Printing advances, structural improvements elevate flexible packaging: winners of FPA's competition exemplify the industry's best technical innovations for foods, beverages, medical items and personal care products

Food & Drug Packaging, March, 2005 by Graham Wiemer

SPonsored by the Flexible Packaging Association, the Flexible Packaging Achievement Awards have honored packaging and converting excellence for the past 55 years. The winning entries in the 2005 competition demonstrate that advancements in printing and design, technical innovation and environmental protection are having a tremendous impact on the way retail, institutional and industrial products are packaged and supplied to consumers.

Significant technical achievements have reduced packaging costs and production time, increased consumer convenience, improved product protection and extended product shelf life. Unique packaging shapes and new barrier structures that provide high-impact graphics are being used to enhance shelf presence. Other innovations include new dispensing solutions, flexible microwaveable packages, increased use of transparent packaging and improvements in print quality using digital processes at the pre-press stage. Many of these innovations were made possible with improved machinability on the packaging line.

An unprecedented 89 packages were entered in the 2005 competition. Twenty-eight entries were recognized with 33 achievement awards, and two packages were selected to receive the Highest Achievement Award. One competition judge noted that the focus of many products is quickly becoming the packaging that surrounds them. Commercials are promoting improved, more convenient packaging, and companies are using the "ad space" on their products' packaging to expand their marketing possibilities.

Flexible Packaging Association

410-694-0888; www.flexpack.org

Microperf Dialyzer

Baxter Healthcare Corp.

(a) Packaging Excellence

(b) Environmental Achievement

(c) Technical Innovation

The Microperf Dialyzer Package is a newly designed ethylene oxide (EtO) sterilizable pouch. Used by Baxter for its single-use dialyzers, the package consists of a 3-millimeter polyethylene copolymer film that is precision perforated to provide controlled porosity for effective EtO sterilization, while maintaining product cleanliness. The perforated film allowed Baxter to automate its dialyzer packaging via a SIG horizontal form-fill-seal machine.

Rollprint Packaging Products Inc.

630-628-1705 x3321; www.rollprint.com

Jennie-O Turkey Bag

Jennie-O Turkey Store, Div. of Hormel Foods

(a) Packaging Excellence

(c) Printing Achievement

The first package to include Curwood's IntegraScore[R] easy-opening feature along the side of a gusseted pouch, the Jennie-O Turkey Bag eliminates the risk of damaging an inner bag when opening the outer pouch. The Turkey Bag also features a unique reinforced handle that makes it easier for consumers to carry the product.

Curwood Inc., A Bemis Co.

920-303-7300; www.curwood.com

Wild Gamekeeper's Spray Hunter's Specialties

(b) Packaging Excellence

This is the first commercial U.S. package that combines a flexible pouch with a trigger sprayer. The package is a result of teamwork between Kapak Corp. (pouch manufacturer) and Fortress Systems International (contract packager/manufacturer). The pouch is filled with water to activate the ingredients, and the solution is then sprayed onto just-harvested game to prevent bacteria from forming.

Kapak Corp.

952-541-0730; www.kapak.com

Fortress Systems International

704-405-5000; www.fsiinc.com

Non-Foil Pouch Asian Style Selections

(b) Packaging Excellence

This microwavable pouch--with Alcan's Ceramis[R] as its clear barrier layer--is the first domestically converted high-barrier, non-foil retort stand-up pouch. It allows consumers to prepare an entire four-serving meal in minutes.

Alcan Packaging

773-399-0804; www.alcan.com

Insta-Bowl[TM] Microwave Popcorn Bag

General Mills Inc.

(b) Technical Innovation

(c) Packaging Excellence

The Insta-Bowl[TM] is a self-contained eating bowl that provides easy access to the microwave-popped popcorn, doing away with the need to transfer the cooked food to another bowl.

Exopack LLC

336-476-3131; www.exopack.com

Autopak[R] Sterilization Pouch

(b) Technical Innovation

Complex multilayer pouch for large medical devices combines transparency with abuse resistance. The bottom ply is a non-woven sheet which is made by BBA. This breathable substrate allows permeation of sterilization gases such as steam, yet still acts as a barrier to bacteria penetration. The middle ply--a polypropylene-based coextrusion from Alcan Packaging--is perforated for permeability. It also contains a unique autoclavable peelable seal which is activated after sterlization. The top ply is a lamination (provided by Alcan) of nylon from DuPont Canada and polypropylene.

Alcan Packaging

773-399-0804; www.alcan.com

Christmas Tree Pouch Chocolates Britt

(b) Printing Achievement

This package uses gravure printing, spot varnish and shaped pouch technology. This stand-up pouch features a hanging fabric loop.

CLP Industries Ltd.

973-808-4441;

www.clp.co.il

Lamb & Rice Medley Nature's Variety

(b) Printing Achievement

The 30-pound size features an advanced multilayer, all plastic construction, which uses printing techniques that increase shelf appeal. A metallized PET layer has been incorporated within the new structure, giving the package a reflective look and making the graphics appear more three dimensional.