打包 | 7分钟阅读

包装强国

On Site: 清除林

材料配方,流延和吹塑薄膜挤出,片材挤出,印刷和层压均在此处理器下进行。

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从卑鄙的人到创新的全球性 打包 powerhouse that despite its size and scope has still managed to maintain an 恩trepreneurial spirit: 那’s the story of 清除林 打包, where materials formulation, 流延和吹膜挤出, 片材挤出,印刷和层压是在伊利诺伊州芝加哥郊区Elk Grove Village的一个屋顶下进行的。

It’也是一个相当大的屋顶,占地面积超过500,000英尺², under which more than 500 people work in development of novel flexible and rigid structures, primarily for food markets. The business operates two facilities in Elk Grove Village, Ill., and one in Nanjing, China. And after spinning off a rather sizeable thermoforming operation last May, 清除林’我们的计划是在胶片和胶片上更大。

James Sanfilippo, 清除林’总裁兼首席运营官,自我描述经营业务“hands-on”推动创新并提高客户价值的方法:“我们所做的一切努力都是为了增加价值,并提供具有独特性能的产品,从而使我们的客户在市场中占据优势。 ”

清除林 成立于1969年,最初是一家小企业,生产休闲食品包装用薄膜。在1970年代初期,它增加了功能—胶片结构和设备—to make cellophane-based lidding for portion control 打包. Then in the late 1990s it merged a modified atmosphere 打包 (MAP) equipment business into the organization. 那 equipment business was ultimately sold off in 2007, but high-barrier 打包 and lidding remain a specialty at 清除林 and the center of lots of innovation, notes Sanfilippo.

Last year, for instance, 清除林 unveiled new Peel and ReSeal Lidding Film, a single structure that replaces the two-piece rigid lid with a shrink band around it. The film opens easily and reseals to the package with a light touch. Compared with containers having a rigid lid, the Peel and ReSeal Lidding Film reduces weight by as much as 30%, improves shipping cube, and provides an 恩hanced safety seal. The film is said to be suited to deli, bakery, produce, and a host of other applications.

“对于当今的大多数食品加工商和零售商而言,可持续性已不仅仅是一种选择,而是正常的经商之道,” states Sanfilippo. “这意味着对包装解决方案的需求不断增长,这些解决方案可帮助企业实现其可持续发展目标,同时提供更高的效率和成本优势。”

Sanfilippo继续:“Today’s consumer is more sophisticated and price sensitive, so any 打包 improvement must provide tangible benefits. 那’s why 清除林’致力于开发能够满足消费者实际需求的包装,同时满足客户需求’的长期可持续性倡议。”

This lidding film is part of another 清除林 innovation that might turn out to be a game changer in 打包. Late last year, the company took the wraps off the PrimaPak package. Several years in development and the result of millions of dollars in R&D,PrimaPak是一种灵活的,可堆叠的,可重新封闭的包装,旨在替代罐头,瓶子和广口瓶。

PrimaPak结构由专有的多层吹塑薄膜组成,该薄膜被层压到几个未公开的基材上以增强耐热性,然后在卷材的垂直成型填充密封(FFS)设备上进行处理。 Sanfilippo说,该包装经过精心设计,可以最大程度地提高制造,仓储,包装,运输和销售的效率。

“PrimaPak可以比其可以替代的吹塑包装轻70%,” Sanfilippo says.  “That’显着减少了材料用量。它’形状为正方形或矩形,可改善立方体。它具有六个方面(包括顶部和底部),这为品牌所有者提供了更多传达信息的空间。”

最初的目标应用是坚果和其他休闲食品。“For nuts, we’我们已经估计,从当前的包装应用转换为PrimaPak可以消除废物流中的1000万磅垃圾。” 清除林 currently holds six patents on the product, with another half-dozen pending. 

Sanfilippo说,更多的创新正在进行中—in particular, mechanical closing of the lidstock. The technology is sold as part of a system that also includes FFS equipment designed and 恩gineered by 清除林.
 

四个部门
 

清除林’的业务分为四个部门。其柔性薄膜部门由分别由马萨诸塞州纳蒂克的细川阿尔卑斯美国公司和马萨诸塞州丹佛斯的Reifenhauser-Kiefel提供的三层和五层共挤生产线提供支持。薄膜的类型从超高阻隔性到可剥性或永久性密封形式的透气结构,可用于奶酪,咸味小吃,肉类,调味品,液体,预备饭菜,餐盒和农产品。在非食品类别中,这些薄膜包装了个人保健产品,洗涤剂,午睡,电子产品,玩具和其他工业产品。

两条生产线均采用最新的重量混合技术,可向挤出机中添加多达10种不同的配料。三层线的运行速度为1500磅/小时,五层线的运行速度约为1000磅/小时。两者都使用Reifenhauser Kiefel的Wintech复卷机将胶片卷取至120英寸。宽和42英寸直径。

清除林 runs flexographic and rotogravure printing presses with up to 10 colors. It has solvent, solventless, and water-based laminators, and large-scale slitting capacity. Its solvent-free laminators were developed in-house to run at speeds up to 1000 ft/min. Printing plates are made in an in-house graphics department.

清除林 is currently in the midst of a $20 million capital-equipment investment plan. It just recently added its fourth high-speed printing press from Windmoeller &R.I.的Hoelscher,Lincoln,以及其他层压能力,并且正在寻求将其扩展到九层薄膜挤出。

清除林 also recently added technology to laser-score and perforate films, a technology that allows for easy opening but, perhaps more importantly, greater control over respiration rates for produce. “我们多达80%的应用程序是自行开发的,” Sanfilippo states. “我们确定市场需求,并致力于开发解决方案。”

清除林 has an extensive polymer-science lab in Elk Grove Village with the full gamut of 测试 设备。这包括用于测试氧气和水蒸气透过率,摩擦系数,粘结强度,薄膜成分,热粘性,冲击力,香气等的机械。”

清除林’s的成型膜部门为热成型者,食品加工商以及提供食品,个人保健产品,电子产品和工业产品的定制制造商提供硬质流延薄膜和薄板卷料。来自宾夕法尼亚州蓝铃市的Welex的三层A-B-A生产线加工PET / RPET,PLA和PS,用于食品,电子产品,个人医疗保健和工业产品。此外,许多定制层压材料包括用于增强氧气阻隔性的EVOH和用于气密密封的聚乙烯。去年第四季度,该公司通过200万美元的投资扩大了其成型膜部门,增加了一条新的片材共挤出生产线,该生产线将提供1500万磅/年的额外产能。

In 2009, 清除林 worked with Stonyfield Farm to convert its yogurt cups from PS to PLA sheet. The PLA sheet was more than 25% thinner than the PS structure it replaced, but the cups were stronger, broke less, and provided better lid adhesion and lower processing temperatures, which save 恩ergy. In addition, 清除林 developed a new generation of innovative barrier structures produced from 80% renewable raw materials. These products allow food processors to reduce the use of petroleum-based plastics without compromising performance.

These new plant-based materials are part of 清除林’s Project EarthClear Initiative. They are used on FFS machines to package such items as pastas, egg rolls, sliced meats, burritos, and other prepared foods. Project EarthClear (projectearthclear.com) was launched by 清除林 in 2005. Its purpose is to foster development of materials and 打包 designs that minimize impact on the 恩vironment. It focuses on three main areas:

•由可再生原料而非石油制成的包装;

•用某种形式的再生塑料或纸制成的包装;

•轻量化的设计和技术。

“我们认为,我们有道义上的义务,即在环境足迹较小的情况下提供优质,可靠,可持续的产品,” Sanfilippo comments. To that 恩d, 清除林 last year signed an agreement with Toyota Tsusho Corp. making it the first North American processor to offer the Bio-PET product in rollstock form. Bio-PET materials are similar to Coca-Cola’s PlantBottle在PET聚合中利用植物来源的单乙二醇。所得的PET是30%可再生的。

Much of 清除林’独特的挤出产品的配制成功归功于另一个部门,即CL聚合物部门。在那里,利用内部开发的双螺杆挤出机,该设备可提供特殊化合物,供内部消费以及出售给外部挤出业务以及注塑和吹塑机。

该部门的主要重点是用于生物塑料的定制复合添加剂,以改善挤出性能,抗冲击性和切削性能。“我们的材料开发知识为我们的PLA平台提供了帮助,” says Sanfilippo. “We’将拜访客户工厂,试用不同的材料,并做任何R&在我们提出一个比客户当前使用的解决方案更好的解决方案之前,D是必需的。”对于需要RPET的应用,CL聚合物提供的添加剂可增强各种温度下的抗冲击性,而不会明显影响透明度。

In addition to its position in the Chicago area, 清除林 has a wholly owned subsidiary in China, 清除林 Flexible Films (Nanjing) Co. Ltd. The 80,000 ft²该工厂生产层压,涂布和印刷膜。
 

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