David Baker, commercial director for RPC Promens, believes rigid plastics’ versatility in being able to reconcile a variety of packaging requirements has been a critical factor in the material’s adoption across a large number of markets. “The different polymers and manufacturing techniques available, along, with the user-friendly benefits of plastics such as light weight and easy handling, plus its flexible design capabilities are key factors for its suitability in packaging application,” he says.
Convenience food provides just one example of how plastics’ versatility has contributed to the creation of a variety of attractive and practical packaging formats, such as squeezy bottles, trays, snack pots and microwavable containers.
Baker also sees key considerations for rigid packaging include the need to maintain product quality and ensure effective protection and preservation. “With the introduction of high-performance barrier technologies, plastics are now able to offer many types of products an extended ambient shelf life of up to 24 months and beyond. From soups to ready meals, dairy products to desserts and nuts to pickles, this has enabled food manufacturers to develop new products and market sectors. Different plastic manufacturing processes can meet different consumer requirements.”
According to Baker, the cosmetics and personal care sectors have also benefitted from plastics’ design flexibility, not least in the creation of many different eye-catching shapes for maximum on-shelf impact and consumer appeal, which are combined with user-friendly features such as easy opening.
Equally important are new advanced manufacturing and decoration techniques which can help to create the luxury, premium image that is so essential for products in this sector. For example, special cooling systems have permitted a reduction of cycle time inside the moulds, without any shrinkage, and this helps to create a superior smooth finish on materials such as PET-G.
Baker says: “Cream jars can be manufactured using a dual-layer construction. The outer container is injection moulded in a type of polystyrene to achieve a thick-walled effect that conveys luxury while remaining lightweight and easy to handle. The inner jar is then manufactured in polypropylene, which can be produced in a range of colours to suit the product and create a compelling visual effect.”
Baker also sees advanced technologies such as silk screen printing, hot stamping, labelling, embossing, vacuum metallising, spray lacquering and electroplating all helping to create a distinctive and individual appearance on shelf.
He says a particular challenge in developing packs for retail markets is the latter’s fast pace, with brands continually being revised and relaunched to match new trends and changing consumer demands. For established brands, any changes or improvements have to ensure that new consumers are attracted without alienating existing customers. Plastic packaging can be highly effective in retaining the core of an original design and re-imagining or enhancing it with a modern twist. Plastic is also an ideal material for the creation of ‘family ranges’ with one design in a variety of different sizes.
However, for the pack manufacturer, Baker says the challenge can sometimes be more than simply creating a new look pack; the characteristics of the product can also be a factor in the pack design. He cites the cosmetics sector where, for example, airless dispensing technology has supported the successful introduction of numerous products of many different viscosities with technical innovations and enhancements. These enable the systems to cope with small particulates or continue to operate smoothly even if air is trapped in the containers.
Baker is also keen to point out the plastic industry has also done a great deal of work on the sustainability benefits of plastic packaging.
“The ongoing lightweighting of containers, for example, saves on raw material usage; lighter packs help reduce the carbon footprint of transportation; and reclosable packs and barrier containers for extended shelf life do much to help reduce food wastage, now widely acknowledged as being a far greater ongoing problem for sustainability than packaging waste. Most important for the majority of consumers, plastics can be recycled,” he says.
“Rigid plastics continue to demonstrate how they can adapt to the needs of our changing world and it is this versatility will stand the material in good stead to deal with the next set of challenges from the retail sector,” he adds.
Left: Plastribution distributes DuClear CE 85 B. Right: other brand
Meanwhile UK polymer distributor Plastribution believes demand for standard material grades is likely to flourish, as is the need for specific properties for certain applications. Plastribution’s long standing relationship with Carmel Olefins and polypropylene producer Ducor Petrochemicals, both part of the Israel-based Bazan Group, has seen a number of transparent versatile copolymers being introduced over the years aimed specifically at rigid packaging processors.
These include Capilene CL 50 E, a speciality soft polypropylene which can be used to produce cast film, compounded, injection moulded and thermoformed products.
DuClear CE 85 E, is a new phthalate-free grade of speciality clarified polypropylene random copolymer, developed for use in extrusion blow moulding, sheet extrusion and thermoforming. It exhibits high transparency and contact clarity, coupled with superior gloss and surface finish.
Resource: http://www.prw.com/article/20160212/PRW/160219953/rigid-packaging-cashes-in-on-the-versatility-of-plastics
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