Top Editors ... Stand-up Pouches

Title: Stand-up Pouches
Date: 24/08/2006
Autor: By Claire Rowan

Innovation and technological performance are fuelling the growth in demand for stand-up pouches in all sectors

Stand-up pouches (SUPs) are making significant inroads into all segments of the food and drink market, as well as every other industry sector, as the benefits of their convenience, lightweight, large print surface, quality and environmental friendliness combine with their novelty to drive sales. In 2005 in all market segments, nearty 100 billion PET containers, 44 billion liquid cartons, 40 billion beverage cans and 30 billion heat processed food cans were produced in Europe compared with just 12 billion SUPs, according to the latest report from the packaging specialist, Schoenwald Consulting Group.
However, in the food industry alone, according to the report The Market for Stand-up Pouches in Western, Central & Eastem Europe, 3.5 billion SUPs were produced during 2005 with this number forecast to rise to 5.3 billion by 2008. This production is split between retorted food producís, for which 1.2 billion pouches were produced and non-retorted with 2.3 billion in 2005; rising to 1.9 billion and 3.4 billion respectively by 2008. Last year, 2.4 billion units were produced for beverages alone and this figure is expected to reach 4 billion SUPs in 2008, according to Schoenwald.

Drivers to this forecast growth include the high production rates afforded by this flexible packaging, which are fuelled by advances in filling and sealing technologies; as well as the developments in materials, laminates and opening devices, which gives greater flexibility and performance throughout the product's life and convenience in application.

At the vanguard of new product development in this área are companies such as Huhtamaki Ronsberg in Germany; Ampac Flexibles in the USA; Amcor Flexibles in the UK and Mondi Packaging of Austria. In tune with the growing demand for stand-up pouches, Tetra Pak has also innovated recently, and created what it says is the world's first high barrier, transparent SUP for aseptic beverage filling.

The Tetra Wedge Aseptic (TWA) Clear can be used on existing Tetra-Pak forming/filling equipment modified to handle the new SUP material, which is a patented multi-layer lamínate with patented barrier properties that both protect the product and withstand the aseptic filling process. It uses polyester films are initially laminated together: one side is then top laminated créate a transparent substrate with excel gas barrier properties. This material is th( printed, and finally outer polyethylene lay are applied as in conventional extrusión lamination.

Tetra Pak worked closely with print specialists to develop inks especially for flexographic process used to print the T Clear SUPs, and it is possible for designi to develop packs that change colour as the drink inside is consumed, for example.

Jumex, the Mexican juice producen is first company to use the new system for latest launch, Mundo Nautix: a juice beverage for children, which is packed ir Tetra Wedge Aseptic Clear 200ml Slim. 1 Pak is now in contact with several interested customers regarding further introductions of aseptic beverages such as juices, nectars, flavoured waters, sports beverages and liquid electrolytes in individual portion-sized, transparent pouches.

In the USA, Wasatch IceWater Company opted for 473ml stand-up pouches from Ampac Flexibles - Converted Products, a división of Ampac Packaging, for the introduction of its new 20,000-year-old artesian water product, which it says is the first water to be marketed in the USA in a flexible pouch. The contaminant-free water ¡s said to have been created during the last ice age and is extracted from a well near the Uinta Mountains by the newly formed company.

"The water free flows from the aquifer to the new plant at just 41°F(6°C)without seeing the light of day," said Craig Binks, chief operating officer of Wasatch IceWater Co, which has been given FDA permission to use the words 'artesian water from glacier ice' on the pack. "It comes straight out of the ground with no Chemicals.

"We wanted to be different. We have a unique product and we wanted a unique package," said Mr Binks about the choice of the Ampac pouches. "The pouch is environmentally friendly, which appeals to many of our consumers. It requires 75% less energy to produce and 95% less land fill compared to a PET (polyethylene terephthalate) bottle."

The end result is a proprietary flexible pouch structure that combines PET and biaxially-oriented nylon with a co-extruded organoleptic inner layer that not only safeguards against compromising taste, odour or J colour, but also prevenís any structural failure. Ampac also incorporated its SmartSpout pouch dispensing system, • which combines three components from Seaquist Closures: a polyethylene base fitment with a spout and a silicone valve, and Seaquist Closures' EZ Turn Cap (a tamper-evident, easy-to-turn, swallow-resistant closure). Consumers can suck directly from the spout, or squeeze the pouch to evacúate the product. However, if the pouch is inverted, the valve prevents any leaks or drips.

Retortabte pouch for microwave steaming

For ready meáis, rice producís, soups and sauces, easy steam cooking is the
object of the latest innovation from Mondi Packaging Flexibles, which launched its NeoSteam retortable stand-up pouch for microwave applications at the end of last year. NeoSteam is an active pack that features a secure, integrated pressure valve that can be adapted to suit the particular foods contained in the pack. The valve is designed to have enough bond strength to withstand the retort processes of 126°C for 60 minutes, and to open in the microwave during the steam-cooking process.

According to Mondi, the integrated, patented VacSys steam valve opens automatically during the steaming process in order for the built-up pressure to escape, so no pre-opening of the pouch is required by consumers. The contents are steamed quickly and under uniform pressure. A transparent barrier layer in the pouch provides an extended shelf life of six to 12 months without refrigeration.

Mondi is already in discussions with customers regarding the use of the new NeoSteam technology, which is designed to be used on traditional stand-up pouch filling machines and in the latest generation of autoclaving equipment. A modified atmosphere packaging film has also been developed for microwaveable, refrigerated or fresh food producís in form seal baps or lidded trays.

Amcor Flexibles has recently picked up two gold awards for Technical Innovation and Packaging Excellence at the Flexible Packaging Association's achievement awards for its SelfVent pouch for microwave cooking of fresh produce. The steam-venting SUP is designed to be easy to open after cooking, and to store upright in the refrigerator. Its self venting properties also ensure ease of use by consumers and that the product is cooked correctly in the microwave. Extended shelf life and reduced dehydration of the product inside are possible through the use of Amcor's P-Plus modified atmosphere packaging technology.

Amcor Flexibles, together with its machine partner Rovema, has also seen its joint development, Amcor FlexCan, grow in popularity since its first introduction a few years ago. One of the latest producís to enjoy success using the pouch is KiMs Norge for its KiMs Polly Peanuts, which picked up a Silver Award for Packaging Excellence at the recent 2006 Flexible Packaging Association's Achievement Awards ceremony in the USA and also a WortdStar trophy at the World Packaging Organisation's awards following its success with a Scanstar prize from the Scandinavian Packaging Association in November last year.

KiMs Norge, Norway's leading peanut producen chose Amcor FlexCan for two of its nut producís: the Polly Peanertter and Polly Tumniks and invested in two VPI machines from Rovema.

"Amcor FlexCan is the perfect consumer-friendly solution for this kind of product since its wide opening makes it easy to help yourself to handfuls of nuts directly from the pack or pour some of the contents into a bowl," said Stein Ronne, QA and R&D manager of KiMs. "It can be re-sealed to keep the product fresh and it stands up in the cupboard to ensure the nuts don't spill out during storage after opening."

The striking red packs are reverse printed in seven colours by Amcor Flexibles Drammen in Norway onto a three-ply laminate of OPP (oriented polypropylene), metallised PET and lapseal PE (produced by AF Otto Nielsen). They also feature Amcor's patented easy-open, redóse flap.

Confectionery in pouches

Multifilm Packaging Corp worked together with its partner company H&N Packaging to créate the perfect innovative pack for Wolfgang Candy Company's new patent-pending Sweet Dark Chocolate Covered Blueberries and Raspberries in the USA. Said to be the first pouch to use cast polypropylene (CPP) as a sealant web, the SUP features a polyester film laminated to Multifilm's proprietary CPP, which also adds clarity and excellent water barrier properties. "When choosing a package for the berries, the pack had to serve two purposes: present a colourful, fresh look and provide protection from impacts that could smash the berries inside the bag," explained Brad McGlaughlin, managing partner of Wolfgang Candy, which uses a proprietary manufacturing method to produce the fresh fruits coated in sweet dark chocolate that gives the product a shelf life of up to one year.

"We recommended Multifilm's proprietary SuperSeal, a high speed flow wrap material that provides high barrier, good hot tack and good seal integrity," said Olle Mannertorp, president and CEO of Multifilm and H&N packaging. "We chose to metallise the film in order to provide an additional barrier, and the hermetic seáis créate the air-tight pillows that Wolfgang needed to cushion and protect the berries inside."

The attractive, 147g SUP features a window that shows the individually wrapped dark chocolate covered berries inside.

Other confectionery products, snacks, ready meáis and beverages will soon be appearing on shelves in pouches, and the market will continué to grow as the technology improves and both protection and shelf lite are optimised.

A can or a pouch?
Cyclero is a new generation of multilayer flexible packaging developed by Huhtamaki Ronsberg of Germany that is designed to overeóme the problems associated with conventional cans, glass or board packs. Working with the machine manufacturers Aisapack, Laudenberg, and Herrmann Ultraschalltechnik, Huhtamaki Ronsberg has created a pack with a round base that can be either flexible or rigid: with or without barrier, depending on the application.

The body consists of a 3 or 4-layer material combination, which can be either transparent or opaque, and provide high barrier properties with or without aluminium. Although it is sturdy and comfortable to hold, the round body ¡s also squeezable.
Designed for any application from ready meáis that require heating in the microwave, to snacks or sports drinks, the Cyclero requires less material and weighs substantially less than traditional packs, according to Huhtamaki Ronsberg. It can be fitted with tamper-evident or recloseable devices, and several patent applications have already been filed for products hoping to tap into these benefits.

A top section in the form of a shoulder makes it possible to fill the pack on high-speed beverage lines - even aseptically, if necessary. And, since production of the Cyclero is combined with the filling operation (in form fill seal configuration or on linked production and filling lines), production can be carried out with reels of material, which also saves on space and removes the need for pre-formed pack storage. Huhtamaki

Pouches for peppers
Sealed Air Cryovac worked together wrth Peppadew International in South África to develop a vertical pouch packaging application that ¡t claims offers significant advantages over rigid containers for the company's Sweet Piquanté Pepper producís.
The Cryovac Vertical Pouch Packaging (VPP) system consists of a product infeed pump conveyor and scales to dose the exact weight of peppers and brine. This is connected to a vertical form fill seal machine and discharge conveyor, linked to a pasteuriser and metal detector. The system produces heat sealed, hermetic, puncture resistant pillow pouches filled with the halved or diced sweet piquanté peppers, with no headspace. Made of fully coextruded, multilayer high barrier film, the 2kg pouches provide the product with protection and a shelf life of 24 months.

"Cryovac VPP is a unique packaging for us. The learning curve has been steep and long for both parties, but the results are simply fantastic," said Phil Ovens, managing director of Peppadew International, which is now looking at introducing consumer size stand-up pouches of the product for retail and has recently acquired an additional Cryovac VPP machine to boost production.

Zippers avoid leaks
Zip-Pak introduced a line of Leak-Proof zipper profiles at the Worldwide Food Expo in Chicago last year.
Designed to allow manufacturers to pack food products that contain liquid into leak-proof resealable consumar packs, the Leak-Proof zippers can be used for flexible pouches of frozen foods, prepared foods with a sauce, and marinated meats, for example. After the zipper ¡s engaged, pressure exerted by the contents of the pouch causes the specially-shaped profiles to lock together, creating an airtight seal, which can withstand high pressures and sustain a vacuum.

The zippers are designed to be used with a variety of different laminates and polyethylene films, and run on horizontal form fill seal, thermoform or pre-made pouch converting equipment. They can be accommodated on existing zipper-ready machines with minor modifications.