Innovative entries from Rollprint Packaging Products Inc. and Curwood Inc. topped the 2005 Flexible Packaging Achievement Awards.
Rollprint of Addison, Ill., was recognized for a sterilizable pouch used by Baxter Healthcare Corp. for single-use dialyzers. Curwood of Oshkosh, Wis., won for an opener on Jennie-O Turkey Store Inc.'s oven-ready frozen turkey bag.
The 28 winners - from a record 88 entries - were disclosed at a ceremony concluding the Flexible Packaging Association's annual meeting, held Feb. 23-25 in Carlsbad. Presenters handed out 33 awards.
For the Microperf dialyzer package, Rollprint uses a new process and a newly developed, 3-mil-thick, blown polyethylene copolymer film that is slit and perforated in-line on a Di-Acro slitter. Controlling porosity is critical and aids ethylene oxide sterilization while maintaining product cleanliness.
The film was developed for durability and reproducible perforation results. In turn, Baxter automated its dialyzer packaging with a horizontal form-fill-seal machine and replaced pre-made pouches that were filled and sealed individually by hand.
Baxter Healthcare is a subsidiary of Deerfield, Ill.-based Baxter International Inc.
The Rollprint entry received a highest achievement award for packaging excellence and gold awards for environmental achievement and technical innovation.
Curwood, a subsidiary of Bemis Co. Inc., won for its IntegraScore opener on the Jennie-O flat, nonshrink bag.
The proprietary opener is positioned vertically along the side of the gusseted pouch. The design eases opening the outer pouch and eliminates the possibility of damaging the inner bag, Curwood said.
A reverse-printed polyester layer is extrusion laminated to a rigid sealant to form the pouch. A reinforced handle has two holes for carrying the package. The Curwood entry received a highest achievement award for packaging excellence and, with its high-impact graphics, a silver award for printing.
Plastics processing was key for five other gold award winners.
Under a U.S. Army pilot contract, Pliant Corp.'s Chippewa Falls, Wis., facility made a high-barrier, laminated PET battery case that eliminates use of heavy steel and has a sealant directly applied to a cell's polarity leads. The lamination contains a proprietary, seven-layer film with barrier resins and PE copolymers.
The case won gold awards for packaging and printing.
Two Alcan Packaging business segments won awards for pouches in food and medical uses.
In August, Wornick Co. began distributing its Asian Style Selections in what Chicago-based Alcan Food Packaging Americas said is the first domestically converted, high-barrier, nonfoil, retort stand-up pouch. Alcan's Ceramis silicon oxide-coated film forms the clear high-barrier layer for the line of four microwavable, 18-ounce meals.
Cardinal Health Inc.'s Autopak sterilization pouch has a nonwoven ply from BBA Group plc for its outer bottom and a blown polypropylene coextrusion film from Alcan for a middle ply. The outer ply is made of an Alcan-laminated nylon from DuPont Canada Co. and transparent Alcan PP.
Alcan's medical flexibles segment makes the coextrusion in Marshall, N.C., and the abuse-resistant PP in Asheville, N.C.
Cryovac of Duncan, S.C., a division of Sealed Air Corp., won for FlexPlay packaging. A 3½-mil-thick, fully coextruded film has oxygen-scavenging and several other layers, and a 10-mil-thick forming web has abuse-resistant, barrier and sealing layers. A FlexPlay DVD's allotted time span for viewing begins when the DVD is removed from the package.
Kapak Co. LLC of St. Louis Park, Minn., won for a trigger-spray-equipped pouch for Hunter's Specialties Inc. of Cedar Rapids, Iowa. Pliant, Alcan and Cryovac received additional awards.
Other winners included entries from CLP Industries Ltd. of Fairfield, N.J.; American Packaging Corp. of Rochester, N.Y.; Polymer Packaging Inc. of North Canton, Ohio; Star Packaging Corp. of College Park, Ga.; LPS Industries Inc. of Moonachie, N.J.; PBM Plastics Inc. of Newport News, Va.; Exopack LLC of Spartanburg, S.C.; FlexAmerica Inc. of Bethesda, Md.; Robbie Manufacturing Inc. of Lenexa, Kan.; and Peel Plastics Products Ltd. of Brampton, Ontario.