DuPont Co.'s annual Awards for Packaging Innovation this year honor new developments from some global giants and their partners.
“The nominees and winners this year show how sustainability considerations are driving innovation,” Shanna Moore, global sustainability director at Wilmington-based DuPont's Packaging & Industrial Polymers, said in a June 13 news release.
Winners were selected from among 200 entries from 26 countries based on excellence in innovation, sustainability and cost/ waste reduction. The winners are:
Cincinnati's Procter & Gamble Co. and Santa Barbara, Calif.-based BeGreen Packaging LLC moved from a clamshell for the Gillette Fusion ProGlide package to a formable tray made of bamboo and bulrush-based material. The package costs and weighs less, is easier to open and has more room for graphics.
Ecovative Design LLC of Green Island, N.Y., won for its mushroom seeds-to-packaging EcoCradle, grown from mycelium and regionally sourced agricultural by- products such as cotton burrs and oat hulls. The jury found it to be a cost-effective and sustainable replacement for expanded polystyrene or other materials.
Cimplast Embalagens of São Paulo and Cimflex Industria e Comercio de Plasticos Ltda. of Maringá, Brazil, won for the Virtuous Cycle system, which allows used, multilayer agrochemical bottles to be diverted from landfills and remade into high-value products. Using DuPont's Fusabond compatibilizer, mixed-material waste can be used for products such as rigid or flexible corrugated pipes and automotive lubricant bottles. The award citation said more than 150,000 tons of plastic agrochemical bottles have been collected since 2002, saving an estimated 374,000 barrels of crude oil and keeping more than 160,000 tons of carbon dioxide out of the atmosphere.
Apeldoorn, Netherlands-based Apeldoorn Flexible Packaging BV and Cloeren Inc. of Orange, Texas, won for Katan-Ex microlayer stretch film, which provides pallet stability at elevated temperatures using 30 percent less material per pallet and reducing damage during transportation by 80 percent.
Crystal Lake, Ill.-based AptarGroup Inc.'s airless cosmetics dispenser is composed completely of polyolefins, enhancing recyclability, the judges said.
Northlake, Ill.-based Scholle Packaging and Houston-based Shell's Global Lubricants unit presented a bag-in-box system for automotive chemicals and fluids. Each box prevents two dozen 1-liter bottles from entering the waste stream. Overall, petroleum-based resin use in the packaging is reduced nearly 90 percent compared with rigid 1-liter bottles. The cube design fits more efficiently in trucks and warehouses, cutting greenhouse gas emission.
Household Essentials LLC of Hazelwood, Mo., packages its ironing board cover in a sewn-in cloth pouch that can be used later as a spray bottle holder. With the outer package elminated, weight is cut 14 percent and about 375,000 pounds of PVC is kept out of landfills. Since the package is 35 percent smaller, shipping costs were cut and retail display space was cut 30 percent.
Yango AL-brand laminate film from Moneta S of Ruzomberok, Slovak Republic, replaces a 14-micron foil structure with 3-micron biaxially oriented polypropylene film and 7-micron foil, resulting in an extremely thin, printable film. The BOPP gives extra strength, scratch resistance, protection and an ink-inside feature.
H.J. Heinz Co. of Pittsburgh and Multivac Inc. of Kansas City, Mo., developed Heinz's Dip & Squeeze ketchup pack for function and convenience. The package, shaped like Heinz's iconic glass bottle, holds three times more ketchup than standard 9-gram sachets and uses less material.
Stonyfield Farm of Londonderry, N.H., Clear Lam Packaging Inc. of Elk Grove Village, Ill., and equipment maker Arcil Inc. of Puiseux-Pontoise, France, won for a breakthrough use of NatureWorks LLC polylactic acid resin in a high-volume dairy application. The form/fill/seal multipack yogurt cups are made of 93 percent PLA — a switch from high-impact PS. PLA use cut greenhouse-gas emissions 48 percent and compression strength rose 15-20 percent, resulting in fewer damaged products during transit.
Coca-Cola Co. used 30 percent plant-based material for its I Lohas bottled water, cutting weight 40 percent over the former design. Once the water is consumed, the bottle is easily compacted.
Indian firm Positive Packaging Industries Ltd. replaced large glass bottles of Nestlé Magi Ar"me seasoning liquid with thermoformed, single-use packages made of flexible laminate. The bottle-shaped packet maintains brand recognition and enhances shelf appeal, according to the company. Its small size also offers easier handling and shipment.
U.S. computer giant Intel Corp. replaced all PVC inserts with thermoformed amorphous PET and corrugated fiberboard in a reduced package size. The sourcing change achieved a reduction of 2.5 million pounds of material, as well as reduced water consumption, greenhouse gas emissions and transportation costs.
GlaxoSmithKline Consumer Healthcare, API Laminates, Chesapeake Packaging, and Blue Marlin Brand Design's transatlantic collaboration resulted in innovative new packaging for Sensodyne toothpaste. The design uses cutting-edge Fresnel lens technology and positional control through the lamination process, allowing the printer to register inks to the lenses to create a unique three-dimensional brand identity. Fresnel lenses have been used in packaging applications as random designs but never in discrete areas aligned with such tight print to register.
Plymouth, Mich.-based Plastipak Holdings Inc. and France's Tescor HR developed ThermoShape, a lightweight PET con- tainer for hot-fill beverages. The bottle uses 20 percent less material, without using vacuum panels or affecting performance.
Perfecseal Inc., an Oshkosh, Wis., unit of Bemis Co. Inc., and Arthrex Inc. in Naples, Fla., devised a wire-coil clamshell to overcome challenges faced in assembling medical suture passing wire. Using a three-paneled, thermoformed package design and eliminating the porous, heat-sealed lid, manufacturing times and costs were reduced while helping medical staff to remove the suture easily for quick use.
The overall objective of the project was to make it easier to load the product and to reduce the cost of an existing product.
“The stiffness of the wire created a challenge in that, when coiled, it would spring outward from the conventional packaging,” Perfecseal project engineer Tad Kinyon said in a June 17 e-mail.
“With the new, three-panel design, the main containment panel allowed two options for assembly: feeding of the wire from the end opening or coiling it under the overhang of the containment panel, or a combination of both,” he said.