Sustainability Watch April 2011

Innovia Films’ Substrate Reduces Waste

Innovia Films, a producer of speciality BOPP and cellulose substrates for a variety of labelling techniques, launched a new range of films suitable for linerless label applications, Rayoface NB.

Working in partnership with machine and technology supplier, Ravenwood Packaging Ltd, the new Rayoface NB films have been developed for use on Ravenwood’s range of Nobac linerless label applicators.

“Rayoface NB films provide the linerless label market with a choice of solutions to minimize packaging waste, drive process efficiencies and create sustainable value through the supply chain,” says Richard Southward, Innovia Films’ product manager for labels.

Rayoface NB films are available in both white and transparent grades and in thicknesses of 92 µm (suitable for replacing carton board sleeves) and 60µm (for conventional pressure sensitive and wraparound label replacement). When converted into linerless labels, Rayoface NB films can be used by retailers on lidded food trays for meat and fish product packs. As the label is applied directly to the pack, a reduction of more than 30 percent in the labelling waste can be achieved.

Based in Bury St. Edmunds, Suffolk, Ravenwood Packaging Ltd sells and services a range of Nobac linerless labelling systems and associated packaging machinery. Paul Beamish, founder of Ravenwood Packaging Ltd, said “We have used Innovia Films’ substrates on our machines for over five years and the development of the Rayoface NB range is another example of how we have worked together to respond to our customers’ needs in the fast-changing label industry.”

Toray Plastics To Construct Solar Field

NORTH KINGSTOWN, R.I.—Toray Plastics, manufacturer of precision-performance polypropylene, polyester, and bio-based films for packaging and industrial applications, plans to begin construction in Q2 2011 on a $2 million, 446 kilowatt (kW) solar photovoltaic (PV) field on its 70-acre campus in North Kingstown, R.I. The new solar field will occupy about three acres, consist of 1,650 PV panels with utility-scale single-access trackers, and be the largest solar-powered system in the state.

Toray Plastics estimates that the efficient clean-energy system, which is designed to produce a higher-energy output when compared with conventional fixed-mounted PV panels, will generate 625 megawatt hours (MWh) a year, help curb escalating energy costs, and reduce CO2 emissions by 340 tons per year. Funding for the solar field will come from Toray, grants and loans from the Rhode Island Economic Development Corporation’s Renewable Energy fund, and state and federal grants made possible by the Federal American Recovery and Reinvestment Act of 2009. Construction is expected to be completed by Q3 2011.

“Choosing solar technology to help power our operations is another example of our commitment to the well-being of our business, the community, and the planet,” says Richard Schloesser, president and CEO, Toray Plastics (America). “Toray has been immersed in sustainable business practices for years and we are very excited to launch this major clean-energy undertaking in 2011. We’re also very pleased that the installation will bring new jobs to Rhode Island residents.”

In 2004 Toray launched a comprehensive sustainability initiative, which has greatly improved its environmental profile, with savings in water, electricity, and waste.

Printers Receive L.I.F.E. Certification

GLOUCESTER, Mass.—Coatesville, Pa.-based Monet Graphics and Aurora, Ill.-based The Label Printers were awarded L.I.F.E. (Label Initiative for the Environment) certification from TLMI. The Project L.I.F.E. program was developed in order to assist TLMI members to find cost-effective ways to reduce their companies’ environmental footprint. L.I.F.E. is a program designed specifically for the narrow-web marketplace and addresses four key elements of the narrow web printing and converting industry: clean production, energy and greenhouse gases, product and environmentally preferable materials, and management practices.
“I would like to congratulate Monet Graphics and The Label Printers on their recent TLMI L.I.F.E. certification,” Frank Sablone, TLMI president, says. “We currently have 22 converter and supplier members certified and we’re seeing a renewed focus on green initiatives and sustainability for 2011. The program has been extremely successful and the TLMI Board of Directors continues to prioritize the program’s exposure and outreach in the marketplace.”

Cartondruck Offers Climate Neutral Production
OBERSULM, Germany—Cartondruck is the world’s first folding box manufacturer to offer its customers climate-neutral production at all of its locations. In doing so, the amount of CO2 emitted during the folding box production is calculated and offset by making investments in a certified climate protection project. In cooperation with the climate consultancy firm, ClimatePartner, the service is offered at Cartondruck’s three locations in Germany, the U.S., and Poland.

The calculation of CO2 emissions emitted during box production is based on the company’s specific carbon footprint, which ClimatePartner calculated for each of Cartondruck’s international locations. Using this as the basis, emissions calculators were designed that are tailored to the data of each respective location and are directly implemented into order calculation software. This integration into the management information system (MIS) makes it possible for Cartondruck to not only name the price on each folding box, but also to automatically assess the carbon footprint produced. Customers can decide for each order on whether the carbon emission volume yielded should be offset by supporting certified climate protection projects in order to produce climate neutral folding boxes

“The cooperation with Cartondruck is a significant milestone for us. We are working together with consistency at all locations to avoid, reduce, and then, as a final step, offset carbon emissions. In doing so, Cartondruck has become a pioneer in voluntary climate protection,” emphasizes Moritz Lehmkuhl, founder and CEO of ClimatePartner.
The production of climate neutral folding boxes represents a fundamental component to the company’s general sustainability philosophy. Additionally, Cartondruck has FSC-certification for all its business locations as well as ISO 14001 environmental management certification.

“Cartondruck offers its customers the possibility of producing their printed matter in a climate-neutral manner,” Marc Prior, GM at CD Cartondruck USA said. “We hope to support our customers not only with the most modern technology and environment-friendly materials, but also to help them to participate in climate protection. That’s why we’ve made the decision to work together with ClimatePartner.”

Henkel, Nordmeccanica Host Scrap Reduction Workshop

EDGEWOOD, N.Y.—Nearly 60 flexible packaging attendees, including many major converters in North America, attended a recent Scrap Reduction Workshop co-hosted by Nordmeccanica and Henkel at Nordmeccanica’s U.S. headquarters.

During the workshop, attendees witnessed a lamination run demonstrating the easy processing and long pot life of Henkel’s new robust laminating adhesive system, Liofol LA7773-21 with Liofol LA6016-21. The run was followed by three demonstrations, each focusing on one of three adhesive attributes that prevent scrap: long life, fast cure, and robustness.

In a concluding presentation, Justin Mehaffy, process solutions director for Henkel, discussed a case study showing the benefits of a structured approach to scrap definition, measurement, analysis, improvement, and control.

“For the supervisors, operators and decision-makers who run flexible packaging operations, scrap is a big issue,” said Jerry Perkins, senior vice president and general manager for Henkel’s packaging, consumer goods, and construction Adhesives business in North America.

“Henkel’s philosophy is to have specialists who understand the flexible packaging market and the issues that are important to our customers. Managing scrap well, with the ultimate goal of eliminating it, can make the difference between being profitable and not being profitable.”

Hill Kilby, technical process partner at Bemis Milprint Packaging in Joplin, Mo., attended the workshop with colleagues from other Bemis locations.

“We got a lot out of it,” he said. “We do solventless lamination in Joplin, so the new technology was great. Shorter cure is something we’re always interested in because it helps us lower inventory levels and work-in-process levels. And we like to keep up with the latest technologies. The demonstrations were pretty impressive, too, because we were able to look and touch and check things out.”

Chesapeake Launches Sustainability Initiative

OLD AMERSHAM BUCKS, U.K.—Chesapeake launched a new initiative, the ‘Chesapeake 100’ which demonstrates its commitment to leadership in environmental management.

“As a responsible global supplier of packaging solutions, we recognize that, due to our scale, making even the smallest changes can deliver impressive results,” Phillip Adams, corporate social responsibility director, said. “As a consequence we have launched the ‘Chesapeake 100’ project—a positive way to ensure our business reduces the environmental impact of its world-wide operations.”

All of Chesapeake’s 40 operations have been tasked with a number of new environmental related initiatives during 2011. This has generated in excess of 100 annual sustainability projects that will help to reduce energy consumption, water and chemical usage, waste, and emissions. These initiatives will also help to improve packaging design, supply chain efficiencies, vehicle fill levels, and environmental management systems.

“We receive a growing number of requests from our customers to confirm Chesapeake’s position in relation to our environmental objectives and targets,” says Adams. “In response, the ‘Chesapeake 100’ will group together all the environmental projects across our business and allow us to respond to these requests in a coordinated and professional manner.” pP