CDF exhibiting IBC liners and Cheertainer bag in box at Expo Pack Mexico 2012

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# 7000.

 Expo Pack Mexico 2012 will be held June 26th to the 29th at the Centro Banamex in Mexico City, Mexico. Expo Pack Mexico 2012 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 2012.
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.

 The Cheertainer, CDF’s innovative 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.

 Formfit liners are manufactured to form fit the internal shape of your intermediate bulk container. 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.

 The Air-Assist liner allows the user to realize a more complete evacuation of their product. Less residual product is left inside the liner, resulting in savings to the user. Air-Assist liners are specifically designed for high viscosity products.

 The most effective moisture and oxygen barrier for packaging environmentally sensitive products is a High- Barrier Foil liner constructed from an aluminum foil lamination. Moisture barrier liners incorporate an impermeable layer of aluminum foil to ensure the long-term integrity of a wide variety of environmentally sensitive products, including nylon, Surlyn®, EVOH, certain pharmaceuticals and various high value foods.

 Pillow-shaped liners are typically constructed with two or three plies of linear low-density polyethylene (LLDPE) and a barrier film when used for aseptic and oxygen-barrier applications. When filled, these industrial tote liners form the shape of a pillow.

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 Corp liners selected over competitive products after going through NASA’s rigorous testing of material and compatible superiority

One of NASA main and more well-known program,, the Space Transportation System (STS), more commonly known as the Space Shuttle program, had its first launch in 1981 and has practiced 122 missions at an average cost of $450 million per launch, according to NASA. The cost and world-wide attention placed on every mission has placed extreme pressure on every facet and every system used for every flight.

Each shuttle that is produced for NASA is projected to have a lifespan of 100 launches or ten years of operating life. From their beginnings they STS program has been innovative in their abilities to accommodate commercial and classified satellites, astronauts, and service parts for the International Space Station. Each shuttle is manufactured with three main components: the Orbiter Vehicle, the rusted color External Tank, and two Reusable Solid Rocket Motors which propel the shuttle to space.

In 1998, through a $2.4 billion contract with ATK Thiokol, NASA extended the Reusable Solid Rocket Motors (RSRM) program for the production and refurbishment of seventy RSRMs. This addition is the sixth in a series of deals, since 1973, for the design, development, production and refurbishment of Solid Rocket Motors for the Space Shuttle Program and signifies a continued relationship between NASA’s Marshall Space Flight center in Huntsville, Ala., and ATK Thiokol. The current RSRM is one of the largest solid motor ever flown and the first developed for reuse.

In 2005, ATK Thiokol chose CDF Corporation’s 5, 12, 30, and 55 gallon drums and pail liners for the use of the first step of preparing the primer and topcoat paint for the outward portion of the RSRM hardware.

A great success for CDF Corp, their liners were chosen over competitive products after going through NASA’s rigorous testing of material and compatible superiority. “Because we work closely with NASA to build a quality product for safe space missions, we have a rigorous qualification process for the products we use within the RSRM program,” stated ATK Thiokol Program Manager Jeff Chapneys, who took a lead role in ATK-CDF Partnership. “CDF was one of few companies whose product satisfied all of the exacting RSRM requirements” he continued.

Laura Beechwood, the Chief Operating Officer of CDF stated, “CDF is proud to have been chosen as NASA’s liner supplier. It is a testament of our product quality, investment in innovative technology, and talented workforce.”

ATK Thiokol commented on CDF’s product quality stating, “Prevents transferable contamination from pail liner to paint of adhesive which may have a significant negative impact on RSRM quality and performance.”

To elevate the 4.5 million pound shuttle into orbit, there are three space shuttle main engines and the two RSRM which provide nearly 80% of the lift and enough thrust the space craft into space. Each RSRM is nearly the height of the Statue of Liberty but weights nearly three times as much. The thrust that is produced during takeoff from the three millions pounds of propellant accelerates the Space Shuttle to a speed of more than 17,000 mph within the first eight minutes of launch. Once the boosters separate from the Shuttle’s Orbiter Vehicle and lands in the ocean, the product is recovered and disassembled while the motors are returned to ATK Thiokol to begin the refurbishing process for the next NASA mission.

There are four segments that create the motor, with the forward segment holding the igniter. In the manufacturing of the motor, ATK Thiokol determined CDF Corporation’s pail liners, “Provided superior performance for a critical application.” The products integrity is ensured the great attention to quality and performance during the production, the inspection, transportation, and storage of motor components.

In addition to CDF Corporations liners being used in the preparation for primers and topcoats, CDF’s pail liners are used in the preparation for adhesive ChemLok prior to application. Champney commented stating, “For specific Reusable Solid Rocket Motor applications, CDF provided the best quality product at the most competitive price.”

The exterior hardware of the RSRM is painted to protect against corrosion and the internal area of the RSRM hardware is Chemlok coated to form a bonding surface between the steel components and the insulation. Guaranteeing the integrity, purity and maximum performance of the materials was essential to the ATK team, highlighting, “CDF’s attention to detail and focus on quality” as underwriting factor to their partnership.

Quality assurance is the key to a successful mission, from the exterior paint to solid fuel propellant, every fact of the space shuttle process must work in harmony flawlessly. ATK Thiokol and all its partners are committed to creating the most efficient products into the future.

CDF’s Joe Sullivan speaking at PPC fall meeting

CDF Corporation, a leading manufacturer of drum, pail and intermediate bulk container liners and flexible packaging, will be presenting “Drum Liners” at the Petroleum Packaging Council 2011 Fall Meeting.

The CDF speech “Drum Liners” will cover benefits of drum liners, markets, various styles and applications, as well as an explanation of thermoforming, blow-molding and heat sealing processes.

Representing CDF will be Joseph Sullivan Jr., President. Joseph has management responsibility for all aspects of CDF Corporation. Prior to being appointed President, Joseph was Director of Operations. As Director of Operations, his core responsibilities included key account management, as well as specifying and procuring all manufacturing equipment throughout the company. In 2008 Joseph was named Co-Manager of Cheer Pack North America. Cheer Pack North America is a partnership between Hosokawa Yoko (Japan), Gualapack (Italy) and CDF Corporation. Joseph is also Chairman of the Board of Directors of Flexipack SA/ CDF Europe, a Swiss based subsidiary of CDF Corporation and Quad Pak, AB.

The Petroleum Packaging Council Fall Meeting will be held August 21-23 at the Canyons Grand Summit Resort in Park City, Utah. 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 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.

CDF announces replacement for rigid pails

In an effort to create a sustainable replacement for rigid pails, CDF Corporation, the leading manufacturer of drum, pail and intermediate bulk container liners and flexible packaging, has developed the Smart Pail, an environmentally-friendly liner-in-box system.  The Smart Pail consists of a light-weight, cubed shaped liner designed for use with a 100% recyclable corrugate overpack.  The Smart Pail provides a significant cost-savings opportunity for the user by reducing input energy and maximizing overall efficiencies without sacrificing the quality and reliability required of pail systems.

The Smart Pail can be seamlessly integrated into existing single and multi-head filling lines, providing companies a means to increase profit and promote sustainable business practice.  The pail liner weighs 87% less than a rigid pail, allowing the customer to maximize energy efficiencies and productivity rates.  In terms of energy savings, one truckload of empty Smart Pails is equal to 5 truckloads of empty rigid pails.  This reduces inbound transportation costs, fuel consumption and greenhouse gas emissions, while maximizing inventory space. 

Due to its cubed construction, the Smart Pail is able to achieve one extra skidded layer over rigid pails, equating to 33% more product-per-pallet.  The corrugate container is 100% recyclable and the liner, made from high-density polyethylene, has recycle code 2 certification.  And, at the end of use, the Smart Pail occupies 76% less space in landfills than rigid pails.

“In today’s business climate, it is becoming all the more important to be cost-effective and environmentally-conscious,” says CDF Chief Operating Officer Laura Beechwood.  “The Smart Pail is a revolutionary product that will cut costs, help drive future business growth, and improve company environmental efforts – creating an all-around smart system.”

Two different lidding options are available for the Smart Pail.  For users handling products that need to maintain freshness or storing capacity, the Smart Pail can be hermetically sealed with a wide range of film structures, creating an air-tight, tamper-proof seal to ensure product purity.  For users that require quick turnaround for their product, the Smart Pail can be used with a snap-on lid to increase the ease of use when filling and emptying the product.

The Smart Pail is designed for use with thick viscous products which are traditionally packed in steel or plastic pails such as paints, inks, cosmetic compounds, drywall mud, roof sealants, powders and flakes.

  The Smart Pail is one of many innovative products in flexible packaging technology offered by CDF.  Such innovations have included the Cheer Pack®, Cheertainer® bag-in-box, EZ-Strainer™ inserts for drums and pails and Air-Assist™ IBC liners.

CDF EZ-Strainer used in agricultural & automotive markets

CDF Corporation, the leading manufacturer of drum, pail, and intermediate bulk container liners and flexible packaging solutions, introduced its EZ-Strainer™ insert for 55-gallon drums and 5-gallon pails into the agricultural and automotive markets.

The newly tested strainer, which allows for more efficient production and reduced customer cost by improving filtering techniques in a time-efficient manner, has been successfully used throughout industry and manufacturing  sectors, but new testing has revealed potential benefits for agricultural and automotive machinery and equipment.

“The EZ-Strainer’s dynamic use fits in all industries and is one of the most innovative products we have developed,” said Vice President of Manufacturing Wayne Morgan. “We are excited about the possibilities of entering new markets; we believe customers throughout the automotive and agricultural markets will be truly impressed.”

The revolutionary EZ-Strainer filters unwanted particles from valuable liquid products.  A patented lip design allows the EZ-Strainer to simply hang from the top of any open-headed 55-gallon drum or 5-gallon pail without the chance of being pulled inside, even with heavy, viscous products.  The EZ-Strainer can be used in those industries mixing liquid products such as inks, paints and urethanes, and for printing purposes.  New testing has targeted the agricultural and automotive markets for use many uses, from filtering maple syrup and other liquid products to filtering oils and fluids for heavy equipment, such as tractors, production machinery, and vehicles.  The EZ-Strainer is currently being used in successful bio-diesel programs around the country.

“We have been continually impressed by the EZ-Strainer,” said President and Founder of Utah Biodiesel Supply Graydon Blair.  “Its durability and ease of use are impressive – it has held up extremely well and we have seen no evidence of tears or other strength defects.”

The EZ-Strainer insert is molded from high molecular weight high-density polyethylene with a center screen that is available in 100 ultra-fine nylon or 200, 400 and 600 multi-element mesh (fine, medium or coarse).  EZ-Strainer inserts are ideal for removing particles from food, paints, coatings, silicone, ink and any other liquid product that needs to be debris free.  The product can be inserted into 55-gallon drums or 5-gallon pails.