Global packaging trends Kenafric - Bosch Packaging Technology
packazine Issue 02/2007
Trend | Global packaging trends Kenafric | Bubble gum balls for African market Bochner Chocolates | Gourmet Chocolates
2 | packazine Table of contents | Editorial
Table of contents
06
10
News Corporate News 04
IPI | Master of Packaging
05
Coffee Symposium | Coffee experts host guests from around the world
Facts & Trends 06
Global Food and Packaging Trends
Customers & Markets Food & Confectionery 10
Löfbergs | Lilac sets the mood
12
Bama | Frozen pie line is one cool system
16
Wycam‘s | The old-fashioned Belgian way
18
Kenafric | Bubble gum balls for the African market
20
Bochner | Robotic solution boosts gourmet chocolate manufacturer
Events 23
Food 2007/2008
Cover The packaging world of tomorrow
www.bosch.com/pa [email protected]
16
packazine | 3
18
Editorial
20
Dear Readers, We are fully aware that we can be successful only when you, our customers, are successful. With this aim, we set standards: we launch innovations onto the market, extend our range of products and services and invest in employee know-how. The amount of orders received shows that our methods bear fruit. More than ever, companies are turning to Bosch when ordering machines and equipment; the reasons being
Friedbert Klefenz
reliability, high availability, flexibility and consistently high perfor-
President
mance.
Bosch Packaging
On behalf of Bosch Packaging Technology, I would like to thank you
Technology
for the trust and confidence you have placed in us. 2007 is an exceptionally good year! Due to the close co-operation in our group, we offer our global customers one-stop, individual line competence. This also includes Bosch services such as audits, consulting, engineering, start-up and commissioning support or the partial operation of plants. We not only demonstrate our technological competence with customers’ orders. Our special events for the industry have, for some time, found a very positive resonance, with guests participating from all over the world, coming together to discuss trends and packaging strategies with experts. This year, we again welcomed several hundred interested guests and experts to the International Coffee Symposium in Stuttgart and the Confectionery Symposium in Hamburg. Our desire for an intensive exchange with our customers goes without saying: we listen, we understand and we define the best solution together with the customer. Your needs, as our valued customers, are also in the forefront of this current issue of our own publication, “packazine”, in which you will learn of successful partnerships and current trends in the foodstuffs and confectionery markets. I hope you all enjoy your reading. Best regards
Friedbert Klefenz
4 | packazine News Corporate News
The Modules of the Master Course Materials – Structures – Systems Materials in Packaging Engineering for Packaging Machines Technology Management Interactions and Processes Converting Process Engineering Fillgood Technologies Interaction and Interfaces Management Strategy and Value Creation Investment and Finance Leadership and Responsibility Communication
„Master of Packaging“ With a “Master of Engineering in Pack-
tions, made in this region as early as
pants acquire extensive knowledge in the
aging Technology” now being awarded
the 19th century, established industrial
following areas:
by the International Packaging Insti-
packaging. Small wonder then that it
u Packaging machinery construction
tute, it might not be long before we see
became the very location for a training
u Material technologies
a “Master of Packaging” walking our
and technological center, when the IPI
u Product-relevant technologies
production lines!
was founded in 2004 in Neuhausen,
u Business administration and manage-
Switzerland.
ment
Bosch Packaging Technology is a leading The International Packaging Institute
partner in the IPI and Friedbert Klefenz,
Next to projects, field studies and
(IPI) has its roots in the needs of the
Chairman of the Bosch Packaging Tech-
interdisciplinary courses, E-Learning
package production and packaging
nology Division Management, is enthu-
is offered as well, in conjunction with
industries for advanced education in
siastic about the institute. He explains,
the School of Packaging at Michigan
packaging technology. Now, alongside
“From the outset, the primary goal was to
State University (USA). All courses are
regular employment, participants in a
give European packaging a technological
held in English. Furthermore, advanced
two-year Masters Study Course obtain
home with a global charisma. A place
studies are provided to those interested
comprehensive knowledge of the entire
where worldwide know-how merges,
on a topic-specific basis at the Bachelor
spectrum of packaging technology.
industrial developments interconnect
level. Individual course modules can
and scientific knowledge, stemming
be booked as “Professional Seminars”
The Region of Schaffhausen and Lake
from various engineering sectors, is
so that anyone can find something
Constance: A European center of
integrated.“
adequate.
In the world of packaging, Schaffhausen
«Master of Engineering in Packaging
For more information please contact:
and the Lake Constance region stand out
Technology»
Dr. Ingo Büren
due to the concentration of packaging
In 16 weekly blocks, of six days each,
Phone +41 52 675 51 51
industry companies. Trailblazing inven-
and spread over 24 months, the partici-
[email protected]
packaging
packazine | 5
1
Coffee experts host guests from around the world for example, they have a positive effect
applied to the requirements of the coffee
large and small coffee producers, from
on marketing opportunities and thus
industry: here too, rapid, unconventional
more than 30 countries, met at the
support his business strategy. In the
decision-making is in demand.
International Coffee Symposium held
From May 9 to 12, representatives of
practical workshops, at the package
The entire event demonstrated how
in Stuttgart, Waiblingen
maker location in Waiblingen, the guests
much Bosch shares the enthusiasm
and Emmerich. The
experienced numerous Bosch solutions
of its customers for coffee, and how
guests were welcomed by
at first hand. Here, Bosch demonstrated
enriching a professional exchange and
Bosch Package Makers
its expertise as a partner, particularly in
global networking can be. Due to the
and Probat, the roasting
the areas of flexibility, aroma protection,
overwhelming response, Bosch and
line producer, to a varied
new packaging styles and materials, and
Probat have decided to organize another
program of technical pre-
package checking.
coffee industry symposium in a similar format for 2010.
sentations and practical
For the trip to the Probat facilities in
workshops.
Emmerich, guests climbed aboard the
The presentations covered
the 1960s. There was ample time to
Katja Vollmer
topics ranging from
party and Franky, playing rock & blues on
Phone +49 711 811 576 44 [email protected]
legendary TEE Rheingold Express from
developments in the raw coffee market,
his electric piano, ensured that no one
to different packaging strategies and new
sat still.
consumer trends. One of the speakers,
At Probat, among many subjects, guests
Thomas Meinl Jr., CEO of Julius Meinl
learned about the human sense of taste
Austria GmbH, reported on a PME 4261
and the influence of different roasting
BN packaging line acquired in 2006,
profiles on the taste of coffee. The pro-
explaining how it permits packaging
gram was rounded out with a fascinating
to be adapted to customer-specific
presentation by Dr. Bertrand Piccard of
requirements. For Meinl, investment
his journey around the world in a hot-air
costs for machines are justified when,
balloon. His experiences can readily be
2
3
For more information please contact:
1 Great interest was shown during the workshops in Waiblingen 2 Thomas Meinl Jr., was impressed by the PME packaging machine 3 Networking and socializing were an important part of the symposium 4 Fritz Storm, 2002 World Barista Champion, demonstrates the key factors required for the preparation of perfect espresso
4
6 | packazine News Facts & Trends
Ageing consumers with purchasing power are the target group of tomorrow
packazine | 7
Global Food and Packaging Trends New product launches are still growing worldwide. The latest trends are not restricted to new flavours or ethical products but see companies positioning products that will appeal to a newly discovered target group with purchasing power.
New markets
Trends are not just about what marketers
In Asia Pacific and Latin America, new
have added to their products. They are
product developments showed sig-
also about what they are taking out.
nificant growth in 2006, while in North
There is increasing demand from con-
America new product introductions grew
sumers for “food free” products, such
more slowly. New flavours with growth
as lactose-free and gluten-free, which
potential, such as açai (a Latin American
target the growing number of consumers
citrus fruit), have been introduced and
suffering food intolerance. Global food
dietary supplements, like antioxidants
and drink launches labelled “gluten-free”
and Omega-3 fortification, attract con-
nearly doubled in 2006.
sumers, promising diverse benefits such as immune support or heart health.
8 | packazine News Facts & Trends
Deliberate buying decisions – Consumers are aware of “food free”
L ACTOSE FREE
VERY 21 %
SOMEWHAT 36 %
NEVER 8 %
products and the Fairtrade certification
Fairtrade and sustainable packaging
is an ecological, economical and social
Increasingly, consumers focus on the
balance throughout the whole value
provenance of products and the wellbe-
chain. The sustainable packaging revolu-
ing of others. Products with the Fairtrade
tion is about to start and the market for
certification help those identifying
sustainable rigid and flexible forms in
goods that meet environmental, labour
food and beverage packaging is expected
and developmental standards. In 2006,
to surpass $ 42 billion by 2010*.
products with the Fairtrade label reached SOMETIMES 35 %
retail sales of 757 million Euros in the
Ageing consumers
EU and 379 million Euros in North
A demographic change in industrialized
America. There is also growth in the use
countries has resulted in changes in
of Fairtrade ingredients in mainstream
market structure, with a much larger
brands and the number of countries
segment consisting of ageing consumers.
offering these certified products is also
In America, the 78 million ageing Baby
increasing.
Boomers (worth around $ 46 billion in
The development of an awareness and
sales) will become the biggest senior
understanding of sustainability in societ-
citizen market the US has ever seen.
pliers and brand owners in “Packaging
ies around the globe is moving forward.
Worldwide, by 2035, Germany will be the
Digest”
Therefore, consumer goods package
country with the oldest residents: almost
How important is sustainability in packaging decisions? Survey of nearly 2000 packaging sup-
(Issue February 2007)
companies have to face an increasing fo-
50 % of the country’s population will be
cus on sustainable packaging. The target
in the 50-plus age group. *Candy & Snack Business, March/April 2007
packazine | 9
Middle East & Africa 9,697
Latin America 29,829
North America 63,088
Global new product introductions by region Region
2004
2005
2006
Total
Europe
30,921
34,055
38,917
103,893
Asia Pacific
19,830
20,538
26,963
67,331
North America
20,830
19,380
22,878
63,088
6,723
10,684
12,422
29,829
Latin America Middle East & Africa Total
2,881
2,929
3,887
9,697
81,185
87,586
105,067
273,838
Asia Pacific 67,331
Europe 103,893
Source: Mintel GNPD
The special needs of ageing consumers
by adding value to every step of the
For more information please contact:
provide fresh challenges. Diminishing
packaging design and implementation
Ulrike Probst
eyesight and decreasing hand strength
process.
require larger print on labels, ergonomic design and easy to open and reclose mechanisms. Staying one step ahead By researching future trends and factors, Bosch Packaging understands the needs and requirements of consumer good markets. As a result, new opening and reclosing mechanisms and the optimized use of packaging materials are some of our recent innovation projects. The early involvement of machine and technology competence is essential for the successful production, marketing and sale of consumer goods. Creativity, combined with our vast engineering expertise, supports this holistic approach to packaging,
Phone +41 52 674 80 53 [email protected]
10 | packazine Customers & Markets Food and Confectionery
Lilac sets the mood In Scandinavia, Lila, meaning lilac, is synonymous with high quality coffee. Produced by Löfbergs, it is one of the best-known coffee brands in northern Europe and is packed solely on Bosch vacuum package makers. When a new, major order challenged Löfbergs’ capacity, the new PKS 3151 BN package maker increased both production capacity and flexibility.
The largest coffee roaster in
Primarily, Löfbergs roasts and sells high
3122 BV high output vacuum package
Scandinavia
value coffee blends for many preparation
makers. At an output rate of up to 130
AB Anders Löfbergs kaffeegrupp, the
forms, such as special blends for the
vacuum packages each, per minute, the
Swedish coffee importer and roaster,
growing catering and horeca markets
lines operate extremely reliably and with
was founded in 1906. The company com-
(hotel, restaurant, café). The bulk of
a high rate of effectiveness.
prises of the production plant Kaffehuset
the coffee production is sold under the
i Karlstad AB, the sales and marketing
Löfbergs Lila brand.
In 2006, a major order was pending from
Meeting customers’ requirements with
Kaffehuset had to be increased at short
Kaffe AS. To this day, Löfbergs is still
reliable technology
notice. In March, 2006, Löfbergs again
a family run company. With sales of
Löfbergs has been using Bosch package
decided in favor of its proven partner
approximately 100 million Euros and 200
makers for more than 35 years. In the
Bosch and invested in the PKS 3151 BN
company Löfbergs Lila AS, Löfbergs Lila International AB and Peter Larsens
a retail chain, and so the capacity of
employees, it is one of the largest north
production plant Kaffehuset in Karlstad
package maker with a FVS 3101 SQ auger
European coffee roasters and also one
(Sweden) the packaging production is
filler and a KWI 3010 N checkweigher.
of Europe’s largest importers of coffee.
performed solely on two Bosch PKD
The Löfbergs team and technical manager, Lars Andersson (second from right), after the successful acceptance of the PKS
packazine | 11
Aroma protection combined with
Everything at a glance
A mere six months had passed when the
flexibility
To start with, Löfbergs produces 250
machine was delivered to the customer.
The new PKS offers Löfbergs modern
gram vacuum packages for ground cof-
Löfbergs can now produce all customary
vacuum packaging technology for pro-
fee, with a flat top, rolled in once and
packaging presentations in the market
duction output of up to 65 packages per
held down with adhesive tape. The typi-
and is looking forward to a rosy, or,
minute. The unique product protection
cal Löfbergs Lila paper wrap around the
should we say, “a lilac future”.
system “neutravac”, with inert gas flush-
vacuum package is produced on a line-
ing and evacuation, guarantees lowest
integrated wrapper machine. The FVS
For more information please contact:
residual oxygen level. The machine is
3101 SQ auger filler, as well as the KWI
Martin Kühl
also capable of producing attractive flex-
3010 N checkweigher, are operated from
Phone +49 711 811 57480
ible packages with various top closures
a centrally installed touch screen. This
[email protected]
and valve packages.
provides the operator with an instant visual access to all production-relevant data on a single monitor.
1 The PKS 3112 BN package maker with auger filler FVS 3101 and KWI 3010 N checkweigher – the flexible alternative for the output range up to 65 packages per minute 2 The aroma protection system “neutravac” combines lowest residual oxygen content with large size flexibility 1
2
12 | packazine Customers & Markets Food and Confectionery
Frozen pie line is one cool system Delta XR31 robots provide system efficiency of 99.7 %! Vision quality control system
each of the 18 robot cells. All this at a
Operational staff at Bama (Tulsa, Oklaho-
rate of 1’400 pies per minute!
ma) are excited about the performance
Several potential suppliers were evalu-
of the recently installed 18-robot system
ated for this major automation project.
provided by Sigpack Systems. And, they
Bama’s Vice President of Engineering,
have good reasons. The line incorporates
Randy Roark, states that “Bama chose to
a unique state-of-the-art vision quality
partner with Sigpack due to the flexibil-
control system, which ensures that only
ity the robot system offered, by picking
products of exact quality are accepted
the pies directly from the main belt and
from the process equipment before
placing them into the cases. Others were
being accurately placed into cases. Each
suggesting row distribution solutions,
shock frozen fruit pie is inspected for
which involved multiple steps and greater
precise color, pattern, and dimensional
complexity. Sigpack streamlined the
shape. The system distinguishes very
process.”
subtle parameter differences and all product information is communicated to
1 Arriving of the apple pies directly out of the freezer 2 1’400 products per minute – more than 2 mio per day! 3 Specialized vision system for quality control 4 Spreading of the products 5 Fast and gentle placing of the apple pies 1
2
packazine | 13
Application challenges
The Sigpack Systems XR31 Delta robot
easy operator and maintenance access
In 2006, the challenges presented to
solution
to each robot within the system. The
Sigpack Systems included an applica-
The frozen fruit pies exit the Bama
robots utilize a custom-designed vacuum
tion involving a frozen product and its
freezer in rows consisting of 20 products.
picker to gently pick and place pies into
environment, a high production rate,
After a series of belt turns, the products
the cases, which move in a counter-flow
complex product inspection and a cin-
enter the packaging room, where tem-
direction to the main belt. The system
namon topping. Production efficiency,
peratures and humidity are controlled.
is also equipped with special filters to
quality control and sanitation were key
The rows of pies are separated via
assist with the collection and removal of
considerations. Roark states that “A test
spreader belts and proceed under an
excess cinnamon dust. Roark describes
at Bama showed it required six people
overhead camera, which examines the
that “The line speed was previously dic-
for a proper visual inspection of the
entire product flow.
tated by available staff. Now, the robots
product. Prior to the design phase of
Nine Sigpack Systems Model XR31
are always ready to perform and we can
the project, Sigpack Systems conducted
Delta robots are positioned on opposite
maintain a more consistent line speed
lab tests, with actual frozen product, to
sides of the main packaging belt. This
and production flow. The added benefit
review Bama’s inspection criteria, as well
layout facilitates complete pick coverage,
is reduced product variability.”
as to confirm the pick reliability of the
reduces overlap and limits excess robot
gripping tool.”
movement. The design also allows for
3
4
5
14 | packazine Customers & Markets Food and Confectionery
18 Delta robots XR31: Compact washdown design
Quality Control system
exact position of the good products with
a stronger foothold for placement of
The heart of the system is the optical
its own vision system and picks, based
robots into frozen food environments.”
quality control with a specialized vision
upon a sophisticated strategy, the best
Bama’s Plant Engineer, Duane Cook,
system. This system acquires a detailed
product for the cycle. Advantages of this
echoes these thoughts. Cook says that,
image of the product carpet at the
centralized quality control against an
“There has been a high level of coopera-
beginning of the line. Every single apple
individual control in each robot cell are
tion and professionalism between the
pie is then evaluated for acceptability,
more reliable operation through easier
two companies. Sigpack Systems is
including minimum and maximum length
calibration and safer retrace ability of
willing to listen, understand and resolve
and width tolerances, partial products,
bad products.
real life production issues.”
and overlapping or connected products. Additionally, the number, shape and
Sigpack Systems’ National Account
For more information please contact:
position of the slits in the surface of the
Manager, Tom Pecht remarks, “The
Tom Pecht
pies are checked, as well as the quality
people at Bama are great to work with
Phone +1 920 662 1258
of the topping. The positions of all ac-
and have welcomed the new technology
[email protected]
ceptable products are communicated
into their operation. In addition, the
to every robot. Each robot detects the
line has helped Sigpack Systems gain
1 Fast and gentle placing of the apple pies 2 Simple and convenient operation of the quality control system 1
2
packazine | 15
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Trend | Global packaging trends Kenafric | Bubble gum balls for African market Bochner Chocolates | Gourmet Chocolates
2 | packazine Table of contents | Editorial
Table of contents
06
10
News Corporate News 04
IPI | Master of Packaging
05
Coffee Symposium | Coffee experts host guests from around the world
Facts & Trends 06
Global Food and Packaging Trends
Customers & Markets Food & Confectionery 10
Löfbergs | Lilac sets the mood
12
Bama | Frozen pie line is one cool system
16
Wycam‘s | The old-fashioned Belgian way
18
Kenafric | Bubble gum balls for the African market
20
Bochner | Robotic solution boosts gourmet chocolate manufacturer
Events 23
Food 2007/2008
Cover The packaging world of tomorrow
www.bosch.com/pa [email protected]
16
packazine | 3
18
Editorial
20
Dear Readers, We are fully aware that we can be successful only when you, our customers, are successful. With this aim, we set standards: we launch innovations onto the market, extend our range of products and services and invest in employee know-how. The amount of orders received shows that our methods bear fruit. More than ever, companies are turning to Bosch when ordering machines and equipment; the reasons being
Friedbert Klefenz
reliability, high availability, flexibility and consistently high perfor-
President
mance.
Bosch Packaging
On behalf of Bosch Packaging Technology, I would like to thank you
Technology
for the trust and confidence you have placed in us. 2007 is an exceptionally good year! Due to the close co-operation in our group, we offer our global customers one-stop, individual line competence. This also includes Bosch services such as audits, consulting, engineering, start-up and commissioning support or the partial operation of plants. We not only demonstrate our technological competence with customers’ orders. Our special events for the industry have, for some time, found a very positive resonance, with guests participating from all over the world, coming together to discuss trends and packaging strategies with experts. This year, we again welcomed several hundred interested guests and experts to the International Coffee Symposium in Stuttgart and the Confectionery Symposium in Hamburg. Our desire for an intensive exchange with our customers goes without saying: we listen, we understand and we define the best solution together with the customer. Your needs, as our valued customers, are also in the forefront of this current issue of our own publication, “packazine”, in which you will learn of successful partnerships and current trends in the foodstuffs and confectionery markets. I hope you all enjoy your reading. Best regards
Friedbert Klefenz
4 | packazine News Corporate News
The Modules of the Master Course Materials – Structures – Systems Materials in Packaging Engineering for Packaging Machines Technology Management Interactions and Processes Converting Process Engineering Fillgood Technologies Interaction and Interfaces Management Strategy and Value Creation Investment and Finance Leadership and Responsibility Communication
„Master of Packaging“ With a “Master of Engineering in Pack-
tions, made in this region as early as
pants acquire extensive knowledge in the
aging Technology” now being awarded
the 19th century, established industrial
following areas:
by the International Packaging Insti-
packaging. Small wonder then that it
u Packaging machinery construction
tute, it might not be long before we see
became the very location for a training
u Material technologies
a “Master of Packaging” walking our
and technological center, when the IPI
u Product-relevant technologies
production lines!
was founded in 2004 in Neuhausen,
u Business administration and manage-
Switzerland.
ment
Bosch Packaging Technology is a leading The International Packaging Institute
partner in the IPI and Friedbert Klefenz,
Next to projects, field studies and
(IPI) has its roots in the needs of the
Chairman of the Bosch Packaging Tech-
interdisciplinary courses, E-Learning
package production and packaging
nology Division Management, is enthu-
is offered as well, in conjunction with
industries for advanced education in
siastic about the institute. He explains,
the School of Packaging at Michigan
packaging technology. Now, alongside
“From the outset, the primary goal was to
State University (USA). All courses are
regular employment, participants in a
give European packaging a technological
held in English. Furthermore, advanced
two-year Masters Study Course obtain
home with a global charisma. A place
studies are provided to those interested
comprehensive knowledge of the entire
where worldwide know-how merges,
on a topic-specific basis at the Bachelor
spectrum of packaging technology.
industrial developments interconnect
level. Individual course modules can
and scientific knowledge, stemming
be booked as “Professional Seminars”
The Region of Schaffhausen and Lake
from various engineering sectors, is
so that anyone can find something
Constance: A European center of
integrated.“
adequate.
In the world of packaging, Schaffhausen
«Master of Engineering in Packaging
For more information please contact:
and the Lake Constance region stand out
Technology»
Dr. Ingo Büren
due to the concentration of packaging
In 16 weekly blocks, of six days each,
Phone +41 52 675 51 51
industry companies. Trailblazing inven-
and spread over 24 months, the partici-
[email protected]
packaging
packazine | 5
1
Coffee experts host guests from around the world for example, they have a positive effect
applied to the requirements of the coffee
large and small coffee producers, from
on marketing opportunities and thus
industry: here too, rapid, unconventional
more than 30 countries, met at the
support his business strategy. In the
decision-making is in demand.
International Coffee Symposium held
From May 9 to 12, representatives of
practical workshops, at the package
The entire event demonstrated how
in Stuttgart, Waiblingen
maker location in Waiblingen, the guests
much Bosch shares the enthusiasm
and Emmerich. The
experienced numerous Bosch solutions
of its customers for coffee, and how
guests were welcomed by
at first hand. Here, Bosch demonstrated
enriching a professional exchange and
Bosch Package Makers
its expertise as a partner, particularly in
global networking can be. Due to the
and Probat, the roasting
the areas of flexibility, aroma protection,
overwhelming response, Bosch and
line producer, to a varied
new packaging styles and materials, and
Probat have decided to organize another
program of technical pre-
package checking.
coffee industry symposium in a similar format for 2010.
sentations and practical
For the trip to the Probat facilities in
workshops.
Emmerich, guests climbed aboard the
The presentations covered
the 1960s. There was ample time to
Katja Vollmer
topics ranging from
party and Franky, playing rock & blues on
Phone +49 711 811 576 44 [email protected]
legendary TEE Rheingold Express from
developments in the raw coffee market,
his electric piano, ensured that no one
to different packaging strategies and new
sat still.
consumer trends. One of the speakers,
At Probat, among many subjects, guests
Thomas Meinl Jr., CEO of Julius Meinl
learned about the human sense of taste
Austria GmbH, reported on a PME 4261
and the influence of different roasting
BN packaging line acquired in 2006,
profiles on the taste of coffee. The pro-
explaining how it permits packaging
gram was rounded out with a fascinating
to be adapted to customer-specific
presentation by Dr. Bertrand Piccard of
requirements. For Meinl, investment
his journey around the world in a hot-air
costs for machines are justified when,
balloon. His experiences can readily be
2
3
For more information please contact:
1 Great interest was shown during the workshops in Waiblingen 2 Thomas Meinl Jr., was impressed by the PME packaging machine 3 Networking and socializing were an important part of the symposium 4 Fritz Storm, 2002 World Barista Champion, demonstrates the key factors required for the preparation of perfect espresso
4
6 | packazine News Facts & Trends
Ageing consumers with purchasing power are the target group of tomorrow
packazine | 7
Global Food and Packaging Trends New product launches are still growing worldwide. The latest trends are not restricted to new flavours or ethical products but see companies positioning products that will appeal to a newly discovered target group with purchasing power.
New markets
Trends are not just about what marketers
In Asia Pacific and Latin America, new
have added to their products. They are
product developments showed sig-
also about what they are taking out.
nificant growth in 2006, while in North
There is increasing demand from con-
America new product introductions grew
sumers for “food free” products, such
more slowly. New flavours with growth
as lactose-free and gluten-free, which
potential, such as açai (a Latin American
target the growing number of consumers
citrus fruit), have been introduced and
suffering food intolerance. Global food
dietary supplements, like antioxidants
and drink launches labelled “gluten-free”
and Omega-3 fortification, attract con-
nearly doubled in 2006.
sumers, promising diverse benefits such as immune support or heart health.
8 | packazine News Facts & Trends
Deliberate buying decisions – Consumers are aware of “food free”
L ACTOSE FREE
VERY 21 %
SOMEWHAT 36 %
NEVER 8 %
products and the Fairtrade certification
Fairtrade and sustainable packaging
is an ecological, economical and social
Increasingly, consumers focus on the
balance throughout the whole value
provenance of products and the wellbe-
chain. The sustainable packaging revolu-
ing of others. Products with the Fairtrade
tion is about to start and the market for
certification help those identifying
sustainable rigid and flexible forms in
goods that meet environmental, labour
food and beverage packaging is expected
and developmental standards. In 2006,
to surpass $ 42 billion by 2010*.
products with the Fairtrade label reached SOMETIMES 35 %
retail sales of 757 million Euros in the
Ageing consumers
EU and 379 million Euros in North
A demographic change in industrialized
America. There is also growth in the use
countries has resulted in changes in
of Fairtrade ingredients in mainstream
market structure, with a much larger
brands and the number of countries
segment consisting of ageing consumers.
offering these certified products is also
In America, the 78 million ageing Baby
increasing.
Boomers (worth around $ 46 billion in
The development of an awareness and
sales) will become the biggest senior
understanding of sustainability in societ-
citizen market the US has ever seen.
pliers and brand owners in “Packaging
ies around the globe is moving forward.
Worldwide, by 2035, Germany will be the
Digest”
Therefore, consumer goods package
country with the oldest residents: almost
How important is sustainability in packaging decisions? Survey of nearly 2000 packaging sup-
(Issue February 2007)
companies have to face an increasing fo-
50 % of the country’s population will be
cus on sustainable packaging. The target
in the 50-plus age group. *Candy & Snack Business, March/April 2007
packazine | 9
Middle East & Africa 9,697
Latin America 29,829
North America 63,088
Global new product introductions by region Region
2004
2005
2006
Total
Europe
30,921
34,055
38,917
103,893
Asia Pacific
19,830
20,538
26,963
67,331
North America
20,830
19,380
22,878
63,088
6,723
10,684
12,422
29,829
Latin America Middle East & Africa Total
2,881
2,929
3,887
9,697
81,185
87,586
105,067
273,838
Asia Pacific 67,331
Europe 103,893
Source: Mintel GNPD
The special needs of ageing consumers
by adding value to every step of the
For more information please contact:
provide fresh challenges. Diminishing
packaging design and implementation
Ulrike Probst
eyesight and decreasing hand strength
process.
require larger print on labels, ergonomic design and easy to open and reclose mechanisms. Staying one step ahead By researching future trends and factors, Bosch Packaging understands the needs and requirements of consumer good markets. As a result, new opening and reclosing mechanisms and the optimized use of packaging materials are some of our recent innovation projects. The early involvement of machine and technology competence is essential for the successful production, marketing and sale of consumer goods. Creativity, combined with our vast engineering expertise, supports this holistic approach to packaging,
Phone +41 52 674 80 53 [email protected]
10 | packazine Customers & Markets Food and Confectionery
Lilac sets the mood In Scandinavia, Lila, meaning lilac, is synonymous with high quality coffee. Produced by Löfbergs, it is one of the best-known coffee brands in northern Europe and is packed solely on Bosch vacuum package makers. When a new, major order challenged Löfbergs’ capacity, the new PKS 3151 BN package maker increased both production capacity and flexibility.
The largest coffee roaster in
Primarily, Löfbergs roasts and sells high
3122 BV high output vacuum package
Scandinavia
value coffee blends for many preparation
makers. At an output rate of up to 130
AB Anders Löfbergs kaffeegrupp, the
forms, such as special blends for the
vacuum packages each, per minute, the
Swedish coffee importer and roaster,
growing catering and horeca markets
lines operate extremely reliably and with
was founded in 1906. The company com-
(hotel, restaurant, café). The bulk of
a high rate of effectiveness.
prises of the production plant Kaffehuset
the coffee production is sold under the
i Karlstad AB, the sales and marketing
Löfbergs Lila brand.
In 2006, a major order was pending from
Meeting customers’ requirements with
Kaffehuset had to be increased at short
Kaffe AS. To this day, Löfbergs is still
reliable technology
notice. In March, 2006, Löfbergs again
a family run company. With sales of
Löfbergs has been using Bosch package
decided in favor of its proven partner
approximately 100 million Euros and 200
makers for more than 35 years. In the
Bosch and invested in the PKS 3151 BN
company Löfbergs Lila AS, Löfbergs Lila International AB and Peter Larsens
a retail chain, and so the capacity of
employees, it is one of the largest north
production plant Kaffehuset in Karlstad
package maker with a FVS 3101 SQ auger
European coffee roasters and also one
(Sweden) the packaging production is
filler and a KWI 3010 N checkweigher.
of Europe’s largest importers of coffee.
performed solely on two Bosch PKD
The Löfbergs team and technical manager, Lars Andersson (second from right), after the successful acceptance of the PKS
packazine | 11
Aroma protection combined with
Everything at a glance
A mere six months had passed when the
flexibility
To start with, Löfbergs produces 250
machine was delivered to the customer.
The new PKS offers Löfbergs modern
gram vacuum packages for ground cof-
Löfbergs can now produce all customary
vacuum packaging technology for pro-
fee, with a flat top, rolled in once and
packaging presentations in the market
duction output of up to 65 packages per
held down with adhesive tape. The typi-
and is looking forward to a rosy, or,
minute. The unique product protection
cal Löfbergs Lila paper wrap around the
should we say, “a lilac future”.
system “neutravac”, with inert gas flush-
vacuum package is produced on a line-
ing and evacuation, guarantees lowest
integrated wrapper machine. The FVS
For more information please contact:
residual oxygen level. The machine is
3101 SQ auger filler, as well as the KWI
Martin Kühl
also capable of producing attractive flex-
3010 N checkweigher, are operated from
Phone +49 711 811 57480
ible packages with various top closures
a centrally installed touch screen. This
[email protected]
and valve packages.
provides the operator with an instant visual access to all production-relevant data on a single monitor.
1 The PKS 3112 BN package maker with auger filler FVS 3101 and KWI 3010 N checkweigher – the flexible alternative for the output range up to 65 packages per minute 2 The aroma protection system “neutravac” combines lowest residual oxygen content with large size flexibility 1
2
12 | packazine Customers & Markets Food and Confectionery
Frozen pie line is one cool system Delta XR31 robots provide system efficiency of 99.7 %! Vision quality control system
each of the 18 robot cells. All this at a
Operational staff at Bama (Tulsa, Oklaho-
rate of 1’400 pies per minute!
ma) are excited about the performance
Several potential suppliers were evalu-
of the recently installed 18-robot system
ated for this major automation project.
provided by Sigpack Systems. And, they
Bama’s Vice President of Engineering,
have good reasons. The line incorporates
Randy Roark, states that “Bama chose to
a unique state-of-the-art vision quality
partner with Sigpack due to the flexibil-
control system, which ensures that only
ity the robot system offered, by picking
products of exact quality are accepted
the pies directly from the main belt and
from the process equipment before
placing them into the cases. Others were
being accurately placed into cases. Each
suggesting row distribution solutions,
shock frozen fruit pie is inspected for
which involved multiple steps and greater
precise color, pattern, and dimensional
complexity. Sigpack streamlined the
shape. The system distinguishes very
process.”
subtle parameter differences and all product information is communicated to
1 Arriving of the apple pies directly out of the freezer 2 1’400 products per minute – more than 2 mio per day! 3 Specialized vision system for quality control 4 Spreading of the products 5 Fast and gentle placing of the apple pies 1
2
packazine | 13
Application challenges
The Sigpack Systems XR31 Delta robot
easy operator and maintenance access
In 2006, the challenges presented to
solution
to each robot within the system. The
Sigpack Systems included an applica-
The frozen fruit pies exit the Bama
robots utilize a custom-designed vacuum
tion involving a frozen product and its
freezer in rows consisting of 20 products.
picker to gently pick and place pies into
environment, a high production rate,
After a series of belt turns, the products
the cases, which move in a counter-flow
complex product inspection and a cin-
enter the packaging room, where tem-
direction to the main belt. The system
namon topping. Production efficiency,
peratures and humidity are controlled.
is also equipped with special filters to
quality control and sanitation were key
The rows of pies are separated via
assist with the collection and removal of
considerations. Roark states that “A test
spreader belts and proceed under an
excess cinnamon dust. Roark describes
at Bama showed it required six people
overhead camera, which examines the
that “The line speed was previously dic-
for a proper visual inspection of the
entire product flow.
tated by available staff. Now, the robots
product. Prior to the design phase of
Nine Sigpack Systems Model XR31
are always ready to perform and we can
the project, Sigpack Systems conducted
Delta robots are positioned on opposite
maintain a more consistent line speed
lab tests, with actual frozen product, to
sides of the main packaging belt. This
and production flow. The added benefit
review Bama’s inspection criteria, as well
layout facilitates complete pick coverage,
is reduced product variability.”
as to confirm the pick reliability of the
reduces overlap and limits excess robot
gripping tool.”
movement. The design also allows for
3
4
5
14 | packazine Customers & Markets Food and Confectionery
18 Delta robots XR31: Compact washdown design
Quality Control system
exact position of the good products with
a stronger foothold for placement of
The heart of the system is the optical
its own vision system and picks, based
robots into frozen food environments.”
quality control with a specialized vision
upon a sophisticated strategy, the best
Bama’s Plant Engineer, Duane Cook,
system. This system acquires a detailed
product for the cycle. Advantages of this
echoes these thoughts. Cook says that,
image of the product carpet at the
centralized quality control against an
“There has been a high level of coopera-
beginning of the line. Every single apple
individual control in each robot cell are
tion and professionalism between the
pie is then evaluated for acceptability,
more reliable operation through easier
two companies. Sigpack Systems is
including minimum and maximum length
calibration and safer retrace ability of
willing to listen, understand and resolve
and width tolerances, partial products,
bad products.
real life production issues.”
and overlapping or connected products. Additionally, the number, shape and
Sigpack Systems’ National Account
For more information please contact:
position of the slits in the surface of the
Manager, Tom Pecht remarks, “The
Tom Pecht
pies are checked, as well as the quality
people at Bama are great to work with
Phone +1 920 662 1258
of the topping. The positions of all ac-
and have welcomed the new technology
[email protected]
ceptable products are communicated
into their operation. In addition, the
to every robot. Each robot detects the
line has helped Sigpack Systems gain
1 Fast and gentle placing of the apple pies 2 Simple and convenient operation of the quality control system 1
2
packazine | 15
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