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Innovative and Sustainable Flexible Packaging: October Spotlights

Our series of innovative packaging from FPA’s 2020 Flexible Packaging Achievement Awards Competition continues! Check out our October spotlights listed below to learn about the benefits of each package, the manufacturers behind the creation, and brands that are using these packages for their product.

Little Baker Coconut Dates, Chocolate

With its eye-catching, cool graphics, this Little Baker Chocolate Coconut Dates stand-up pouch with zipper and euro punch stands out from the rest of the packages on the shelf earning it a Silver Achievement Award for Shelf Impact. The matte film gives the pouch a rich and soft feel. The resealable zipper keeps the product fresh for a longer time without having to switch it to another container. To learn more about the manufacturer, visit their website here.

XTough™ High Strength Pouch for Daisy Brand Sour Cream 

Berry Global created a film that dramatically improved the Daisy Sour Cream package’s ability to survive through the distribution system which eliminated complaints and credits for package damage. The package features an oxygen barrier, excellent sealability, and extreme toughness. The package uses flexographic printing for brand and product identification. To learn more about the manufacturer, visit their website here.

EcoVue® FlexPac®

The flexible EcoVue® FlexPac® packaging for ultrasound gel features custom flexible packaging film with many benefits to the consumer and society overall! It’s easy to hold and easy to use, but it is also lightweight and requires less energy to manufacture and transport. This innovative package earned a Silver Achievement Award for Packaging Excellence. To learn more about the manufacturer, visit their website here.

Wander Beyond Brewing 

Wander Beyond Brewing searched for decorative labels that matched their natural, sustainable values. For this differentiation, the craft brewers incorporated EarthFirst® TDO labels for displaying their unique creativity and commitment to environmentally responsible decoration. EarthFirst® PLA labels are made from annually renewable, bio-based materials. Eco-friendly packaging was a must-have for the craft brewers to align with their high quality, premium beer position. To learn more about the manufacturer, visit their website here.

Amcor SmartTack™ Resealable Label with Premium Tamper Evidence

The SmartTack™ resealable label with premium tamper evidence is a packaging solution that fully protects the perimeter of the label. This innovative design improves packaging security by clearly indicating to a consumer if the package was opened from an area other than the peel tab. This new and innovative solution earned a Silver Achievement Award for Technical Innovation. To learn more about the manufacturer behind this packaging, visit their website here.

Perfect Packaging Life Cycle Assessment

One of the most beloved condiments has been evolving over the last few years to perfect its packaging and reduce its environmental impact. Glenroy, Inc and the Flexible Packaging Association partnered to perform a life cycle assessment of the packaging used for ketchup: the new STANDCAP Pouch vs. the rigid PET bottle. 

This Life Cycle Assessment evaluates the two forms of packaging in relation to water consumption, greenhouse gas emissions, fossil fuel consumption, source reduction benefits and recovery benefits. 

Water Consumption 

The premade flexible STANDCAP Pouch uses approximately three quarters less water (-75.3%) than the rigid container. PET bottles require a more water-intensive stretch blow molding process as compared to the laminating and extrusion process for multilayer pouches. 

Greenhouse Gas Emissions 

The manufacturing of the PET bottle produces 58.8% more emissions than the flexible, inverted pouch. The high rate of emissions can be attributed to the additional energy and heat needed during the stretch blow molding process for the bottle.

Fossil Fuel Consumption

The premade STANDCAP Pouch results in 52.7% lower fossil fuel use because it takes less material to produce than the PET bottle. Additionally, the stretch blow molding for the bottle manufacturing process uses more fossil fuel than the pouch’s laminating and extruding process. 

Source Reduction Benefits 

According to the U.S. EPA Waste Hierarchy, the most preferred method for waste management is source reduction and reuse. A major benefit of flexible packaging is the high product-to-package ratio that it offers.

Recovery Benefits 

While many multi-material flexible packages are not yet widely recovered and recycled, they still reduce a substantial amount of material sent to landfills versus other types of packaging. The PET bottle results in about 40% more material landfilled, which is notable considering its 29.2% recycling rate and the lack of any credit for the flexible pouch recycling.

The premade STANDCAP Pouch results in lower environmental impacts across a wide range of metrics as shown above. This is driven by the efficient material usage of the flexible pouch, which uses less than half the amount of material needed to package the same amount of ketchup.

Sustainable and Innovative Flexible Packaging: September Spotlights

Our series of innovative flexible packaging from FPA’s 2020 Flexible Packaging Achievement Awards Competition continues! Check out our September spotlights listed below to learn about the benefits of each package, the manufacturers behind the creation, and brands that are using these packages for their product.

Oreo “Game of Thrones” Cookie Package 

Bend the knee to this package—this package belongs on the throne!  Mondelez launched the limited-edition “Game of Thrones” Oreos to bring something unexpected to the classic cookie as a tribute to the HBO show’s legacy. In addition to the 4 distinct edible insignias on the cookies, Sonoco’s packaging incorporates a registered matte/gloss feature and spells out “Oreo” in the show’s logo font using glossy metallic effects. The package also incorporates Sonoco’s SmartSeal® technology, a patented built-in precision die-cut easy open and reclose feature with tamper evidence. To learn more about the manufacturer, visit their website here!

FLEXPET™ F-STF ULTRA SOFT SUPER DURABLE BOPET FILM

F-STF is a soft touch/velvet feel matte BOPET film that is specially designed to laminate high-quality graphic media with a velvet feel similar to peach skin. The key features include excellent matte homogeneity/dispersion; excellent soft velvet feel; low gloss on the matte side; excellent contact clarity; good scratch resistance; enhanced graphics; and package differential with a luxury feel and look. Flex Films (USA) Inc. earned a Silver Achievement Award for Shelf Impact with this innovative flexible packaging. To learn more about the manufacturer, visit their website here!

REDKEN® Flash Lift Bonder Inside 

REDKEN® Flash Lift Bonder Inside is a groundbreaking spouted pouch design for Health & Beauty that replaces a rigid container with an internal bag to promote product safety. ProAmpac and REDKEN® redesigned this pouch to create a unique experience for customers. The creative directional spout design minimizes powder fumes while dispensing cleanly into the dosing lid/cap. It was also created with an internal “cross” design into the spout to assist with easy pour and separating potential powders that make up the product. The shape of the pouch provides an excellent billboard to promote the brand, and the print required copy eliminates the need for an instruction insert. In keeping with sustainable goals, this redesign reduced the number of packaging components and the total weight of the new packaging to ship more product and less packaging. To learn more about the manufacturer, visit their website here!

Nestlé Toll House Artisan Collection Premium Backing Chip-Extra Dark

The design and print of the Nestlé package elevate the overall presentation for this high-end product from the first sight. The smooth pink and purple vignette of the flower design complements the dark black background and metallic gold creating a high contrast and high impact overall presentation. Coupling this printed artwork with consistent high-quality films creates a secure package with a high-end fit, finish, and appearance. American Packaging Corporation received a Silver Achievement Award in Printing for the design. To learn more about the manufacturer, visit their website here!

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