It’s the Packaging, Stupid

The revolution that’s quietly changing the face of the food industry has only a tangential relationship to the product. The real transformation lies in the packaging.
This is the firm belief of Mike Wagner, business development manager for packaging at Milwaukee, Wis.-based Rockwell Automation, Inc. “Take the low-carb craze,” Wagner exclaims. “To get consumers to buy any of the hundreds of low-carb products out there, it’s not OK just to say they’re different. The manufacturer has to make the product look different, which usually means lots of glitz and glamour.
“Plus retail shelf space is getting more and more competitive. Products are fighting for space. Package shape is becoming the key factor.”
Wagner gives the example of Procter & Gamble’s liquid soap business. With only 5% of the market, the company decided to repackage and reformulate the product. It decided to pack a highly concentrated form of its liquid soap in a square box.
This solution not only attracted the interest of retailers who could now stack it more efficiently in half the previously allocated space, but it also piqued the interest of the consumer. The result was that within two years, P&G’s share of the liquid soap market soared to 80%.
“You also have to consider that what Wal-Mart wants today, the rest of the retail industry will demand tomorrow,” Wagner points out. For example, Wal-Mart accounts for 65% of Unilever’s personal care and food product distribution and it’s growing. Yet at the same time, Wal-Mart is adopting Unilever’s packaging solutions and then placing its similarly-packed store-brand items alongside.
Moreover, one of Wal-Mart’s more astonishing logistical requirements is to demand that every incoming SKU, regardless of quantity, be separately overwrapped. The point is that in terms of market share and the economics of distribution and retailing, it’s the packaging that sets the pace of change.
“Consumers are being inundated with new types of food products, and while there may be some formulaic changes, the effects of these will be nothing compared to the impact on consumer choice of neat, sexy, glamorous packaging,” Wagner notes.
And the ironic thing is that even the most sophisticated-looking package — such as high-metallic, barrier pouches, for example — are economically priced, especially when considering that certain types of packaging, like the barrier container, can be recycled and re-sanitized.
“The issue is that when a snack food producer wants to make a hit with a grocery, it’s not the product benefit that will sway the vice president of purchasing, but the glitzy packaging that will open up that final corner slot,” Wagner declares.
To provide feeder customers with an alternative to steel, AccuRate now offers an LDPE hopper and cover for its MECHATRON feeder product line. Its advantages include: translucence; interchangeability; lighter model; domed cover – water and materials are easily shed, making it excellent for wash-down environments. The new hopper is available in a 7.5 cu. ft. capacity with manual or refill covers. 1-800-558-0184
APV Baker will showcase five moulders - the SofTouch moulder, EM390, a mid-range yet fully featured moulder, low stress SofTouch divider, 540 Wirecut, and Accurist ram and knife divider. Its benefits range from improved bread quality to lower cost, retrofitability. It’s also gravity assisted, has precise product weight control and unsurpassed accuracy. 1-616-784-3111
Booth Number: 4151
Boston Gear, a member of the Colfax Power Transmission Group, introduces the PosiVent, a unique pressure equalization system designed to keep water, washdown solutions and other airborne contaminants out of gearboxes in food processing and material handling applications. Gearbox failure associated with contaminants such as bakery dust breaking down lubricants and causing premature failure is prevented, ultimately increasing performance. In aggressive production environments, the PosiVent system replaces traditional vent plugs. Built with a single seam, the PosiVent system can be mounted in any position without fear of leakage at a facility. The PosiVent sytem is easy-to-use and fits into standard pipe plugs. 1-888-999-9860
Booth Number: 653
Burford is offering practical solutions through innovative technology with its PS-2 Pattern Splitter. Patterns and splits in baked goods are appealing and give products a mouth-watering finish. The splitter can be programmed to produce a variety of split patterns. Completely automatic, its other features include no pan delays, continuous pan flows and precise dough splitting. 1-800-654-4530
Booth Number: 2405
Chicago Metallic, a division of C.M. Products, Inc. now offers Rilon Elast Pan Coatings to its customers in North America. Rilon Elast is a durable, high-quality silicone coating with excellent non-stick properties and good heat stability. The thick, multi-layer coating will not decompose even in temperatures up to 660°F. When applied to bun and roll pans, Rilon will last for approximately 1,500 bakes under normal conditions and up to 2,000 bakes for baguette pans. 1-800-323-3966
Christy Machine Company has developed an automatic, controlled coating dispenser. Christy Extrusion Coaters apply a precisely controlled, continuous, automatic coating of dry, free-flowing powders to surfaces of extruded products as they leave the extruder die. The Christy Extrusion Coaters have, among other benefits, a range of hopper sizes and heights, infinite speed controls and an enclosed system reduces contamination. 1-888-332-6451
Booth Number: 1307
Wash belts, remove allergens, save water and labor with a patented Cyclone Belt Washer from Douglas Machines Corp. Designed for a wide variety of conveyor, freezer and oven belts, the portable Cyclone spray-head features high pressure rotating nozzles to remove stubborn stains. A portable cart allows you to move from one belt to another for quick cleanup. An optional “air blast” blower with portable air knives aids drying. 1-800-331-6870
Booth Number: 1529
EPI Exact Packaging, Inc., introduces a new system operating at speeds up to 300 per minute - ideal for applying 3-in.x 3-in. labels to boxes. The labeler is integrated directly with the packaging line, utilizing a product sensor to indicate when a label is to be dispensed. The unit is easy to operate and has few moving or wear parts. It operates by blowing a label gently onto the package as the product moves down the packaging line. 1-800-755-8344
Booth Number: 2719
Federal Industries presents new Counter Top Self-Serve Display Cases. The refrigerated, non-refrigerated and hot display cases are designed for continuous case line-up. Taking impulse sales into consideration, cases feature modern styling with easy access to products. Curved glass, adjustable shelving, removable sliding rear doors and lighted display shelves highlight products. Cases are available in lengths of 3-ft. and 4-ft. with optional accessories. 1-800-356-4206
Booth Number: 1621
Formost Packaging Machines, Inc., has developed a Transpositor Conveyor for extruded products. This conveyor transfers and repositions rows of product for wrapping which increases packaging efficiency. Positioned ahead of product turning, aligning, accumulating and flow-metering systems, the Transpositor maximizes line balance in high-speed wrapping operations. 1-425-483-9090
Booth Number: 3505
For short-term storage and responsive on-demand delivery of fragile baked products and snacks, Heat and Control’s new MinuteMan accumulation conveyor reduces drop heights to minimize product breakage. The product pack is limited to a low 20-in. to reduce breakage, yet MinuteMan still provides 90 cubic feet of storage capacity. An optional let-down chute provides only a 6-in. initial drop. Soft vulcanized belts cushion product landings. A down-sloping discharge belt further helps prevent breakage as product leaves MinuteMan. 1-800-227-5980
Booth Number: 3850
Marq Packaging Systems has designed a machine to speed up the packing process. An operator folds the trailing minor as the case is pushed onto the deck. This process folds the leading minor as well. The erected case is then assisted into the extended infeed side belts that move the case into position and hold it steady. The bottom minor flaps are folded, the bottom major flaps begin to fold and the case is in position to be packed. When the case is full, the full case moves into the sealer. All four top flaps are folded in unison with the bottom major flaps. The case is both top and bottom sealed. Easily accessible for servicing adjustments, the machine processes up to 15 cpm, based on case size and operator speed. Constructed of heavy-duty welded steel, it’s built to withstand 24/7 operation. 1-509-966-4300
Nu-Pak clean-design filling and handling systems have 100% stainless steel product-contact surfaces. The design includes USDA-compliant features critical to sanitation. Options include: high-floor clearance, dust-proof bag clamp, balance line-fitting which exhausts air from bag during filling, bag inflation – prior to filling and two-point cut-off with dribble fill. 1-952-279-5210
The T-PAK 550 is the latest model from O/K International’s T-PAK systems. This high-quality concept in bag handling and sealing technology combines a heavy-duty conveyor system, full-width compression belt, and OK Supersealer SS2 bag sealer machine. An unchallenged heat-sealing system, superior performance, and speed at low maintenance cost make it particularly suited to products like pizza and tortillas. Designed for excess air removal from bags, it offers optimum seal quality, mobility and easy access for maintenance. Ideal for use in harsh environments. 1-800-521-2908
Booth Number: 4021
The Fedco Manifold Depositor from The Peerless Group accurately deposits a variety of products into pans or directly onto a conveyor or oven band. Applications include snack cakes, jelly, marshmallow and icing for toaster pastries. Product is fed under pressure from either a continuous mixer/aerator or pump. It has a hard anodized aluminum balancing chamber and valve chamber, stainless steel balancing screws and a rotary valve which produces clean, dripless deposits. 1-800-999-3327
Booth Number: 3171
Cleveland, Ohio based Perfect Score Company, Inc., an industry leader in the manufacturing of scoring systems, product aligners, conveying systems and other specialty baking equipment, has a new way to score bread. Bread scoring or splitting not only provides an appealing and appetizing look, but it can also affect the taste of the product. The art of bread scoring goes back centuries. Automated scoring is an underrated process with many bakeries still using the manual process of cutting by hand. Today’s technology has provided the industry with cost-effective automated options, such as lower maintenance, ease of operation, and quick change scoring heads for switching product lines and scoring patterns. Automated scoring gets the “perfect score.” 1-216-883-8000
Booth Number: 4172
This latest technology from The Fred D. Pfening Co. creates a uniform temperature and humidity throughout the proof box and performs over 100 air changes per hour. 43% newly conditioned air circulates through the radiator and 57% recycled air is drawn in at the ceiling. Air is then discharged at the floor. Features include: rugged corrosion resistant aluminum structural frame, sealed panels, heavy-duty solid-core doors with latches and hinges. The Pfening Model B Digital Controller is accurate to within 1/2% for both temperature and relative humidity. 1-614-294-5361
Liquid Direct Injection (LDI) is the latest development from Schaaf’s patented turbo technology, which allows for direct expanded products with multiple colors and textures. In liquid direct injection, fluids are injected into the turbo chamber at a pressure of 60-100 bars. Depending on the configuration of the turbo tools, fluids can be mixed homogeneously or kept as distinct layers in extrusion dough. For multicolor extrudates, dough flow is separated during extruder processing into two streams. Colored fluid is then injected into one stream with a high-pressure pump. In order to avoid re-mixing, the doughs are brought together before exiting the die. Partial mixing, which gives a marbled appearance can also be achieved. For a multi-textured product, injecting fluid periodically through the dough stream can change dough composition. With a combination of dough mixing in the extruder, products with softer or harder areas or fine-pored or coarse-pored areas provide for new concepts in the field of direct-extrusion. 06434/9172-0
The Double Arm Sigma Mixer from Shaffer Manufacturing Corp., offers the perfect mix of quality, service and dependability. Durable and efficient, the mixer is designed to handle the most demanding product requirements. Ideal for wire cut cookies, cream fillings, icings, muffin batters, pie dough, granola mixtures, pretzels and sweet doughs, its other benefits include solid stainless steel #304 product zone (bowl, agitator, canopy), a stainless clad framework, double end “no spin” drive or single end drive 2 speed TEFC motor with SMC high torque design, and a NEMA 4 operator and starter panels. 1-630-257-5200
Booth Number: 3919
Sonoco has extented its line of rigid paper packaging solutions with SonoWrap single-wrap pack, a new range of rigid paperboard packaging targeted at the European market. Packaging in round and non-round formats is now being marketed. SonoWrap packs use a single laminated structure composed of paperboard and a choice of a low, medium or high hermetic barrier liner. The structure is then printed, die-cut and formed into a tapered, nestable cup shape. A paperboard bottom, membrane top and overcap complete the packaging. The packs are available in a range of heights and diameters. In addition to high-quality litho printing, embossing, hot foil stamping and UV inks can be added for a distinct seasonal and promotional package. 1-843-383-7794
The High Speed Frag Mixer from Spooner Vicars is specifically designed to mix all biscuit doughs when a particular work input is required. The efficient mixing action uses a split double helix beater, continually pulling dough in from the edges of the mixer to the center where it is forced past a static post or sprag. This kneading action, which is similar to hand kneading, has the extra benefit of low shear, which does not damage the developed particulates or cut developed gluten. A thermocouple is contained within the sprag and measures the temperature of the dough within the mixer. 1-330-342-8244
Booth Number: 3480
TNA has introduced the ROBAG 3 and announced that a stainless steel version of its V/F/F/S packaging system is now available for packing snack foods. The patented stripper/tube-closer enables the ROBAG 3 to pack a wider range of products including potato chips, pretzels, tortilla chips, peanuts and pork crackles. Features are easy reconfiguration, a unique film spindle and single-action film-threading capacity. Greater film clearance from swing-out mechanism. 1-972-462-6500
Urschel Co. manufactures more than 40 different machines for the high-speed cutting of products involving slicing, dicing, strip-cutting, shredding, granulating, and comminuting. Urschel’s new Comitrol Processor Model 3600 is a milling machine with unique particle-size reduction principle. The unit is suited for difficult bakery and snack food re-work applications where the product has a cream, fruit, or jelly-filled component. The Comitrol Processor cuts the product into precise increments using incremental shear, is simple to operate, uses minimal floor space, and performs in pilot plants and full-scale production lines.
Features include:
• Varying speeds
• Multiple cutting-head styles
• Feeding methods
• Different types of impellers
Booth Number:2215
Kess Industries introduces its newest coating equipment, a Half Icer with optional Glazer and String Icer attachments. The Half Icer coats the bottom and then flips the product, the Glazer top glazes the product and the oscillating String Icer applies strings of icing. Stainless steel construction and wash down duty components make for excellent cleanability and dependable equipment. Units are available in any glazing/icing combination or separately. Other options include air-blow off and tank level control. 1-800-578-5564
www.kessind.comSee us at IBIE Expo
The .175-in. crinkle head assembly from Urschel offers processors more waves and slightly deeper waves than the standard crinkle head assembly. Standard crinkle head assembly offers slices with 3-1/3 waves to the inch, while the .175-in. crinkle head offers 5.7 waves to the inch. The .175-in. crinkle head assembly is currently available in magnesium aluminum bronze. 1-219-464-4811
Booth Number: 2215
Intralox’s new Series 1600 Nub Top belt provides the triple benefit of easy product release, gentle transfers and easy, effective cleaning for processors conveying sticky, delicate products. Surface nubs create a “lifting” effect to prevent products from sticking to the belt and closely spaced nubs accommodate very small products. To prevent product sticking in the incline/decline applications, No-Cling flights featuring vertical ribs on both sides are available. 1-800-535-8848
Booth Number: 4363
The new UltralYte from Formers of Houston is manufactured with lightweight materials, weighing at least 50% less than conventional bag forming assemblies. It also requires less time and physical effort to load, unload and change out and is ergonomically safer to handle than bulkier assemblies. The UltralYte concept adapts to any bag forming assembly, regardless of size, shape or style. The former uses FDA-approved coating for safety and durability. 1-800-468-5224
FMC FoodTech introduces the Electronic Seasoning Applicator, offered exclusively by Allen Systems. This new design of electrostatic seasoning for powder, oil, and slurry coating is an environmentally responsible way to apply coating materials, significantly increasing the quality of the finished product while substantially decreasing powder/oil costs through more effective materials. Other advantages include an increased transfer efficiency, reduced over spray, reduced dusting or misting emissions and more. 1-800-246-2034
Booth Number: 5029
The compact in-store flour tortilla system from Casa Herrera is designed for supermarket and restaurant use and perfectly meets the requirements of in-store and in-restaurant production of tortillas. Easily operated, it works with great efficiency to form, press, bake and cool moderate quantities of flour tortillas. It can produce limited pita bread, chapattis and pizzas as well. The cooling conveyor has three stainless steel conveyor belts with extended incline discharge, a three pass baking oven with atmospheric combustion and more. Additionally, the electrical safety interlocks and disconnects and the six heaters per platen offer optimum heat distribution and lower amperage use. 1-800-624-3916
IBIE Booth # 5021
Fritsch offers the Multiline and Multicut. The basic versions of the machine are compact at 4.2 m and 6.5 m respectively. Switch cabinets are integrated into the machines and the flour strewing units are integrated into the protection hoods. Also, the cross roller and calibrating unit form a space-saving entity. Dough sheeter capacity ranges from 100 to 800 kg per hour, and due to a multitude of additional units, there is an almost unlimited abundance of product ideas. Both machines are coordinated by a start-stop connection or horizontally networked via Ethernet and electronic control. Modern touch-screen technology allow for easy handling of products. 1-708-388-7766
Booth Number: 4873
The Fred D. Pfening Company offers the Model 110A Proof Box manufactured with specifications to order, such as number of lanes wide and racks deep, rack dimensions and electrical power supply voltage. The company manufactures material handling, proofing and liquid metering systems. 1-614-294-5361
Booth Number: 4141
Hybrid ovens from Spooner Vicars have a modular design that offer radiant and convection bake in the same oven. A percentage of DGF, forced convection, cyclotherm to suit the product, give this easily controlled and flexible oven an even bake and make it a fuel-efficient machine. The number and size of zones is almost limitless. Spooner Vicars also offers oven ancillaries like prover loaders and unloaders, oven loader and unloaders, feed and delivery end terminals, band polishing units and more. 1-330-342-8244
Booth Number: 3480
Blue Print Automation introduces the Robotic Vertical Packer, with a patented high-speed collation method. The case packing system is ideal for vertical case packing of flexible bags and fragile products such as bags of chips and other snacks. The machine can reach up to 150 bags per minute, has a small footprint and simple design. 1-804-520-5400
Shick USA’s Tote Systems are used to store and transfer various liquid ingredients. The totes feed a reservoir from a pump that draws product and distributes it out to one or more use-points. When the tote is empty, the inline level switch sends a signal to a PLC or local indicator. Typical reservoir design provides at least 15 minutes of changeover time. Standard equipment includes a tote adapter, a sanitary inline switch and more, all mounted on a 304 stainless steel tote stand. Options on the machine include a 40-gal. tank for larger batch sizes, a sanitary strainer, a sanitary magnet trap, mass flow meter and tank heater. 1-816-861-7224
Booth Number: 3251
Packaging Progressions, Inc., manufactures stainless steel interleavers and a full line of modular counter stackers for the efficient and sanitary handling of tortillas, empanadas, pitas and various other portion-controlled bakery products. The PPI-200 accurately and consistently places a pre-programmed sheet of film, foil or paper under dough portions at speeds up to 1,100 dozen per lane. Single or multiple lanes of product are conveyed to PPI stackers, which automatically count and stack portions into uniform groups. The stackers can be used in conjunction with PPI interleavers or with other processing equipment and can accommodate a great variety of sizes, shapes, fresh, frozen and very delicate products. 1-610-489-8601
Introducing the patented C-Cure Edge open-mesh, stainless steel wire belting from Wire Belt Company of America, specially designed to enhance productivity and upgrade safety in the production environment. The belts have closed-looped ends, eliminating tangling and minimizing risk of accidents from sharp or burred open ends. The belts run side by side without snagging or catching. The C-Cure Edge belts are ideal for food applications like breading, enrobing, cooling and frying. 1-603-644-2500
Booth Number: 3920
The Shaffer Single Sigma Arm Mixer Model SOFD (Sanitary Open Frame Design) is manufactured with a #304 Stainless Steel Product Zone featuring an ultra sanitary stainless tubular frame. The high torque two speed TEFC motor is frame mounted with direct drive to the agitator shaft, eliminating the need for belt or chain. Standard features include hydraulic bowl tilt, pneumatic flour gate, liquid inlets in the canopy and a touch-screen operator panel with PLC interface. The mixer is ideal for mixing rotary cut doughs, wire cut doughs, corn masa, sweet doughs, muffins, fillings and granola/energy bars. 1-630-257-5200
Booth Number: 3919
Sonoco’s distinctive composite can is made of 100% recycled paperboard with a metal bottom. The can is strong yet lightweight, protecting fragile products inside from crumbling. Instead of a traditional ring-pull opening system, cans, like Leclerc Vienna Wafer Rolls, can feature Sonoco’s UltraSeal peelable membrane closure that requires minimal strength to pull away from the top of the can. The metal rim of the can is gently rounded with no sharp edges so there is no threat to fingers or hands. 1-800-5-SONOCO
The heavy-duty SuperGrain Model P3 Cross-Grain Moulder from Peerless is a precision sheeting and molding system designed to produce quality white breads, variety breads, baguettes and string products. Features include a powered infeed conveyor with adjustable pre-sheeting roller and self-centering adjustable side guides, four roller sheeting head with cast iron side frames, table top pan conveyor and self-centering pan guides, a stainless steel exterior, heavy-duty stainless steel sheeting head base and more. Options include a double eliminator, a 3-dimensional sheeting head, casters for portability a remote electrical panel and other options.1-800-999-3327
Booth Number: 3171
Belt conveyors from Meyer Machine combine proven designs with durable construction. The belt conveyors are available in a wide range of sizes and configurations to accommodate inspection, cooling, storing or transporting of products. Featuring a modular design that allows for change, these conveyors offer a wide range of options including stainless steel or mild steel construction and a choice of bed, belt, pulley or discharge options. 1-210-736-1811
Christy Machine Co. offers the Dust-Rite economical flour duster. Ideal for flour dusting on a bread production line, the Dust-Rite uses two urethane wiper blades, both with a striated finger system for the best in flour depositing. The adjustable shut-off fingers are customized to specific areas of deposit, and the sanitary design provides a continuous, controlled flow of flour. 1-888-332-6451
Booth Number: 1307
The T-PAK 550 from O/K International is a new, high-quality concept in bag handling and sealing technology. The machine is a combination of a heavy-duty conveyor system, with a full-width compression belt, and the OK Supersealer SS2 bag sealer machine. The result is a heat sealing system for many applications, including products like pizza and tortillas. Benefits of the machine include removing excess air from the bags, optimum seal quality and aesthetics, mobility and easy access for maintenance and ideal for use in food processing plants and harsh environments. 1-508-303-8286
Booth Number: 4021
TNA introduces the ROBAG 3, the latest in packing machinery. The patented stripper/tube-closer enables the machine to pack an even wider range of products with ease, including, potato chips, pretzels, tortillas, and more. It is capable of packing up to 220 bags per minute on a Rotary Double Jaw configuration. Jaws, knives and drive belts can each be changed in 60 seconds, and all digital and servo technology enables rapid product changeover and eliminates 60% of moving parts with no mechanical adjustments for operators. 1-972-462-6500
A new system for packaging premium bread fast and efficiently has been developed by Formost Packaging Machines using a Formost model GT-4 or JV-60 horizontal bread bagger at the beginning, end or both ends of the line, or at one end with an existing bagger at the other. The high-speed system reduces bottlenecks, saves cost in equipment changeovers and increases throughput. For added versatility, the sealer can be easily replaced with a closure unit for running standard pound and a half loaves, and the second bagger can be designed to package two loaves in a single outer bag for club packs. 1-425-483-9090
Booth Number: 3505
APV Baker offers its Accurist 9000 divider. This knife and ram divider offer superb accuracy. The divider is portable and can be moved away from its base docking station, making cleaning easier and faster than ever. Performance features include Silverstone coating on the tilting stainless dough hopper, polymer wear surfaces, variable frequency drive, safety disengagement clutch, adjustable ram pressure and self-oiling. These features enable the machine to deliver sustained scaling accuracy and reduce long-term ownership costs to a minimum. 1-616-784-3111
Booth Number: 4151
Split-top bread and rolls are easily produced using the Burford Water Splitter and Butter Applicator. Following an accurately applied stream of low-pressure water which splits the proofed product, a stream of melted butter is applied into the split, producing an attractive product with special appeal. Features of the machine include stainless steel construction, removable covers, a tank with both heating and cooling capabilities allowing a paste form of butter to be applied, dual pneumatic pumps for constant flow, and more. 1-800-654-4530
Booth Number: 2405
Christy Machine’s salt and fine granular material dispensing machines provide precise control. Applications include sodium-content mixtures and other free-flowing materials, which are controlled with accuracy almost to the granule. Precision and continuous dispensing occur for materials ranging from superfine to coarse, including ranges of salt, flour salt, fine granular toppings and non-food granules. The c-frame mount on casters allows easy movability, and brackets, rails and pivots can be furnished for attachment to horizontal or vertical surfaces. 1-888-332-6451
Booth Number: 1307
The Peters Double & Split Deposits from Peerless features speeds up to 800 sandwiches per lane and most basic shapes can be used to produce double and split deposit sandwiches like rounds, squares, rectangles and specialty shapes. The technology also allows a standard run of 40 mm to 70 mm as well as smaller and larger base cakes. A wide variety of fillings can be used, such as creams and peanut butter. Cheese and jam and sandwiches can be discharged or stacked flat in rows or counted groups. 1-800-999-3327
Booth Number: 3171