With the theme for this year’s conference being “Packaging: Fit for the Future”, David will be taking part in the Future Paper Innovations breakout session on day one with his session “Get more fibre in your packaging diet”.
In a first for the AIP, the entire program will be run virtually with all speaker sessions available both live and on demand through to the end of 2020 to ensure participants can access the wealth of knowledge being shared throughout the many sessions.
Zipform Packaging will also be hosting interactive morning tea sessions on day two and three to discuss innovations in paperboard and rigid composite packaging, with members of the Zipform team available to answer questions throughout the session.
To view the program and book your place today, visit the event website. The conference is open to all in the Australasian packaging industry.
#australianinstituteofpackaging #2020aipconference
]]>There are challenges for the industry as manufacturers and brand owners grapple with the requirements for recycled content without impacting food safety, product quality and cost. These pressures are more prominent for plastic where the increase in recycled content is to increase from a lowly 2% to 20%.
As has been known for a long time now, paperboard leads the way in recycling rates within Australia together with the recycled content rate (currently 49%, targeted to increase to 60% by 2025). Together with coming from a renewable resource, this makes paper a perfect solution for improving packaging sustainability.
At Zipform Packaging, thanks to the unique linear form technology, packs are currently made from >60% recycled content i.e. already above the 2025 target, without any compromise to food safety, product quality or cost, making rigid composite packs an ideal solution to ensure packaging circularity.
With a primary packaging source that meets APCO 2025 recycled content targets, ensures food safety through a high barrier hermetically sealed pack and a cost base comparable to existing rigid packaging there is no reason not to put more fibre in your packaging diet!
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The expected outcomes of the project over the next 2 years are:
]]>“Food waste is a huge socio-economic problem both globally and locally here in Australia. We applaud the initiatives undertaken within the body of the Fight Food Waste CRC, and as a responsible packaging manufacturer we are particularly pleased to be involved at the heart of the issue as it relates to packaging. At Zipform Packaging we strive continually to come up with packaging solutions that can improve shelf-life, provide excellent openability and resealabilty characteristics and which also have a positive sustainability message. Our engagement in the project led by AIP is another signal of our intent to be a key player in the ever-demanding world of packaging and support such key industry initiatives.” John Bigley - CEO
The first stage of the AIP Project is to undertake an on-line survey to better understand what importance Save Food Packaging design plays in packaging development considerations.
Zipform Packaging, as one of the Project Contributors for the Save Food Packaging Consortium, would like to invite you to participate in the 'Stakeholder Review and On-line Survey of Product-Packaging Design Processes' component of the 'Save Food Packaging Design Criteria and Framework' research project within the Fight Food Waste Cooperative Research Centre. We are interested in learning more about current product-packaging design and development processes; consideration of designing packaging to save food; barriers, gaps and opportunities.*Please refer to Plain Language Explanation. *Please read this sheet carefully and be confident that you understand its contents before deciding whether to participate. The outcomes of the project will be made public through the commissioned report, public briefing document, and a journal article, all completed for the Fight Food Waste Cooperative Research Centre.
To commence the survey please use the below link. This survey will take approximately 5 minutes and your feedback is extremely important to the project. We would also ask that you please pass the survey on to all relevant stakeholders within your supply chain and invite them to participate.
Stakeholder Review and On-line Survey of Product-Packaging Design Processes
On-line Survey Link...
As a leader in paper packaging innovation, Zipform Packaging is challenging this misconception with a range of paperboard packaging solutions suitable for chilled and frozen applications alike with exceptional decoration enabling brands to stand out on busy supermarket shelves.
Not only is paperboard an aesthetically pleasing material for use with dairy products, but thanks to significant advancements in material composition and advanced manufacturing processes, Zipform Packaging can enhance the functional performance of paperboard beyond that of the everyday use of the material.
Zipform’s Rigid Composite Packs are comprised of multiple layers including aluminium enabling manufacturers to create a hermetically sealed pack with an excellent barrier to light, oxygen and moisture transmission to protect even the most demanding products.
In addition to this, the unique format of Zipform’s manufacturing process means that multiple pack sizes can be made from a single tool, creating the potential for single serve, family and bulk packaging without investment in multiple toolsets.
As an alternative to Rigid Composite packs, Zipform Packaging can supply paper cup and tub solutions for use within the chilled cabinet.
With the ability to adopt alternative paperboard specifications to meet the requirements of the product including microwave safe and high barrier paperboard packaging, the opportunity to enhance the customer’s experience with a sustainable packaging option is within reach.
With exquisite decoration options on offer, high barrier paperboard cups and rigid composite packs from Zipform Packaging are sure to capture the consumer’s attention while meeting the most stringent technical requirements in a completely unique format for the category.
Contact Zipform Packaging to explore how a partnership could bring a fresh approach to your product.
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As the global FMCG industry begins to recognise the impacts of packaging on the environment, a tsunami of change has swept the globe with brand owners committing to ensure all packaging is both recyclable and has strong sustainability credentials with ambitious timelines.
Through the use of Zipform Packaging's unique manufacturing process, these aspirations can be met with Rigid Composite Packaging that is curbside recyclable throughout Australia and New Zealand.
Not only is Zipform Packaging's Rigid Composite Packaging recyclable, each pack contains over 70% post-consumer recycled material together with FSC certified paperboard linear-formed in unison to ensure the integrity of the pack remains uncompromised while reducing the impact of packaging on the environment.
As a member of the Australian Packaging Covenant and as a partner of the Australian Institute of Packaging, Zipform Packaging continues to work within the industry to ensure packaging solutions support the ambitions of businesses to utilise recyclable packaging. We are also working with food manufacturers limit the harm food waste can cause to the environment through packaging that protects the product and enables ease of use to consumers. The PREP tool available to all APCO members is also used to analyse and demonstrate that Zipform Packaging’s Rigid Composite Packaging is recyclable within Australia and New Zealand.
The introduction of a paperboard base in Zipform Packaging's rigid composite packaging assists in the recovery and recycling process, while also enabling the Rigid Composite Packs to be used for a wide variety of contents from dry powders through to dairy and beverages with the potential for shelf life extension thanks to the exceptional barrier properties inherent in the packs.
Get in touch with Zipform Packaging today to learn more!
]]>Many people are aware of the premium whiskey brand, Limeburners, and if you’re not one of them, perhaps you should try a sip or two.
The Limeburners business is defined by a carefully crafted product, a premium, small-batch brand and lovely packaging.
“It is always exciting to be retained by a business that is focussed on beautifully crafted products. We love the challenges of developing packaging to match a high benchmark set by the brand and product. This was certainly the case with Limeburners and everyone involved was delighted when the final solution included costs savings in addition to achieving a premium finish.”
John Bigley, Zipform Packaging CEO
When Zipform Packaging engaged with Limeburners, our challenge was to create a solution for the manufacture of a premium whisky pack without a metal bottom that would be suitable for this great southern WA whisky distillery.
We are always happy to look for solutions where we can replace metal and plastic with paper solutions to combine improved sustainability, with a premium finish and uncompromised function.
The solution we developed involves a strong paper composite pack that our team designed with a top metal plug.
The weight a full bottle of whiskey is significant due to the combination of glass and liquid. So, for Limeburners one of the defining requirements in this project was to create a packaging product that was sturdy and robust. To achieve this, we designed a pack that incorporates a heavy duty drink coaster in the base to add extra strength, plus gold foil stamping to create a highly premium detail.
With no metal bottom, this premium whisky packaging solution is recyclable in the paper stream, unlike similar imported packs which do incorporate a metal bottom. Zipform Packaging's packaging contains 80% recycled paper content.
Limeburners is a great example of a business who want to achieve sustainable packaging solutions by reducing plastic and metal usage, while still retaining a premium finish that matches the quality of their products. With this solution, we were able to meet both key requirements of the client’s brief.
Quite remarkably, in this case, the client was moving from an unbranded packaging solution that was basic by comparison. Even within that context, the Zipform Packaging solution still achieved cost savings when compared to the previous packaging option.
]]>We were presented with a challenge to develop a premium over-cap that includes the integration of a ‘window’ to allow good visibility of the product.
This project challenge is a good example of our ability to work on an existing solution to re-consider it, and make it better. Our goals in cases such as this one is to improve function and performance and create a new variation on an existing solution.
“Our team are highly skilled at taking existing solutions, and working to evolve them. We understand the language of packaging, and how to combine design with more sustainable solutions to produce a more progressive outcome. In this case, innovation delivered a premium product that is a great solution for many clients.”
Eddy Pahor, Zipform Packaging Commercial Director
While a clear PET lid is available, it did not meet the premium requirements that some of our clients were looking for to combine with the product visibility function. So, our goal with this project was to retain the function of a clear window that gives the end-users a clear view of the products they are purchasing and consuming, while elevating the solution with a finish that creates a more premium look and feel.
To evolve the existing see-through lid solution into a new iteration that delivers a more premium packaging product, we worked closely with our paper lid manufacturer. The outcome was the development of printed paper lids with windows that work for both round and non-round packs.
Our new ‘premium window’ packaging lid includes the application of a clear polypropylene window in the centre of a paper lid. The end result is a new lid variant that provides a print area and product visibility at the same time. The ability to print around the window, and the paper finishing, delivers on the premium requirement, and also gives clients the flexibility to create different looks depending on the graphics, text and colour they choose to print around the window.
The final benefits delivered to clients is a super-premium look that delivers impressive on-shelf differentiation with a beautiful and practical pack for use in or out of home. We have also increased the sustainability credentials of this lid solution and we are proud that this product is recyclable in the paper stream because of the low percentage of plastic used for the window.
In terms of cost and efficiencies, we can now deliver a highly affordable premium option that in many cases will prove to be a more attractive, and practical solution for clients looking for a point of difference with their lidded packaging.
Clients that have adopted this new solution and are enjoying the benefits, include Mix My Muesli and Rowies Cakes and they are in good company as more people adopt this solution.
]]>In the area of ovenable packaging for the food service industry, Zipform Packaging are proud to have a solution that advances performance by using new techniques and technologies to solve a common issue with PET coated products. Our solutions increase the integrity and overall performance of these products, to make life much easier for the companies, and the experience far more pleasant for the consumer.
The Zipform Packaging offering is ovenable folding cartons without a PET coating that achieves the performance enhancements summarised above.
“We are always very happy to be approached by industries with specific needs and challenges. Our dedication to innovation and exploring new solutions places us perfectly to respond to our clients challenges, and solve them. As an example, we have created a product that gives the airline industry a new benchmark in packing performance for inflight food service.”
David Kilpatrick, Zipform Packaging Research, Development & Quality Director
A less progressive way to supply ovenable boxes suitable for in-flight meal and snack services on aircrafts loaded in Australia utilises a combination of PET and ovenable board. PET coating acts as a barrier on the board to protect against fats and liquids. But these boxes were often subject to twisting, warping and even blistering of the PET due to the high oven temperatures and the length of time the food is held at those high temperatures.
The team at Zipform Packaging were asked to source a paperboard product more suitable for aircraft food service applications and to manufacture boxes which addressed and improved on the common problems and concerns.
In our search for the right product, we identified a European board provider as the ideal supplier, because they manufacture a virgin FSC board suitable for the required aircraft applications. We set up a supply chain to manage the stock locally and convert the board into finished boxes on a just-in-time basis.
This new product and process created a number of benefits. The product that is currently supplied and used is rated to 210°C and has performed reliably for a number of years. The board conversion process has been simplified, and the boxes perform better for in-flight service. They also provide a better yield when recycled in the paper stream, because they are made from 100% virgin FSC paper, making them a fully sustainable solution.
In addition to these benefits, Zipform Packaging have provided cost savings to our clients. The boxes produced are significantly cheaper than boxes made from equivalent ovenable PET or paper laminate structures.
“We find great pride in creating solutions that not only solve specific functionality challenges by using new techniques, but also offer the client greater efficiencies at the same time. There is nothing better than delivering a solution that includes multiple wins for our clients on performance, innovation and cost.”
John Bigley, Zipform Packaging CEO
We are very happy to have been in a position to help some great clients in SnapFresh (Qantas), and Rowies (Virgin) with these innovations and see them enjoy the multiple benefits.
]]>Zipform Packaging is well equipped with the technology to design, develop and supply ovenable packs and trays that offer increased performance, a better end-user experience, increased sustainability and impressive cost savings.
Utilising our Linear Forming and Closing technologies, our team can manufacture packs suitable for cooking and reheating food and liquids in both conventional ovens and microwave ovens.
“We dedicated significant time to research and development, and then a comprehensive testing phase to make sure that the materials and final solutions meet our standards. It’s always exciting to bring a new option in the packaging space, and our Ovenabl™ range will provide an excellent new option to our clients.”
David Kilpatrick, Zipform Packaging Research Development & Quality Director
In our quest to find the right materials for our oven-safe packs and trays, we identified and evaluated a range of products and materials, all certified for conventional oven use up to 200°C and safe for microwave use as well. To make sure we are supplying our clients with the best possible ovenable solutions, we trialled the materials in varying combinations before selecting two different specifications for our new Ovenabl™ range.
Our Ovenabl™ packs will be available by mid-2018 and will be suitable for conventional oven use at 200°C for 20 minutes and for all microwave oven use. In addition to their oven-safe qualities, all of the packs can be used for baking and freezing in commercial bakehouses and kitchens, and they will be available in a range of sizes to suit different applications. As always, flexibility and providing options is at the centre of what we offer.
The Ovenabl™ range provides a number of benefits to business owners, their team members and customers. The packs are up to 40% more time efficient when cooking or re-heating contents in the microwave, and the simple-to-open design enables a more even cooking or reheating of the food. In turn, this improves the customer’s experience with the edible products they have purchased. The packs are also cooler to touch and hold after cooking and reheating, providing safer and more comfortable handling for end-users.
The whole pack can be printed or branded to the client’s specific needs, eliminating the need for the addition of separate sleeves or inner cartons. Our ability to deliver a more streamlined solution and increased performance fits perfectly with our overall vision as a progressive packaging supplier. The packs are also dimensionally accurate, and therefore suitable for high speed processing. And last, but certainly not least, they are incredibly strong, making it possible to dispense with an outer carton and deliver trays or packs in pallet layers.
As always, sustainability is at the core of our processes, and our ovenable packs and trays are comprised of over 75% virgin FSC paper and they are generally recyclable in the paper stream. Council standards for paper recycling may differ in certain areas, so it is always best to check the products comply with your council’s recycling criteria before adding them to the recyclables.
Our ovenable packs can offer clients cost savings of up to 20%, depending on their current pack specification and source.
]]>In line with our ongoing commitment to increase sustainability and offering advanced environmentally friendly packaging options to our clients, the Zipform Packaging team are proud to offer paper bottoms and membrane tops in place of metal closures on composite packs.
Manufacturing a pack that offers the benefits of barrier properties, strength, cost, and recyclable paper content with a paper composite bottom closure and a membrane top closure can be a challenge. But we love a good challenge and finding a great solution to offer our clients is even more enjoyable. In this case, we were able to source a product that perfectly suits our needs, and delivers the performance demanded by the businesses we work with.
“The commitment of the Zipform Packaging team to understanding our client’s challenges, and finding new, best-practice ways to meet those challenges continues to impress me. We have a genuine passion for solving ongoing challenges with new technologies that improve pack integrity, performance and offers increased sustainability.”
John Bigley, Zipform Packaging CEO
Our team identified the very best manufacturing equipment to deliver high speed, robust solutions for this leading edge technology. Capable of reliably closing 120 packs per minute, the combination of equipment and labour productivity, with low material costs, delivers outstanding value for money in a recyclable paper composite pack.
With our technology, packs are delivered by conveyor direct from the body-making line to ensure efficiency and a speedy turnaround time. This process completes a number of complex operations, including forming a top curl and closing the bottom of the pack before delivering the finished product to our robotic palletising facility.
The technology enables us to cost effectively close both round and non-round packs and results in a more sustainable packaging specification for improved environmental outcomes. It also ensures the pack is lighter in weight than conventional, metal-closed composite packs by approximately 15%. These advantages are impressive and we’re proud to be leading the way in delivering these solutions in the Australian and Asia-Pacific markets.
This process is sustainable and one that we work on continually to refine and make additional improvements. We found that by increasing the percentage of recycled and FSC virgin paper, and substantially decreasing the percentage of metal in the pack we have made significant progress towards a fully sustainable packaging specification. Currently, our pack is generally recyclable in the paper stream, however, different councils apply different standards and criteria for paper recycling, so it is always best to check before adding packaging to the recycling.
“We find that all sorts of companies are happy to engage with us when they understand the combination of benefits we deliver. When we offer new technologies, reduced the use of metal and plastic, increase sustainability, achieve better performance and include fantastic savings, it makes for a compelling argument.”
Eddy Pahor, Zipform Packaging Commercial Director
We typically offer customers significant savings compared with conventional composite packs. The flexibility, improved sustainability, replacement of metals and of course, the cost savings, make these solutions appealing to many clients. Mix My Muesli, Inca Organics, Limeburners, Real Pet Food companies, Matcha Tea and Rowies Cakes are amongst the many clients who have benefited from our paper bottom and membrane top closures.
]]>In 2018 companies are looking for progression and flexibility with their packaging. The emphasis on a total sustainable solution that meets the technical specifications, and delivers shelf impact, is increasing.
We’re here to meet those demands and our investment in technologies and processes that deliver flexibility and variety has been significant.
Zipform Packaging offers composite packaging solutions in a variety of shapes and non-round options that allow our clients to find the format for the packaging for their products.
To manufacture a pack that offers the benefits of barrier properties, strength, cost, and recyclability in shapes other than and including round profiles was a challenge. We had to spend some time looking for the right technologies and the best solution.“Our team carries a combination of experience and learning, combined with a passion for progress and looking for exciting new technologies that expand what we are capable of offering our clients. There’s nothing we love more than meeting difficult challenges with solutions that exceed expectations.”
Eddy Pahor, Zipform Packaging Commercial Director
Currently, we have one non-round 401E tooling set available for a pack with an equivalent footprint to a 99mm cylindrical can. By utilising this tool set, these packs can be made in any height between 45mm and 230mm.
We are also in the process of planning our next stage of investments that will include a larger non-round tool set. This will give us the capabilities to provide a 127mm cylindrical can equivalent, suitable for products in segments such as infant and adult nutrition as well as beverage powders.
The pack is fully recyclable in the paper stream that handles beverage cartons and UHT packs. All of the paper content is either recycled or from FSC resources. On average, the pack is comprised of 80% recycled content without compromising food safety. Migration issues are resolved because of the presence of foil acting as an impermeable barrier within the pack. In addition, approximately 85% of the pack is comprised of renewable resources.
The pack also offers weight savings when compared with both conventional composite cans with a metal bottom, and with rigid plastic packs.
“These specifications are another great example of our commitment to progressive technologies that increase both the sustainability and the performance of the final product.”
John Bigley, Zipform Packaging CEO
Non-round composite cans offer multiple benefits to brands and businesses, including excellent product differentiation in the marketplace and on-shelf with a larger facings combined with easier handling for consumers. Other benefits include ease of transport, storage and shelf density compared with the 99mm round cans, and we typically offer customers savings of between 15 and 20% compared with conventional composite cans.
These solutions and their benefits have attracted the attention of several Zipform Packaging clients including Baskin Robbins, Wondersnack, and Gilbert's Fresh, all benefiting from our non-round composite can innovations.
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