packaging systems from Cryovac Food Packaging division, a subsidiary of Sealed Air. The machinery provided by Cryovac included Model CL-20 bag loaders, a UBT 20 block turner and RG 20 bag regusseting machine. The company also uses Cryovac equipment for barrier bags and cut and wrap items, and has a Cryovac BetaVac vacuum chamber. The new in-line cheese-bagging system handles blocks of cheese produced in a set of towers and can turn out two packs per minute. The waste reduction using this new system comes to around 200lb of cheese per day. PROCESS The six CL-20 bag loaders can operate with a variety of sizes and with quick changeovers. These were installed adjacent to the six cheese block-forming towers, with the work on-site being completed within a week. "The company uses over 1.1 million pounds of milk per day." The CL-20 system takes the 40lb blocks of cheese from the towers and then packs them into pre-produced bags supplied from a stainless steel cartridge/cassette system. The bags are made from gusseted nylon-based film supplied by Cryovac, 25.5in × 19in long. There are 300 bags on each machine lasting four hours. The blocks of cheese are pushed into the bagger chute and then into the gusseted bag. The company packs around 5,500 blocks per day (330,000lb), requiring around three changes of cassette to replenish the bags. The CL-20 machines have been fully integrated with the cheese towers control panel and there is also a display for status and diagnostics during operations. Other controls on the machine allow easy access for wash downs at the end of the packaging cycle/shift. The packaging process at Mullins also introduced the UBT20 block turner to the packaging process, which rotates the cheese blocks by 180° so that the blocks can align with the sealing bar of the BetaVac vacuum sealing system. This withdraws air and allows the bags to be sealed closely around the cheese. The block turner also works with RG-20 regusseting equipment, which folds the edge of the bag to prepare it for sealing on the BetaVac. The regusseting machine folds the leading edge of the bag so that the bag does not become wrinkled when sealed. PACKAGING The cheese blocks are passed from the cheese-forming towers to the in-line bag loaders. The loaders lift the loose bags from the cassette using a pickup device. The string of bags is transferred into a guide chute, which releases them so the open end of the bag slides into the bag-opening mechanism. This works by applying a vacuum to both faces of the bag. "The company packs around 5,500 blocks of cheese per day." The bag is held open by spreader plates and is positioned for the cheese block to be inserted; this takes 6‐8 seconds. In the next stage the bagged cheese is passed to the turner and regusseter for refolding and sealing. The regusseter can process 360 bags per hour. The finished bagged cheese blocks are then passed through a Cintex metal detector (from Loma Systems) and finally to a case-erector-sealer provided by Massman Automation Designs, which can produce corrugated cardboard cases at a rate of 12 per minute. The cases are then palletised, with 54 cases per pallet, using an ABC palletising machine from ABC Packaging. http://www.packaging-technology.com/projects/krasnadorbottling/ Wed, 07 May 2008 00:00:00 GMT http://www.packaging-technology.com/projects/krasnadorbottling/ Krasnodar Glass Bottling Plant, Krasnodar Russia is a much more sophisticated market for food and beverage products than it used to be; over the last 20 years a number of companies have moved into Russia to provide items that were not available before. The South of Russia, near the border with Turkey in the Black Sea and North Caucasus regions, is a vast market for beer, wine and mineral water. However, a plentiful supply of bottles is required for production and there is very little bottle production in the region, which has only 4% of the glass container production capacity of Russia. "The capacity upon completion will be around 240,000 bottles a year." Consequently, a well-known Turkish company, Turkiye Sise ve Cam Fabrikalari A.S. (SiseCam Group), is building a new bottle plant on a greenfield site. The Krasnodar plant will be operated by a new company, Ruscam-Kuban LLC, which is a majority-owned subsidiary of Anadolu Cam, a member of SiseCam Group. GLASS ECONOMY The new plant will have an immediate twin effect on the economy of the region. Firstly, suppliers for the quality materials for glass production such as soda ash and sand will have to be sourced. SiseCam is aware that it needs to educate local suppliers as to the quality required. Secondly, the wine-producing sector is centred in Krasnodar and is growing at a rate of 10‐15% per year. The plant will therefore want to be in a position to provide bottles for the sector, focusing on sparkling wine producers in the Central Volga region. In addition, the mineral water production of Russia is very much concentrated in the south of the country, from the mineral water sources in North Caucasus, and the new bottle plant will also be able to provide bottles for this. The brand new plant will be situated in Krymsk, about 40km from the Black Sea port of Novorossiysk and will employ 450 people. The capacity upon completion will be around 240,000 bottles a year. The company's three existing bottle plants in Russia produce around 3 billion bottles a year, one third of Russia's total output. CONSTRUCTION The Krasnodar Glass Packaging Plant is being built using part funding from the European Bank for Reconstruction and Development (EBRDA) amounting to around €52.5m. This was announced in April 2008. The total investment for the plant will approach a figure of €75m. The plant will be constructed in two phases with an initial capacity with one furnace of 140,000t per annum. A future phase will see production doubled to 280,000t per year when a second furnace is constructed. "The total investment for the plant will approach a figure of €75m." The bottle production will based on narrow-neck-press and blow technology (NNPB), which uses around 20% less material than conventional production, has less breakages and allows a faster production cycle. The plant is being constructed by Saint Gobain of France and is scheduled to be on stream (first phase) by 2010 using state-of-the-art production technology. EBRD FINANCE The EBRD finance initially provided will be €37.5m (debt, seven-year loan), in two lots which will be timed to match the investment for each furnace. The two sums will be initially €26.3m (phase one) and then later €11.2m (phase two). In addition, the EBRD will provide €15m of an equity investment into the company as it is a new special purpose vehicle (SPV). http://www.packaging-technology.com/projects/cristiliawater/ Thu, 24 Apr 2008 00:00:00 GMT http://www.packaging-technology.com/projects/cristiliawater/ Cristalia Water, Cristalia Premium Water is one of the Caribbean's best-known and most popular bottled water brands. The company's revenue has increased by 400% over the last eight years, fed by the huge growth in the tourist trade. "The company's revenue has increased by 400% over the last eight years." Because of the success of the brand, the company is now in the process of completing construction of a new 80,000ft² bottling plant in Carolina, near San Juan Airport. The fully integrated plant will process water, produce bottles and ship to the customer. The new facility will be four times bigger than the current plant and the company will spend $12m on water processing, bottle production and bottling equipment. The new plant is expected to be completed and in operation by June 2008. The company has a goal to have a turnover of $100m during the next ten years. PALLETISING SYSTEM Cristalia Premium had problems with the efficiency of its packaging operation at its Ponce facility, despite its success, leading to high labour costs and an inability to meet demand. The Ponce facility is 20,000ft² and has four water bottling lines for 16oz bottles, multi-packs, five gallon bottles for water coolers and one-gallon containers. "The machine can palletise at a rate of around 30 cartons per minute." Each of these lines was manually palletised and space dictated that only one line could have automated palletisation. The line where manual handling was deemed to be the most difficult and time consuming was the one-gallon container line, with four workers on hourly rotation to lift the 27lb cases. The multipack and small bottle lines only needed one worker per shift. The one-gallon line was chosen for automatic palletisation because this would relieve a bottleneck in one of the highest-producing lines and give the most benefit in cost saving. PALLETISATION SOLUTION FKI Logistex provided a GS100 series case palletiser. There was no room for an accumulation conveyor but the smaller footprint solution does allow full forklift access. The companies involved in the automation and upgrading of this section of the facility included Inter-Strap Packaging of Puerto Rico. The model picked for the task was the GS140 with a pallet dispenser and full pallet handling discharge. The machine can palletise at a rate of around 30 cartons per minute; workers fill one pallet in around 2.5 min, which is much slower. The new equipment allows the production of an extra 1,000 cases per shift, reducing labour costs by 25% and increasing productivity by 20%. There are no staff breaks necessary and the machine runs throughout the entire shift. SYSTEM OPERATION In the new system, an existing line shaft roller conveyor transports cases from the one-gallon production line to the 'infeed' of the new GS140. The palletiser forms 16-case layers, with each of the case units containing three one-gallon jugs of Cristalia water. "The new equipment allows the production of an extra 1,000 cases per shift." Inside the palletiser, the cases are oriented by a cushioned turning device that rotates them according to the required pack pattern. The GS140 then constructs the load on the chain conveyor, so that the pallets have either three or four layers, depending on customer specification. When the load is finally completed, it is automatically discharged from the load-build cavity and a new empty pallet is dispensed into position. The GS140 has had the effect of completely automating the gallon production line with a ten-pallet-capacity lift-and-separate pallet dispenser, using 40 × 48in wooden pallets. Empty pallets are loaded by fork truck into the empty pallet dispenser, which automatically feeds another pallet for the next load. In the summer time the plant is staffed to operate three eight-hour shifts a day, at least six days a week. In the winter, this drops to three shifts a day, five days a week.