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Plant-based dairy on trend

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combidome: new products | combisafe: additional 440 ml-volume | Brazil: plant extension completed; new projects | frischli: new customer opts for food option filling machine | screw cap combiSwift now also for food composite | 40 % of all SIG cartons FSC-labeled | web-shop and print portal online | Fully automated feeding of sleeves for high-speed filling machines

Edition 1/2015

2 SIG COMBIBLOC MAGAZINE 1/15 ///

IMPRINT /// SIG COMBIBLOC MAGAZINE 1/15

Published bySIG International Services GmbH Rurstrasse 58; D-52441 Linnich

EditorsCarolina Boni, Ingo Büttgen, Bea Callanta, Luciana Galvão, Jan Gansow, Norman Gierow, Sandra Hallaschka, Dominik Haug, Matthias Krusche, Claudia Meza, Bianca Roßkopf, Heike Thevis, Jörg Trebels, Julia Trebels

Concept and designArnold.KircherBurkhardt AG, Uerikon, Switzerland SIG International Services

PicturesSIG Combibloc Flamisch Foto + Film istockphoto fotolia Diego Pisante Jaqueline Alves

LithographyAppel Grafik, Frankfurt

PrintAppel Grafik, Düsseldorf

ContactT: +49 2426 79 -0 [email protected]

Internetwww.sig.biz

SIG Combibloc Magazine is published in German, English, Spanish, French, Italian, Portuguese, Polish, Russian and Chinese.

All rights reserved. Articles indicated as being contributed by other writers do not necessarily reflect the views of the publisher. No part of this publication may be reproduced or electronically distributed without the prior permission of the editorial team.

Dear readers,We hope you’ve had a great start to the New Year. In 2015, again our mission is to offer our customers added value that makes their lives easier. A recent example of this is SIGdesign2print, a new website which we’ll be introducing to you in this issue. With this website, we’re supporting our customers to make the process from packaging design to preprint faster and easier. In addition, the new Online Spare Parts Shop offers our customers the chance to order the spare parts they need, anytime and in a simple way.

We also want to offer our customers technical solutions and packaging options that are tailored to their needs and unique in our industry. In this respect, we offer with combisafe in a 440 ml- volume a first in the field of autoclavable carton packs: food prod-ucts in carton packs are now also available in exactly the same drained weight consumers know from the food metal can. Another example is our combidome cardboard bottle, which is proving a suc-cess. Dutch company HERO, for instance, has opted for this inno-vative packaging. Industry specialists are excited about it too: combidome won numerous design and innovation awards last year.

As unique as combidome is our Food Option Technology. German dairy group frischli has opted for this technology, establishing the basis for a range of innovative products. Thanks to the Food Option Technology, frischli is able to fill highly viscous products and prod-ucts with particulates in carton packs using the slightly adapted standard filling machine for beverages. And in the push towards greater automation, we’ve taken a big step forward: with the Robotic Magazine, we can now offer a fully automated magazine for our high-speed filling machines.

I hope you’ll enjoy reading about these and other topics in our new customer magazine. Markus Boehm, Chief Market Officer SIG Combibloc

/// SIG COMBIBLOC MAGAZINE 1/15 3

06

32Useful tips for designing SIG Combibloc carton packsWith a new, special website, SIG is supporting its customers to make the design process more efficient.

34Ordering online: SIG Spare Parts ShopWith the new spare parts shop, it is now possible to order spare parts any time, quickly and easily.

COVER STORY

Plant-based dairy on trendThey are among the fastest-growing beverage segments world-wide: plant-based beverages as alternatives to dairy products. And soy is no longer the main driver of this growth. Innovative beverages made from nuts and grains are more in demand than ever.

28Success in fast-growing market Start of extrusion line at SIG's production plant in Brazil. And six new filling machines have been installed at the premises of Quatá Alimentos.

04A world first in retort carton combisafe now also available in 440 ml volume.

14combidome: A real hero for 'Hero' Netherlands: popular juice brand now available in the innovative carton bottle.

16Fully automated sleeve feed-ing system for high-speed filling machinesSave time and costs with the Robotic Magazine.

20combiSwift now also for food carton packsUltimate convenience: screw cap now available for carton packs spe cially made for food products.

22frischli creates the basis for innovative of productsGerman dairy company invests in Food Option Technology: more than 100 products filled in combiblocStandard.

2620 years of FSC™

Recognition and popularity are increasing. 40 per cent of all SIG carton packs carry the FSC-label.

Contents


A world first in retort carton Germany: Three ‘Bio Sonne’ brand vegetable varieties have been launched in combisafe. For the first time, the heat-resistant carton pack is available in the 440 ml-volume – exactly the same drained weight consumers know from the food metal can.

440 ml


appearing all the time. World-wide, more and more retailers, food companies and consum-ers are being won over by the advantages, and are reaching for products in carton packs." With the launch of peas, corn,

and peas & carrots in the heat-resistant carton pack from SIG Combibloc, the first

combisafe carton packs in the new 440 ml- volume are on sale in Germany. The ‘Bio Sonne’ brand vegetable varieties are filled by German food manufacturer Jütro.

The usual quantity, greater convenienceThe 440 ml-volume is an innovation in the in-dustry, because products which consumers have traditionally bought in standard food metal cans are now also on sales shelves in car-ton packs, packaged in exactly the same drained weight like in metal cans. It means consumers do not need to get used to a new product quantity when they opt for tradition-ally canned products packaged in a carton pack. On the contrary: They can get the usual product quantity, and benefit from the many advantages of the carton pack. The perforation right across the carton top makes it possible to open the pack easily without additional tools such as scissors or knives, and empty it out completely: Another reason for consumers to rethink their opinion and start making use of traditionally canned products packaged in car-tons packs.

Until now, combisafe has come in 200, 300, 400 and 500 ml volumes. Now, the 440 ml- volume can also be offered. All can be filled on a single SIG Combibloc filling machine. Dominik Haug, Global Product Manager Food at SIG Combibloc: "The major strengths of car-ton packs are their convenience, their product protection qualities and their good environ-mental characteristics. And in terms of logis-tics and advertising effectiveness on the sales shelf, cartons clearly outperform competing packaging solutions. In addition, our carton packs are, of course, free from Bisphenol A.

More than 200 products are currently sold in the heat-resistant carton pack, and more are

combisafe

combisafe is a carton packaging from SIG Combibloc that is suitable above all for particularly chunky foods, and for all food products that cannot pass through a pumping system and an aseptic process – such as pulses and vegetables, fruit, convenience foods and stews.

Through the use of three modular filling units, including a high-precision multi-head weigher, a hugely diverse range of products can be filled in combisafe. After the products have been filled into the carton pack, which is open at the top, the carton top is sealed ultrasonically. The carton packs are then automatically con-veyed into an autoclave, which can be either static or rotary. In the area of long-life food carton packs, the use of rotary autoclaves is a world first. Not only do these rotary autoclaves, in which package and product are sterilised together, guarantee maximum product quality; through the continuous rotation of the carton packs during heating, they also make it possible to fill and process certain products in the first place.


Plant-based dairy on trendThey are among the fastest-growing beverage segments world-wide: plant-based beverages as alternatives to dairy products. And soy is no longer the main driver of this growth. Innovative bever-ages made from nuts, grains, seeds and ancient grain varieties are more in demand than ever.


It is estimated that in 2013 alone, more than 1,000 new plant-based dairy alternative products came onto the market – around twice as many as five years ago. And soy is

no longer the main driver of this growth. Innovative beverages made from nuts, grains, seeds and from ancient grain varieties such as quinoa, buckwheat and millet are more in demand than ev-er. In addition, vegetable protein beverages made from coconuts and pulses are also finding a ready market with consumers.

The reasons for this growth in the segment are many and varied. Lactose in-tolerance is one of the drivers. In addition, more and more consumers are making a conscious effort to eat healthily. For this reason, they pay close attention to the foods they consume. The ingredients analysis of the food plays just as much of a role as its provenence, cultivation and processing. Plant-based dairy alternatives are naturally lac-tose-free and are generally considered to be lower in cholesterol and fat than milk from an-imals. But they usually offer a similar protein, mineral and vitamin content. From a health viewpoint, plant-based dairy alternatives are often more easily digested than dairy products – this also applies for people who do not suffer from lactose intolerance.

Matthias Krusche, Global Market Segment Manager at SIG Combibloc: “More and more consumers are experiencing sensitivity reac-tions to particular foods, and so are paying closer attention to what they eat. More than a third of all consumers now specifically avoid products due to allergies or intolerance prob-lems. For many consumers who, due to issues such as lactose intolerance, have to avoid ani-mal-origin products, or who choose to give up

these products for other reasons, these days soy no longer has to be the first choice as an alternative. Some consumers even develop al-lergies and intolerance problems with soy. Almond milk, on the other hand, is one of the

products seeing very dynamic growth. And coconut, rice and oat drinks are

also high on consumers’ popu-larity scale”.

The trend for consuming plant-based beverages as a protein source has its roots in Asia. Cows have never been very prevalent in the history of Asian civilisation.

Consequently, the number of people who suffer from lactose

intolerance is higher than in western countries. The production

and consumption of dairy substitutes is therefore traditionally higher in Asia than in the west. However, in western countries too a turn around is now becoming noticeable, in terms of the consumption of milk and milk al-ternatives. Matthias Krusche: “Until just a few years ago, most market launches of plant-based dairy alternatives were appearing on retail shelves in Asia, but now it’s the USA, Brazil, South Africa and European countries such as the UK, Belgium and Spain where growth rates have jumped substantially, and where there is still further potential in the future. Surveys conducted by various market research institutes suggest that up to 2018, worldwide growth in the plant-based dairy alternatives market will be in excess of 15 per cent per annum”.

Soymilk: no lactose, little fatBeverages made from soy continue to be pop-ular as dairy alternatives, even though they are no longer the main drivers of growth in the segment. To make soy milk, soy beans are shelled, soaked and ground with hot

“Market research institutes suggest that up to 2018, world-wide

growth in the plant-based dairy market will be in excess of 15 per cent

per year.”Matthias Krusche


Plant-based dairy market (in million litres)

2009 2013 2019

America North 336.2 434.4 584.9

America South 120.0 134.3 164.4

Asia Pacific 2,886.0 5,010.5 8,797.0

Europe 426.3 465.6 506.3

Middle East/Africa 14.4 34.0 69.5

Total 3,782.9 6,078.8 10,122.1

Wordwide, the segment of plant-based milk alternatives shows continuous growth. Source: SIG Business Intelligence


Tofutown: Vegetarian treats from Germany

It all started in 1981, with a small vegetarian

‘hippie collective’ called Soyastern. This collec-

tive has now grown into Tofutown, a pioneer

and innovator in the field of vegetarian foods,

which is garnering world-wide attention with its

products. In Europe, Tofutown is one of the lead-

ing producers of meat and dairy alternatives man-

ufactured from plant sources. The company relies

on filling technology from SIG Combibloc, and

uses a CFA 310 filling machine to fill a range of

soy and rice drinks in combiblocSlimline.

After initially having the products filled in

SIG Combibloc carton packs by a co-packer, com-

pany founder Bernd Drosihn decided that Tofutown

should invest in a SIG Combibloc filling machine of

its own: “We’ve been won over by the efficiency

and flexibility of the machine. The individual pro-

cesses are perfectly coordinated with one another.

It runs like a toy on a slot car track – smooth as silk!”

More than 110 vegetarian productsBernd Drosihn: “In a single sentence, our business

model is: we make foods that people like eating

and drinking, without resorting to the use of ani-

mal products. We use organic raw materials such

as wheat, soy beans and organic vege tables. Over-

all, at our three German factories in Wiesbaum

(Vulkaneifel), Lüneburg and now also Neukirchen

in North Hesse, we make more than 110 vegetari-

an products – around 35 per cent of which are

exported”. And not just within Europe. Tofutown

products are also available in North America and

in some parts of Asia, Australia and the Middle

East. The product portfolio extends from vegetari-

an burgers and sausages to tofu products, sand-

wich spreads, vegetarian lards and cheeses, soy

and rice drinks and pasta sauces. In addition, in

2004 Tofutown developed the world’s first

whippable organic soy cream. The cream products,

and the company’s rice and soy drinks, are on sale

in carton packs.

For Drosihn, healthy, moderate growth is the

company’s motto. In pursuing this aim, ‘Dr. Tofu’,

as he is sometimes known, is taking a fresh and

novel direction. For instance, in his video cooking

blog he presents, among other things, self-tests

of Tofutown products: www.youtube.com/user/

VianaTV. Drohsin also runs the Tofumusic record

label: At www.youtube.com/user/TofumusicTV,

viewers can judge his musical activities.

More on Tofutown products at www.tofutown.com


Seeds and grains: high in carbohydrate and fibre Dairy alternatives made from grains or seeds such as rice, oats, hemp or quinoa look similar to cow’s milk, but have a lower protein content and a higher carbohydrate and fibre content. Beverages made from grains and seeds also contain no lactose and are low in fat.

Rice drinks are popular because of their creaminess. They have the highest sugar con-tent among the plant-based dairy alternatives. To make the beverages, rice is ground, boiled in water and mashed. After sieving and filter-ing, safflower or sunflower oil is added to the filtrate, which emulsifies it and refines the taste. The rice itself is virtually fat-free. The protein content in rice drinks is 0.1 grams per 100 ml, so it is low compared to other plant-based dairy alternatives.

water. Soy milk has a high protein and vitamin content, comparable to that of cow’s milk. 100 ml of a soy drink delivers about 3 grams of protein; cow’s milk has around 3.2 grams. But soy milk is much lower in fat, and thus also lower in calories, than cow’s milk, and is free from cholesterol and gluten.

Almond milk: the favourite alternativeIt is almond milk that accounts for much of the global growth in the plant-based dairy alter-natives market. To make almond milk, toast-ed and ground almonds are mixed with water. Almond milk is low in fat and sugar, and so has few calories – about 20 per 100 ml. But at 0.5 grams per 100 ml, the protein content is comparatively low. Just like soy drinks, al-mond milk is cholesterol- and gluten-free.


To make oat drinks, which are climbing up the popularity scale with consumers, dehusked oats are coarsely ground, added to water and boiled. The liquid is fermented for several hours, then sieved and filtered. In this case too, the filtrate is emulsified with sun-flower or rapeseed oil, to give it the white col-our characteristic of milk. An oat drink deliv-ers around 1 per cent protein per 100 ml, and an equivalent quantity of beta-glucane. This is a substance which helps lower the cholesterol level in the human body.

Coconut milk: plenty of potentialCoconut milk too has plenty of potential in the area of non-dairy protein sources. Depending on manufacturer, these beverages, made from finely ground coconut flesh and water, have up to 2 grams of protein per 100 ml. These prod-ucts are also cholesterol-free and have little

sugar and fat, and they are well-received by consumers particularly thanks to their creamy texture.

Less water, a plus for the environmentThe popularity of plant-based beverages is giv-en a further boost by consumers’ growing environmental awareness. According to man-ufacturer’s information, producing one litre of soy, almond or coconut milk, filled in a carton pack, requires around 70 per cent less water than is needed to produce the same quantity of cow’s milk.

Carton packs have established themselves as a particularly apt packaging solution for plant-based beverages because they fit with the philosophy of most food manufacturers, for whom naturalness and the responsible use of resources are important issues.


New coconut beverages make not just holidays ‘So Delicious!’

They are made exclusively from GM-free

organic coconuts, are guaranteed dairy-free,

and ‘So Delicious!’: the creamy coconut bev-

erages from US food manufacturer So Delicious

Dairy Free are made for everyone who, for health

reasons or simply on principle, wants to avoid

dairy products, or is just looking for new ways to

eat a varied and healthy diet. Following the mar-

ket success of Cococcino Latte and Cococcino

Mocha, summery iced coffees made from organic

coconut milk and Fairtrade coffee, for the winter

season, So Delicious Dairy Free launched the three

flavours Pumpkin Spice (pumpkin flavoured), Nog

(eggnog with nutmeg) and Mint Chocolate (cocoa

and mint) in the aseptic carton pack combifitMidi

with combiSwift screw cap.

Successful for more than 25 yearsFor more than 25 years, So Delicious Dairy Free

from Oregon has been developing high-quality,

dairy-free and plant-based beverages.

Mike Murray, Vice President Marketing/R&D at

So Delicious Dairy Free: “Our company philosophy

is based on treating everything with respect –

people, animals and plants. For that reason, we

have specialised in dairy-free products made from

ingredients that are proven GM-free”. And success

has followed. The ambitious company’s product

range now includes beverages, coffee creamers,

ice cream desserts, yoghurt products and various

products such as soups and sauces, as well as in-

gredients for fancy cakes and other baked goods –

all entirely without milk.

In the last five years, the company has record-

ed extraordinary growth of more than 30 per

cent. For Murray proof that the dairy-free pro-

ducts segment has some of the best prospects in

the food industry. In contrast to soy-based dairy-

free products, it is in particular almond and coco-

nut milk that have strong potential. The reason for

this lies in the growing number of consumers who

are using dairy-free products not due to tolerance

problems, but because they place value on sus-

tainable consumption and are looking for ways to

eat more healthily. Mike Murray: “Many people

prefer the taste of almond and coconut milk, and

often consumers also like the texture of the prod-

ucts better than that of other dairy-free products.

At the same time, these days many people have a

sceptical attitude towards soy products, in terms

of genetic modifications. When consuming al-

mond and coconut milk, it’s a completely different

story. We guarantee consumers that our products

are made exclusively from GM-free ingredients”.

More on ‘So Delicious!’ at www.sodeliciousdairyfree.com or on Facebook


Nothing suits a real ‘hero’ better than superhero packaging. So well-established Dutch company Hero (part of the Swiss-based Hero Group) is pack-aging its newly introduced ‘Hero’ Fairtrade juices in

combidome. The innovative carton bottle, which pairs the best features of a bottle with the best features of a carton pack, has already won multiple high-profile international packaging and design awards.

“When exacting quality standards, technical expertise and attention to detail come together, something very special is cre-ated. Consumers experience this every single day when they drink our ‘Hero’ Fairtrade juices. The standards we set for our-selves are the same ones we demand from the packaging in which our products are put on the market”, says Ralf Wijnveldt, Channel Marketeer at Dutch food manufacturer ‘Hero’. For that reason the company, founded in 1914 with offices in Breda, has now opted for the combidome carton bottle from SIG Combibloc. The juices with 100 per cent fruit and Fairtrade ingredients come in Orange, Apple and Multivitamin flavours. They are available in the Netherlands in combidome 1,000 ml.

Ralf Wijnveldt: “The prize-winning combidome carton bottle gives our ‘Hero’ products not just optimal protection, but a fit-ting, interesting face as well. We’re committed to keeping up traditions, but we also aim to move with the times and set the benchmark when it comes to outstanding quality – so we’re on the right track with combidome”.

combidome: A real hero for ‘Hero’Netherlands: popular juice brand now available in the innovative carton bottle.


Fully automated sleeve feeding system for high-speed filling machinesSave time and costs with the Robotic Magazine from SIG Combibloc.


“Thanks to a special line set up and the

Robotic Magazine, we are now able to run a high-

speed packaging line with one operator at a high

efficiency rate.”Peter Bratsch, Arla Foods

With the new Robotic Ma gazine (R-CAM) for high-speed filling machines, capable of filling up to 24,000 carton packs per

hour, SIG Combibloc is now offering customers a packaging line component that is of interest on the road to more automation. The new Robotic Magazine fully automatically loads the filling machine with carton sleeves which im-proves the organisational efficiency and reduces labour costs.

Food and beverage manufacturers using fill-ing machines from SIG Combibloc receive the carton sleeves in shipping boxes on pallets. Up to now, the shipping boxes had to be removed from the pallet and loaded into the high-speed filling machine's magazine by an employee. With six tracks and a top speed of up to 24,000 cartons per hour, this ties up personnel.

Jan Gansow, Global Product Manager re-sponsible for line automation at SIG Combibloc: “The aim was to develop an automatic maga-zine for high-speed filling machines similar to the Combibloc Automatic Magazine (CAM) which is already available for other types of SIG Combibloc filling machines. With the new Robotic Magazine, we even went one step further and developed a fully automated magazine: the shipping boxes are removed from the pallet, R-CAM 724: Pallet magazine

opened and the filling machine is loaded with carton sleeves. This process does not require any action from the machine operator. This means using the Robotic Magazine reduces costs as it saves labour time and improves organisa-tional efficiency”.

Running up to 2.5 hours – without the need to load a new palletThe Robotic Magazine consists of two parts: a pal-let magazine and an unpacking station. The pallet magazine offers space for a Euro pallet, industrial pallet or Australian pallet. Once the pallet is inside the magazine, a scanner


reads the pallet pattern, i.e. how the ship-ping boxes are loaded on the pallet. The gripper arm moves the shipping box to the unpacking station. The Robotic Magazine includes an inter-nal buffer to ensure that production can con-tinue to run smoothly even while a new pal-let is being loaded into the pallet magazine. This buffer can hold up to 20 shipping boxes of carton sleeves. The magazine operates for up to 2.5 hours (CFA 724/124) without the need to top it up with a new pallet. Inside the unpacking station, the shipping boxes are opened and the sleeves are removed from the box. The sleeves are automatically filled into

the appropriate track of the filling machine. The shipping box is folded flat and placed in-to a container for disposal.

Prototype successfully running at Arla Foods The first R-CAM 724 prototype was installed at Arla Foods in Pronsfeld, Germany. “With the new Robotic Magazine and an optimised line layout where the tray packer is positioned close to the filling machine, we are able to run a complete high-speed packaging line with one operator at a high efficiency rate”, says Peter Bratsch, responsible for the R-CAM Prototype at Arla Foods.

R-CAM 724: Robotic Magazine at Arla Foods production plant.


Jan Gansow adds: "The Robotic Magazine also paves the way for a fully automated pack-aging line of the future, where Laser Guided Vehicles (LGV) automatically transport the pallets with the packaging material from the central warehouse to the R-CAM. This is an important step towards fully automated lines for the smart factories of tomorrow."

In an initial step, the new Robotic Magazine is available for the CFA 724 high-speed filling machine for filling products in the small-size packaging format combiblocSmall. In a next step, it will also be offered for CFA 124 for fill-ing products in the small-size carton packs

combiblocMini. Fully automated solutions for machines filling beverages in the medi-um-sized packages combiblocStandard and combiblocSlimline are planned to follow.

All CFA 724 and CFA 124 models already installed can be upgraded with the Robotic Magazine which can also be integrated into the SIG Combibloc ECS Line Monitoring System.

Benefits at a glance

• Fully automated depalletising and unpacking of sleeve boxes

• Reduction of labour costs and increase of organisational efficiency

• Continuous operation for up to 2.5 hours without changing the pallet

• Internal buffer: no stop when changing pallets

• Empty shipping boxes are compressed and collected in a small container

• Integration into SIG Combibloc's ECS Line Monitoring System


combiSwift now also on food carton packsUltimate convenience: screw cap is now also available for carton packs made of a special food composite.


soups containing chunks of meat or vegeta-bles, stocks with a higher free-fat content, chunky tomatoes or more viscous desserts, an easy-to-use and reclosable screw cap is very practical. And it gives an added benefit for food manufacturers, also: with this extra feature, the products are clearly differentiated from competing packaging on the sales shelf, and grab the interest of consumers to whom our combiSwift offers a high degree of additional convenience”.

One of the first customers to bring out products in food carton packs with combiSwift is Gallina Blanca.

The convenient combiSwift screw cap is now also available for food carton packs from SIG Combibloc. This screw cap offers ultimate convenience when

opening the carton packs, and when pouring and portioning out long-life foods such as soups, sauces, tomato products and desserts. Because the carton packs can be reclosed, the products are still protected after initial opening.

Hanno Bertling, Global Product Manager for Opening Solutions at SIG Combibloc: “combiSwift is one of our most modern screw caps. It’s designed specifically to suit consum-ers’ need for convenience. The closure, made from high-quality, recyclable plastic, can be opened effortlessly with a single twist."

With the launch of combiSwift for carton packs made of a special food composite to fill food products on aseptic food filling machines from SIG Combibloc, the product range is ex-panding once again. These food carton packs are aimed for more viscous products that also have a higher free-fat content. Hanno Bertling: “When handling products such as sauces and

combiSwift

combiSwift made its market debut in 2006 and was initially applied to carton packs for milk and dairy products. It was very well-received by consumers. Since then, more and more man-ufacturers have opted for carton packs with combiSwift. The closure has since also become widely established in the field of non-carbonated soft drinks, and in the area of liquid food prod-ucts which can be filled on

standard filling machines from SIG Combibloc for Liquid Dairy and NCSD products. The closure is applied over a laminated hole, and on first opening the consum-er only has to pierce razor-thin aluminium and polymer layers. To make this technique work, holes of the correct size are first punched into the carton and are then coated with aluminium and polymers. The closure consists of a flange with an integrated

cutting ring and a cap. The ring integrated into the flange opens the thin layers with a twisting motion. combiSwift has an over-all height of 12.6 mm and weighs 2.7 grams. At the premises of SIG Combibloc’s customers, the three-part closure is applied to the outside of the carton pack after the aseptic filling of the product and subsequent sealing of the carton pack inside the fill-ing machine.


frischli creates the basis for innovative productsGerman dairy company opts for the Food Option Technology: more than 100 products filled in combiblocStandard.


Dairy company frischli has opted for filling technology from SIG Combibloc. With the installation and bringing into service of two

CFA 512 filling machines, including a Food Option filling machine, frischli is putting things in place to enable it to launch a wide range of innovative products in aseptic carton packs from SIG Combibloc. frischli, a well- established owner-operated company founded in 1901, is today one of the biggest dairies in

Germany, and internationally markets its dairy products and foods for retail sale, food service and industry.

High performance and low overall system costs are the outstanding features of the high-speed filling machines from SIG Combibloc. With the CFA 512 filling machines that are now in operation at frischli, up to 12,000 combiblocStandard carton packs can be asepti-cally filled per hour. This speed is combined with an unrivalled low wastage rate and

Food Option Technology: Be able to do today, what will be needed tomorrow

Food Option filling machines are filling machines based on SIG Combibloc’s standard filling technology: A few minor techni-cal adjustments are made to the standard machine prior to deliv-ery which allow food manufac-turers to fill a whole range of additional food products. And SIG has done this in a very straightforward way, without

bringing additional complexity into the overall system and with-out high investment costs. If a filling machine has been fitted with the Food Option capability, the content of chunky product ingredients can be up to 10 per cent, the size of the particulates up to 6 mm, and the size of the fibres 1 x 15 mm; viscosity can potentially be up to 3,500 mPas.

This means Food Option filling machines make it possible to aseptically fill an unrivalled spec-trum of food products – quickly and without major investment. The flexibility of the filling ma-chine technology is also the key to products that allow higher margins.

Standard:• viscosity up to 1,000 mPas• fibres up to 5 mm

+ Food Option:• particulates up to 6 mm• fibres up to 15 mm• viscosity up to 3,500 mPas


one-of-a-kind flexibility in formats, vol-umes, decor and products. Their robust, well-engineered construction ensures the ma-chines will continue to run reliably for many years.

Extra possibilitiesOne of the filling machines installed at the premises of frischli, is a Food Option filling machine. It is based on SIG Combibloc’s stand-ard filling technology, but is additionally de-signed to fill a whole range of further pasty and highly viscous food products, and products containing particulates. For frischli the new filling machines offer the chance to further expand the company’s extensive range of long-life dairy products. A total of around 100 dif-ferent frischli products are set to be available in carton packs from SIG Combibloc.

About 100 different frischli products will be available in combiblocStandard

Facts & Figures: frischli

€ 497 mioannual turnover

676employees

1,330milk producers

823 mio kgof milk is processed every year

/// SIG COMBIBLOC MAGAZINE 1/15 25/// SIG COMBIBLOC MAGAZINE 1/15 25

Interview with Dr. Timo Winkelmann and Michael Dökel.

Dr. Timo Winkelmann, General Manager at frischli and Michael Dökel, Production Super visor at frischli, about the decision in favour of the SIG Combibloc filling technology.

Mr Winkelmann, what is the advantage of the filling technology from SIG Combibloc?Winkelmann: By choosing the filling technology from SIG Combibloc, we’ve created a strong basis to enable us to re-spond flexibly and efficiently to shifts in the market, which are dictated primarily by the needs of our food industry customers and the requests of consumers. With the two filling machines we’re now highly flexible as far as the product range, decors and volumes are concerned.

What products will be available in the new packages that you could not fill into carton packs before? Winkelmann: With these two filling machines, we are now able to fill not only milk, cream and milk mix drinks, but also more viscous sauces, puddings custard and rice pudding – even products with particulates like pieces of fruits or vegetables, herbs and spices are possible.

Mr Dökel, these two machines are the first SIG Combibloc filling machines at your plant. Can you say something about the cooperation with the SIG team when installing the new machines? Dökel: We were impressed by the outstanding service the team from SIG Combibloc provided when they installed the new filling machines and brought them into service. The special challenge in that task was to keep the regular production process running. The team made sure everything worked smoothly, and the machines were able to be brought into service on schedule.

»Firstrate service and flexible technology open up new possibilites.«

The Forest Stewardship Council is an independent, not-for-profit organisation that campaigns for responsible management of the planet’s forests. Through its forest certification programme, the FSC works world-wide to

promote responsible forest management. Today, the FSC is one of the world's leading forestry certification systems in terms of its global reach, robustness of certification criteria and the number of companies certified.

More than 28,400 companies are FSC certified – in more than 80 countries. Added to this are 150,000 certified small-holders. In a global market survey conducted by the FSC in 2012, 98 per cent of FSC-certified companies stated that FSC certification increased the value of their company and their products, and that they planned to maintain their certification and thereby retain the right to put the FSC label on their products.

FSC label enables purchasing decisions that benefit the forestsThis sort of qualifying label on products can generate a key stimulus in the consumer. The number of consumers who take a very responsible attitude to their own consumption behav-iour has been increasing for many years. These people are

20 years of FSC™: recognition and popularity are increasingIn its 20-year history, the Forest Stewardship Council™ (FSC™) has faced a number of challenges and accomplished many things. Today, the FSC is one of the leading forestry certification systems.

Facts & Figures: FSC

184 mio haof forest is FSC-certified world-wide

28,300Chain-of-Custory certificate holders in 81 countries

150,000smallholders around the world are FSC certified


FSC label on 40 per cent of all SIG carton packs

In 2009, in cooperation with German trade chain Lidl, SIG Combibloc put the first juice drink carton packs with FSCTM label on Europe’s supermarket shelves. The label shows consumers that appro-

priate quantities of wood sourced from FSC- certified, responsibly managed forests and other controlled sources were used to make the cartons. Since then, the label has become increasingly popular and more widely recog-nised among food and beverage manufacturers, and also among retailers and the public. More than 3,000 different products packaged in SIG Combibloc carton packs now carry the FSC label – in 27 countries. By the end of 2014, 40 per cent of all SIG carton packs carried the FSC label. “We’re very proud to have been the trailblazer in our industry on the issue of the FSC label. It is one of SIG Combibloc’s fantastic success stories”, says Michael Hecker, Head of Global Environment, Health and Safety.

20 billionth carton pack with FSC label produced

In September 2014, the 20 billionth FSC-labelled carton pack was produced at SIG Combibloc's packag-ing plant in Rayong, Thailand, for our customer FrieslandCampina.

aware that with their purchase choices, they can personally contribute to the success of sustain able and responsibly produced goods. It is crucial that the labels on the products be credible. FSC is currently the most rigorous and the most wide ly accepted certification for responsible forest management.

Studies in various parts of the world have shown that the level of public awareness of the FSC label is increasing. In Germany, for in-stance, in 2012 the level of prompted aware-ness of the FSC label was around 33 per cent. In a repeat survey conducted by the market re-search institute TNS Emnid in September 2014, this had increased by 17 per cent, to a current level of 50 per cent, in just two years. 72 per cent of respondents who recognised the label also said that they trusted it. Another ex-ample is the UK, where awareness is also at 50 per cent – signifying an increase of 12 per cent in just one year. The level of awareness of the label has actually more than doubled there since 2007. In Brazil, 90 per cent of industry representatives and 23 per cent of consumers recognize the FSC-label and know what it stands for. (Sources: www.fsc-deutschland.de/aktuelles; FSC UK annual review 2013/2014; FSC Brazil).


Extrusion line at SIG Combibloc's production plant in Brazil.


Brazil is currently South America’s big-gest market for aseptic carton packs; and world-wide, in fact, the country is in second place, right behind China.

According to market research institute Canadean, Brazil is the world’s biggest market for UHT milk, with annual consumption of around seven billion litres. For SIG Combibloc, building a local factory was simply a logical step to meet the demands of this fast-growing market.

Extrusion plant at Paraná factory put into operation The starting signal for this long-term building project in Brazil was given in 2010, when SIG Combibloc began construction of its first packaging plant in South America. In mid-2011, the factory came on line. With the pro-duction line installed, the pre-laminated pack-aging material used to make the carton packs was printed, cut to size, stamped and sealed. In 2014 an extrusion line was added, where the unprocessed cardboard is laminated with poly mers and aluminium. The facility will laminate around 250 million metres of pack-aging material each year.

Optimally preparedRicardo Rodriguez, Director and General Manager South America at SIG Combibloc: “We’ve captured this market by offering our customers a real alternative, unique added benefits and a tailor-made service. With this fresh major investment of around 40 million Euros for the installation of the extrusion plant, we’ve laid the groundwork to be opti-mally prepared to meet the ever-increasing de-mand for aseptic carton packs. We can now produce on-site in Brazil the packaging mate-rial needed in South America for our carton packs”.

Success in fast-growing marketThe installation of the extrusion line completes SIG Combibloc’s major investment in its Brazil production site. Business relations with custom-ers have been developed further: at the premises of our customer Quatá, for instance, six new filling machines have been put into operation.

Market BrazilAccording to the Canadean research institute, in 2014 more than 15.5 billion carton packs for long-life food were sold in Brazil. This figure is expected to rise to more than 21 billion by 2019, equivalent to an increase in volume of around 7 % per annum (in units). Milk is now the product most commonly filled in aseptic carton packs in Brazil. In the 1980s, unpasteurised milk dominated the market. The share of UHT milk has increased slowly but steadily, to a current level of about 60 %.


SIG Combibloc’s prospects in Brazil are very promising, in part because, thanks to the new factory, business relations with existing customers have been further strengthened. Rodriguez: “Again, we managed to end the 2014 financial year with a considerable growth. We’ve been able to win new customers, and further consolidate our ties with existing customers”.

Successful customer relations: Nine filling machines for Quatá AlimentosOne example of successful customer relation is the cooperation with the food manufacturer Quatá Alimentos. In 2012, the company opted for the filling machine technology and aseptic carton packs from SIG Combibloc. Since Au-gust 2012, two filling machines – a CFA 512 and a CFA 712 – have been in operation at Quatá’s Campo Belo facility in the Brazilian state of Minas Gerais. Another one is running at Quatá's prouction plant in Bom Jesus dos Perdões.

José Henrique Coutinho, managing direc-tor of Quatá, remembers the company’s first SIG Combibloc filling machine: “For the mod-ernisation of our factory in Campo Belo, we chose the filling technology from SIG Combibloc, as this flexible technology met all our requirements. The filling machines perform very well and have low waste rates – we’ve significantly improved our productivity”.

The filling technology from SIG has obvi-ously convinced Quatá: in 2014 alone, a fur-ther five filling machines were installed, and at the beginning of 2015 an additional one started production. There are now nine filling machines in operation at three Quatá produc-tion sites filling UHT full milk, UHT semi-skimmed milk, UHT skimmed milk, UHT chocolate flavoured milk, cream and sweet condensed milk in combiblocStandard and combiblocSmall.

Quatá Alimentos

Quatá Alimentos was founded in 1990 and has specialised in two product lines: UHT milk prod-ucts and cheese. The products are sold under the brand names Quatá, Gloria and Cristina, through retail and wholesale channels (for cafés, restaurants, catering establishments etc). Quatá is active predominantly in the states of Rio de Janeiro, Espirito Santo and Minas Gerais. The company has seven production plants: three in Minas Gerais, two in São Paulo and one each in Rio de Janeiro and Paraná.


SIG Combibloc filling machine at Quatá's production plant in Campo Belo.


Just a few clicks: useful tips for designing SIG Combibloc carton packsWith a new, special website, SIG Combibloc is supporting its customers to make the design process more efficient.


Our customers’ marketing depart-ments and design agencies invest a great deal of time in redesigning cartons or creating new carton de-

signs. Once the customer is happy with the design, it is sent to SIG Combibloc so the car-tons can be produced in one of the packaging plants. Before production, the design must go through preprint. “Preprint is where the de-sign is checked and adjusted so that our print-ing machines can produce the sharpest, most optimal print image”, says Erol Öztürk, Head of Preprint Management Europe.

The more information packaging designers have about the characteristics of the printing process SIG Combibloc is using, the more they are able to take these features into considera-tion at an early stage in the creation of the de-sign files, and the fewer adjustments need to be made later on. That saves time spent on rounds of corrections, and ultimately it saves money.

SIG Combibloc is now making all this information available on the new website www.SIGdesign2print.com, so every packaging designer worldwide can view it whenever they want. The most important tips from the 34-page SIG Combibloc print manual are clearly demonstrated in an explanatory video. “In just three and a half minutes, packaging designers can familiarise themselves with the key information”, says Boris Remmler, Print Manager at SIG Combibloc, who was involved in compiling and producing the contents of the video and the website. The website further provides useful tips and downloads like key-lines, background information on the SIG printing process as well as contact information for every region.

www.SIGdesign2print.com

Features at a glance

Video and factsheetA three-minute explanatory video gives the most important information on packaging design for SIG Combibloc carton packs. All figures and values are also summarized in a factsheet.

KeylinesKeylines form the basis for all carton designs on SIG Combibloc carton packs. For each format and volume, there is a file with all the technical information such as cut lines and crease lines, as well as text areas.

Artwork manualThe artwork manual contains all the informa-tion that needs to be considered when planning and revising a design – from working with the keylines, to the opening devices and the colour composition, right up to the data transfer.

SIG colour bookThe SIG colour guide contains all spot colours that can be used in the specific rotogravure printing process and on the packaging material.

FSC labelling guideThe FSC labelling guide shows how the FSC label can be displayed on the carton packs.

Checklist for data transferThe checklist contains all information on data and documentation SIG Combibloc needs in order to be able to print a final, finished and edited design.

FAQsThe FAQs provide the answers to the most frequently asked questions regarding the SIG Combibloc printing process.


Ordering online: SIG Spare Parts ShopWith the new spare parts shop, it is now possible to order necessary spare parts any time, quickly and easily – seven days a week, 24 hours a day.


The SIG Combibloc Spare Parts Shop allows our customers to order spare parts quickly and easily. It takes just minutes to place an order. New tech-

nology, advanced functions, modern look and feel – users are responding very positively.

A variety of search options takes the user straight to the correct spare part. Pre-defined shopping carts make it even easier to order frequently needed parts. And any time our customers need to order a large number of dif-ferent spare parts, they can simply upload an Excel file containing the required part num-bers. Of course, all orders and their delivery status can be viewed at any time.

Before the launch of the new spare parts shop, customers usually ordered the spare parts they needed by telephone or fax. The new online shop is set to change that. Custom-ers now order their spare parts directly online at the shop. This leads to a reduction of pro-cessing time and makes spare parts ordering even faster. This is one more example of how SIG provides added value for its customers.

“A wide range of search options help cus-tomers to find the required parts easily. The shop shows detailed order status and tracking information which gives our customers full transparency about their purchase orders. Thus customers can plan their resources efficiently”, says Norbert Schmitz, Head of Global Service Projects. “We’re also particu-larly pleased to see that our shop is receiving a lot of praise in comparison to those of our competitors”.

Features at a glance

Ordering any timeEasy ordering 24 hours a day / 7 days a week.

Various search optionsQuick and easy identification of correct parts.

File upload‘File upload’ to order a large number of spare parts at once by simply uploading a file with part numbers and desired quantity.

Spare parts catalogueOrder directly by browsing the ‘spare parts catalogue’ featuring equipment and part images in 2D and 3D.

Pre-defined shopping cartsLess time and effort for large orders and re-ordering parts by using saved shopping carts.

Order status/trackingKnow your order and delivery status by check-ing online at any time via order status tracking option.

Our customers receive login data for the SIG Combibloc Spare Parts Shop from their Service Account Manager or from the regional service contact partners.

For any further questions or comments, please contact: [email protected]

www.sig.biz

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