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FLEXO Magazine : July 2011
Breakthrough use of polyactic acid (PLA) films broke significant barriers for high-volume dairy applications for Stonyfield and Clear Lam, according to judges. The new form/fill/seal multipack yogurt cups are made of 93 per- cent PLA, a switch from polystyrene (HIPS), believed to be the first for this market. The PLA is made by Natureworks and results in 48 percent lower GHG (greenhouse gas) emissions vs. HIPS. Expert analysts noted, “Compression strength increased by 15-20 percent, resulting in fewer dam- aged products during transit. Stonyfield also overcame the difficult challenge of applying a good lidding seal to a PLA cup, as the lidding film needs to withstand heat during ap- plication. In addition, using 93 percent plant-based material further drives their reputation as a leader in sustainability. ” The package captured a Silver medal. Coca-Cola Japan was also saluted for its use of plant- based materials, which won it a Silver award. Judges stated, “ In a small, highly populated country like Japan, space is at a premium. I Lohas, a mineral water brand, saw its PET bottle weight reduced by 40 percent, compared to the former design, while guaranteeing consumer usability. I Lohas PET bottles are also Japan’s lightest in the 1,000 ml class. Once consumed, the bottle is easily twisted, which crushes the bottle to a very small size. This smaller size reduces transport cost to the recycler and improves transportation efficiency. It also supports the needs of the local market by reducing the volume that comes out of Japanese households. This PET bottle is extremely light and has the environmental benefit of using up to 30 percent plant-based material, reducing the petroleum-based materials.” It won a Silver medal. SMALL SIZE, BIG IMPACT Yet another Silver medalist, Intel, reduced overall package size and enhanced cube efficiency for its line of processors by replacing all PVC inserts with thermoformed APET and corru- gated fiberboard. The innovation was credited with engineer- ing a a substantial improvement in environmental impact for this high-volume product line. Responsible sourcing achieved a reduction of 2.5 million pounds of material, reduced water consumption and reduced GHG emissions. Also of note, this package reduction enabled a significant reduction in the number of vehicles required for transportation of raw materi- als and finished goods. Finally, Sensodyne’s new package design brings out the “ WOW” in stopping power. Created by GlaxoSmithKline Consumer Healthcare’s Global Packaging Team (PacX- perience) and their collaborators, it is the first oral health care brand to use cutting-edge Fresnel lens technology to create dramatic results and capture a Silver medal. Judges explained, “The combination of deep embossed Fresnel lens and positional control through the lamination process allows the printer to register inks to the lenses to create a unique 3D brand identity. ” n 26 FLEXO july 2011 www.flexography.org