Derek Dlugosh-Ostap

Pretty and Green: Is there a compromise?

Most definitely, at Pack-Smart high visibility packaging represents a significant part of our business. There are many ways of making packaging friendly not only to mother earth but also to the consumer while maintaining a good visual at the same time. Collaboration among marketing, procurement, logistics and production -- that is where we need to start. Feedback from experienced production personnel can have significant impact on the sustainability of the package. Often extra packaging components, such as inserters, handles, and reinforcements can be integrated in a single step process without requiring extra materials/cost, simply by utilizing “by-products” of that same packaging. Materials like recycled PET windows, corrugated inserters and paper foam reinforcements can be integrated during the folding/gluing procedure, creating slick and secured packaging formerly seen exclusively in personal care and liqueur markets. Let’s use one of our recent examples. We have recently worked with a client that had four requirements for a windowed box, the product inside was high-end chocolate candy. 1. Eliminate PVC window 2. Make window removable for recycling purposes (allow consumer to remove window without extreme effort) 3. Eliminate printing on both sides of board, 4. Eliminate requirement for corona treated silver foil board. Originally our customer would have to perform the following steps: 1. Purchase silver foil board, have it corona treated 2. Print both sides of silver foil board 3. Go though die cutting process 4. Send die cut blanks to windowing department 5. Apply Glue to PVC window 6. Fold glue windowed carton 7. Send flats to packaging department, have them erected on convectional carton erector. 8. Add plastic insert to protect the products inside the package Employing Pack-Smart's integrated window application system and a high speed folder gluer, we were able to add a 10 mil, PET window (instead of original PVC) at the same time as the folding and gluing process is completed, without compromising speed and performance. Thanks to the creativity of the structural designer and finishing supervisor we were able to secure the window inside the box by using a tiny dot of cold adhesive. This design allows the consumer to pull on the tab and remove the window and place it in the appropriate recycling bin. Just before we completed the final fold we placed a corrugated insert which eliminates the need for a vacuum thermoformed protector. At the end the PVC window was eliminated and replaced by a removable PET window. A corrugated insert eliminated the vacuum formed protector and the need for corona treated board. The package looks slicker, costs dropped by 40%, not to mention the environmental impact and reduced “procurement grief factor” of getting corona treated board. Another important element that should motivate manufacturers to think green is the consumer. We found that consumers themselves want to contribute. Once they notice the “green message” on packaging they feel obligated to follow through and participate in the process. Luxury packaging does not to be shiny gold. Derek Dlugosh-Ostap President Pack-Smart Incorporated Toronto, Canada www.packsmartinc.com

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