Flexible Options

Flexible packaging offers considerable value and sustainability benefits.

Ensuring a secure, safe environment is paramount to consumers, retailers and manufacturers alike. Recent developments in packaging technology satisfy these safety concerns while providing a greener footprint. Traditionally, many adhesive and sealant manufacturers have used pails and drums for transporting their products. Although these containers provide many benefits, other products can better satisfy a large gap in the market—sustainability. Flexible packaging offers considerable value and sustainability benefits to manufacturers, retailers and consumers while addressing the many packaging challenges faced by the adhesives and sealants industry.

Multiple Benefits

Residue control is a substantial problem for the adhesives and sealants industry. Various components used to manufacture adhesives and sealants can contaminate a steel drum or pail, making it difficult to reuse, recondition or recycle. Flexible packaging keeps drums and pails clean, eliminating container cleaning costs and resulting in immediate reuse of drums and pails.

Product purity is essential to maintaining product quality and performance; flexible packaging preserves and protects products. In addition, full product recovery is vital for valuable raw materials, and flexible packaging increases product recovery.

Flexible packaging also offers several less obvious benefits that are strong sustainability advantages. Flexible packaging materials weigh significantly less than other packaging formats, and they ship and store flat, so transportation and warehouse efficiency is maximized. Flexible packaging is also manufactured with less energy than rigid packaging and containers. Carbon dioxide emissions are further reduced by the space savings advantage created by using flexible packaging over pails and drums. Flexible packaging also provides important source reduction benefits. Source reduction is the Environmental Protection Agency’s preferred waste management strategy.

Liners

Flexible packaging exists in a number of formats: liners for pails, drums, intermediate bulk containers and bag-in-box systems, and inserts for pails and drums. Liners are heat sealed, include seams and have wall thicknesses ranging from 4-12.8 mil. Liners are available for 5-gal pails; 12-, 16-, 30-, 55- and 85-gal drums; 55- to 300-gal intermediate bulk containers; and 1.25-, 2.5- and 5-gal bag-in-box systems.

Liner types include flat seamed, round bottom, cube shaped and pillow shaped. Flat-seamed and round-bottom liners for pails and drums are designed for easy installation and can be simply twisted and tied off to protect contents. Cube-shaped liners are manufactured to form fit the internal shape of an intermediate bulk container or bag-in-box system. No pockets or folds trap residual product while emptying cube-shaped liners. Pillow-shaped liners for intermediate bulk containers and bag-in-box systems take the form of a pillow when filled. Pillow-shaped liners are typically constructed with two or three plies of linear low-density polyethylene and a barrier film when used for aseptic and oxygen-barrier applications.

Liners are manufactured through a heat-sealing process, where a thin, clear thermoplastic sheet is bonded by heat, time and pressure to form a closure. Heat-sealing technology is simple in concept and provides cost-effective products, but the process is not trivial. Tight tolerances, proven materials, precise timing and temperature control all play key roles in providing products that meet demanding requirements. A variety of films can be heat sealed, including metalized polyester and foil laminates for moisture protection, conductive laminates and anti-static films for volatile materials, nylon and co-extruded films for chemical resistance, polypropylene for high-temperature requirements, and low-density polyethylene for general use.

Inserts

Inserts are vacuum formed or blow molded, seamless and have wall thicknesses ranging from 10-24 mils. Inserts are available for 2- to 6-gal pails and 12-, 16-, 30- and 55-gal drums. The four types of drum inserts include: straight sided, accordion, combination and vented. Straight-sided inserts fit smoothly into new drums and are ideal when using follower plates. Accordion inserts have flexible, pleated side walls that accommodate variations in reconditioned drum heights. Combination inserts combine a straight-sided design with a band of accordion pleats to accommodate both drum height variations and follower plate use. Vented inserts include four holes near the top to vent trapped air during a fill, allowing drums to be filled with the lid on.

Blow molding is the process used to manufacture inserts. Blow molding technology provides extra performance in maintaining package integrity and durability. With this technology, components are typically cylindrical, but square or rectangular shapes can be made.

In extrusion blow molding (EBM), plastic is melted and extruded into a hollow tube (a parison). This parison is then captured by closing it into a cooled metal mold. Air is then blown into the parison, inflating it into the shape of the hollow bottle, container or part. After the plastic has cooled sufficiently, the mold is opened and the part is ejected. EBM processes may be either continuous (constant extrusion of the parison) or intermittent.

Compared to injection molding, blow molding is a low-pressure process, with typical blow air pressures of 25-150 psi. This low-pressure process allows the production of economical low-force clamping stations, while parts can still be produced with textured surface finishes. The resulting low stresses in the molded parts also help make the containers resistant to strain and environmental stress cracking.

Although injection molding is probably the most popular form of plastics processing, it is not conducive to liner manufacturing. In order to form a part as tall as a drum, the walls would have to be much thicker than is needed in thermoforming or blow molding, which would increase the part cost. Thicker parts also mean longer cycle times, which also increases costs. Injection molds are also typically more expensive and generally require more taper than thermoforming molds, so the liner will not fit the drum as well. In addition, inherent stress points at the sprue and gate (injection points) may cause a fracture point and consequently a leak point.

Sustainable Solutions

Flexible packaging offers significant value and sustainability benefits to consumers, retailers and manufacturers by reducing waste, energy use, and greenhouse gas emissions. Flexible packaging is an excellent sustainable choice that satisfies the adhesives and sealants industry’s packaging challenges while providing a greener footprint.

CDF exhibits at Expo Pack Mexico

CDF Corporation, a leading manufacturer of liners for drums, pails, intermediate bulk containers and flexible packaging, will display flexible packaging solutions at Expo Pack Mexico, Booth#4616.

 Expo Pack Mexico 2011 will be held June 21st to the 24th at the Centro Banamex in Mexico City, Mexico. Expo Pack Mexico 2011 will showcase the latest solutions in packaging and processing machinery, materials, containers and other related goods and services. Expo Pack Mexico offers direct access to the packaging and processing industries in Latin America attracting buyers from throughout the region. 22,000 customers/buyers from over 20 countries will attend Expo Pack Mexico 2011.

Packaging professionals from all major Mexican States attend the event, such as Mexico City, Estado de Mexico, Puebla, Guanajuato, Jalisco, Queretaro, Hidalgo, Morelos, Veracruz and Nuevo Leon. Delegations from Guatemala, El Salvador, Costa Rica and Honduras also attend. Attendees include packaging and processing professionals from a wide range of industries, including food, beverage, pharmaceutical, personal care, graphic arts, medical, chemical and automotive.

 CDF has a wide range of flexible products to satisfy the needs of product manufacturers and producers. CDF’s liners for intermediate bulk containers, bag in box, drums and pails provide outstanding performance in critical food applications. Read more

CDF Corporation adds European division for bag in box

Recently appointed Managing Director, Laura Beechwood, will be leading the operations and marketing the launch of CDF Europe, the first division of CDF Corporation outside of the United States.  As part of the expansion, CDF has purchased the Swiss-based Flexipack SA and will base its European headquarters in Lamone, Switzerland.

CDF Europe will manufacture and market Cheertainer UN™, Europe’s first UN certified bag in box.  In addition, the Lamone manufacturing facility will produce the premiere line of Cheertainer® bag in boxes and distribute pillow bags and IBC (1000 litre) liners to the EU market.

“We have been preparing for this European launch for several months.  CDF is the leader in flexible packaging for liquids in the U.S.,” said Laura Beechwood, Managing Director for CDF Europe.  “We built our business on an unwavering commitment to quality and an enthusiasm for innovation.  My job is to bring structure to our business in Europe and build upon the technical expertise that already exists in abundance here.”

Ms. Beechwood is an owner and former Chief Operating Officer of CDF Corporation and sits on the Board of Directors.  She was instrumental in creating and implementing the Global Strategic Business Plan.

CDF Corporation, based in the United States, is the brand leader in the manufacture of thermo-formed and heat sealed flexible packaging and bag in box liners.  CDF has products across a variety of markets and industries including food and beverage, chemicals and petrochemicals, paints and coatings and adhesives.

CDF pioneered the patented Cheetainer in the U.S. markets and is formally launching this brand and premiere product with the CDF Europe Division.  The Cheertainer is a revolutionary, form-fitting, multi-ply bag capable of dispensing many liquids with benefits not found in traditional pillow bags.  It also employs CDF1 Smart Seal Technology™ which optimizes consistency in temperature, time and pressure for every seal on every liner.

The Cheertainer UN is the world’s first U.N. Certified flexible package in 5 litre, 10 litre and 20 litre sizes.  As a certified product, it can be used for international transport of certain hazardous goods.

“To obtain U.N. Certification requires expertise in film procurement, packaging design, machinery specifications and processing parameters,” said Marco Dariol, Director of Operations, CDF Europe.  “Everything must work in conjunction to get the unique requirements necessary for certification performance.  It is both an art and a science.”

CDF Europe will be fully operational by June 1, 2011.  Michael Watson former Sales Manager for Northern Europe for Flexipack has accepted the position of CDF Europe Director of Sales. Marco Dariol will be Director of Operations and Technical Director.

“This is an excellent opportunity for the next generation of bag in box to really take off in Europe,” said Michael Watson, Director of Sales, CDF Europe.  “We have a truly unique product in the UN Certified Cheertainer.  It is by far the most innovative product of its kind available in Europe at the present time. And it is great to have CDF Europe’s support and resources for all of our Sales and Marketing initiatives.”

 

Cheertainer bag in box used for beverages

The idea of bringing great tasting beverages to consumers in an ecologically friendly way is the entire idea behind Big Easy Blends. In 2007 Antonio LaMartina and Craig Cordes in an entrepreneurial venture had manufactured all natural margarita beverages; their next venture is to find a durable and ecological packaging.

The product formally launched earlier this year, the product was marketed under the Cordina Mar-GO-rita brand and now has expanded from Louisiana to Florida, Texas and California with further expansion on the horizon to South Korea, Vietnam, Brazil and Israel.

The creation of the Cordina Mar-GO-rita came after there was a dispute on a public beach where the use of glass containers was prohibited. The company, according to Craig Cordes, “wanted a better way to carry premixed beverages” that was permitted in public areas.

The launch of the Big Easy Blends on-the-go pouch has come with great success, not only with packing but with the product itself. The company has sold the single-serve retail product, but in addition to that they have ventured out into the restaurants industry which requires larger capacity packaging. “Restaurants liked the drink mix, but wanted a version to better control inventory and to deliver a more consistent product to the consumer,” explained Cordes.

In April 2009, while attending the Nation Restaurant Association trade show in Chicago, IL, Big Easy Blends was introduced to the CDF Corporation. The CDF Corporation, the manufacturer of the Cheertainer, a flexible form-fit bag-in-box, provided the ideal solution to Cordes’ need.

Now instead of selling their pouches directly to bars and restaurants Big Easy Blends fills their products in CDF’s five gallon bag-in-box. The company then distributes the completed package to restaurants across the southern United States as a more cost effective to market their product in bulk.

Cheertainer’s strength, durability and ease-of-use is one of the things that has impressed Cordes, further noting “the structural quality if amazing” and has had no complaints with leaking or flex cracking; two significant detractors for competitive products.

As oppose to traditional packaging, the Cheertainer is an environmentally conscious, innovative, alternative. Manufactured in standard sizes of 5, 10 and 20 liters (1,2,5 gallons), the form-fit, square design allows for seamless filling and full dispensing of the product.

Due to its unique design and material strength, the Cheetainer improves efficiencies in the restaurant industry because it can be stored in many capacities; whether it is frozen or needed to be kept dry. The Cheertainer solves many of the common problems associated with competitive products, like fitment positioning, dispense operation and flex cracking. The Cheertainer provides and eco-smart choice for the customer, without sacrificing the quality and reliability demanded throughout the marketplace. Its reduced plastic consumption minimizes packaging requirements and maximizes transportation and storage efficiencies.

For Big Easy Blends, the Cheertainer has aided in the company’s expansion into new markets. In addition to the restaurant industry, Big Easy Blends product has expanded into retail outlets, liquor stores and convenience stores. Furthermore, the company is looking to grow to include daiquiris and mojitos. The Cheetainer has aided this growth, providing consumers with a user-friendly product that improves efficiencies and turnover.

By moving forward with cost-effective and an environmentally responsible direction, Big Easy Blends will realize continued growth, expanded opportunity and a sustainable future.

CDF’s bag in box on exhibit at Wal-Mart sustainability show

CDF Corporation, a leading manufacturer of liners for drums, pails, intermediate bulk containers and flexible packaging, will display Cheertainer’s flexible packaging solutions at the Packaging Sustainable Value Network’s 6th Annual Sustainable Packaging Exposition.

The Packaging Sustainable Value Network’s (SVN) 6th Annual Sustainable Packaging Exposition for Walmart and Sam’s Club will be held April 12th and 13th at the John Q Hammons Convention Center in Rogers, Arkansas. This event combines the exhibition of hundreds of packaging suppliers’ products and services, highlighting their successes in developing and delivering innovative and sustainable packaging to Walmart and Sam’s Club over the past year. The interesting and valuable information sessions are designed to provide you with the most up to date information on achievements and challenges to the industry. Read more

CDF speaks & exhibits at PPC

CDF Corporation, a leading manufacturer of drum, pail and intermediate bulk container liners and flexible packaging, will be presenting “Filling Solutions for Flexible Packaging” at the Petroleum Packaging Council 2011 Spring Meeting.

The CDF speech “Filling Solutions for Flexible Packaging” will cover a review of the filling equipment used for rigid containers, why standard rigid fillers cannot be used for bag in box filling, the benefits and operation of a bag in box filling system and a review of the options to consider when selecting bag-in-box filling equipment.

Representing CDF will be Steve Gosling, Technical Director and Iris Kennedy, Cheertainer Product Manager. Steve is responsible for all technical issues including product development, filling systems, quality, product applications, manufacturing and distribution. Steve is a frequent speaker at industry trade events on a variety of topics, including aseptic filling for spouted flexible pouch technology, solutions for IBC totes and e-beam technology.

In her current role as Product Manager of the Cheertainer bag in box product line, Iris is responsible for the development and growth of the Cheertainer brand in North America. Her business goals are to increase awareness of the benefits of flexible packaging and to increase Cheertainer market share in North America. Iris is working closely with the beverage, chemical and petroleum markets. Iris will be exhibiting the Cheertainer during the tradeshow portion of the Petroleum Packaging Council Spring Meeting.

The Petroleum Packaging Council  Spring Meeting will be held March 20-22 at the Renaissance Tampa International Plaza Hotel in Tampa, Florida. The Petroleum Packaging Council (PPC) provides technical leadership and education to the petroleum packaging industry, while providing a forum where members can exchange pertinent information for the betterment of the industry and the world we live in. This is done via lectures, seminars, training courses, supplier trade shows and general discussions. www.ppcouncil.org

CDF exhibited flexible packaging at Pack Expo

CDF, manufacturer of liquid packaging products and solutions that meet customers’ environmental goals, exhibited at Pack Expo Oct 31-Nov 3, 2010, Booth# 4169, North Hall. CDF demonstrated Cheertainer bag in box and Cheer Pack consumer pouch filling at the booth. CDF’s showcased products included liners and accessories for pails, drums, intermediate bulk containers, bag in box and pouches.

CDF selected to exhibit for Nestle

CDF Corporation displayed flexible packaging solutions at TOPS Exhibition & Innovation Fair at Nestle PTC. CDF was one of ten packaging suppliers selected by Nestle to exhibit. The packaging focus of the show was sustainability (greener design, reduced energy consumption, waste management), new trends and cost-cutting solutions.

Representing CDF was Steve Gosling, Technical Director of New Product Development and Iris Kennedy, Cheertainer Product Manager.

With over 30 years of management experience, Gosling has covered a wide array of applications throughout the packaging industry. In his current role as President of Cheer Pack North America, Steve is responsible for the successful integration of Cheer Pack into the North America market. Cheer Pack North America is an international partnership between CDF Corporation, Gualapack and Hosokawa Yoko. Steve is playing a critical role in the launch, development and growth of Cheer Pack North America.

In her current role as Product Manager of the Cheertainer bag-in-box product line, Iris is responsible for the development and growth of the Cheertainer brand in North America and the subsequent coordination with CDF’s European business affiliate. Her current business goals are to increase awareness of the benefits of flexible packaging and to increase Cheertainer market share in North America. Iris is working closely with the beverage, chemical and petroleum markets.

CDF offers a wide range of flexible products that satisfy customer’s environmental needs.

The Cheertainer, CDF’s form-fit bag in box, is an ideal solution for small and large volume needs. Ranging in size from 5 to 20 liters, the Cheertainer is UN certified and manufactured with CDF1 Smart Seal Technology™, ensuring the ultimate reliability of the package.

The Cheer Pack is a flexible spouted single-serve retail pouch serving the food and beverage and cosmetic industries. The Cheer Pack is currently being sold throughout Asia and Europe in annual quantities of up to 1.5 billion and has recently made its North American debut.

CDF presented at the Petroleum Packaging Council

Laura Beechwood, Chief Operating Office and Iris Kennedy, Cheertainer Bag in Box Product Manager represented CDF in their speech “Liners & Flexible Packaging for the Petroleum Industry”. The lecture covered the benefits of using liners in the petroleum industry, technical considerations and types of drum, pail and intermediate bulk container liners and innovations in the flexible packaging industry. The presentation can be viewed at http://www.ppcouncil.org.

CDF eco-smart packaging solutions

Since 1971, CDF has been an industry leader in sustainable packaging. Decades ago, we launched the 55 gallon drum liner. For the first time, this 55 gallon steel drum liner allowed drums to be reused, eliminating cleaning costs and landfill waste.

In the 1980’s CDF introduced round bottom technology to manufacture economical, lighter weight liners and barrier films for oxygen, moisture and hot filling applications. These innovations permitted the outer rigid container to be easily reused or recycled.

CDF’s intermediate bulk container liners were introduced in the 1990’s to reduce the need for expensive rigid packaging. With the use of our IBC liners, CDF’s customers are able to reduce transportation costs of rigid containers. The patented design maximized product efficiency, allowing the customer to get the most product possible out of the container.

CDF continues to be a pioneer in introducing product breakthroughs that result in environmental benefits and reduce customer cost.

The Cheertainer bag in box is an environmentally-friendly, alternative to traditional packaging. Its form-fit, square design provides an eco-smart bag in box option; its reduced plastic consumption minimizes packaging requirements, while maximizing transportation and storage efficiency.

The Smart Pail is a semi-rigid, flexible vacuum-formed plastic liner with a hermetically sealed plastic lid and/or snap-on plastic cover, corrugated box and corrugated lid. Due to its design, the Smart Pail reduces plastic consumption by 76% and is able to achieve one extra skidded layer during transport than standard rigid pails, equating to 33% more transportation and warehousing efficiency.