From the Sector

Purchase marks company’s second in two years as growth continues

Paper Converting Machine Company (PCMC), announced that Prestige-Pak of Fond du Lac has purchased a new Fusion C flexographic press. The press will be the second Fusion C (and the fourth PCMC press) for Prestige-Pak, a second-generation, family-owned business, and producer of printed and laminated flexible packaging materials.

“We’re looking forward to our new Fusion C press,” said Vince Kuber, President of Prestige-Pak. “Our Fusion C and Fusion presses have helped us better meet the needs and requirements of our customers. We’ve experienced significant growth, and that has prompted us to add an additional press. One deciding factor in choosing PCMC is the fact that the company’s machines are engineered and built in the United States.”

The Fusion C is loaded with fast make-ready and waste-saving features, all in a smaller footprint with fewer parts. This reliable flexographic press also includes PCMC’s SteadyPrint print-stabilization technology, winner of the 2019 FTA Technical Innovation Award. With this feature, the bearing arrangement is coupled with an algorithm that uses noise-canceling technology to largely remove the impact of bounce when printing graphics with hard edges. With patents pending on all features, SteadyPrint is currently the only product on the market using this kind of technology to eliminate disturbances and monitor in real time.

Sustainable packaging solutions are a hot topic all over the world. Sappi, market leader in innovative packaging barrier and sealable papers, is already producing such solutions and can point to numerous successful examples. Demand from customers and interested parties from a wide spectrum of industries continues to grow. The world’s leading paper and paperboard manufacturer therefore recently added two new grammages to its Sappi Seal range. In addition to the 67 g/m² version, the new 85 g/m² and 100 g/m² papers enable branded goods manufacturers to package an even more extensive variety of products with this functional paper – either as primary or secondary packaging.

The requirements for packaging papers are becoming increasingly demanding. They need to offer greater functionality, be environmentally friendly, recyclable and provide optimal protection for the packaged products. While many paper manufacturers are still talking about such multi-functional solutions, the innovation leader Sappi has already expanded its portfolio. The 85 g/m² and 100 g/m² grammages are now available in the Sappi Seal product family. Converters and manufacturers of food products, such as sugar, tea and confectionery, as well as non-food items, like children’s toys and DIY products, now have even more possibilities to use this functional paper and move from fossil-based materials to environmentally friendly packaging. The wide range of projects that Sappi has already completed for well-known customers, highlight its relevance for the market.

A successful autumn season for Sappi at a collection of trade fairs, with exceptional interest shown in innovative packaging papers

Sappi Europe has presented its solutions for sustainable, future-oriented packaging at three trade fairs in the past few weeks. The globally operating paper specialist’s extensive product range has been serving as a benchmark in the industry for years and now includes the functional barrier papers from the Sappi Guard family, the sealable packaging paper Sappi Seal and the folding boxboard Atelier. The showcasing of innovations in sustainable packaging papers will continue at interpack in Düsseldorf in May 2020.

“Environmentally friendly packaging” was the first leading theme of FachPack, which, according to Messe Nürnberg, really had its finger on the pulse. This theme also was given top priority by visitors that were attracted to the Sappi stand, by its wide range of innovative and sustainable application solutions.

Huge demand for specific projects
Almost fifty per cent more branded goods manufacturers, converters, established customers and interested parties visited the FachPack stand in Nuremberg compared to the previous year – with specific projects in mind. For those planning to replace composite packaging with a paper-based solution with integrated functionality, Sappi presented its Sappi Guard barrierpapers and highlighted some related best practice references. This included the packaging solution for a new nut-fruit bar, recently introduced to the market, from a well-known brand manufacturer. The Sappi Guard range includes Sappi Guard M and Sappi Guard MS with a mineral oil barrier (MOB) and a grease barrier of Kit 11 or Kit 7. All Guard papers guarantee very high product safety and can be completely recycled. The integrated heat sealability was the focus of the development of Sappi Seal. René Köhler, Head of Business Development Packaging and Speciality Papers at Sappi, says: “Reducing the consumption of fossil resources in packaging is a major concern for Sappi. On this account, we developed Sappi Seal, a functional paper with integrated heat sealing functionality which is integrated in the form of a dispersion coating on the reverse side of the paper and can replace papers with a PE coating.” Sappi presented a wide range of successfully completed projects in order to demonstrate the specific application of this paper to the trade fair visitors.

New polyethylene and polypropylene-based monomaterial pouch solutions developed in value-chain collaboration

Borealis and Borouge have developed a series of new, monomaterial pouch solutions based on polyethylene (PE) and polypropylene (PP). Designed specifically for recycling, and in collaboration with value-chain partners, these new pouch solutions are suitable for the most demanding consumer packaging applications. In line with the EverMinds™ approach to Thinking Circular, these solutions further expand the range of more sustainable options available to the flexible packaging industry. Several of the pouches will be showcased at the K 2019 in October, including one exemplar containing 35% post-consumer recyclate (PCR).

Communicating brand values and product characteristics in an emotional way and staging them in an appropriate manner is becoming increasingly important for brand manufacturers. To connect with the end consumer, they need to have paperboards that enhance the visual and tactile experience. In response to these needs, Sappi is now introducing the next generation of its popular and proven Algro Design portfolio – with an enhanced paperboard version and a change of name.

More and more consumers want exclusive, customised packaging that reflects a brand’s unique selling points and special character. For even more flexibility and design scope, Sappi is expanding its range of premium solid bleached boards to include an additional variety as of 1 October 2019: Algro Design Advanced. This gives customers a choice of four different reverse side surfaces within the popular Algro Design portfolio, which means one more paperboard variety than before. The paperboards differ with regard to the reverse side coating; the top sides are identical and always double coated. As part of the ongoing development of the popular Algro Design paperboard, the term “Nature” is now added. This further underlines the brand’s natural look on the uncoated reverse side and its haptic character. A specification of this kind is in great demand today, as the reverse side of the paperboard is being used more and more frequently as the outward face of a finished box. The product itself and all properties remain the same.

Checkpoint Systems has announced the launch of its new dual-purpose RF merchandise protection label – the Super Flag Tag.

The innovative, dual purpose, Super Flag Tag safeguards against theft and product tampering, enabling retailers and brands to protect a greater variety of products without obscuring messaging or impacting the planogram. There is no other label on the market that combines these benefits, enabling visible Source Tagging without obscuring legal wording or branding.

The tamper resistant tag wraps easily around the corners of boxes, sealing the opening and features a large surface area with a high-bond adhesive making it difficult to remove without visibly damaging the products packaging.

Equipped with the world’s smallest best performing RF label range with optional Black Lock logo, proven to reduce shrink by up to 50%, Checkpoint’s Super Flag Tag is ideal for protecting small, high-risk items such as cosmetics, pharmaceutical goods and other accessories from theft, while the clear label ensures barcodes and other key information are not obscured.

Sappi to present its innovative papers and packaging solutions at FachPack 2019

Environmentally friendly packaging is a hot topic worldwide. Sappi has been a pioneer in the field of innovative and sustainable packaging solutions for years. The company will present its latest innovations at Stand 9-260 at FachPack in Nuremberg. Alongside barrier papers, these include the heat-sealable Sappi Seal paper. This is notable for being completely recyclable and can replace existing PE-coated packaging. The recently launched Atelier paperboard will be another focus of the trade fair presentation. This offers brilliant colour reproduction and a silky touch and feel.

China is the world's largest producer and exporter of nonwoven fabrics, as well as having the largest consumer market for products made from nonwovens, making the upcoming biennial China International Nonwovens Expo & Forum (CINE – supported by Techtextil) the place to be for industry players from 3 – 5 June. This year’s event will relocate to a different venue, the Shanghai Convention & Exhibition Center of International Sourcing, located conveniently between Hongqiao airport and downtown Shanghai.

“The nonwovens market has been one of the fastest growing sectors of the Chinese textile industry over the last decade, and we expect this to continue in the coming years,” Wendy Wen, Senior General Manager of the fair’s co-organiser, Messe Frankfurt (HK) Ltd, commented. “The demographic changes, evolution of the manufacturing sector and greater awareness of environmental protection that have driven growth in China, among other factors, are also evident in a number of markets in the region, particularly Southeast Asia, so we anticipate production growth will remain strong to meet export demand, even if the Chinese economy slows further.”

Reports by the China Nonwovens & Industrial Textiles Association (CNITA), the Freedonia Group and Smithers Pira support this. Nonwovens output in China grew year-on-year by 9.67% for the first 11 months of 2018, exceeding the corresponding figure for 2017 of 8.71%, while demand for nonwovens is predicted to reach 4.9 million metric tons in 2022, a 6.9% per year increase over this period.

Turning to the region, in 2015 Asia occupied 43.1% of the global nonwovens market – with China alone accounting for more than half of the share – with this figure expected to increase to 47.1% in 2020. The Freedonia report also notes that healthy growth in markets nearby to China such as India, Indonesia, Malaysia, the Philippines and Vietnam will also fuel nonwovens output in the country to meet export demand.

Globally, nonwovens demand is expected to increase 4.4% per year to 12.2 million metric tons in 2022, with developing regions being the main driver of this, in particular within Asia-Pacific. In the PP nonwovens sector, output is predicted to nearly double between 2013 and 2020, with the major drivers of this growth being baby diaper, adult incontinence and feminine hygiene products. In the durable nonwovens sector, annual growth of 6 to 7% for the period 2017 – 2023 is also anticipated for filtration, engineering construction and packaging uses.

This September’s Cinte Techtextil China will once again provide a strong barometer of the state of the global technical textiles industry, and in particular which sectors in Asia as a whole, and China specifically, are performing well. Two of these for certain are Buildtech and Mobiltech, with a number of leading global and Chinese brands exhibiting to eager buyers from these sectors.

Cinte Techtextil China is Asia’s leading biennial fair for the technical textiles and nonwovens sector, and will feature an expected 500-plus total exhibitors from around 20 countries & regions from 4 – 6 September. The fair offers products and technologies for 12 application areas* which cover the entire industry.

Buildtech benefits from Belt & Road and other infrastructure investment

With a huge boom in national and regional infrastructure projects, the market for Buildtech products, especially geotextiles and construction textiles, is rapidly expanding. In particular, the government’s global Belt & Road project, as well as continued investment at home in highways, high-speed rail and more, is fuelling this expansion. According to CNITA, in 2017 China started 35 new railway projects, with additional private capital investment in this sector totalling some USD 53 billion that year. The same investment in highway construction increased 17.7%, while water conservation project investment by private firms reached a new record of USD 105 billion.

With this potential in the Asian market, it’s no surprise a number of new exhibitors will feature in the Buildtech sector at the fair, including FPC Technical Textile from Saudi Arabia, Kobe-cz from the Czech Republic, as well as Lenzing Plastics, while Johns Manville are one of the returning exhibitors this year.

• FPC Technical Textile (Saudi Arabia) produce high-end specialty fabrics including PVC coated fabrics and fibre glass PTFE fabrics, and will focus on the latter at the fair.
• Kobe-cz (Czech Republic) will showcase their nonwoven fabrics, mainly from glass fibre with temperature resistance up to 800°C.
• Exhibiting for the first time at the fair with their Plastics division, Lenzing (Austria) will feature their technical laminates for building industries, roofing membranes, vapour barriers, isolation facings and barrier packaging, as well as PROFILEN® PTFE yarns, films and fibres at Cinte Techtextil.
• Johns Manville’s (US) products on offer include polyester spunbond, PP & PBT meltblown, glass fibre nonwovens, micro glass fibre nonwovens, hybrid nonwovens, glass fibre needle mat and glass microfibers.

Mobiltech benefits from huge increases in automobile production in China

With new textile innovations and application possibilities spreading throughout the automobile industry, coupled with the fact China is the world’s largest auto producer, Cinte Techtextil is the place to see the latest products and technologies for this sector this September. Automobile production in China reached 29 million units in 2017, an increase of 3% year-on-year. Staggeringly, new-energy vehicle production grew by 53% last year, while SUVs and commercial vehicles increased 13.81% and 13.95% respectively.

With such strong growth in China, a number of leading international Mobiltech producers, as well as top domestic suppliers, will be at Cinte Techtextil this year, including:

• Abifor (Switzerland): their focus at the fair is on products designed for automotive, construction and other technical applications, in particular their specialty hot-melt powders. The company has its own production unit in Shanghai, and reports that an increasing number of domestic customers are starting to focus on more sophisticated products.
• SKS Group (Sweden): will showcase high performance single end yarn for automotive and industrial hoses, and single end cord for automotive and industrial belts.
• Swisstulle (Switzerland): will have a range of products on offer for automotive, rail and aviation uses, including sunshade materials, nets, tube reinforcements and new possibilities for luggage compartment covers.
• Windel Textile Far East (Germany): with production undertaken in China, this German firm offers textile greige, half-done and finished materials. They offer nonwoven, knitted and woven fabrics (substrates), and glass fibre solutions. At the fair, they will showcase substrates for adhesive tapes / wire harnessing tapes, and Maliwatt- and coagulated microfibre fleece for covering vehicle interiors.
• Protechnic (France): they will feature hot melt thermoadhesive nets, webs and films, as well as laminating process in automotive and other industrial applications at Cinte 2018.
• Kuangda Technology Group (China): having supplied products for global brands such as Volkswagen and Audi, this Chinese supplier will offer automotive interiors, including interior fabrics, seat covers and cushions at the fair.
• Shanghai Shenda (ShanghaiTex Group) (China): specialising in automotive interior textiles, they manufacture a full range of products including grey car carpet, moulding car carpet, head liners (warp-knitting and nonwoven), seat belt, seat fabrics and more, and have supplied the likes of Mercedes-Benz, BMW, Volkswagen and GM.

Cinte Techtextil China is organised by Messe Frankfurt (HK) Ltd; the Sub-Council of Textile Industry, CCPIT; and the China Nonwovens & Industrial Textiles Association (CNITA). To find out more about the fair, please visit: www.techtextilchina.com.

Packaging solution made of 100% plastic recyclate delivers circular economy proof point
Borealis, a leading provider of innovative solutions in the fields of polyolefins, base chemicals and fertilizers, announces the successful launch of a new packaging solution produced entirely with post-consumer recycled (PCR) material. Developed in close collaboration with the German consumer and industrial goods company Henkel and two additional value chain partners, this truly sustainable packaging solution is further evidence of how mtm plastics GmbH, a member of the Borealis Group, is helping increase the circularity of plastics. The launch has significance for the consumer goods industry because the robustness of this new packaging solution provides further evidence that plastic recyclate is indeed suitable for a variety of demanding packaging applications, in this case a popular adhesive brand marketed by Henkel.

Value chain collaboration yields plastic bottle and nozzle composed of 100% PCR material
In 2016, Borealis acquired leading German recycler mtm plastics GmbH, which is now a member of the Borealis Group. By leveraging their respective areas of expertise and decades of experience as a virgin polyolefins producer and “upcycler”, respectively, Borealis and mtm plastics are exploring new growth opportunities with joint forces.

A success story originating from this exploration is a recently completed pilot project with Henkel, the global leader for adhesives, sealants and functional coatings. The companies have worked to develop a new packaging solution based on recycled material for the Made-at-Home all-purpose glue bottle and cap, which Henkel is marketing under its well-known Pattex brand.  The aim was to replace the virgin plastic material traditionally used for this packaging with a recyclate-based resin. The resin, however, had to fulfil the diverse material demands for packaging of an adhesive product.

After extensive and joint application development, a new bottle was developed with the proprietary mtm product Purpolen® PE, a high-quality polyethylene regranulate produced by mtm at its facilities in Niedergebra, Germany. Value chain partner KKT Kaller Kunststoff Technik GmbH, a plastics processor also based in Germany, manufactured the bottles. For the three separate components of the adjustable applicator nozzle, which is used for both filigree and wide-area gluing, high-quality Purpolen® PP polypropylene regranulate produced by mtm was identified as the ideal solution. German plastic components manufacturer bomo trendline Technik GmbH produced the applicator nozzles.

The new Pattex Made-at-Home packaging solution successfully passed extensive application tests, including a three-month storage test and other tests of mechanical properties. It was launched on the European market in 2018.

“Our commitment to leadership in sustainability is deeply embedded in our companies´ values,” explained Matthias Schaefer, Project Manager for Global Packaging Engineering at Henkel Adhesive Technologies. “We are at the forefront of the industry when it comes to new sustainability strategies in packaging.  Thus, we identified Pattex Made-at-Home as a candidate for exploring the use of recyclate instead of virgin plastics. This constructive collaboration with our partners proves the viability of 100% PCR material for an adhesive product like Made-at Home. It also underscores our efforts at Henkel to drive leadership in sustainability in the consumer goods sector.”

“As a virgin polyolefins producer, Borealis is thrilled to be among the pioneers in using plastic recyclate in new applications,” says Günter Stephan, Head of Borealis Circular Economy Solutions. “Even though momentum is gaining in the drive to increase the circularity of plastics, we still need to prove without a doubt within the industry that using recyclates – and even 100% PCR – is a suitable and effective option, even for demanding applications. Thanks to this successful value chain cooperation with our partners Henkel, KKT and bomo, we are giving plastics a second life and are thus one step closer to the goal of a more circular economy of plastics.”