Latest / Through the Line: Packaging and Processing / Flexible Packaging Trends at PACK EXPO 2025: Packaging World
Transcript
- 0:03SPEAKER_00: Welcome to Through the Line, a podcast exploring innovations and information across the packaging and processing landscape.
- 0:11SPEAKER_00: From topics impacting consumer packaged goods and healthcare packaging to the latest technologies in food processing operations.
- 0:22SPEAKER_01: Hello and welcome to Through the Line.
- 0:24SPEAKER_01: I'm Anne-Marie Mohan, senior editor at Packaging World.
- 0:28SPEAKER_01: And joining me today is our chief editor, Matt Reynolds.
- 0:31SPEAKER_01: Matt, thank you for being here.
- 0:33SPEAKER_02: Thanks for having me.
- 0:34SPEAKER_02: Glad to be here.
- 0:36SPEAKER_01: So Pac Expo International hits McCormick Place here in Chicago in not too long, in October 18th through the 21st.
- 0:44SPEAKER_01: It only comes around every other year.
- 0:46SPEAKER_01: So if you're going, you're probably already thinking about how you want to spend your time there, what you want to look at, what you what's new, what's exciting.
- 0:54SPEAKER_01: So today we're going to be looking at flexible packaging.
- 0:57SPEAKER_01: We're going to look at both halves of it.
- 0:59SPEAKER_01: So the machinery that forms fills and seals, pouches and bags, and the films and the papers that run through them.
- 1:07SPEAKER_01: So that turns out to be one story rather than two.
- 1:12SPEAKER_01: Last year at PECExpo Las Vegas, Matt spent three days walking the show floor, doing dozens of booth visits along with the rest of our editorial team.
- 1:23SPEAKER_01: And what he found there is a reasonable guide to the kinds of innovations that you're likely to see in Chicago.
- 1:29SPEAKER_01: It's a good reminder that the show floor is still where a lot of this new technology gets announced.
- 1:35SPEAKER_01: So PacExpo has always been known for a place where the exhibitors and the packaging, machinery, and materials suppliers unveil new products.
- 1:46SPEAKER_01: And then when it comes to film, a spec sheet can only tell you so much.
- 1:51SPEAKER_01: It can't tell you, though, how that film is going to run in the ceiling draws.
- 1:56SPEAKER_01: That's something you will only learn when you're standing in front of the machine.
- 2:00SPEAKER_01: Matt was also at Interpak and Dusseldorf this spring.
- 2:03SPEAKER_01: So we've got a more current picture than Las Vegas alone would give us and a better sense of what's likely to turn up in Chicago.
- 2:11SPEAKER_01: So today we'll go over the trends he saw and what to look for in October.
- 2:14SPEAKER_01: So, Matt, why don't we start in Las Vegas?
- 2:18SPEAKER_02: Sounds good.
- 2:19SPEAKER_02: I would like to start in Las Vegas.
- 2:22SPEAKER_01: So it's not true that what happens in Las Vegas is in Las Vegas.
- 2:27SPEAKER_01: No, we're breaking the rules.
- 2:28SPEAKER_02: We're delivering what happens in Vegas to a wider audience.
- 2:31SPEAKER_01: Absolutely.
- 2:33SPEAKER_01: And so when we talk about flexible packaging, it's one of the busiest categories on the show floor.
- 2:40SPEAKER_01: So what's the story you're watching as we're heading into the Chicago show?
- 2:46SPEAKER_02: So I guess sealing was never a problem up until the sustainability movement, let's say, hasn't been a problem recently because for years we've been running on this equipment and through these ceiling jaws, multi-layer laminations that had a layer devoted specifically.
- 3:05SPEAKER_02: Its only job was to help with the sealing and to make sure that the ceiling window was really wide and forgiving.
- 3:12SPEAKER_02: So take that layer away for, let's say, recyclability of the move to mono material.
- 3:17SPEAKER_02: And then that seal layer and the structural layer become the same polymer.
- 3:21SPEAKER_02: So you lose that hyper-optimized sealing layer.
- 3:24SPEAKER_02: So now the temperature that seals it is close to the temperature that destroys it.
- 3:29SPEAKER_02: That window is extremely narrow.
- 3:31SPEAKER_02: So the practical consequences are you're going to have a narrower heat window, different dwell times, more sensitivity to contamination in the seal run area.
- 3:40SPEAKER_02: Imagine any of the product itself that gets in there, you're going to have a lot more trouble with the monomaterial than when you had an actual sealing layer that was devoted to dealing with that.
- 3:50SPEAKER_02: So if you run yesterday's forgiving settings on today's newer monomaterial films, you're going to end up getting burn through or a seal that looks fine but actually fails in the distribution center.
- 4:02SPEAKER_02: Some major forward-looking OEMs are trying to address that.
- 4:07SPEAKER_02: One of them was Syntagon.
- 4:08SPEAKER_02: Obviously, they had a big presence both in Las Vegas last year and at Interpack, that's their home ground in Germany.
- 4:14SPEAKER_02: And they were introducing their amplified heat sealing at both locations.
- 4:19SPEAKER_02: It really combines the rotational and linear jaw motion for a tighter, more consistent seal.
- 4:24SPEAKER_02: And it's squarely aimed at mono materials.
- 4:27SPEAKER_02: So it ran on their HCM flow wrapper.
- 4:29SPEAKER_02: So I was there in Vegas, and it's the machine that basically explicitly says we built this machine because the films around you and the films that you're using are changing.
- 4:38SPEAKER_02: So another answer, another kind of a way to skin the cat is ultrasonic.
- 4:42SPEAKER_02: So skip the heat window altogether.
- 4:45SPEAKER_02: Rinco, they showed a servo-driven ultrasonic pouch, a top sealer that seals through product contamination in the seal area.
- 4:53SPEAKER_02: So that's the failure mode that nobody likes to talk about, especially on powder and really granular lines.
- 4:59SPEAKER_02: So think about, I don't know, baby food or flour, these types of things.
- 5:03SPEAKER_02: Parcraft poucher is one that uses a Herman ultrasonic sealer with optional 100% seal inspection.
- 5:10SPEAKER_02: Our colleagues Casey and Rick saw those in Las Vegas last year.
- 5:14SPEAKER_02: Here's a sleeper one that isn't really a packaging machine per se.
- 5:18SPEAKER_02: It's a lab instrument.
- 5:19SPEAKER_02: And that's Physics SL25.
- 5:21SPEAKER_02: That's a heat sealer with hot tack testing.
- 5:24SPEAKER_02: This again was in Las Vegas last year, and it lets you adjust the temperature, dwell time, jaw configuration to find the actual correct window for a given film.
- 5:33SPEAKER_02: And that hot tack tells you how the seal behaves immediately after sealing before it cools.
- 5:38SPEAKER_02: It might have been a boring booth because it's laboratory equipment, but this is the tool that connects the material half of the conversation with the machine half.
- 5:46SPEAKER_02: So if you're in Chicago this year and you're looking into new films, as we always do, we look for the new materials.
- 5:52SPEAKER_02: The question you have to keep in the back of your mind is asking that machine builder, can you run it on this equipment?
- 5:57SPEAKER_02: It's not what it used to be with the optimized seal layer.
- 6:00SPEAKER_02: So now it's the question is how wide is the seal window and what happens at the edge of it.
- 6:06SPEAKER_01: Okay.
- 6:07SPEAKER_01: So you talked a lot about the equipment and when the past sustainable packaging or talking about flexible films, it was all about just the materials.
- 6:17SPEAKER_01: But as they're changing faster than they have ever before with new structures, are these film producers leaving it up to the machinery builders to figure out how it's going to run?
- 6:29SPEAKER_01: Or are they providing new innovation to enable that sealing to happen?
- 6:36SPEAKER_02: Yeah, that might have been the original state of affairs, but I think you're seeing more machinery and materials providers working hand in glove to tackle these problems.
- 6:45SPEAKER_02: So they're acknowledging it.
- 6:46SPEAKER_02: And the way you can tell is that heat resistance factor, it's becoming a headline feature in their new products, their new films, rather than just a footnote that's buried somewhere in the spec sheet.
- 6:56SPEAKER_02: So CMG, Chutter Next, they were introducing their green arrow MDOPE, polyethylene.
- 7:02SPEAKER_02: Anne-Marie, you're actually at this booth.
- 7:04SPEAKER_02: I think you remember that the sustainability story is the matte finish that's also store drop-off recyclable with no overprint varnish.
- 7:10SPEAKER_02: So that was the sustainability splash.
- 7:13SPEAKER_02: But in this conversation, what was important was that the machine ability story and that that machine direction orientation, that's the MDO in the name of the film, it adds a stiffness and it adds heat resistance.
- 7:25SPEAKER_02: And that's exactly what widens that window and lets you go thinner at higher speeds.
- 7:30SPEAKER_02: And the high speed is important.
- 7:31SPEAKER_02: So you don't want to switch to a more sustainable material only to reduce throughput significantly.
- 7:36SPEAKER_02: So you have to balance all these trade-offs.
- 7:38SPEAKER_02: Another one was TC Transcontinentals, they're oriented polyethylene, the OPE or BOP, as some people might say.
- 7:45SPEAKER_02: It's the same double reading.
- 7:46SPEAKER_02: It's APR, that's the certifying body.
- 7:48SPEAKER_02: So it's APR certified, store drop-off, qualifiable.
- 7:51SPEAKER_02: Yeah, but it's on a new production line.
- 7:53SPEAKER_02: It's running about 21 feet line uh wide.
- 7:56SPEAKER_02: So it's already commercial in doy packs and stand-up formats, and it's sold on strength, clarity, heat resistance, and also printability.
- 8:04SPEAKER_02: So the converters have a say in this, and that's a supply at scale story as much as a sustainability one.
- 8:10SPEAKER_02: So we've been talking about sustainability, machine ability is suddenly front and center.
- 8:14SPEAKER_02: And then across the pond at Interpack, there were two that pushed even further.
- 8:18SPEAKER_02: I'm gonna mangle this name, but Itochu, they had a mono material PE film with a heat resistance to 250 degrees Fahrenheit.
- 8:26SPEAKER_02: And that's the number at which mono PE can either laminate or not laminate.
- 8:32SPEAKER_02: And another one, Dow with Messpack, showed a monomaterial PE stick packs with barriers they claim are comparable to aluminum-based laminations.
- 8:40SPEAKER_02: So aluminum has classically been a great barrier layer for longer shelf life, but it's a difficulty to recycle that material when you've got whether it's PE or other materials laminated with metallics like aluminum.
- 8:54SPEAKER_02: So and then finally, Tagleaf was another one.
- 8:56SPEAKER_02: I spent a lot of time at the tagleaf booth, really, because this is on the compostable side of things, and it's the version of the same argument.
- 9:02SPEAKER_02: So they've got a D822, and they told me there that it's the first biaxialite-oriented PHA film.
- 9:10SPEAKER_02: So it's home compostable, not industrial compostable, and it's also notably quiet.
- 9:15SPEAKER_02: So we remember when I think it was Sunchips came out maybe a decade ago with a compostable bag that everybody got upset about because it crinkled and made a lot of noise.
- 9:23SPEAKER_02: There's no crinkle on this, and that's what really killed the original onset of compostable snap bags 10 years ago.
- 9:30SPEAKER_02: So today, the sibling of the D822 is the D823, and it's specifically designed for seal integrity on high-speed machines.
- 9:39SPEAKER_02: Cavana is in a slow wrapping OEM, and they ran it at their booth.
- 9:43SPEAKER_02: So it's still pre-commercial, or at least it was at Interpak, but I know PepsiCo is in development, so we may see it on shelf before too long.
- 9:51SPEAKER_01: Really interesting.
- 9:52SPEAKER_02: Yeah, when it yeah, I was gonna say when a film supplier leads with seal integrity, or when they lead with heat resistance as opposed to all the sustainability elements that the film was likely created for, it tells you that they understand the problem of machinability.
- 10:07SPEAKER_02: So again, it's OEMs and their and then the film suppliers and the converters all working hand in glove to solve the same problem for brand owners.
- 10:16SPEAKER_01: I feel like that's a really new kind of synergy, the machinery and flexible film suppliers working together.
- 10:25SPEAKER_01: As I said, it seemed like in the past the flexibles were over here developing new materials, but then when it got to the machinery, that was where they found out that it wasn't going to work.
- 10:36SPEAKER_01: But now you, as you've talked about, there really is quite a cooperation there to make sure that these materials will work on the machinery that is in the brand owner's operations.
- 10:48SPEAKER_01: So that's very that's great.
- 10:50SPEAKER_02: It's pretty cool.
- 10:50SPEAKER_02: I think the biggest thing there is they do a lot of work in a pre-competitive setting.
- 10:55SPEAKER_02: So because every converter or every film supplier is going to sell to all of their brand owners' customers, and every OEM is going to sell to all of their brand owner customers.
- 11:07SPEAKER_02: So sometimes there's overlap, and the worry often was of IP for a certain type of material or a certain type of material handling technology.
- 11:15SPEAKER_02: But a lot of work is being done by all the major players to enter a pre-competitive space where these problems can be solved in a way that won't be divulging or risking IP leaking out where it wasn't, where they don't want it leaked.
- 11:29SPEAKER_02: So the ultimate winner here, though, for that pre-competitive collaboration is going to be the brand owners themselves who actually get to reap the rewards of all of this collaboration upstream.
- 11:39SPEAKER_01: Yes, absolutely.
- 11:40SPEAKER_01: And the environment overall when you let's not forget about that.
- 11:45SPEAKER_01: Yeah.
- 11:46SPEAKER_01: So now you came back from Dusseldorf and InterPEC, and from some of the reporting that I saw that you did, you were talking a lot about paper.
- 11:57SPEAKER_01: So paper isn't really a new idea when it comes to flexibles.
- 12:01SPEAKER_01: What's different now?
- 12:03SPEAKER_01: What did you see at InterPEC?
- 12:05SPEAKER_02: One of the choke points in introducing paper or replacing plastic with paper has been speed.
- 12:11SPEAKER_02: Paper would have to run more slowly on existing equipment, even with retrofits and new OEMs are coming out with new equipment that can address that.
- 12:19SPEAKER_02: But I think just in general, paper as a flexible substrate is now starting to run at speed, which is what big brand owners with high volumes need.
- 12:28SPEAKER_02: They need that throughput.
- 12:29SPEAKER_02: One example, and I think you and I have both reported on this over the past couple of years, is ProAmpac, their RP2000.
- 12:36SPEAKER_02: So that's running at 900 packs a minute on an RA Jones as a Coesia company machine with no retrofitted, no seal jaw changes, no hardware changes, just process settings only.
- 12:48SPEAKER_02: And even the cutoff is working.
- 12:50SPEAKER_02: I talked to my buddy Sal Palingra, and his framing was that they're getting fiber applications, paper-based films, almost equivalent to film-based.
- 12:59SPEAKER_02: And that includes machine ability, not just the barrier that we've been talking about for the past five or six years.
- 13:04SPEAKER_02: So that really makes that noteworthy.
- 13:06SPEAKER_02: So not only are you getting the barrier and shelf life, but it's you're getting that speed and machine ability.
- 13:11SPEAKER_02: Kohler, we when we you can't talk about paper and barrier paper without Kohler.
- 13:16SPEAKER_02: There are Next Plus Seal Pure MOB is another commercial example.
- 13:20SPEAKER_02: Anne Marie, I think you might have written about this also, but the German brand, it's either RUS or rough.
- 13:25SPEAKER_02: I don't know.
- 13:25SPEAKER_02: I'm here in the US, I don't purchase this product, but it's converted its porridge and pudding packaging off a plastic film onto a heat sealable barrier paper with a mineral oil barrier.
- 13:36SPEAKER_02: So it runs on conventional flow wrappers and vertical baggers, whether the horizontal or vertical, it's going to be running with, I guess the only real maintenance is occasional sealed jaw tooling adjustments just for the width or the caliper of the paper.
- 13:50SPEAKER_02: And it's about 90% less polymer due to that mineral oil-based barrier.
- 13:55SPEAKER_02: And they did it without having to advertise.
- 13:57SPEAKER_02: There's no marketing campaign.
- 13:59SPEAKER_02: They just switched it out.
- 14:00SPEAKER_02: And that tells you it's a supply decision, not a consumer story.
- 14:04SPEAKER_02: So another one, Michaelman and UPM and BOPS, again, we're talking about these collaborations a lot.
- 14:10SPEAKER_02: They showed pre-validated coated paper structures built around a really wide ceiling window.
- 14:15SPEAKER_02: That's in their words, for tea envelopes.
- 14:18SPEAKER_02: So I'm drinking tea right now, and we've got the little Lipton tea envelopes.
- 14:22SPEAKER_02: Also, it could be used for, let's say, sugar stick packs or oatmeal sachets.
- 14:27SPEAKER_02: SAPI's guardline covers a similar ground, including metallized grade for cold sealing.
- 14:32SPEAKER_02: And then two from Vegas that kind of will this machinery that kind of anticipated this problem.
- 14:38SPEAKER_02: One of them was IMTEX My Way that basically forms stand-up pouches from flat film or paper, roll stock, integrates a zipper, side seal if you need it.
- 14:47SPEAKER_02: And then it's a fill and top seal all in one system.
- 14:50SPEAKER_02: So our colleague Casey went to go see these folks.
- 14:53SPEAKER_02: And then Parsons Eagle duplex uh Parsons Eagle has a duplex bagger that runs at about 100 bags a minute.
- 14:59SPEAKER_02: And it takes paper bags and recycle-ready monolayer polyethylene on the same machine.
- 15:05SPEAKER_02: So, Anne Marie, not too long ago, you and I recorded an episode on sustainability.
- 15:10SPEAKER_02: There's a lot of overlap here.
- 15:11SPEAKER_02: So one that we both talked about was Copar's hyperbarrier paper.
- 15:15SPEAKER_02: And that was in Vegas.
- 15:16SPEAKER_02: I think you saw that last year, with a heat-sealable nanocomposite coating.
- 15:20SPEAKER_02: And that runs again.
- 15:21SPEAKER_02: Wait for it.
- 15:22SPEAKER_02: Standard machinery.
- 15:23SPEAKER_02: Very little or even no necessity for tweaks or anything like that.
- 15:28SPEAKER_02: So really the big picture is paper's no longer the compromise material where you have to sacrifice speed for sustainability.
- 15:36SPEAKER_02: So ask when you're in Chicago, ask with the switch to paper on whether it's a flow wrap or horizontal machine or a vertical.
- 15:42SPEAKER_02: What does that switch to paper do to your cycle rate?
- 15:45SPEAKER_02: Don't ask whether it works.
- 15:46SPEAKER_02: It should work by now.
- 15:47SPEAKER_02: Everybody's doing it.
- 15:48SPEAKER_02: But what does it do to your throughput?
- 15:51SPEAKER_01: I find that really amazing because I wrote about Nestle back in 2021.
- 15:59SPEAKER_01: They changed over their Smarties packaging from flexible film to paper for over 400 skiers.
- 16:06SPEAKER_01: And the biggest challenge for them really was ensuring that these new packs could run on their equipment at the same speed.
- 16:15SPEAKER_01: They wanted to make this change to a more sustainable material, but they couldn't afford to run slower.
- 16:22SPEAKER_01: So that was only what five years ago.
- 16:25SPEAKER_01: And already we're seeing all these new machines that take that challenge out of the out of the process or out of the consideration as to whether to switch from film to paper.
- 16:37SPEAKER_01: Although there are many other considerations, but that's pretty exciting that they brands can now make that switch and be confident that there is a machine out there that will run it.
- 16:49SPEAKER_02: Absolutely.
- 16:49SPEAKER_02: I remember that cover well.
- 16:50SPEAKER_02: And I remember that Smarty's story well.
- 16:52SPEAKER_02: And that was, yeah, that was a time when it was at the dawn or the outset of paperization.
- 16:57SPEAKER_02: Now we're full on, there's enough wind in the sails such that the entire value chain, the machinery and everything is adjusting to it.
- 17:05SPEAKER_02: And I would add, yeah, the the films themselves are adjusting to the machinery at the same time, working in a very symbiotic way there.
- 17:13SPEAKER_01: So, Matt, if someone's walking the halls in Chicago at PEC Expo International, what should they ask when they come upon a flexible materials or a machinery supplier?
- 17:25SPEAKER_02: I think the first question is how wide is the ceiling window on this material for the material itself?
- 17:31SPEAKER_02: And then what happens right at the edges?
- 17:33SPEAKER_02: Bring your film, whatever film you're planning on using, or several that you might be thinking about using, to the machine booth.
- 17:39SPEAKER_02: It's a lot easier to do that than bringing a machine to your film.
- 17:42SPEAKER_02: Be sure to do that first.
- 17:43SPEAKER_02: Bring some samples and see what the vertical form fill seal, the horizontal, the flow wrap people can do and how that substrate might work with that equipment.
- 17:52SPEAKER_02: Another one is what can this machine run?
- 17:56SPEAKER_02: It's a little more forward-looking.
- 17:57SPEAKER_02: What can this machine run that I might not even be able to anticipate?
- 18:01SPEAKER_02: So the wizards at some of these materials supplier companies, what are if they come up with something, is this machinery going to be able to pivot and be able to have enough flexibility to run films, papers, new gauges that we haven't even heard of yet?
- 18:17SPEAKER_02: And then also you have an installed base.
- 18:20SPEAKER_02: You have equipment that's either in your facility or in your partner's facility right now that is expected to last decades.
- 18:27SPEAKER_02: So you have to ask what you can retrofit?
- 18:30SPEAKER_02: So you're going to be putting in zipper applicators, seal heads, modular stations.
- 18:36SPEAKER_02: Being able to retrofit existing equipment is always cheaper than buying a whole new line.
- 18:40SPEAKER_02: It might not be as optimized, but it's less expensive and it's faster than material qualification.
- 18:46SPEAKER_02: And finally, I would say, how long does that qualification really take?
- 18:50SPEAKER_02: So the real answer is 36 months.
- 18:53SPEAKER_02: It really is going to be three years for a barrier paper to be going from a concept that might be on a booth graphic that might be able to run to actually seeing that out in the wild.
- 19:03SPEAKER_02: So the films that are they're coming out.
- 19:06SPEAKER_02: I mean, with EPR and EPWR in Europe, these films are arriving.
- 19:10SPEAKER_02: Brands are going to need to use them.
- 19:12SPEAKER_02: So whether your lines are ready or not, they're coming down the pike.
- 19:16SPEAKER_02: So Chicago, which is a famously a machinery-heavy show with all the machinery that's out there on the show floor, it's a great place to find out which side of that gap you're standing at.
- 19:26SPEAKER_02: You've got the equipment or you've got the films to be doing the catch-up.
- 19:29SPEAKER_02: And the machines that are going to be hopefully still useful when the next film that we haven't even heard of shows up.
- 19:36SPEAKER_01: Thank you so much, Matt, for walking us through all of that.
- 19:39SPEAKER_01: That's a lot of information.
- 19:41SPEAKER_01: Great advice.
- 19:44SPEAKER_02: Yeah, you're welcome.
- 19:45SPEAKER_02: This has been fun.
- 19:47SPEAKER_01: So, listeners, if you're planning your time in Chicago, flexibles equipment and materials are definitely worth putting on your list.
- 19:53SPEAKER_01: And as Matt advised, bring your film to the machine booth rather than the other way around.
- 19:59SPEAKER_01: So Pac Expo International runs October 18th through the 21st at McCormick Place.
- 20:05SPEAKER_01: And as we said, it only comes around every other year.
- 20:08SPEAKER_01: Otherwise, you'll have to go to Vegas.
- 20:10SPEAKER_01: So it's a great opportunity to see all of these things that Matt has just talked about.
- 20:16SPEAKER_01: Registration and the exhibitor directory are available at pacexpointernational.com.
- 20:22SPEAKER_01: And the directory is the fastest way to map out which boats are showing what before you get there.
- 20:28SPEAKER_01: And this is one of several Pac Expo previews we've put together.
- 20:32SPEAKER_01: If flexibles aren't your only interest, we've also covered robotics, coding and marking, and sustainability.
- 20:39SPEAKER_01: So you'll find those wherever you're listening to this podcast.
- 20:43SPEAKER_01: And you can find all of our reporting at packworld.com.
- 20:47SPEAKER_01: So that's it for this edition of Through the Line.
- 20:50SPEAKER_01: Thank you for listening, and we'll see you in Chicago.
- 20:54SPEAKER_00: Thank you for listening to Through the Line Packaging and Processing.
- 20:58SPEAKER_00: You can listen to more episodes on all streaming platforms.
- 21:02SPEAKER_00: Be sure to visit us at packworld.com, profoodworld.com, and healthcarepackaging.com for more packaging and processing news.
- 21:10SPEAKER_00: This podcast was edited by Brie Guns.