Bag-in-box

Bag-in-Box Containers: 5 Things You Need to Know

Sustainability in packaging cuts across the entire supply and manufacturing chains. This means that every step in the process must contribute to the sustainability of the finished product, while providing the benefits brand owners want.

Why Flexible Packaging Matters

One of the primary goals of brand owners and food packaging suppliers is zero food waste. To attain that goal requires the use of advanced flexible packaging technology. Bag-in-Box technology is becoming increasingly popular  for liquids such as wine, juices, and other liquid consumer products, as well as for food products such as ice cream and other dairy items.

Flexible plastic packaging for Bag-in-Box applications comes in a variety of thicknesses depending on the requirements of the brand owner, the food producers’ fill lines, and polymer materials to meet specifications. To help food to be more shelf-stable and to last longer when refrigerated after opening, barrier packaging is one of the newest technologies used for flexible packaging applications for food.

Barrier film is a multi-layer film consisting of co-extruded polymer materials such as high-barrier Nylon (Nylon 6 or Nylon 66)/EVOH and PET (polyethylene)/oriented Nylon. Nylon offers excellent clarity and stiffness, and provides a good oxygen and aroma barrier.

Bag-in-Box Makes the Grade

CDF’s Bag-in-Box, a combination of a fiberboard box encasing a polymer inner bag, has proven to be an ideal solution for many food packaging applications. Here are five things you need to know about this packaging:

1. Protection and Lightweight Properties:  Bag-in-Box offers high levels of protection for the contents, both food and beverage, during transportation, while the lighter weight of the packaging combination reduces overall weight of the shipment, saving on fuel costs and lowering the carbon footprint.

2. Food Waste Reduction:  The multi-material barrier layers keep food fresher longer, thus helping to reduce food waste, and are FDA-approved for food contact.

3. Certified as Safe: Bag-in-box flexible packaging offers additional safety for food products. For instance, CDF recently passed the rigorous testing requirements for the design of its Bag-in-Box, receiving the UN Certification for its 20 Liter packaging.

4. Greater Sustainability:  The plastic bag in the Bag-in-Box packaging is sustainable in many other ways as well. Plastic file is energy-efficient to produce. At end-of-life, the Bag-in-Box can be completely recycled through both the fiberboard and the appropriate polymer recycling streams, including the injection molded dispensing nozzles found in liquid dispensing Bag-in-Box applications.

5. Security: Bag-in-box packaging can offer additional security for food contents. For example, with CDF’s Smart Seal Technology, the contents of the Bag-in-Box are secure whether a pillow or form-fit bag is used.

Bag-in-box

CDF’s Bag-in-box packaging makes the grade for sustainability.

Reaping the Rewards of Bag-in-Box Packaging

Flexible bags, which are easily accommodated by automated fill lines, help manufacturers reduce food waste while offering sustainability through end-of-life package recycling. This makes bag-in-box packaging an ideal choice for brand owners and food and beverage producers alike.

With more than 40 years of experience in packaging design and manufacturing, using the latest state-of-the-art polymer processing/extrusion machinery, CDF is a total solutions packaging provider with the know-how to give you the latest technology combined with CDF’s innovative approach to customer challenges. Download our Bag-In-Box brochure to learn more.

Flexible packaging

Exploring the Role of Flexible Packaging in a Circular Economy

What kind of spin can flexible packaging put on the “circular economy”?

For years, sustainability has become an increasingly important aspect of packaging. The latest significant development in sustainability has been the concept of the circular economy. As applied to packaging, simply put, this involves planning every aspect of packaging—materials, design, conversion techniques, distribution, use and recovery—with an eye toward minimizing consumption of materials and energy, and maximizing reuse. To be truly effective, a circular economy requires participation by everyone in the supply chain, including: packaging materials suppliers, converters, product manufacturers, retailers, consumers, and recyclers.

Challenges for Flexible Packaging

With flexible packaging, especially for food, users face a unique set of challenges in participating in the circular economy.

One of the biggest such challenges is that in most cases, truly closed-loop recycling—i.e., making food packaging into more food packaging—is not an option. With few exceptions, Food and Drug Administration regulations prohibit recycled material from being used in food-contact packaging.

Even if recycled material could be used for food, flexible packaging has some inherent disadvantages. Many flexible films used for food consist of multiple layers of different polymers, such as polyethylene terephthalate (PET) and ethylene vinyl alcohol (EVOH). Recycling different polymers together is impossible when, as often happens, they have incompatible molecular structures. Also, most recycling centers are not set up to process flexible packaging; their machinery can only handle rigid plastics.

IBC and Bag-in-Box Contribute to Circular Economy

However, bulk flexible packaging, such as intermediate bulk containers (IBCs) and bag-in-box, has a big advantage when it comes to the circular economy—and its manufacturers and users are in a position to minimize or overcome its disadvantages.

A major aspect of the circular economy is energy consumption. A big part of that is minimizing fuel used for transportation, by cutting down on distances—and weight. The latter is an ongoing, inherent advantage of bulk flexible packaging. It is lighter and takes up less space than almost all rigid bulk packaging alternatives, meaning that more product can be delivered per tankload of fuel. And because it is almost always one-way packaging, there are no transportation return costs.

IBCs are used almost exclusively for industrial applications. In the food sector, this means delivering bulk loads of liquid, semi-viscous, or powdered ingredients to food processing plants. (Bag-in-box often is also used this way, to deliver smaller loads.) This means the supply and return chains can be more tightly controlled than with consumer products. It is therefore easier for suppliers and their industrial customers to make sure that used flexible packaging gets collected and delivered to a recycling facility that is equipped to handle it.

Environmentally friendly food packaging

When the flexible material is monolayer, or consists of multiple layers that are chemically compatible, recycling is relatively straightforward. Even some film structures that comprise incompatible materials can be processed with a “compatibilizer” chemical such as DuPont’s Fusabond.

Because of FDA regulations, most resin recycled from flexible material cannot be processed into material intended for food contact. However, it will be available for non-food end uses such as shipping bags, sacks of fertilizer and other farming/gardening materials, newspaper bags, etc. This does not quite close the circle perfectly, but it comes much closer to the “circular economy” model than simply landfilling the discarded material.

For more information about smart flexible packaging choices, download our Bag-In-Box brochure today.

Flexible packaging

Exploring the Role of Robust HACCP Plans in Flexible Packaging

Hazard Analysis and Critical Control Points or HACCP was born of the need to actively manage and control the risk factors that cause foodborne illnesses. According to the FDA, food safety is everyone’s responsibility, from food preparation and packaging to transportation and retail handling.

At its best, HACCP principles benefit every gear in the food processing, preparation, retail, and end-user machine. It does not just protect the consumer; it supports the well being of the businesses involved.

HACCP Consists of Seven Guiding Principles

The FDA explains that HACCP is made of seven primary principles. They include:

  1. Performing hazard analysis
  2. Deciding on Critical Control Points (CCPs)
  3. Determining critical limits
  4. Establishing CCP monitoring procedures
  5. Establishing Corrective Measures
  6. Establishing verification procedures
  7. Establishing a documentation and record keeping system

Because each food product and food-related industry is different, no single HACCP program can cover each hazard. Food safety hazard mitigation needs a custom approach which involves careful evaluation, development, implementation, training, and monitoring.

A Sound HACCP Plan Addresses Several Key Issues

The best HACCP plan fits the unique hazards and needs of the facility. According to Food Safety Magazine,   examining these multifaceted issues can help create the best program framework.

  • Industry- and process-specific training
  • Content register creation directed at the facility’s unique characteristics
  • Risk assessment of nontraditional operations under the “New HACCP Applications”
  • Assessment of food ingredients, pathogens, and pathogen introduction avenues unique to the ingredients
  • Service provider risks, including airflow during handling and transport, uniform laundry chemicals, cleaning water temperatures, and driver food safety training

Monitoring, Verification, and Validation Keep a Robust HACCP Program on Track

The development and implementation stage of an HACCP plan is only the beginning. As a customized program that addresses the specific needs of the facility, your HACCP plan should also be a dynamic one which includes continual monitoring with data collection, verification of practices, and growth as needed.

The FDA points out that monitoring and verification are two separate operations. In fact, monitoring should also be verified. To ensure accuracy, verification should be left in the hands of an unrelated HACCP team member or an unbiased outside source.

Validation helps the HACCP program stay relevant. New products, processes, and suppliers introduce new food safety issues. Periodic reevaluation helps prevent hazards from slipping through the cracks.

Flexible packaging

Partners with Active HACCP Plans Support Improved Food Safety

Your operation’s HACCP plan deals with known issues that affect the safety of food in your care. Unfortunately, each vendor, supplier, or handler has its own vast array of potential issues and hazards.

For example, you might know the temperature and airflow conditions inside a transport vehicle. But what happens if a driver wears the same gloves for refueling the vehicle and offloading food or packaging materials?

Every gear in the HACCP machine affects the other in direct and indirect ways, but you cannot control what you do not see. That is why a partner with a sound HACCP plan is the safest bet. If you know that your flexible packaging provider uses the same level of care with HACCP plan development, monitoring, verification, and validation as your organization does, you can focus on mitigating in-house hazards.

HACCP is not just one plan; it is almost limitless in scope. Further, your plan is always in a state of fine-tuning and evolution to maintain the highest standards possible. Mitigating food safety hazards takes a customized approach. With a conscientious flexible packaging partner that has an HACCP plan in place such as CDF Corporation, you can focus on your operations and skip unnecessary worry about introduced hazards.

Download our food packaging product and pricing brochure to learn more about our flexible packaging options and why CDF is a safe and healthy choice for your food packaging needs.

Flexible packaging

Flexible Packaging Makes Cosmetics Companies Look Beautiful

While you’re busy helping people look beautiful, flexible packaging makes you look brilliant. What could be better? It also saves space, money and reduces carbon emissions.

There’s a growing trend toward flexible packaging for cosmetics and other industries, according to Smithers Pira packaging experts. Consumer demand is one reason. But the benefits for manufacturers, distributors, and wholesalers show that it’s more than just a trend or a fad; it’s the future.

Which Cosmetics Markets Need Flexible Packaging?

One of the greatest things about flexible packaging is that it’s adaptable for so many different types of products. It’s ideal for containing and dispensing liquids. But it’s also a good solution for creams, lotions, and powders.

Tanning salons love flexible packaging for products such as spray-tan liquids, oils, and tanning lotions. Here are a few other markets where flexible materials are a boon:

  • Cosmetics manufacturers
  • Contract filling and co-packing operations
  • Cosmetic processing plants
  • Wholesale suppliers
  • Cosmetic distributors
  • Salons

Why is Flexible Better Than Rigid or Semi-Rigid?

Flexible bag-in-box packaging offers variety in the bag type used as well as bag materials. For example, CDF offers pillow style and form-fit bags for bag-in-box containers. And they’re available in several different bag thicknesses and materials, such as high-barrier co-extruded nylon/EVOH and a polyethylene/oriented nylon blend.

Flexible packaging is light and portable, much more so than rigid or semi-rigid containers. It uses less shelf space in a salon, warehouse or freight vehicle. Transportation costs go down when you make the switch to flexible from rigid or semi-rigid, which also reduces your carbon footprint.

Flexible packaging

A great product is only as good as its delivery to the end user.

What are the Most Important Benefits For Cosmetics?

A beautiful product only matters if it remains beautiful until the end-user receives it. Flexible packaging gives unsurpassed product freshness, quality, and purity. That’s why CDF only uses allergen-free, FDA-approved resins in our container manufacturing process. We’re also ISO 9001:2008 compliant, which gives you peace of mind.

With some products, the dispensing methods affect product integrity. With flexible materials, you can choose from several packaging designs and taps that evacuate more product. There’s no need to scrub the containers, either.

Flexible packaging keeps lotions, creams, tanning sprays and many other cosmetic products fresh and safe from contamination. They’re smaller and lightweight, which aligns with the packaging industry’s “lightweighting” goals. And they’re easy to fill and dispense.

Whether you want small containers or large, if you’re packaging shampoo, body oil or cosmetic powders, flexible materials quickly adapt. They can take on nearly any shape and dispense cosmetic products with less waste than rigid containers.

Our customer service representatives work directly with you to design and produce a container that meets all of your needs. And that’s a beautiful thing, indeed. Download our Bag-In-Box brochure to learn why the possibilities are endless.

CDF Achieves SQF Level 2 Certification

CDF Corporation, a leading manufacturer of drum liners, pail liners, intermediate bulk container liners, bag in box liners and flexible packaging, has successfully achieved SQF (Safe Quality Food) Level 2 Certification at both manufacturing facilities. The Flexible Packaging Group facility received a score of 97, the Drum and Pail facility received a score of 95.

 

SQF is a HACCP (Hazard Analysis Critical Control Points) based food safety program recognized by GFSI (Global Food Safety Initiative). SQF certification is a food safety standard that is comparable to BRC (British Retail Consortium) and FSSC 22000 (Food Safety System Certification). The SQF certification program ensures that products have passed thorough international standards for food quality and safety. SQF is recognized by retailers and foodservice providers around the world who require a rigorous, credible food safety management system.

 

“CDF’s SQF Level 2 Certification further demonstrates our commitment to exceed the existing basic food safety and quality expectations. Each step throughout our various processes engages our employees in the food safety culture. This certification reinforces to our customers that we are committed to being a reliable packaging supplier within our various supply chains,” says Tom McCarthy, Flexible Packaging General Manager at CDF Corporation.

 

CDF has 30 quality and food safety programs in place, the following are some of the programs: Document Control, Management Audits/ Monthly Audits, Good Manufacturing Practices, Pest Control, Chemical Control, Storage and Handling, Training, Quality Control, Customer Quality/Complaint Management, Traceability, Hold and Release Protocol, Glass and Brittle Plastics, Sanitation and Maintenance. CDF is committed to making food safe products for all customers. With food safety as a priority, CDF customers know there is no risk in using CDF products for in-process manufacturing or as a finished consumer package.

ISO 2001

Why Our ISO Certification Is Important for CDF Customers

Quality, reliability and customer satisfaction depend on consistency in manufacturing. That’s why the Internal Organization for Standardization developed the ISO 9001 and other standards, and why we adhere to them in every internal process and food packaging product we make.

ISO 9001 compliance represents a promise. Customers know that the procedures by which the company makes products are geared toward quality, consistency, efficiency, safety, transparency and, ultimately, a happy customer.

Here’s how our commitment benefits you.

Predictable Product Quality

Surprises are great for birthdays, but they’re bad for business. Product consistency gives you the assurance that when a food packaging order arrives, your product is right and your production schedule can stay on course.

The International Organization for Standardization has this to say about why it’s so good for customers:

“When products and services conform to International Standards consumers can have confidence that they are safe, reliable and of good quality.”

ISO compliance gives you confidence that the product you order today will have the same quality as your last order and the orders you place in the future. There’s a lot to be said for peace of mind.

ISO 9001

Dependable Delivery Schedules

Order delays have a ripple effect. They spread out to interfere with production, create unnecessary worker downtime and can cost you money. If delays interfere frequently with your schedule, they can breed ill will with your customers.

ISO compliance leaves fewer opportunities for delays because manufacturing processes are known, set in force and adhered to. We run a tight ship so that you can, too.

Efficient Internal Record Control

You might not think our internal record controls affect your business. But the more streamlined our processes, and the more people on our team who adhere to the same system, the more efficiently we can work for you.

If you call, we have answers. If there’s a production or delivery snag, we can find and resolve it quickly. That means less time spent waiting. In a broader sense, better record keeping also keeps our own processes on track across every department.

ISO Quality Services Limited explains that standardized record control creates an efficient method for document identification so anyone can find what they need when they need it. It covers filing, retrieving, storing, retaining, and even destroying company records.

Ongoing, Monitored Compliance

Certification isn’t “once and done.” First, a company must agree to ISO standards and commit to implementation throughout the company. Then an independent auditor evaluates the company’s success, requesting corrective measures if necessary.

ISO certification is only awarded if the company and all employees are on board. It begins with upper management and flows throughout every level and function of the company.

After certification, every ISO compliant company has an annual checkup or audit. If any inconsistencies emerge, they’re corrected and preventative action is implemented to avoid it in the future.

Our ISO 9001 certification is more than just a document to frame and mount on an office wall. It represents a company-wide commitment to enacting the best possible practices for every aspect of business.

For CDF customers, ISO certification means quality and dependability. Good relationships are built on trust. We invest in internationally-recognized standards to help your business succeed because, not in spite, of us.

Contact us to learn more about flexible food packaging and why our quality supports your quality.

Flexible packaging

6 Benefits of Flexible Food Packaging

Food packaging is in a transition period. Heavy, rigid cardboard and plastic containers are on their way out. To a large degree, flexible packaging is sliding in to take their place.

According to the Flexible Packaging Association (FPA), it’s the “second largest packaging segment in the U.S.,” capturing nearly a 20 percent share of the $164 billion market.

From small plants to major industries, flexible packaging accounts for 60 percent of shipments, says the FPA. And here are a few reasons why.

#1: Flexible Packaging Costs Less

Flexible food packaging requires fewer materials for production and costs less to manufacture than heavy, rigid plastics. They’re budget-smart, but without compromising quality.

Bag-in-box systems, for example, use notably less plastic than a rigid container of similar capacity, and they cost much less. The Smart Pail system has the durability of a rigid pail, but in a lighter, 2-part system with a thin, film seal instead of a bulky lid.

#2: Liners, Containers, and Lids Offer Plenty of Choices

Flexibility doesn’t just describe the way Smart Pail and bag-in-box packaging can bend, flex and expand. They offer flexible design choices, as well.

Several styles of Smart Pail lid film are available for a wide range of purposes. Choose from tamper-evident, peel and reseal, disposable and oxygen barrier films. Bag-in-box flexible packaging offers pillow-shape or form-fit liners, multiple film thicknesses and strengths, and several tap options.

Flexible packaging

Flexible packaging helps long-haul carriers enjoy more efficient performance, too.

#3: Lower Transportation Costs and Emissions Support Budget and Sustainability Goals

With fewer materials and a lighter product, shipping costs less. It’s much more cost-efficient to transport flexible materials than rigid containers. They’re significantly lighter, and flexible containers take up less space. Some packaging collapses to lie flat, making transport even easier.

Smaller freight loads also put less strain on the environment. They help you do your part toward fewer greenhouse gas emissions and a lower carbon footprint. Less transportation, lower freight costs, and cleaner air make everyone a winner.

#4: Food Stays Protected and Enjoys a Longer Shelf Life

If you need optimum food purity and protection from contamination, flexible packaging is your best bet. Multi-layer liners are strong and durable, and high-barrier liners prevent oxygen infiltration to keep products fresher longer.

Smart Pail’s lidding has a resealable, tamper-evident film. Oxygen barrier lidding takes product purity up a notch. And without a removable lid to drop or misplace, there’s no risk of accidental cross-contamination.

#5: There’s Virtually No Burden on Landfills

There’s no material that combines as many benefits with eco-friendliness as flexible packaging. It’s one of the most responsible choices that you can make. The Smart Pail system uses LLDPE or HDPE recyclable materials and a corrugated container, which helps eliminate the amount of product your facility sends to a landfill.

#6 Flexible Packaging Conserves Space

Smart Pail and Bag-in-Box flexible food packaging components are designed to conserve space. That’s true, whether they’re unfilled, stacked and waiting, or filled and ready for the end-user.

Numerous unfilled bags take up less storage space than one empty rigid container. Even Smart Pail packaging nests and stacks smaller, requiring less room on a warehouse shelf or transport truck.

Consumer demand drives the popularity of flexible packaging, according to Packaging Digest. It’s easy to handle and fits neatly on a shelf. Cost, performance, and sustainability make it the right choice on the production end.

It’s the direction global food packaging is headed and for good reason. As technology improves, expect more choices, better performance and a larger presence in the food packaging industry.

Contact CDF Corporation to learn how we can help your budget, product performance and sustainability goals merge in one smart choice.

Plastic Packaging Better for Environment than Alternatives Made with Other Materials

A recent life cycle assessment analyzed the energy and climate benefits of alternative plastic materials in contrast to plastic material. The categories included caps and closures, beverage containers, other rigid containers carrier bags, stretch/shrink wrap, and other flexible packaging materials. Carol Hochu, President and CEO of the Canadian Plastic Industry Association noted, “Plastic packaging enables the safe and efficient delivery of various products which form part of our daily lives, everything from food to essential health and safety aids. However, many are unaware that plastics carry out these functions while at the same time conserving energy and lowering greenhouse gas emissions.”

 

In Canada, the LCA found that replacing all plastic packaging the non-plastic packaging would:

 

  1. Require nearly 4.4 times as much packaging material by weight. Increasing by nearly 5.5 million tons.
  2. This would also increase energy use by 2.0 times. This was calculated as being equivalent to the amount of oil transported by 18 supertankers
  3. This would result in 2.3 times more global warming potential. This was equated to adding 3.3 million more cars to the road.

 

Engineering in plastic packaging enables innovation and performance – the ability to extend the shelf life of foods and medicines. Plastic packaging viewed from the entire life cycle have more benefits than the snapshot that has been taken in years.

 

The afterlife of plastic is further contributing to sustainability in many ways. The ability to recycle, reuse and repurpose for energy value and converted to liquid oil, electricity and into other fuels.

 

There have been great strides made in the reusability and repurposing of plastic containers. These valuable resources are used to make fleece jackets, new plastic bottles, pipes, pallets, creates and buckets, decking and other lawn and garden products. The majority of product stemming from recycled plastic bottles, non-bottle rigid plastics such as deli and dairy containers, bakery, vegetable, fruit containers, and plastic film, bags and outer wrap.

 

Plastic enhances our lifestyles, our economy, and the environment.

 

Source: Canadian Plastics Industry Association

CDF Corporation exhibiting IBC and Bag-in-Box at the IDFA Ice Cream Technology Conference

CDF Corporation, a global company that specializes in the manufacture and sale of high quality pail, drum, intermediate bulk container and bag in box liners and flexible packaging, will display an IBC tote liner and bag-in-box at booth# 5 at the International Dairy Foods Association Ice Cream Technology Conference.

 

The International Dairy Foods Association Ice Cream Technology Conference will be held April 12th through the 13th at the Hyatt Coconut Point Resort & Spa in Bonita Springs, Florida. This event is for ice cream and frozen dessert professionals. The Ice Cream Technology Conference focuses specifically on frozen dessert research, technology, new market trends, food safety, labeling and opportunities.

 

CDF offers a wide range of flexible products that satisfy ice cream manufacturers’ needs. Form-fit IBC (cube-shaped) liners provide high performance in critical applications, such as top-fill applications using a bridge or automated filler; containers with no access doors for placing a liner at the bottom; high speed fills and viscous products that would get caught in the folds of pillow-shaped liners.

 

Air-Assist® liners are specially designed for convenient dispense and improved evacuation of high viscosity products. The Air-Assist liner features a Form-fit liner with an attached air bladder. As the air bladder is inflated, it pushes against the Form-fit liner, forcing the viscous product out of the bottom dispense fitment, resulting in less residual product left in the liner.

 

Bag-in-box will also be on display. Bag-in-box is the ideal packaging solution for food applications ranging in size from 1 liter to 25 liters. CDF offers both form-fit and pillow styles to meet all your bag in box needs.

 

Representing CDF will be Leigh Vaughn, Regional Manager. Leigh has 25 years of sales management experience in the flexible packaging industry. Combining a deep understanding of packaging, industrial applications and direct customer relationships allows Leigh to offer a consultative approach in these areas.

 

CDF exhibiting flexible packaging for petroleum products at the PPC Spring Meeting

CDF Corporation will exhibit bag-in-box liners and drum and pail products at the Petroleum Packaging Council’s Spring Meeting and Tradeshow.

 

The Petroleum Packaging Council’s Spring Meeting and Tradeshow will be held March 20th to the 22nd at the Hilton Sandestin Beach Golf Resort & Spa in Destin, Florida.

 

CDF has a wide range of flexible products to satisfy the needs of petroleum manufacturers. Bag-in-box is the ideal packaging solution for chemical applications ranging in size from 1 liter to 25 liters. CDF offers both form-fit and pillow styles to meet all your bag in box needs. CDF Corporation has recently passed the design qualification testing of a combination package; fiberboard box with a plastic bag. CDF’s UN certified bag-in-box will provide the highest levels of protection for transporting hazardous products requiring class II and III packaging.

 

CDF’s drum and pail liners provide outstanding performance in critical lubricant applications. CDF has the industry’s most comprehensive selection of drum and pail liners and accessories. CDF products range from tough, leak-proof, vacuum-formed inserts, to economical, round-bottom liners to the special protection of barrier-film liners. These liners and inserts can be used with many chemical applications, such as adhesives, automotive, coatings, detergent, greases, ink, lubricants, paint, sealants and soap. CDF’s line of drum and pail accessories include EZ-Strainers, dust caps, cover sheets and lids.