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Part of BillerudKorsnäs Group This document contains information belonging to Paccess which is privileged and confidential. Any unauthorized copying, use or distribution of this material is strictly prohibited.
Part of BillerudKorsnäs Group This document contains information belonging to Paccess which is privileged and confidential. Any unauthorized copying, use or distribution of this material is strictly prohibited.
TLC CONFERENCE Packaging Protection Overview March 17, 2014 Rick Hawley
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Part of BillerudKorsnäs Group This document contains information belonging to Paccess which is privileged and confidential. Any unauthorized copying, use or distribution of this material is strictly prohibited. 3
Part of BillerudKorsnäs Group This document contains information belonging to Paccess which is privileged and confidential. Any unauthorized copying, use or distribution of this material is strictly prohibited. 4
Part of BillerudKorsnäs Group This document contains information belonging to Paccess which is privileged and confidential. Any unauthorized copying, use or distribution of this material is strictly prohibited.
THE CHALLENGE WITH PACKAGING GLOBALLY SOURCED PACKAGING IS NOT DESIGNED WITH SUPPLY CHAIN EFFICIENCY OR BRAND NEEDS IN MIND
The Result…..Loss of Packaging Control • Lack of packaging cost transparency • Packaging not optimized for the supply chain, over/under specified • Excessive freight spend • Unapproved changes made by factory • Packaging doesn’t meet performance standards • Inaccurate product data; product claims, weights, measures • Barcodes not readable at automated distribution centers
Who Has These Challenges…..Brands that Source Packaging Globally • Retailers • Private Label • Apparel • Footwear • Toy
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• Automotive • Home Goods • Fresh Produce Suppliers • Sporting Goods • Heavy Industrial
Part of BillerudKorsnäs Group This document contains information belonging to Paccess which is privileged and confidential. Any unauthorized copying, use or distribution of this material is strictly prohibited.
THE ELEMENTS OF GOOD PACKAGING THE COMPONENTS OF GOOD PACKAGING DESIGN THAT WORKS FOR THE SUPPLY CHAIN – EASY TO SAY, HARDER TO ACHIEVE
Design the right box
Size the right box
Source the right box
Pack the right box
Protection is the number one goal of packaging!
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Part of BillerudKorsnäs Group This document contains information belonging to Paccess which is privileged and confidential. Any unauthorized copying, use or distribution of this material is strictly prohibited.
SUPPLY CHAIN WE LIVE IN THIS WORLD
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THE TREMENDOUS COST OF DAMAGED PACKAGING THE NUMBER ONE GOAL OF PACKAGING IS TO PROTECT THE PRODUCT. THE REASON IS SIMPLE, THE COST OF RETURNS AND DAMAGED PRODUCT IS HUGE
According to an Aberdeen Group Study in 2010 ...the average manufacturer will spend 9% to 15% of total revenue on returns
“Reverse logistics is no small matter in the supply chain ... “Total U.S. revenue impacted by returns is estimated between $52 billion and $104 billion.”
Unsaleables are estimated to be a $15 billion annual cost to the grocery industry (or 1 percent to 2 percent of gross sales on average)
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CORRUGATED BOARD BASICS TRANSPORT PACKAGING MATERIALS
Liners and Medium
Fluting: ACBEF ... Other microflutes
Singlewall board
Doublewall and Triplewall
Starch based adhesive
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THE PACKAGING DESIGN PROCESS THE WAY WE APPROACH IMPLEMENTING A TRANSPORT PACKAGING PROGRAM WITH PROTECTION IN MIND
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NATIONAL MOTOR FREIGHT RULES AND PACKAGING THE CARRIER RULES ARE CALLED ITEM 222 FOR THE NMFC AND RULE 41 FOR THE UFC (RAIL)
Minimum strength standards that must be met for claims
Performance based specifications depending on the weight and outside dimensions of a carton with its product
ECT added as a performance spec in 1991 = good news!
ECT allows for greater strength at lower basis weight (amt of fiber in paper)
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BMC EXPLAINED
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Burst strength of the carton – the amount of force to puncture. There’s also an ECT version that’s similar
This is the summation of weight per thousand square feet of all facings in the board excluding medium and adhesives or other additives.
Not to exceed outside dimensions
Not to exceed fill weight
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THE PERFORMANCE TESTS ON A CORRUGATED BOX EDGE CRUSH TEST AND BURST (OR MULLEN) ARE THE TWO TESTS RECOGNIZED BY THE NMFC (MOTOR FREIGHT) AND UFC (RAILROAD) ASSOCIATIONS
TAPPI – Technical Arm of the American Pulp and Paper Industry
Establishes testing methods for testing paper and packaging
Two relevant tests T811 – Edge Crush Test T810 – Burst or Mullen
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USE BURST OR ECT? THERE ARE A LOT OF OPINIONS ON WHEN TO USE A BURST OR ECT – THE ANSWER IS “IT DEPENDS ON YOUR SUPPLY CHAIN”
Burst specification – a function of the liner – puncture resistance Apparel and softgoods Floor loaded containers – smaller cartons Rough handling Where product leaves open voids
ECT is used when product in the supply chain requires a lot of stack strength When product is shipped in unitized loads (pallets and film wrapped) Stacked long periods of time before sale or use If you have high stacking heights in your DC or other parts of the supply chain – some DC’s do not have racking When stacking strength is more important than puncture resistance
Work with packaging engineers to build packaging at the paper levels – specific liners and mediums that meet both ECT and burst or your specific supply chain
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ADDITIONAL TESTING DEPENDING ON SUPPLY CHAIN IN THE COLD SUPPLY CHAIN OR SHIPPING VERY HEAVY ITEMS, ADDITIONAL TESTING MIGHT BE USED TO DETERMINE THE BEST SPECIFICATION
Flexural Stiffness of Corrugated Board T820
BCT – Box Compression Test – platen device used to measure the failure point of the carton
ECT and the McKee formula – calculates the ability of a box to carry the weight of cartons on top
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U = box outline in mm d = thickness of corrugated board in mm
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PAPER APPROXIMATELY 70% OF THE COST OF A SHIPPING CARTON IS THE PAPER
Virgin fiber from well managed forests is best for overall strength and moisture resistance
Paper can only be effectively recycled 5-7 times
Kraft paper used in the US for protective packaging – has mostly virgin fiber, but some recycled content – 75/25
OCC – old corrugated containers Trim waste from paper mills and converters
Paper’s that are FSC or SFI certified come from well managed, sustainable forests
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TRUE PERFORMANCE BOX COMPRESSION TEST (BCT)
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BILLERUD FLUTE® - 220 G/M2 HOW FAR CAN WE REACH?
Billerud Flute® 220 g/m2 – so strong that it can replace wooden boxes!
PaperOutside liner Kraftliner WS 440 g/m² A-flute Billerud Flute 165 g/m² Center liner Kraftliner WS 440 g/m² A-flute Billerud Flute 165 g/m² Inside liner Kraftliner WS 440 g/m²
Package
BCT [N] 29500BCT [kg] 3000FEFCO code 201LxWxH 1000x1000x1000
PaperOutside liner Kraftliner WS 440 g/m² A-flute Billerud Flute 220 g/m² Center liner Kraftliner WS 440 g/m² A-flute Billerud Flute 220 g/m² Inside liner Kraftliner WS 440 g/m²
Package
BCT [N] 32000BCT [kg] 3260FEFCO code 201LxWxH 1000x1000x1000
Before Now
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REPLACING WOODEN PACKAGING WITH PAPER
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IS YOUR SUPPLY CHAIN A GOLDMINE? IS THERE HIDDEN VALUE IN YOUR SUPPLY CHAIN? SOMETIMES THERE’S NICKELS, DIMES AND QUARTERS PER UNIT HIDDEN IN YOUR SUPPLY CHAIN.
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THERE’S VALUE IN CONTROLLING PACKAGING WE HAVE MANY EXAMPLES. WE GENERALLY SEE SAVINGS IN IMPROVED FREIGHT DENSITY AND IMPROVED MATERIALS, AND ALSO REDUCED DAMAGE
Right sizing the packaging to the product Increased freight density – more product units per CBM shipped 10% – 40% improvements 4%-9% freight density improvement moving from Doublewall to Singlewall shippers
Retail and Transport Packaging Redesign Smaller more efficient structures Raw material specifications that are “right fit” for the product and distribution systems Innovative structures that enhance the brand in retail Design in “Green” initiatives 5% - 30% improvement through design
Reduction in Damage Going from excessive to an acceptable damage number – for example, 16% to less than 2%
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THANK YOU!
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Part of BillerudKorsnäs Group This document contains information belonging to Paccess which is privileged and confidential. Any unauthorized copying, use or distribution of this material is strictly prohibited. 23
Part of BillerudKorsnäs Group This document contains information belonging to Paccess which is privileged and confidential. Any unauthorized copying, use or distribution of this material is strictly prohibited. 24
Part of BillerudKorsnäs Group This document contains information belonging to Paccess which is privileged and confidential. Any unauthorized copying, use or distribution of this material is strictly prohibited.
ADDITIONAL SLIDES - APPENDIX
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COATED WHITE TOP KRAFTLINER
KORSNÄS DESIGN For high quality flexo pre-print/screen/digital Superior print quality and reproduction of images High gloss
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High strength and bulk gives considerable yield saving potential Food safety – 100% pure fibres Grammages: 130, 145, 160, 175 and 200 gsm
KORSNÄS DECOR For high quality post print flexo Excellent print quality and gloss Washboard reduction in post print thanks to: High strength and stiffness – can withstand forces better High surface smoothness – less printing pressure, less glue
High strength and bulk offers considerable yield saving potential Food safety – 100% pure fibres Grammages: 120, 145 and 170 gsm
KORSNÄS SUPREME Designed for high quality offset printing and litho-laminated packaging Superior print quality and reproduction of images High strength and bulk gives considerable yield saving potential
Food safety – 100% pure fibres Can be supplied in sheets Grammages: 160, 175 and 200 gsm
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WHITE TOP KRAFTLINER
KORSNÄS CLASSIC Extremely high-strength properties for:
Demanding constructions Dramatic weight savings
Washboard reduction
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High quality consistency for high printing speed and corrugator runnability Food safety – 100% pure fibres – resistance to moisture Grammages: 130, 160, 175 and 200 gsm
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FULLY WHITE KRAFTLINER
BILLERUD PURE WHITE High and consistent whiteness Superior runnability Based on 100% primary fibres Produced in compliance with FDA and BfR food packaging norms
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Mainly used for food applications including fruit and vegetables Grammages: 80, 90, 100, 110, 120, 135, 170, 190 gsm
BILLERUD PURE BRIGHT Enhanced whiteness Designed for packaging of luxury products such as beauty care and fashion products
Based on 100% primary fibres Grammages: 80, 90, 100, 110, 120 and 135 gsm
BILLERUD PURE ARCHIVE Fully bleached liner specially designed to be used for archive boxes Fulfilling requirements for imposed preservation and durability
Certified for performance in accordance with ANSI/NISCO Z 39.48, ISO 9706 and ISO 16245. Basis weights: 120, 135, 170 and 190 gsm
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THE RIGHT LINER FOR THE RIGHT PRINT APPLICATION
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HIGH QUALITY PRE-PRINT HIGH QUALITY POST-PRINT
OFFSET litho-laminated
FLEXO
FLEXO Premium
FLEXO Basic
SCREEN, INKJET, OFFSET
KORSNÄS SUPREME
KORSNÄS DESIGN
KORSNÄS DECOR
KORSNÄS CLASSIC
BILLERUD PURE WHITE
BILLERUD PURE BRIGHT
Meets all requirements An excellent choice in most situations
Premium Basic
Premium: Demands on high resolution and screen count, highest gloss and very good colour reproduction in high quality process printing. Basic: Basic process printing, vignettes and solids. Possibility to achieve a matt appearance.
Compared to uncoated grades, coated grades require more drying capacity and finer anilox screening in order to achieve best print result.
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SEMI-CHEMICAL FLUTING
BILLERUD CENTRE LINER Semi-chemical liner based on 100% primary fibres Specifically designed for use as center liner in double wall constructions
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New possibilities for cost and performance optimisation of the corrugated construction Basis weight: 105 gsm
BILLERUD FLUTE Superior semi-chemical fluting based on 100% primary fibres Extremely high strength for boxes exposed to long demanding transport chains and humidity
High creep resistance which means high strength and durability over time with constant load in tough climates
Produced in compliance with FDA and BfR food packaging norms Mainly used for food applications including fruit and vegetables and for premium heavy duty goods Basis weights: 120, 130, 140, 150, 165 and 175 gsm
BILLERUD FLUTE LIGHT Low grammage semi-chemical fluting Produced from 100% primary fibres
Particularly suitable for micro corrugated and food contact applications Basis weights: 105 gsm
BILLERUD FLUTE S Semi-chemical fluting with consistent quality and excellent runnability Recycled fibre content Particularly suitable for fruit and vegetables and industrial products
Produced in Skärblacka which is certified in accordance with ISO 9001, ISO 14 001 Basis weights: 112, 127, 140, 150 and 165 gsm
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ANALYSIS OF PAPER PROPERTIES
CCT, Corrugated Crush Test The maximum compression force per unit length that a laboratory corrugated test piece can support until the onset of break, where the force is applied in the direction of the flute tubes. SCAN-P42
CMT, Corrugated Medium Test The maximum force, expressed as the mean force in Newton, that a laboratory corrugated test piece will withstand before the flutes collapse, under an increasing force applied perpendicular to its surface. ISO 7263
Z-strength The maximum tensile strength per unit area, expressed in kPa, that a paper can withstand until the onset of break, when the force is applied perpendicular to its surface. SCAN-P80
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CORRUGATED BOARD/BOX ANALYSIS
ECT, Edgewise Compression Test The maximum compression force a test piece of corrugated board can withstand without collapsing, with the flutes standing perpendicular to the plane. (ISO 3037)
4-point bending stiffness Bending stiffness relates the bending moment to the resulting deflection in the elastic area, and is mainly determined by the thickness of the material together with the quality (mainly tensile stiffness) of the inner and outer liners. (ISO 5628)
BCT, Box Compression Test The maximum compression force a corrugated box can withstand without collapsing. The BCT value can be estimated theoretically by using the ECT-value, the bending stiffness in both machine and cross-machine directions and the periphery of the box (McKee formula). (ISO 12048)
FCT, Flat Crush Test TAPPI T825
Bottom deflection UNE 49706, UNI 6719
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