Brand owners & design

Korozo and Zertus develop Baileys stand-up pouches

Akanksha Meena — Tue, 17 Dec 2024 12:02:38 +0000

International flexible packaging specialist Korozo Group has partnered with Zertus UK and Ireland for the introduction of an award-winning snack range that has helped Baileys with its transition from an after-dinner tipple to an anytime adult treat.

Baileys Chocolate Nut Mix is a new range developed to continue to take the renowned Irish cream liqueur into new product categories, such as the adult snack market. The product itself combines chocolate-coated almonds, a mix of caramelized almonds, cashews, hazelnuts and peanuts with a hint of Baileys flavor and salted toffee popcorn.

To get this product onto retail shelves and into the hands of consumers, Zertus UK and Ireland collaborated with Korozo Group for the development of new stand-up pouches. Printed in eight colors using the flexographic process, in addition to the application of a partial surface matte lacquer, Korozo’s proprietary KoroRCY film was laminated to a PE layer with EVOH component to achieve the required barrier properties that ensure product integrity without compromising the recyclability of the stand-up pouch. Laser scribing was used to create an easy-tear opening and a zipper is integrated for the resealing of opened packs.

Irem Altinay, field sales manager, food flexibles for the UK and Ireland at Korozo Group, said: ‘For this important product launch, packaging was required that was highly functional but also striking on the shelf. Our advanced flexographic printing technology was used to create the strong visual appeal needed to ensure on-shelf success, with a sophisticated look and feel that mimics the luxurious and indulgent nature of the product.

‘Our expertise in developing sustainable packaging solutions meant we were able to provide a pack that was recyclable and resealable, supporting the brand’s sustainability goals while keeping the product in tip-top condition through the supply chain.’

Success has also been achieved at the recent The Grocer New Product & Packaging Awards, where Baileys Chocolate Nut Mix was crowned Champion in the ‘Crisps, Nuts & Bagged Snacks’ category.

Louise O'Reilly, product development manager at Zertus UK and Ireland, said: ‘Adult snacks and the festive nut mix category are competitive spaces with crowded retail shelves. Winning The Grocer award is evidence of the product’s successful entry into the market.

‘This is complemented by packaging that is effortlessly functional and visually appealing. With consumers preferring convenience and quality while at the same time seeking out sustainable options and products, Korozo Group was the perfect partner to provide the flexible packaging solution for this product.’

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4 days 13 hours ago

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Korozo and Zertus develop Baileys stand-up pouches

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The brand's pouches are printed in eight colors using the flexographic process.

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The brand's pouches are printed in eight colors using the flexographic process.

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Sappi and Jungdruck develop multi-layer beverage label

Piotr Wnuk — Thu, 05 Dec 2024 20:22:25 +0000

Sustainable materials manufacturer Sappi has partnered with German converter Jungdruck to develop innovative multi-layer wet-glue labels for beverage bottles offering a new range of options in terms of product information and marketing.

Multi-layer wet-glue labels are part of the Jungdruck printing company's core business, but they have so far been used mainly in the chemical and feed industries. At BrauBeviale 2024, Sappi and Jungdruck presented a jointly developed multi-layer label for beverage bottles for the first time, which was demonstrated using beer bottles.

The first layer of the label can be folded up. The second layer contains more information, in this case, a recipe for beer barbecue sauce. The new multi-layer label offers beverage manufacturers a range of options in terms of product information and marketing. For this innovation, Jungdruck used the Parade Label WS Gloss label paper from Sappi, a leading manufacturer of packaging and specialty papers.

As a full-service print shop, Jungdruck combines all production levels – from prepress to printing and finishing – under one roof and offers its customers a diverse and high-quality portfolio. However, the company, which is based in the city of Radevormwald in North Rhine-Westphalia, has been specializing in multi-layer labels for the wet-glue sector for about ten years. These are mainly used in the chemical and feed industry, for example on spray paints, aerosol packs or animal feed cans.

Gernot Jung, managing director and sales manager of Jungdruck, said: ‘Legal labeling is mandatory for chemical products. In addition, sales benefit from information published in several languages. For such cases, we can provide our customers with labels that contain up to five layers. In the pet food sector, multi-layer labels are more likely to be used for promotional campaigns, for example to publish a competition or a QR code with further information for animal lovers. The additional space offers a wide range of possibilities for marketing.’

Jungdruck has long used Sappi papers for its labels and has always had excellent experiences with them.

‘Depending on the industry, we use both the wet-strength Parade Label WS and the non-wet-resistant Parade Label Pro from Sappi. You could say that these flagship papers are our standard papers, which we also recommend to new customers again and again.’ Added Jung. ‘In addition, however, we attach great importance to other aspects. High quality and good processability are relevant points for the paper. However, the decisive factor is that the material can be guaranteed by the provider. At Sappi, we know that we can rely one hundred per cent on our ability to deliver and reliability. This is extremely important for our customers. When they are producing, the required material, such as the labels, must be available at exactly the time planned.’

For the premiere of the joint project, BrauBeviale stood out as the leading industry meeting place for the beverage industry. The multi-layer label can be used on all returnable bottles but was presented by Sappi and Jungdruck at the trade fair as an example on a beer bottle. The first page of the multi-layer label is in dark green, yellow, turquoise and white, and shows a graphic representation of a hop plant.

Stefan Raabe, sales manager at Sappi, added: ‘The design as well as the recipe are exemplary applications. The additional space opens up a wide range of opportunities for breweries and beverage manufacturers for creative advertising campaigns and targeted customer loyalty measures. They also benefit from the surprise effect at the POS, because multi-layer labels on beverage bottles have never existed in this form before.’

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2 weeks 2 days ago

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Sappi and Jungdruck develop multi-layer beverage label

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Parade Label WS Gloss from Sappi creates a basis for a new type of multi-layer label for beverage bottles.

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Parade Label WS Gloss from Sappi creates a basis for a new type of multi-layer label for beverage bottles.

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GS1 UK and GS1 US partner with io.tt

Piotr Wnuk — Tue, 03 Dec 2024 22:55:23 +0000

GS1 UK and GS1 US have named io.tt, an enterprise connected products platform, as their official partner to scale the wider benefits of QR codes for brands in support of the global transition from linear barcodes to 2D QR codes.

The collaboration will see GS1 UK, GS1 US and io.tt working together with brand owners, retailers and the wider supply chain to make the transition to accepting QR codes powered by GS1 at the point-of-sale (POS) - referred to as Sunrise 2027. (Read more in the latest issue of L&L magazine).

io.tt believes that by working in partnership with GS1 UK and GS1 US, brands can use the switch to tell dynamic brand stories and open a new media channel that they own themselves - one that can engage consumers with unique experiences, collect first-party data through consumer interaction, and ensure regulatory compliance across a brand owner’s portfolio. To ensure this future reality for its clients, io.tt has also verified its capabilities as a GS1 UK and GS1 US-compliant platform.

Globally, GS1 aims to ensure a comprehensive rollout by 2027. To prepare, retailers need to ensure their POS systems are equipped with scanners capable of reading both traditional barcodes and QR codes powered by GS1. The shift has already begun, with the new technology being tested in 48 countries across the world, representing 88 percent of the world’s GDP. The changes mean, in practice, that a QR barcode can convey information to the retailer and the consumer.

Brand owners and retailers, including Barilla, L’Oreal, Nestle, P&G, Yili, Alibaba and Lidl, signed up to support the switch earlier this year, recognizing the multiple benefits for both supply chain and consumers that can be achieved through the switch.

The transition promises to aid regulatory compliance, transparency and sustainability, as well as enhance consumer engagement and deliver wider business solutions through connected experiences.

Applications can cover many areas, helping solve business challenges such as increasing loyalty and engagement, reducing consumer first-party data collection costs and ensuring compliance across portfolios with regulations such as the EU’s ESPR.

io.tt already works with brands including Walgreens Boots Alliance, Estée Lauder Companies and PepsiCo supporting connected experiences such as driving Digital Product Passport (DPP) compliance, using NFC tags to authenticate products, and creating product support experiences to drive usage.

‘We’ve intentionally been a little late to the party, observing very closely from the sidelines while we got our clients (some of the world’s biggest brand owners) actually ready to scale across their businesses to meaningfully embrace these exciting new changes to the mighty QR Code,’ said Cameron Worth, CEO and founder of io.tt. ‘Our io.tt platform generates billions of QR Codes for brand packaging annually, and we expect to reach 1 trillion IDs under management in 2025. This means we take this partnership very seriously as we believe wholeheartedly in the potential opportunities QR codes powered by GS1 will drive going forward.’

Anne Godfrey, CEO of GS1 UK, said: "The global transition to 2D QR codes powered by GS1 represents a once-in-a-generation opportunity to revolutionize how businesses operate, connect with consumers, and meet the constantly evolving demands of a digital-first world.

‘This partnership with io.tt is a significant step forward in helping brands leverage the power of GS1 standards to deliver richer product information, ensure compliance, and create more meaningful consumer experiences. At GS1 UK, we are committed to supporting businesses in preparing for this transformation, ensuring they not only meet the challenges of today but thrive in a more transparent, sustainable, and connected future.’

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2 weeks 4 days ago

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GS1 UK and GS1 US partner with io.tt

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Partnership to help scale QR codes across the world’s biggest brand owners and help transition from linear barcodes.

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Partnership to help scale QR codes across the world’s biggest brand owners and help transition from linear barcodes.

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Esko publishes 2025 Packaging Trends study

Piotr Wnuk — Tue, 26 Nov 2024 02:53:42 +0000

Esko has published its new Packaging Trends study, which examines significant packaging trends that will shape the industry in the coming year, including sustainability, cybersecurity and the integration of AI.

The annual report, which will form the basis of the latest Packaging Trends Talk early in 2025, includes insights gathered from nearly 500 experts worldwide and across the industry. It details thoughts and opinions on expected packaging trends, challenges and opportunities for reflection.

‘In Packaging Trends 2025, we explore how the most successful packaging companies will be those that recognize it is no longer an option simply to be a part of the modern packaging market – but instead are fully prepared to thrive within it,’ said Matthew Haws, chief marketing officer at Esko. ‘Through our interviews and research, we have been able to determine the continued consumer demand for packaging sustainability, the ongoing adoption of enhanced cybersecurity protocols, and further integration of the latest iterations of AI, automation, and digitalization in day-to-day packaging operations as being among the key factors most likely to affect those comprising the packaging supply chain in 2025.

‘Shaped by new technology, shifting consumer preferences, and a growing focus on sustainability, the packaging industry is always changing. It is incumbent on packaging professionals to seize all opportunities to boost sustainability, to leverage the latest technological advancements, to refine supply chain processes and ultimately to improve their operational efficiency. Through this new report and our latest online event, we offer an in-depth look at the key packaging trends that are set to have the largest impact on the market in the year ahead.’

From examining the driving forces behind sustainable packaging and navigating the regulatory landscape to a close look at the integration of AI in packaging processes and overcoming challenges in the implementation of automation, the 2025 Packaging Trends report explores how the sector must adopt more streamlined, robust, and sustainable methodologies to overcome the numerous obstacles faced both now and in the future.

‘Each year, the Esko Packaging Trends ebook delivers practical solutions that assist brands and suppliers as they adapt to changing market conditions, trends and challenges,” said Haws. ‘With a clear focus on meeting the growing demand for sustainability, strengthening cybersecurity measures, and adopting the latest innovations, we’re excited that 2025 is filled with limitless potential just waiting to be realized.’

The 2025 Packaging Trends ebook is now available on the Esko website. The latest Packaging Trends Talk from Esko will take place in early 2025, with details to be announced soon.

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3 weeks 4 days ago

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Esko publishes 2025 Packaging Trends study

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The new ebook and Trends Talk webinar examine 2025 packaging trends, challenges and opportunities.

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The new ebook and Trends Talk webinar examine 2025 packaging trends, challenges and opportunities.

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RRD releases 2024 Packaging & Labels Insight Report

Piotr Wnuk — Wed, 20 Nov 2024 01:52:51 +0000

RRD's 2024 Packaging and Labels Insight Report has highlighted that most companies facing inflation-related pressures prioritize packaging, label functionality and product safety. They are also investing in sustainability initiatives and expanding their e-commerce operations to meet customer demand better.

The company’s third-annual survey of 300 packaging and label decision-makers shows that, with increased in-store and online competition, inflation, and rising material costs, many are paying specific attention to the core fundamentals of production protection and material composition.

‘As consumers demand higher accountability from the brands they choose to support, building functional design and safety features into packaging remains essential to ensuring product integrity and a great user experience,’ said Lisa Pruett, president of the RRD packaging and labels segment. ‘Meeting this increasing demand will require a balance between three competing priorities: protection, convenience, and brand appeal. Brands that strike this balance with their packaging will have an opportunity to deliver a product experience customers can trust, boosting loyalty and reducing damage concerns.’

As e-commerce demand increases, functionality and product safety remain top priorities, and brands are willing to invest in the right materials. RRD’s latest report shows three quarters (75 percent) of packaging and over half (60 percent) of label respondents expect to make functional design-related changes (strength, size, opening) in the next two years, while 73 percent and 70 percent, respectively, plan to make material composition changes. Additionally, most packaging (86 percent) and label (79 percent) respondents agree that inflation and rising costs of raw materials have caused changes in how their organization sources packaging and labels over the past year.

When asked to assess factors motivating their expected packaging changes, respondents rated consumer or end-user appeal (48 percent), efficiencies in storage/distribution (47 percent), and increased product protection (46 percent) as the top three major priorities. Top motivations for label respondents include pressure to lower costs (45 percent), meeting new regulations (41 percent), and new products or product changes (40 percent).

Along with a focus on materials, companies continue to prioritize, track, and make adjustments that impact overall company sustainability performance. With a heightened emphasis on brand sustainability performance and increasing customer demand for eco-friendly products, companies strive to meet internal and external stakeholder expectations. Fifty-seven percent of packaging respondents indicate they are taking sustainable and eco-friendly aesthetic direction over the next two years to appeal to buyers.

Most packaging (83 percent) and label (80 percent) respondents say their companies have moved closer to their sustainability goals, with 81 and 79 percent, respectively, indicating their packaging and label operations specifically have moved them closer to their sustainability goals. For packaging respondents, the reduction of material waste (69 percent) remains a top sustainability consideration when making packaging design decisions, followed by material recyclability (68 percent) and material removal/light-weighting (54 percent).

Following a year of tremendous e-commerce growth shown in RRD’s 2023 report, most packaging (78 percent) and label (79 percent) respondents reported a rise in their e-commerce business over the past year. From customer preferences for convenience to brand agility and cost-saving considerations, e-commerce continues to evolve, and companies are investing in ways to attract customer attention online.

Of those trying to meet growing demand, over half (55 percent) of respondents have designed packaging specifically for e-commerce, up 18 percent from RRD’s 2023 report. Of those who have seen an increase in e-commerce activity, product protection and customer satisfaction were top considerations for companies. When asked how companies are ensuring products are packaged safely and arrive without issue, packaging (64 percent) and label (67 percent) respondents say they are using specialized materials for added protection, and 58 and 66 percent, respectively, are focusing on end-user feedback and reviews to impact packaging decisions.

Read the full report at www.rrd.com/packaging-labels-report-2024.

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1 month ago

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RRD releases 2024 Packaging & Labels Insight Report

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Packaging and label decision-makers consider new appeals and materials as e-commerce grows.

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Packaging and label decision-makers consider new appeals and materials as e-commerce grows.

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Vicentini packages tea bags in Futamura's NatureFlex films

Selah Zighelboim — Tue, 19 Nov 2024 16:22:25 +0000

Vicentini 1920 SRL, an Italian family-run company established at the beginning of the 20th century, initially supplied confectioneries in Europe. Four generations of the Vicentini family later, the company produces a range of teas and infusions.

Vicentini's Regina Di Fiori brand offers a line of herbal teas in practical and elegant consumer packaging. The individual tea bags are wrapped to ensure that their aroma is protected and to avoid the product being handled by multiple individuals, which is particularly valuable in hotel or conference settings.

Vicentini uses Futamura's NatureFlex compostable film to maintain tea quality throughout the supply chain. The wrap preserves the aromas and flavors of each individual tea bag. This is particularly important in mixed flavor boxes, as cross-contamination must be avoided, and each aroma must be protected until it reaches the consumer. In addition to being convenient, these individual wrappers can be composted along with teabags.

NatureFlex films are produced from renewable wood pulp, harvested from responsibly managed plantations. The films meet relevant standards for industrial composting, including EU (EN13432) and US (ASTM D6400). They are also certified for home composting according to the OK Compost Home protocol or by Din Certco / ABA for the French or Australian home composting standards.

Vincentini’s tea products include a cardboard tag linked to the filter, which can be composted alongside the film to offer a complete pack.

Marco Vicentini, CEO of Vicentini 1920 SRL, said: ‘NatureFlex delivers all of the technical properties that our packaging requires in order to protect the flavors and aromas. In addition, the film runs well on our packaging machine. To fulfill both of these key elements but also be compostable, both at home and industrially, NatureFlex provides the complete packaging solution for us.'

Giorgio Berton, Italian Sales Manager at Futamura UK, added: ‘I am thrilled by the success of Vicentini and their brand Regina di Fiori. They’ve achieved a beautiful piece of packaging, which is both aesthetically pleasing as well as technically brilliant. I look forward to continuing to work alongside Vicentini.’

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1 month ago

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Vicentini packages tea bags in Futamura's NatureFlex films

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The NatureFlex films are compostable and maintain tea quality throughout the supply chain.

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The NatureFlex films are compostable and maintain tea quality throughout the supply chain.

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Ocado to use Polytag QR code technology

Piotr Wnuk — Tue, 12 Nov 2024 22:33:23 +0000

Polytag, one of the leading technology businesses specializing in sustainability initiatives, has bolstered its partnership with Ocado Retail, one of the biggest online supermarket chains in the UK, which has expanded the use of Polytag QR technology to more than 60 product ranges.

Over 60 of Ocado’s food, drink and household product ranges now feature Polytag’s Digital Link QR codes, empowering consumers to delve deeper into product information and sustainability practices with a simple scan.

The expanded range of Polytag-enabled packaging follows the success of the project Polytag ran with Ocado Retail in 2023 to deliver a nationwide digital deposit return scheme (DDRS) trial. Over eight weeks, 20,000 20-pence rewards were given to consumers who had purchased and recycled Ocado's milk bottles via standard kerbside collection methods. Post-trial surveys revealed that 93 percent of the pilot users felt ‘positively’ towards the idea of a DDRS in the UK.

The initiative will now see the UK’s online grocer package dry food and cleaning products in refillable containers to reduce single-use plastic and encourage reuse behaviors. Polytag’s QR codes will be used to educate customers on how to take part in the refill scheme and return their products.

Polytag's QR codes provide brands and retailers with a national direct-to-consumer marketing channel. Once customers scan the codes with their smartphones, they are taken to a landing page with bespoke and specific information on the product.

Ocado Retail uses the regularly updated bespoke landing pages to dynamically engage with and educate its customers on key sustainability topics such as sourcing initiatives, recycling and food waste prevention. The landing page technology also supports links, videos and surveys.

Laura Fernandez, senior packaging and sustainability manager at Ocado Retail, said: ‘We are proud to be the first major supermarket to pilot an online reusable packaging scheme. Polytag’s QR codes give us the opportunity to explain how re-using can eliminate single-use packaging and how easy and convenient the Ocado solution is, right to their doors. We continue to expand the number of Ocado Own Range products featuring Polytag QR codes, reflecting our growing focus on digital solutions to communicate key information and messaging to our customers.’

Alice Rackley, CEO of Polytag, added: ‘Surpassing 60 products with Ocado Retail - including its new refillable options - is a step forward in making sustainable shopping more accessible. By integrating our Digital Link QR codes, powered by GS1, we’re providing new ways to quantify the success of sustainability programs and enabling the reuse process all through accurate tracing of packaging through the supply chain.

‘Our world-first trial in 2023 was just the beginning of all of this. As the largest deployer of GS1-powered QR codes in the UK grocery market, Ocado has found our platform easy to integrate, enhancing its packaging design with endless digital possibilities. We’re beyond proud to support Ocado Retail in delivering both convenience and an impactful sustainability message.’

Anne Godfrey, CEO of GS1, commented: ‘Improving the way we recycle is not merely a regulatory requirement; it is a vital component of our shared responsibility to protect the planet. By adopting GS1 standards and QR codes powered by GS1, businesses can lead the charge in transforming recycling into an efficient, user-friendly process that aligns with consumer needs.

‘Our collaboration with Polytag illustrates how innovative thinking and powerful partnerships can lead to actionable solutions in the ongoing challenge of packaging waste. As we look ahead, the insights gained from this pilot will be instrumental in shaping the future of recycling, driving us closer to a more circular economy where sustainability is integral to consumer choices.’

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1 month 1 week ago

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Ocado to use Polytag QR code technology

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QR codes will educate customers on participating in the refill scheme and returning their products.

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QR codes will educate customers on participating in the refill scheme and returning their products.

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Perfecting the label with Rock Paper Rum

Akanksha Meena — Fri, 08 Nov 2024 09:19:50 +0000

Brand owners & design 11 November 2024

Perfecting the label with Rock Paper Rum

Mumbai, India-based spirit brand Rock Paper Rum brings innovation to the rum industry through its flavors and distinctive packaging.

Rock Paper Rum was founded by Lalit Kalani in October 2022 after three years of planning. Originally from Mumbai, Kalani moved to the US for higher education and spent 18 years there. In 2011, he launched Bandar Foods in the US, specializing in Indian-inspired snacks and sauces. He returned to India in 2020 and was so inspired by the country's booming liquor industry that he decided to start a liquor brand. With over five decades of family experience in the liquor business, Kalani was well-prepared to make his mark in the industry.

The brand’s triple-distilled rum is handcrafted in small batches, delivering spiced notes with a playful, punchy character. Made from sugarcane, a staple of India, Rock Paper Rum blends tradition with innovation and whlile offering a quality product. The bottles for the brand are outsourced.

‘The challenge was to stand out in a market flooded with standard bottle designs. We opted for a distinctive bottle shape, investing in its design to ensure uniqueness from day one,’ Kalani says.

Our current label incorporates small elements like the hand symbols for Rock Paper Rum written in Hindi. This small detail helps convey the handcrafted nature of our product while maintaining a premium look at an affordable price point

The brand’s labels were designed by First Base packaging design agency based in Gurgaon, India run by a designer who had worked with large brands.

‘We had bottle shapes ready, but there's a long story behind the labels,’ Kalani begins.

He was about to launch the brand in early 2022 with the first version of packaging and labels, but ‘something did not feel right’.

‘We then delayed its entire launch by almost nine months because we didn't feel that everything had come together,’ he states.

He started by sharing the values of his brand with the designers at First Base.

‘Rock Paper Rum blends Indian cultural elements with a bold, risk-taking spirit inspired by the game Rock Paper Scissors. Our flagship product, Indian Spiced Rum, captures this spirit of adventure. Balancing traditional Indian heritage with a modern twist was essential in shaping our brand concept.’

The labels were much simpler in design. They did not represent the brand story Kalani wanted to convey. ‘Our current label does this effectively, incorporating small elements like the hand symbols for Rock Paper Rum written in Hindi. This small detail helps convey the handcrafted nature of our product while maintaining a premium look at an affordable price point. Previously, we felt we were doing an injustice to the brand story by not having that reflected on the label,’ he explains.

Rock Paper Rum’s labels were designed by First Base packaging design agency.

The biggest challenge stemmed from the product's price point. The brand had to ensure that production and label costs were aligned with this pricing. The product is neither high-end nor inexpensive, so finding the right balance was crucial. ‘How do you create something without all the bells and whistles, yet still make it look and feel premium? Achieving this balance while keeping costs in mind was our major challenge,’ Kalani highlights.

The quality of the product is crucial, but the first impression is based on its appearance. Making the product stand out visually was essential, especially in the rum category, which has seen little innovation, Kalani says. Although a large category, this lack of innovation presented an opportunity to introduce something different for Rock Paper Rum.

‘When we launched, there were not many brands that looked appealing, giving us a chance to stand out from legacy and older brands. This approach resonated well with our target segment, particularly millennials, who appreciate unique and cool designs,’ he adds.

Creating the perfect label

The packaging agency connected the brand with a couple of converters and the brand also reached out to production partners. Initially, the brand worked with a converter in Mumbai and has since worked with a few more.

The brand led the decision-making discussions, including pricing, but the design agency was also involved in ensuring accurate color matching between the digital designs and the physical product. This seemingly simple task required careful comparison of Pantone swatches, which all looked very similar to the untrained eye. The initial process involved going back and forth. Fortunately, the production house was only 15 minutes from where Kalani was staying in Mumbai, allowing for frequent in-person visits to oversee the printing process.

The white rum label was designed in a way that allowed for future variations to use the same template, with only the color combinations changing

During these visits, he ensured the colors matched and made adjustments, such as increasing the whiteness of the font when it appeared too fine and not white enough.

‘Our emblem seal, and the word “handcrafted” and Rock Paper Rum in Hindi features fine gold foiling, including a rope design on the border of the label that says "small batch." While the design looked great on the computer, translating it into production posed challenges. We had to sit down, produce a few samples, and make adjustments during the initial attempts.’ Kalani explains.

Rock Paper Rum’s labels include intricate gold foiling details that add a premium touch to its products

‘During the initial attempts, there was a push and pull between the agency, which wanted the design to match exactly as it was on paper, and the label converter, which faced challenges in translating it. I had to ensure everything progressed smoothly despite these differences. These technicalities, which might seem simple at first, truly make a difference in the final outcome.’

When choosing the right print partner, the brand had specific criteria in mind due to the competition in the industry.

‘Initially, we chose one for its convenience and proximity, knowing it would require hands-on supervision. Being close allowed me to oversee the process, which involved several visits. Once the first run was successful, replication became easier. After that, cost, quality and market reputation became our primary considerations. Now, we have developed relationships with a couple of vendors, focusing on quality and turnaround times,’ Kalani says.

Finding the right balance

As a startup brand, Rock Paper Rum cannot hold too much label inventory, but it also can't hold too little.

‘Initially, we produced short runs because we were not sure how things would go. Now, we do slightly longer runs. While we are not a large company, we are no longer doing the short runs like we did initially,’ the founder says.

The brand uses both flexo and digital printing, depending on its products. Some of its products have surpassed a certain volume threshold and their labels runs have moved to flexo printing. New, experimental flavors, which require shorter runs, are still printed digitally.

Sustainability

Sustainability is crucial for Kalani and his background reflects that passion.

Four years before starting Rock Paper Rum, he worked for a sustainable packaging company based in the US, leading sales for Europe and Asia, which brought him back to India.

‘I have been deeply involved in the sustainable packaging space, producing compostable packaging products made from agro-waste. Currently, I serve as an advisor and investor in an Indian sustainability startup that produces sustainable and compostable packaging products from agro-waste, such as bags. Sustainability remains a core focus for me,’ Kalani adds.

While it is not our primary selling point right now, it will be an important focus as our brand grows. We are considering various sustainable options, such as compostable inks and paper

In the alcohol industry, where the brand is just starting out, sustainability will become more prominent over time.

‘While it is not our primary selling point right now, it will be an important focus as our brand grows. We are considering various sustainable options, such as compostable inks and paper. If the paper is not plastic-coated, it can be compostable. We are exploring eco-friendly and compostable inks, although we have not delved deeply into this yet. In our sustainable packaging business, we are also looking at compostable and food-grade inks. The knowledge we gain from this will hopefully be applied to Rock Paper Rum in the future,’ Kalani explains.

The brand uses both flexo and digital printing for its labels

Planning and designing for future success

Sharing insights from his experience, Kalani says that when working with an agency or designer, being clear about a brand’s needs and beliefs upfront can save time and prevent unnecessary changes.

‘Gather as much information as possible, such as the size of the bottle, the size of the panel, and all mandatory requirements, from the start. Making changes later increases the time and cost. It is also crucial to communicate any budget restrictions for packaging so the designer or agency can create something that fits within those limits,’ he says.
Considering both future and current needs in mind helps create a design process that is efficient and is adaptable with time.

For instance, when Rock Paper Rum started, it launched spiced and a white rum variants, with the goal of adding more variants after two years, assuming the initial test was successful. By informing the designer of long-term plans, the brand made the spiced rum its flagship premium product.

‘The white rum label was designed in a way that allowed for future variations to use the same template, with only the color combinations changing. This template approach meant we did not have to redesign from scratch for each new variant. By providing a vision for the future, we streamlined the process and avoided repeatedly going back to the drawing board,’ Kalani concludes.

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Akanksha Meena

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Ravenwood linerless technology used in new Zespri kiwi packaging

Selah Zighelboim — Mon, 28 Oct 2024 16:27:07 +0000

Global kiwi supplier Zespri has collaborated with Tesco for its new kiwi packaging design. Ravenwood Packaging’s linerless technology was used to create the packaging, which was given the green light for driving consumer engagement and boosting sales. A marketing campaign was launched this past summer.

The primary focus of the campaign was to transition away from plastic flow wrap, for a packaging overhaul that would meet the criteria for the marketing campaign. 

Zespri and Tesco collaborated to introduce a more practical and attractive design that would be both sustainable and fully recyclable. The packaging redesign needed to be fresh and vibrant.

A linerless fruit lid and carton board tray were approved for use in individual kiwi packs. When combined, the fruit lid and tray create a fully integrated package, which UK linerless printer ProPrint Group refers to as ‘ProProduce.’ This food-grade packaging eliminates the need for the plastic flow wrap that was previously used for the kiwis.

For the first time, Tesco is showcasing a branded kiwi product in store, moving away from traditional private label branding.

Smurfit Westrock supplied the carton board tray for the fruit lid and carton board tray packs, while Smurfit Kappa supplied the wholesale box. Ravenwood Packaging supplied the linerless label technology. ProPrint Group, the linerless label printer, supplied the tray and label graphic design.

The design and branding of the label and carton board tray was applied to both the linerless fruit lid and carton board tray.

The graphic design features shades of orange and yellow, capturing the taste of the fruit.

Specialty tooling is used to die cut sections of the fruit lid to resemble ‘sun rays’ that feature in Zespri’s logo.

This tooling is necessary for die-cutting and removing waste at high speeds, making the product commercially viable for larger volume runs.

Instead of using backing paper on the reel, linerless labels stick to themselves with corresponding strips of adhesive and silicone applied to the label's underside and surface. This design minimizes material usage and waste. By removing the liner, which is typically sent to landfill, linerless labels lower CO2 emissions, offering a more sustainable and recyclable alternative.

A Ravenwood Nobac 5000L linerless applicator was used to apply the linerless fruit lids to the carton board trays. With a speed capacity of 70 packs per minute, the applicator helps meet order fulfillment lead times.

In addition to sleeving fixed-weight, the Nobac 5000L can link to weigh-scales from a range of manufacturers for variable-weight products, as well as check weighing.

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Ravenwood linerless technology used in new Zespri kiwi packaging

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New kiwi packaging made from a linerless fruit lid and carton board tray eliminates the need for the plastic flow wrap that was previously used

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New kiwi packaging made from a linerless fruit lid and carton board tray eliminates the need for the plastic flow wrap that was previously used

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Brewing a greener cup

Akanksha Meena — Mon, 07 Oct 2024 05:23:27 +0000

Brand owners & design 28 October 2024

Brewing a greener cup

The coffee industry is leading the charge in sustainable packaging within the CPG sector, with the market demanding innovative materials.

The coffee industry is leading the charge in sustainable packaging within the CPG sector, with the market demanding innovative materials that not only stand out on the shelf but also preserve coffee’s freshness and flavor.

Starting the day with freshly brewed coffee is a cherished ritual for many. Globally a beloved household staple, the coffee market is set to grow from USD 132.13 billion in 2024 to USD 166.39 billion by 2029, with a CAGR of 4.72 percent, according to Mordor Intelligence. New coffee brands are emerging to capture a share of this market.

Steve Halford, product development technologist at Parkside, a global flexible packaging producer, says: ‘Roast and ground products and beans are benefiting from the continuing “Starbucks effect” – the move towards consumption of coffee shop-style coffees in the home. This has remained strong even after the Covid lockdowns were over, with further growth seen in start-up, independent and regional roasters each carving their niche.’

Besides creating a unique product, brands must address sustainability in packaging to appeal to environmentally-conscious consumers.

The desire for sustainability in coffee extends from longstanding, established mainstream brands to smaller, often premium brands – including start-ups.

What these brands all have in common is the desire for their packaging to be a crucial part of their sustainability goals.

In particular, Halford adds that smaller brands have been leading the way in sustainable packaging for several years, with more prominent brands generally playing catch up and some household name brands making relatively recent moves.

Across categories, roast and ground coffee bean brands were the first to make the switch to sustainable packaging, while the larger volume instant coffee sector was slower to move.

For many coffee brands, the move toward sustainable packaging is two-fold these brands can replace their traditional weighty glass jars with refill pouches and pouches are the clear transport winner over rigid packaging. The lightweight packs offer significant efficiencies throughout the supply chain, as the flexible pouches mean more packs can be shipped in each container, and their lighter weight significantly reduces supply chain transport emissions.

‘Key brands such as Kenco, Nescafe, and L’Or all now have pouches available in the hot beverage aisle at supermarkets.’ Halford notes. However, flexible packaging, with its multiple layers, is not recyclable, and those multiple layers are crucial for keeping coffee fresh.

Parkside has developed a range of sustainable fl exible packaging for the coff ee market including monopolymer and compostable packaging.

Barrier for freshness

Coffee brands must carefully select their sustainable packaging that can preserve the rich, delicious flavor of coffee, or they risk losing their loyal customers.

Exposure to oxygen is the main culprit behind stale coffee. Historically, a high-barrier, multi-layer PET/ALU/ PE would be the default option to provide barrier protection, but it is not a sustainable option.

Paper is generally more desirable due to its recyclability, but the roast and ground coffee segment faces challenges. The oils in the beans require barrier functionality and the CO2 they release post-roasting means pouches need a one-way valve to let gas out without letting oxygen in. Structural features such as reclosure zippers and adhesives help maintain coffee quality but add plastic or foil, complicating recycling.

Therefore, paper has not been an ideal alternative without some level of plastic or foil for the necessary barrier.

There are ways of tackling this issue – often involving material innovations such as water-based barrier coatings and monolayer packaging.

Coffee is probably one of the most progressive CPG sectors when it comes to sustainable packaging and broader ESG policies

‘The development of high-performance barrier coatings represents a significant moment for the industry. Kraft paper laminated with PE or foil grants the required barrier performance for packaging roast and ground coffee but not the desired recyclability. Development of paper substrates and barrier coatings will enable brands to begin switching to a more sustainable, recyclable packaging model,’

Halford explains. Parkside is resolving this issue with a new recyclable metalized packaging, made entirely of paper. Its Recoflex monopolymer material is designed to make plastic more sustainable. Because it is made from a single polymer, it is technically recyclable. However, its full benefits would be hard to achieve without investments in suitable recycling infrastructure.

‘For example, Nescafe initially moved to monopolymer refi ll pouches, reportedly the first recyclable coffee pouches on the market compatible with front-of-store recycling schemes. This move has enabled Nescafe to highlight its sustainability credentials in an immediately visible way. The company has since moved on to fully recyclable paper packaging,’ Halford shares.

Harry Baker, sales and operations, BakPac also notes that coffee packaging buyers ask for compostable paper constructions. The challenge has been finding the high barrier properties coffee requires to maintain the freshness of the product and extend its shelf life.

‘The tactile feel was popular in the coffee market, which led to a demand for compostable structures,’ Baker notes. ‘However, the demand is now moving away from compostable structures as the view on multi-laminate structures is changing. Brands are moving towards mono-material structures as they’re seen as a more sustainable decision when looking at the supply chain holistically.’

Harry Baker, sales and operations at BakPac

BakPac has developed a mono-polymer range that claims to offer comparable barrier properties.

BakPac helped a coffee brand that was previously using a tin with an inner bag switch to a high-barrier, mono-material stand-up pouch with a coffee valve.

‘This allowed the brand to avoid sourcing its packaging from multiple suppliers. They can also utilize the full surface area of a stand-up pouch for branding instead of being restricted by the size of the label,’ Baker explains.

Another challenge Baker notes is the coffee industry’s preference for the flat bottom pouch format that BakPac currently does not offer. In response, the converter purchased a flat bottom pouching line from Indian manufacturer Galaxy Packtech that will be installed later this year. ‘Come January 2025, we will be the first UK producer of flat bottom, digitally printed pouches,’ Baker highlights.

Compostable packaging

Single-cup coffee and espresso brew systems are incredibly popular for their simplicity and convenience. Coffee pods are often made from recyclable plastic but throwing them in curbside recycling can contaminate the waste stream. To recycle a pod fully, consumers must remove the lid, grounds, and filter, rinse the pod, and then recycle it. Compostable pods exist, but the lids often prevent full compostability, and the lid is crucial for controlling heat, steam, pressure and water during brewing.

The challenge is to find a material that can withstand the brewing process and break down in compost conditions, which involves high heat, pressure and moisture.

After two years of development, S-One Labels Packaging’s R&D team created a compostable, bio-based lid that meets ASTM D6400 standards and is awaiting third-party certification. S-OneLP worked with Stella Brands, a Las Vegas-based contract packager for the coffee pods market. The material is a printable paper-based prelaminated structure with a sealant web.

Come January 2025, we will be the first UK producer of flat bottom, digitally printed pouches

Greiner Packaging and Constantia Flexibles have also developed a fully home-compostable coffee capsule. In this collaboration, Greiner Packaging supplies the body of the capsule, while Constantia Flexibles provides the lid – EcoPressoLid.

The capsule body, developed by Greiner Packaging, preserves the freshness of the coffee and is compatible with conventional coffee capsule machines. This packaging offers consumers a more sustainable option without compromising on quality or convenience and supports a circular economy by reducing waste and minimizing environmental impact.

Constantia Flexibles’ capsule lidding, EcoPressoLid, offers a high oxygen barrier, sealing for compostable coffee capsules, and quality coffee brewing performance. It is compatible with commonly used capsule filling and sealing machines on the market.

The EcoPressoLid is paper-based and can be used to seal both the top and bottom of the capsules. The capsule body and lid received the ‘OK Compost Home’ certification from TÜV Austria together as a system.

Similarly, Parkside has achieved long-term success using compostable materials for roast and ground coffee applications.

‘Coffee seems to fit well with compostable material, as the grounds themselves can also be composted along with the packaging, including zips and valves, helping brands to offer a truly circular product to their consumers. This approach helped one of our clients on their journey to achieving B-Corp status,’ Halford says.

Halford mentions that this brand has developed a closed-loop composting system, collecting packaging waste from customers and composting it at its roastery. The resulting compost is used in its coffee shop gardens, which also serve as a space for local food service businesses to grow fresh produce.

‘Every job we take on is a collaboration where we grow to understand our customers’ exact needs before applying our design expertise and technology to respond to them. Some projects involve more development, while others use existing technology and materials. We are currently developing new paper, coatings and integral valves for coffee pouches,’ Halford says.

Nescafe used the first recyclable coffee pouches on the market compatible with front-of-store recycling schemes

He adds that as films become more mainstream, economies of scale bring costs down until sustainability becomes the norm, helped by key brands in the category making large steps toward sustainable packaging.

‘Coffee is probably one of the most progressive CPG sectors when it comes to sustainable packaging and broader ESG policies,’ Halford adds.

Similarly, converters such as BakPac prefer to form relationships and make collaborative efforts with brands rather than be a simple me-too supplier.

‘We want to open our customers’ minds to what is achievable using our print technology. The coffee market, in particular, likes to push design boundaries as far as possible and often offers many product variations and blends, which work perfectly with digital. It also allows larger brands to dip their toes with a new idea and test the market rather than commit to a larger MOQ,’ Baker adds.

Brands leading the way

New-age brands such as Pact Coffee and Café Buendía are shifting to sustainable packaging to attract eco-conscious consumers and contribute to a more sustainable future, setting a positive example for the industry.

Pact Coffee

UK-based coffee brand Pact Coffee has already switched to sustainable pouches for its packaging.

Will Sowerby, communications and content lead at Pact Coffee, says: ‘Our core mission has been to make the coffee industry better for the farmer since the beginning, and we wanted to improve our practices at home, too.’

It took Pact Coffee two years to develop its new sustainable packaging.

Pact Coffee’s flexible bags are made from 70 percent recycled plastic, with the remaining 30 percent virgin plastic

‘Freshness has been absolutely key to Pact Coffee since we began over a decade ago, and the challenge was maintaining this with recyclable packaging,’ Sowerby explains.

‘Sacrificing any quality that comes with coffee freshness would have been a significant mistake that would have disappointed many of our loyal customers. But we knew that continuing to use landfill-bound packaging was unacceptable.’

More widely used sustainable packaging, like paper, would have allowed in too much oxygen, so we needed to get creative

Oxygen quickly kills off the flavor and aroma of coffee, whether pre-ground or whole beans. Pact Coffee had to find a way to create the most sustainable packaging possible while also keeping oxygen at bay.

‘More widely used sustainable packaging, like paper, would have allowed in too much oxygen, so we needed to get creative. After plenty of trials and errors, we found the answer in LDPE #4.’

Pact Coffee’s bags are made from 70 percent recycled plastic, with the remaining 30 percent virgin plastic that the brand needs to use to keep its coffee food-safe and preserve freshness. The bag is then recyclable.

Specifically, it is made from LDPE #4 (a low-density polyethylene). The number ‘4’ signals its density, with LDPE #1 being the densest. The brand reduced this number as much as possible to reduce its usage.

‘For us, it is about being better today than yesterday – so this was a significant breakthrough,’ Sowerby says.

Pact Coffee’s bag features a QR code that customers can scan to go to a page that tells them how to recycle it

Compared to the brand’s previous packaging, it shows a 58 percent reduction in carbon, a 70 percent reduction in virgin fossil fuels, a 20 percent reduction in materials, and a 70 percent usage of recycled materials – promoting a circular economy.

In addition to choosing sustainable, flexible packaging, the brand is actively educating customers about its recyclability and the post-consumer handling process.

Each bag features a QR code that customers can scan to go to a page that tells them how to recycle it. Pact Coffee also releases a yearly impact report that contains information on the packaging and its social impact.

Will Sowerby, communications and content lead at Pact Coffee

The carbon footprint of these bags is offset by SeaTrees. This project protects and regenerates coastal ecosystems by planting and restoring aquatic plants.

‘These plants, like mangroves, kelp and coral, can be up to 10 times more effective than rainforests at removing carbon from the air. These bags also fund this project, which stops plastic bottles from entering our oceans,’ Sowerby notes.

‘For every kilogram of packaging we purchase, this initiative saves the equivalent of two plastic bottles from rivers in Asia. If they weren’t to be recovered and recycled by this initiative, they’d end up in the ocean.’

This initiative has collected over 20 thousand plastic bottles from rivers and recycled them.

Café Buendía

Columbian coffee brand Café Buendía presented during Label Summit Latin America in Columbia how it has adopted sustainable packaging that aligns with its brand values and meets the growing consumer demand for products packed in eco-friendly packaging. In partnership with Dow and Alico, the brand’s material and packaging suppliers, Café Buendía developed a mono-material packaging.

As noted earlier, packaging for high-barrier products such as coffee, cocoa and milk powder traditionally required metalized structures to maintain freshness and quality. These structures, however, posed significant challenges in terms of recyclability. Café Buendía needed packaging that could offer the necessary barrier properties while being environmentally friendly and recyclable.

Café Buendía has switched to Alico’s Reciplus Alico monomaterial structure for its flexible packaging variant

Café Buendía chose Alico’s Reciplus Alico mono-material structure, which preserves coffee’s taste, aroma characteristics and shelf life. The mono-material structure utilizes high-performance polyethylene resins. This packaging is claimed to maintain the functionality of traditional laminated packaging while enabling closed-loop recycling. It offers a high barrier against moisture, oxygen and light. This innovative structure has been recognized with two awards at the Dow Chemical Awards for its easy recyclability.

According to Alico, Reciplus is also resistant to tears and punctures, ensuring the product remains intact during transit and storage. Additionally, it requires a lower sealing temperature, reducing overall energy consumption, and is lighter than rigid packaging.

By using Reciplus, Café Buendía successfully introduced what it claims is the world’s first freeze-dried coffee in 100 percent recyclable packaging. This move has boosted the brand’s reputation and demonstrated its commitment to sustainability.

HP India Sales signed a memorandum of understanding (MoU) with the Atal Incubation Centre of Coffee Board (AIC CCRI CED) on May 22, 2024, in a significant move to foster innovation and growth among startups. Under this collaboration, HP will offer comprehensive support to these startups, including insights into industry trends, best practices and the latest advancements in printing and packaging technologies. The MoU was formally signed by Praveen HJ, CEO of AIC-CCRI-CED, Coffee Board, and Appadurai, country manager of Indigo and inkjet solutions at HP India.

The signing ceremony was attended by Naipal Singh, business development manager at HP India sales, along with members of the AIC-CCRI-CED team.

HP Indigo will set up an experience zone at the Coffee Board’s incubation center to showcase a gallery of applications possible using HP Indigo presses, displaying various packaging formats for startup brands. With 300 Indigo press installations across India, 15-20 percent of which are with label and packaging providers, HP Indigo aims to help startups connect with these users. This initiative will enable startups to prototype, test, proof, and place their orders with established HP Indigo customers.

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Akanksha Meena

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Akanksha Meena

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Ravenwood linerless technology used in new Zespri kiwi packaging

Brewing a greener cup

Barrier for freshness

Compostable packaging

Brands leading the way

Pact Coffee

Café Buendía

Akanksha Meena

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