can · 2007-09-05 · editorial comment cantech international november 2013 3 ack in the summer,...

Can TechI N T E R N AT I O N A L

NOVEMBER 2013

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NTEC

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TION

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EMBER 2013

BAMA speaks up

Unilever tops awards

Keeping a clean can

Inside:

The aerosols issue

Editorial Comment

CanTech International November 2013 3

ack in the summer, CanTech International had the

honour of being among the judges in the World

Aluminium Aerosol Can Awards 2013, and after

sifting through an interesting variety of both new and

established products, we eventually opted for the

‘autumn’ can from Tubex – which, having recently

scooped first prize in the prototypes category, is pictured

on this month’s cover.

The most aesthetically pleasing candidate – courtesy

of new digital printing technologies – I was also impressed

by the smooth, glossy feel of the product. The aerosol can

has been established for many years without a great deal

of variation, so it’s refreshing to see first-hand the level of

innovation that can be applied to give this type of can a

completely different look and feel. I’m already intrigued

to see what next year’s entrants will put forth.

During the judging process, little did I realise this would

just be the start of an apparent aerosol ‘boom’, in which

innovations and success stories about the product have

popped up from across the globe. This trend is reflected

throughout this month’s issue, which details the aerosol’s

origins, latest developments, and a look at what lies

ahead for this interesting category.

Elsewhere, we explore the marketing possibilities that a

can has to offer, many of which are only just being realised

for the first time. The look and appearance of the product

has a huge impact on whether or not the customer com-

mits to buy, but the importance of this is often overlooked.

This story forms the basis of our two-piece can update,

which can be found on pages 17-18.

Meanwhile, AsiaCanTech will likely be underway by

the time you have this magazine in your hands, and I’m

pleased to report that we’re anticipating a very strong

turnout, with delegates and exhibitors expected from

around the world. Full details from the event will feature in

next month’s show review.

The aerosol boom

continues

B

EditorialAdvisory Board

Geoff Courtney Chairman ofthe Can Makers

James Peterson Vice President of Marketing and Corporate Affairs at

Ball Corporation

Simon Jennings Owner and advisorof Nomis Consultancy

Robert Gary Executive VicePresident Global Solutions forStolle Machinery Company

Adrian Long Global Account Manager for CMB Engineering

Atit Bhatia Senior Vice Presidentat Hindustan Tin Works

Gordon Shade Chief ExecutiveOfficer of the European Metal

Packaging Association (Empac)

Simon Rowley, Editor,

CanTech International

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PublisherNeil [email protected]

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November 2013 Contents


7

REGULARS

3 Comment

7 World News

36 Equipment News The latest machinery and equipment for the can line

37 New Products New cans and ends in the market place

38 Filling Focus News The latest from can fillers around the world

40 Craft Beer Update Russ Phillips updates readers on the canned craft beer market in the US and reviews the best cans and beers

58 Candid John Bigley, managing director metal – Australia & New Zealand, Ardagh Group

FEATURES

14 Can Corner In the latest in our series of articles from Rexam, Bill Neilson, the company’s VP technical for Europe, talks BPA and coatings

17 Two-Piece Update CanTech contributor Evert van de Weg looks at the latest innovations in the two-piece can and details why appearance is becoming increasingly important

20 Aerosols Atit Bhatia, senior vice president of Hindustan Tin Works, looks at the origins of the aerosol can and where its future lies

22 BAMA Awards The British Aerosol Manufacturers’ Association (BAMA) has announced the winners and finalists of the 2013 BAMA Awards

25 Aerosols Dr John Morris is the executive director of the British Aerosol Manufacturers’ Association. Here, he explains why the UK is such a strong aerosol producer, and what challenges lie ahead

November 2013

Volume 21, Number 3

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NOVEMBER 2013


CA

NTEC

H IN

TERNA

TION

AL N

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EMBER 2013

BAMA speaks up

Unilever tops awards

Keeping a clean can

Inside:

The aerosols issue

Send address changes to: CanTech International, The Maltings, 57 Bath Street, Gravesend, Kent DA11 0DF, UK. Published by Bell Publishing Ltd. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without the prior written permission of Bell Publishing Ltd. Printed in the UK by Buxton Press ISSN: 1466-7851

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43

Contents

22

17 Two-Piece Update

36

28 Aerosols Véronique Curulla of Crown Aerosols and Speciality Packaging Europe explains the trends driving the latest aerosol designs

32 Cleaning Frank McDonough and Jim Vandenberg of Quaker Chemical Corporation explore the benefits of using advanced alkaline cleaning technology for aluminium beverage cans

41 Buyers Guide

14

CanTech International November 2013

World News

Cans for Pets

News and views from the metal packaging industry

Cans for Pets, a recycling campaign based in Western Pennsylvania, USA, has announced that during its first ten months, animal lovers have recycled over 64,000 aluminium pet food cans – and raised several thousand dollars to aid homeless animals in the process.

The campaign, which launched in November 2012, is organ-ised by Alcoa Foundation and Pennsylvania Resources Council. For every aluminium pet food can recycled, five cents is being donated to the Animal Rescue League to aid animals in the area.

The campaign is part of a two-year effort to raise awareness whilst also increasing the total number of aluminium pet food cans recycled each year. A recent industry survey revealed that recycling rates for aluminium pet food cans (20%) is considerably lower than that of aluminium beverage cans (65%).

7

The winners of the World Aluminium Aerosol Can Awards 2013 were presented at this year’s Aerobal congress, the global association for manufacturers of aluminium aerosol cans.

The coveted award for prod-ucts already on the market went to Tubex from Germany for its aluminium aerosol can for the ‘wellaflex’ brand. The can is designed to attract attention at the point of sale: in the middle it features a break in the emboss-ing around a large ‘W’ and ‘F’ in order to create space to print the brand name ‘wellaflex’. Along with an aesthetically-pleasing appearance, it also provides a haptic experience. Thanks to optimisation of the process steps, the rate of production for the can is no lower than for a con-

Tubex scoops aerosol awards

ventional can without embossing.The first prize in the prototypes

category also went to Tubex for its ‘Autumn’ aerosol can, which makes use of modern, innovative printing techniques and special inks. Digital printing reproduc-es a photo-realistic image of a young woman with perfect and extremely fine nuances in the skin tones, right down to the highlights in her cheekbones. “The jury’s decision is an indication of where the development of the aerosol can is heading,” explains Gregor Spengler, secretary general of Aerobal. “In addition to its unique

barrier properties, its high stand-ards of reliability and quality as a result of it being a one-piece can – and its good recyclability – the aluminium can scores above all because of the interesting pos-sibilities it offers when it comes to printing and shaping. Here, it is increasingly making greater use of its advantages over other comparable forms of packaging. For the client’s market activities, it thus offers a whole host of addi-tional opportunities to convey visual effects and brand imag-es and to appeal to customers effectively at the point of sale.”

The European Aluminium Association (EAA) has announced the appointment of Magdalena Garczynska as the director of its new recycling department. This new post will strengthen the exper-tise of EAA on an industry segment that is a cornerstone of the alumin-ium industry’s sustainability.

EAA’s director general Gerd Götz says, “The appointment of Garczynska comes at a crucial time as the EU starts to revise its

EAA reinforces its recycling dimensionwaste legislation. Being a recycling champion, the aluminium industry has a key role to play in this revi-sion. We want the future waste legislation to contribute to secure access to secondary raw materials for the recycling industry and to unlock the recycling potential of our industry.”

Speaking about her appoint-ment, Garczynska notes, “I am pleased to join a sector that has such a positive and innovative

contribution to the EU’s sustaina-bility objectives. I look forward to working with our members and all the actors of the recycling value chain to ensure that EU decision-makers recognise the infinite recy-clability of this material”.

Garczynska, who is a Polish national, has more than ten years’ experience in both engineering and public affairs. Prior to joining the EAA, she was a technical man-ager at the European Association

of the Machine Tool Industries (CECIMO), where she guided the association’s work on environmen-tal, energy and other issues.

The EAA has enlarged its mem-bership to recyclers that were previously represented by the Organisation of the European Aluminium Recycling industry (OEA), and consequently found-ed a new Recycling Department to be headed by the recycling director.

November 2013 CanTech International 10 8

World News

Rexam Beverage Can Europe has announced the results of its third annual Community Can Challenge, supporting the over-all efforts of the beverage can manufacturer in promoting and employing more sustainable ways of working.

Now in its third year, the Community Can Challenge runs over a ten-week period in nine European countries and sees Rexam’s plant teams work closely with their local communities to educate about recycling whilst raising money for charity. This year saw yet another impressive response from Rexam’s workforce.

The scheme collected a remark-able 5.7 tonnes of cans (14% more than the previous year’s chal-lenge), equating to over 345,000 cans and 52 tonnes of Carbon Dioxide savings. 1.7 tonnes of these cans were collected by Rexam’s engineering facility in Milton Keynes, UK, which won the Weight Prize and £5,000 to donate to a charity of their choice.

Rexam’s Valdemorillo, Spain and Manisa, Turkey plants both received the Community Engagement Award for engaging

Rexam Community Can Challenge results revealed

with a range of different com-munity groups in a number of surrounding towns, as well as the use of local media to raise awareness of their activities.

Iain Percival, Rexam’s sector director for Europe, says, “Whilst recycling cans is only part of Rexam’s wider sustainability pro-gramme, the Community Can Challenge is a visible way in which our employees can participate in and support the company’s com-mitment to running a sustainable company and build even better relationships with the communities in which they work. Those plants and locations that took part truly embraced the opportunity to edu-cate their local communities about the importance of recycling and to help us make a difference in running a sustainable business.”

Crown Holdings, a supplier of metal packaging products, has announced the official opening and commercialisation of three

Crown opens new facilities in China of its Chinese facilities in Heshan (Guangdong province), Ziyang (Sichuan province) and Putian (Fujian province).

“These new plants will pri-marily supply local customers, although they may also be called upon to serve other parts of the coun-try,” says Jozef Salaerts, presi-dent of Crown Asia Pacific. “As brand owners and consumers recognise the many benefits aluminium bever-

age cans bring, demand for the package continues to increase. Crown is committed to support-ing its customers’ growth, and we are pleased that we are working together to meet both new and existing demand.”

The Heshan facility currently operates one can line and one end line, with an initial annual production capacity of approx-imately 725 million two-piece 330ml and 355ml beverage cans and 1.4 billion 202-diameter ends. Production of ends began in June 2012, while beverage can produc-tion started in October 2012. The facility will also have the ability to produce 500ml beverage cans.

The Ziyang facility began producing beverage cans at the end of July 2012. One can line is

currently in operation, giving the plant an annual production capacity of approximately 650 million two-piece 330ml and 355ml beverage cans.

The Putian facility operates two lines and is able to pro-duce 150ml, 330ml and 500ml two-piece cans. The first line began production in April 2012, while the second line started operations this year in February. The plant has an initial annual production capacity of 1.4 billion 330ml beverage cans.

The Heshan plant had its offi-cial opening ceremony on July 9, Ziyang on July 30, and Putian on August 1. The three plants will bring the total number of Crown beverage can plants in China to seven.

Metal Container Manufacturers Association of India (MCMA) has expressed serious concern relating to an approximate 8% increase in tinplate prices by a local produc-er, which it believes are abnormal and unjustified. MCMA believes that this has been done primarily to benefit from adverse rupee dol-lar parity in the last two months, in which the landing cost of imports has gone up.

The major cost component for production of tinplate is hot rolled coil, which is produced locally. Internationally, the HR Coil prices have been stable at around $550 per metre, but there has been a declining trend since April 2013 and only nominal increases in the months of August and September. The domestic HR prices, mean-while, have been increased by about 2000 Indian Rupees ($32.54) per metre. The company believes that the change in Rupee Dollar parity – particularly in July and August – resulted into a substantial increase in the landed internation-al price. Additionally, in the 2012 budget, the Indian government increased import duty on tiplate from 5% to 7.5%. As a result of these

Tinplate prices on therise in India

factors, prices for tinplate in India have increased by approximately 10% since April 2013, from which around 8% was from October onwards. Tinplate accounts for approximately 60% of the cost of a metal can, and it is anticipated that the ‘abnormal’ increase by the local producer will hit the metal packaging industry adversely as it is already struggling with the lowest growth in the packaging segment due to shift of various products to alternate packs.

Sanjay Bhatia, president of MCMA, has appealed to the domestic producer to review the increase in the tinplate pric-es, keeping in mind the declining trend in tinplate price globally and nominal increase in HR coil pric-es locally. The Metal Packaging Industry has protested against such an increase and called for the gov-ernment to completely withdraw the import duty on tinplate; noting that it is difficult for the industry to absorb such a heavy increase, as this is likely to result in closure of various small and medium compa-nies in the metal packaging sector. MCMA has appealed to various ministries to intervene in the matter.


World News

At the 28th FEA International Aerosol Congress in Madrid, Ball introduced its Matte & Gloss printing technology for impact extruded aerosol cans and beverage bottles.

By enabling custom-ers to combine the two finishes on the same can, the Matte & Gloss printing process can help differentiate and enhance a product’s shelf appeal through sight and touch.

It can be applied to any design or colour for a contrast effect where the gloss reflects light and the matte offers a subdued soft look. Matte & Gloss is available on Ball’s impact extruded aerosol cans and beverage bottles.

“As the global packaging leader, we’re able to leverage our cross-enterprise expertise to continually innovate and

9

introduce industry-leading solutions, like our new Matte & Gloss printing technology, which help our customers build and differentiate their brands,” says Dan Rabbitt, vice president and general manager, Ball Aerocan Americas (a division of Ball’s global metal food and house-hold products packaging segment).

Returnable packaging specialist PLS (Packaging Logistics Services) has expanded its European footprint after securing a five-year contract in Poland with global beverage can manufacturer Can-Pack S.A. The agreement covers the supply of all of the company’s plastic layer pad requirements on a fully managed rental basis.

Valued at €5m (£4.2m), the agreement represents the compa-ny’s largest operation outside of the UK to date and provides the ideal platform for further expansion, the firm reports.

PLS, which is part of the Bibby Distribution Group, secured the new contract based upon the quality of its service delivery for Can-Pack in the UK, which began in 2009. As a part of the group, PLS allows Bibby to offer bespoke returnable transit packaging solutions to its customers.

The company has invested more than €1.5m (£1.3m) in establishing the new venture, which is based in Katowice, southern Poland, where staff work a two-shift system, five days per week, managing more than three million plastic layer pad movements a year.

Robert Skoropad, group planning and procurement manager at Can-Pack’s worldwide headquarters in Krakow, says, “PLS continues to impress our UK colleagues, so the next logical step was to invite them to service two of our main opera-tions here in Poland. Together, we’re working to implement new systems to improve packaging traceability and further increase the efficiency of our business.”

Formed in 1994, Poland-based Can-Pack is one of the world’s larg-est suppliers of aluminium two-piece cans, glass bottles, three-piece tin plate cans and bottle closures for the drinks industry. It has operations in Finland, the UK, Poland, Romania, Russia, Morocco, India, Dubai, Ukraine and the Philippines.

Can-Pack’s UK operations are set to open a second beverage can line in Scunthorpe, UK in the first quarter of 2014. This new line will have a capacity of 650 million cans per year, with future extension up to one million cans per year, according to the company.

PLS securesCan-Pack deal

MPMA announces passingof technical expert

The Metal Packaging Manufacturers Association has announced the sad loss of its technical manager, David Smith, who passed away on 19 October following a short illness.

Representing the metal packaging sector on matters relating to product and oper-ational environmental issues, Smith also acted as secretary to the MPMA’s many techni-cal committees. He also served as secretary for the EMPAC Food Contact Commission and worked across many other related European committees.

Mr Smith joined MPMA in 2000 from a long career in the pack-aging industry which included a variety of technical positions at Metal Box, and Courtaulds Coatings; both in the UK and overseas.

MPMA director and chief executive, Nick Mullen, says,

“David was a popular and highly respected industry figure and he will be sorely missed by his many MPMA and industry colleagues and friends.

He provided expert scientific counsel and guidance on num- erous, highly complex issues affecting our sector and made an immensely valuable contri-bution to our sector and to the wider packaging industry.”

Matte and gloss printing

November 2013 CanTech International

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World News

11

Novelis, an aluminium rolling and recycling specialist, has announced the completion of a two-year, $400 million expan-sion programme in South Korea. The expansion of its Yeongju and Ulsan plants increases the com-pany’s production capacity in the region by more than 50% to approximately one million metric tons of aluminium sheet per year.

“Investing further in Korea has been a key element in the com-pany’s global strategy,” says Phil Martens, president and CEO of Novelis. “Asia is the largest and fastest growing region in the world for aluminium, and this expansion allows us to maintain our leadership in this dynamic region across key markets such as beverage cans, consumer electronics and automobiles.”

Novelis completes expansion in Korea Novelis began the expansion

of its aluminium rolling and recy-cling facilities in 2011 to meet rising demand for flat rolled aluminium in high value-added products in the Asian market.

As part of the company’s commitment toward reducing its carbon footprint, it has also recently published Sustainability Through Disruptive Innovation, its third annual sustainability report. It highlights an increase in the recy-cled content of its products from 33% to 43% in the first two years since announcing its ambitious target to achieve 80% recycled content by 2020. The publication also reports that Novelis became the world’s largest recycler of aluminium this year, as it continues to expand its recycling capacity around the world.

For breaking news visit


and three-piece food cans and ends based in Spain. The cash transaction is val-ued at €1.2bn (£1bn).

Based in Murcia, Spain, Mivisa is the largest food can producer in both the Iberian

Peninsula and Morocco. Primarily serving the vegetable, fruit, fish and meat segments, Mivisa currently operates ten manufacturing facilities, including six in Spain and

Crown Holdings, a global lead-er in consumer packaging, has announced that it has entered into an agreement to acquire Mivisa Envases, a manufacturer of two

Crown acquires Mivisa Envases one in Morocco.

Commenting on the transaction, Crown chairman and CEO John W. Conway, states, “We are excited about the acquisition of Mivisa, as it will significantly build upon Crown’s existing position in the strategically important European food can segment by substantially increasing our presence in Spain, which is one of Europe’s leading agricultural economies.

“Mivisa has demonstrated impressive sales and profitability growth in recent years through prudent investment, highly efficient manufacturing practices, focused

innovation and excellent customer relationships.

“We believe that adding this well-performing business to our broad network of food can operations in Europe will result in compelling benefits to both cus-tomers and shareholders.”

The acquisition, which is subject to review by the European Commission and other compe-tition authorities, is expected to close during 2014 and to be earnings accretive.

Debt financing has been fully committed in support of the transaction.

November 2013 CanTech International 12

GThe y

Rexam has launched an online design portal that aims to support its customers in obtaining the best printed design for their cans.

The recently launched portal is accompanied by a new Global Can catalogue that provides customers with an overview of Rexam’s range of cans, fusion aluminium bottles and ends. Both the portal and the catalogue are designed to ensure that Rexam’s customers have the information they require in an easily acces-sible format, helping them to develop the desired packaging for their product.

The online design portal is being launched in two parts: the first section, now live, includes information on the print

Online design portal and can catalogue

Ball Corporation has reported third quarter net earnings attributable to the corporation of $115.2m (£71.9m), up on $115.1 million from the same quarter of 2012.

Improved operational results were put down to better than expected global beverage can volumes, an improved seasonal vegetable harvest and solid exe-cution companywide.

In the Americas and Asia, metal beverage packaging volumes were down compared to the same quarter last year ($134.8m of earnings compared to $142.2m in 2012), largely due to a previously announced loss of business in North

Ball announces third quarter earnings

processes on Rexam’s cans. Visitors can download design templates for every Rexam product, as well as a checklist to guide them through can design development.

The second stage, which will be going live later in the year, will concentrate on the content of the design, from information and guidelines for QR codes to special printing finishes, text sizes and colour.

Paul Winwright, European customer service manager, comments, “Stage one is up and running and feedback is very pos-itive. We are now looking forward to the second stage being live and available to our customers.

When fully launched, Winwright continues, “It will be a unique service which – whilst aimed at

World News

all Rexam customers – is likely to be of most use to our small to medium-sized customers, many of whose design agencies are new to

America. However, the company notes that growth in speciality con-tainers increased significantly.

Ball’s facility in Milwaukee, US ceased production of 12oz beverage cans, while other region-al specialty can lines ramped up production. Meanwhile, the Alagoinhas, Brazil, facility complet-ed installation of a second can line capable of manufacturing multiple can sizes, whilst the Chinese beverage can market continued high single-digit growth.

Metal beverage packaging in Europe witnessed segment oper-ating earnings of $60.5 (up from $54.3m in last year’s third quar-

ter). This is attributed to stronger than expected volume growth, improved operating efficiencies and initial progress on cost-out initiatives announced in the first half of 2013.

Metal food and household prod-ucts packaging volumes were up and contributed favourably to third quarter operational results. Solid global demand for aerosol containers, as well as improved year-over-year volumes in North America, drove volume growth. Ball continues to invest in its extrud-ed aluminium manufacturing capabilities to meet increasing market demand.

The global market for metal cans was $43.8bn (£27.3bn) in 2012 and is expected to reach $51.6bn (£32.2bn) in 2019, growing at a CAGR of 2.4% from 2013 to 2019, according to Transparency Market Research. Its report, Metal cans market for foods, beverages – global industry analysis, size, share, growth, trends and forecast, 2013-2019, also shows that for volume, the market was 344.48 billion cans in 2012 and is expected to grow at a CAGR of 2.9% from 2013 to 2019.

Beverage cans were the largest consumed product, accounting for over 75% of the global metal cans consumption in 2012. This is expected to be the fastest grow-ing segment owing to increasing demand for carbonated soft drinks and alcoholic beverages.

Europe was the largest consum-er of metal cans with over 109 billion cans in 2012, followed by North America. The Asia Pacific region is expected to witness fast-est growth over the forecast period due to increased manufacturing activities because of lower labour and material costs. China and India are expected to dominate the metal cans market over the next few years. Visit www.transpar-encymarketresearch.com for more information.

can printing.”The catalogue is now avail-

able to view online at www.rexamcatalogue.com

Industry recycling of aluminium beverage containers in the United States continued its decade-long upward trend in 2012 with a rate of 67%, according to data released by the Aluminum Association, Can Manufacturers Institute (CMI) and Institute of Scrap Recycling Industries (ISRI). This is the high-est recycling rate since the early 1990s and the second highest rate reported since the survey began in 1972. The new rate marks progress toward the industry’s goal of 75% recycling by 2015.

The new rate means that in 2012,

the aluminium can industry recy-cled some 62 billion domestic and imported cans, while shipping 92 billion cans in the US. The energy saved from this recycling equalled 19 million barrels of crude oil, which could fuel more than 1.7 million cars for a full year. “It’s great news to see the aluminium can extend its lead as the most recycled beverage container, far exceeding compa-rable rates for glass and plastic,” says Heidi Brock, president of the Aluminum Association.

The increase in the industry’s recycling rate in recent years has

been driven largely by the addi-tion of cans imported into the US. Because of the closed loop aspect of aluminium can recycling – along with aluminium’s significantly high-er inherent value in the recycling stream – used cans easily cross bor-ders and are extremely attractive for recycling. In fact, US recyclers often import cans from Mexico, Canada, Saudi Arabia, Poland and other countries. In 2012 alone, the industry imported and recycled close to 13 billion cans, nearly dou-ble the amount imported just five years ago.

US can recycling reaches high of 67% Global market to grow


Can Corner

core requirement. Any proposed changes in legislation

would set off a programme of work, with the aim being to

either ensure current products meet the requirements or

develop alternatives that do. Developing alternatives is a

very time consuming and costly process and should not be

underestimated.

The functional requirements of can inside coatings vary

enormously. Just in the beverage can industry, there are

a wide variety of products and processing techniques

that the coating must protect against, which makes the

development a time-consuming activity.

As part of the due diligence process, the industry must

take all relevant information into account. For new and

existing products, there will be information available on

exposure to specific materials and the effects that they

may have. Where scientific information is not available,

the position is more difficult and risk assessments should be

carried out. Having this information will then allow a consid-

ered judgement to be made as to the viability and safety

of any alternative products.

New coatingsProduct safety must be determined for the intended use of

any new lacquers in the regions where they are to be used.

Recognised third party laboratories are used to ensure the

components of any coating are compliant with the food

contact regulations.

This is achieved by full disclosure of what goes into

the coating between the lacquer supplier and the

laboratory, which can then be assessed against positive

lists and specific requirements. The laboratory will then test

the coating using simulants in conditions that replicate the

actual end use. The tests are carried out to ensure that the

coating performance exceeds the levels set with regard

to overall and specific migration of substances into the

foodstuff and will provide a suitable barrier in the can for

the intended use. The coating has to be able to withstand

the application, filling and distribution processes, and allow

the contents of the can to get to the consumer in the

condition required.

The final stage is to gain approval from the customers

In the latest in our series of articles from Rexam, Bill Neilson, the company’s VP technical for Europe,talks BPA and coatings

The compound bisphenol A (BPA) has been common in most industrial processes – including beverage can coatings – for many years. There have been countless studies where the scientific evidence shows the possible

exposure to the substance from beverage cans is at an

entirely safe level. Despite this, some parties have claimed

the contrary and so, as a precautionary measure to meet

any possible legislative change, can manufacturers and

their lacquer suppliers have been developing alternative

coatings that would meet the strict requirements necessary

for a food contact surface.

In order to ensure that alternatives meet these require-

ments, the industry follows four key principles: legal com-

pliance, due diligence, product safety and customer

acceptance.

ComplianceCompliance with the laws and regulations in all regions

where a product is placed on the market is, of course, a

14

Coatings and regulations

Bill Neilson


Can Corner

15

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and D & I aerosol can production

13_248_Anz_Cup_Sys_100_300_en_RZ.indd 1 09.08.13 16:38

BPA – Fast facts • BPA is used to make certain plastics and epoxy resins; it has been in commercial use since 1957. • Epoxy resins containing BPA are used as coatings on the inside of many food and beverage cans. • It is part of the bisphenols group of chemical compounds with two hydroxyphenyl groups. • It is a colourless solid that is soluble in organic solvents, but poorly soluble in water. • World production capacity of this compound was one million tons in the 1980s and more than 2.2 million tons in 2009.

Source: Wikipedia

for the products that have been developed. As well as meeting migration

requirements, the coatings must not affect the contents of the can with respect

to flavour, odour or appearance and should provide the necessary barrier

properties to protect the metal substrate. The standard approach is to take

commercially filled test packs, store them at elevated temperature and test the

products at set intervals. Any anomalies with regard to metal pickup or organo-

leptic properties can then be identified more quickly and rectified either in the

product formulation or the application process. Although this is time consuming,

it is an important step to ensure the quality of the applied product and confirm

the shelf life for the filled package.

Risks and assuranceThere are certain risks associated with the introduction of new materials.

However, by following the principles described, can makers and their suppliers

will ensure the safety and legal compliance of any new coatings and also

that the package will deliver the contents to the consumer at the quality level

expected by the brand owner. ❑

November 2013 CanTech International16


S ince their inception, cans have been responsible not only for housing the contents, but for revealing impor-tant information pertaining to what’s inside – with the latter aspect becoming increasingly important in recent

times. Beverage cans have always competed in a fiercely

competitive packaging environment, but with big brands

such as Coca-Cola, Pepsi Cola and Red Bull involved –

along with a wide array of global beer manufacturers

– these huge companies possess significant marketing

power and the ability to generate interest in a number of

different ways.

This means they demand the best available tools from

their packaging suppliers to extend their marketing efforts

to reach final consumers, also by means of the packages

used. And beverage cans happen to offer a great plat-

form for brand exposure.

Sylvia Blömker, director public relations at Ball Packaging

Europe, has not only witnessed the developments in

making beverage cans a platform for communication with

consumers, but is actively involved in these developments

too.

She comments, “The can allows brands to communicate

in a great way. Brand owners use the excellent printing

possibilities of cans to differentiate themselves at the

point of sale. If you think about it, the can wall is virtually

a 360-degree billboard available for communication. We,

as can makers, are obliged to come up with as many

innovations as possible in the printing quality to serve our

customers maximally.”

Marc Schöppner, product manager at Ball, adds, “We

see a megatrend versus mass customisation, in which

Two-Piece Update

CanTech contributor Evert van de Weg looks at the latest innovations in the two-piece can and details why appearance is becoming increasingly important

All aboutappearance

brand owners try to offer individual consumers prod-

ucts that are as tailor-made and interactive as possible.

Therefore, our key research focuses on innovations that

enable this mass customisation.”

Printing technologiesPrinting two-piece beverage cans is advanced tech-

nology, and the print quality achievable has been satisfac-

tory for many decades. But for critical brand owners and

for can makers, this simply wasn’t good enough anymore.

“Continuously trying to improve printing technology

is very high on our agenda, and this has resulted in

developments like Premium Print, which offers very sharp

contrasts and an abundance of details by the laser-image

plate technology”, Schöppner explains. “The needs in the

marketplace, our own R&D efforts and well-focused

research (of our coating suppliers, for example) chal-

lenged us to think differently, which has resulted in a

number of new presentation options that we are now

offering commercially. For several years, we have been

able to offer cans with special finishes.

“An important and very functional finish is our Thermo-

Effect technology. Temperature-sensitive pigments in the

printing ink change with temperature and indicate when

the drink is cold enough for consumption. We also apply

other finishes that have special effects, such as a tactile

touch, an embossed touch or a matt touch.”

November 2013 CanTech International18

Two-Piece Update

Special-effect finishes“Quite recently, we presented three new

special-effect finishes. The first, cans with the

sunlight effect, contain hidden messages

via the use of invisible ink. The messages only

become visible when you place the can in

the sun and the UV rays hit the beverage

can. The second, cans with the neon effect,

have special ink pigments that produce

striking colour effects and sharp contrasts,

particularly against a black background.

The third, cans with the silk and shine effect,

are eye-catching and even surprising for

consumers. With this, we combine the

effects of high gloss and matt printing. The

tactile-like effect that certain parts of the

can design show adds an exclusive look

that goes well for premium products.”

Blömker continues, “Earlier this year, we

presented our Dynamark printing tech-

nology, which enables us to print 24 design

variations with alternating images or

messages – versatility that is required in

today’s can printing world. Coca-Cola has

achieved huge success via its ‘Share a

Coke’ campaign, in which a great variety

of jokey expressions – such as ‘Party Animal’,

‘Air Guitarist’, ‘Lover Boy’ and ‘Gorgeous

Girl’ – were printed thanks to Dynamark

technology. Developments such as these

enable an extremely high degree of

individualisation.”

Digital window printingSchöppner adds, “The new Digital Window

Process we are presenting right now is also

a big step forward in individualisation of

can designs towards consumers. Here’s

how it works: in the first step, we print 33cl

or 50cl cans the usual way, but leave a

window unprinted. This window can have

any shape you want. In the second step, the

window left unprinted is then printed in the

digital printing line with a fully customised

design (one which meets the exact space

requirements of the area left unprinted).

“Digital Window Printing enables the

production of 36 individually designed cans,

but in theory, every individual can in a

production run could get another design

in its unprinted window. This is the best

possible way for a brand owner to engage its

consumers to the fullest extent.”

Shapes and attributes for convenienceA common marketing law is to offer cus-

tomers products in the shape and size they

like best. By adopting this mentality, brand

owners in the global beverage makets,

along with their can makers, have been highly

successful.

Blömker notes, “Particularly striking is the width of the

range in shapes and sizes of beverage cans today in

comparison with – for example – the 1990s. At that time,

there were only a handful of can sizes and now there are

tens of sizes, from 15cl to 100cl or even more. The brand

owners tune in on the individual needs of the consum-

ers, which are varying for the rest from one consumption

moment to the other, depending on the situation. For

airplane passengers, 15cl cans often prove an adequate

volume, but consumers in Eastern Europe like to share their

can of beer with friends at home, so for these types of

occasions, we recently launched our 32oz (946ml) can.

“A packaging shape can have a positive impact on

the overall presentation. A good example is the longneck

version of our Impact Bottle we are introducing. This shape

underlines the exclusive quality of the beverage packed

in it, which fits in with the luxurious lifestyle of the buyer.”

Blömker concludes, “A perfect example of a good fit

between a can size and a category of drinks is what we

see in the market of wine in 20cl aluminium cans. For some

time, we’ve worked closely together with French company

Fabulous Brands, which is the first to offer medal-winning

wines of the quality ‘Appellation d’Origine Contrôlée’.

We developed a special can specification with specific

coatings that guarantee a shelf life of 12 months. Wines

are particularly sensitive to oxygen, so the filling process

has to take that into account as well. We see a bright

future for wine in cans, because of the good protection

properties and the convenience that cans offer for

single-serve portions.” ❑

An example of digital window printing


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Aerosols

containing insecticides, were available to the public in

1947. Abplanalp’s development, made of lightweight

aluminium, made the cans a cheap and practical way to

dispense liquids foams, powders, and creams.

As a result, the aerosol dispenser has developed into one

of the most widespread packaging solutions for hairsprays,

deodorants and other personal care products.

AdvantagesAerosol containers give consumers the use of products

unavailable in any other form. Only an aerosol container

can provide the variation of propellant pressure and the

wide range of spray patterns and particle sizes that make

possible products specially designed for specific consumer

needs.

These include:

• Long-distance spray insecticides protect humans

from harmful insects without exposure to bites or stings

• Asthmatic inhalers produce a mist fine enough to pene-

trate deeply into the bronchial area

• Specially formulated insecticides penetrate behind

cabinets and walls to remove vermin in homes, schools

and work areas

• First aid products can be applied without direct contact

and can protect the damaged area from air contact

• Lubricating products can be applied to hard-to-

reach machine parts and to machinery in operation

• Contact lens solutions in a spray form eliminate the need

to touch the lens itself

• Stable foam products, such as shaving cream and

furniture polish, cannot be created in any other way.

Atit Bhatia, senior vice president of Hindustan Tin Works,looks at the origins of the aerosol can and where its future lies

Aerosol cans are ubiquitous objects in today’s world. They are used throughout the day. One starts the day with shaving gel, followed by aftershave, and then deodorant in the bathroom. This is followed by oil

spray over the omelette for breakfast. You then put on your

shirt that has been ironed with spray-on starch. The janitor

has cleaned your office, sprayed the corners with insect

killers and finally perfumed the room with an air freshen-

er. Your car comes from the garage with the scratches

all mended with paint sprayed from an aerosol can. The

breath freshener comes out of your pocket before you

step into the restaurant to meet your date. Your sound

sleep is ensured by the mosquito repellant sprayed earlier.

From dawn to dusk, this little object protects, perfumes and

enhances your life.

BeginningsThe concept of the pressurised container came into being

long before the lightweight metal can became popular.

In France, pressurised containers of carbonated beverage

were introduced. In 1837, a man called Perpigna invent-

ed a soda siphon incorporating a valve, and by as early

as 1862, metal spray cans were being tested. However,

these were made of thick steel and never commercially

successful.

In November 1927, Norwegian engineer Erik Rotheim

patented the first aerosol can and valve that could hold

and dispense products and propellant systems. This was

the forerunner of the modern aerosol can and valve and

in 1998, the Norwegian post office issued a stamp celebrat-

ing the Norwegian invention of the spray can.

During World War II, the US government funded research

into a portable method for servicemen to carry insecticide.

Department of Agriculture researchers, Lyle Goodhue

and William Sullivan, developed a small aerosol can pres-

surised by a liquified gas (a fluorocarbon) in 1943. It was

their design that made products like hair spray possible,

along with the work of another inventor named Robert

Abplanalp.

In 1949, 27-year-old Abplanalp’s invention of a crimp

on valve enabled liquids to be sprayed from a can

under the pressure of an inert gas. Spray cans, mainly

20

Aerosols: a forceto be reckoned with


Aerosols

21

globe. Known for their leak-proof features, these cans are

widely used to pack a variety of liquids. Almost 53 per cent

of aerosol cans are made of tinplate, while the remaining

47 per cent are made of aluminium (1).

The aerosol market in India has shown a fair amount of

dynamism; in terms of volume, the aerosol can market has

grown from 170 million units in 2008-09 to around 330 million

units in 2012-13, registering a CAGR of approximately 17.2

per cent. The Indian aerosol market is currently made up

of 58 per cent aluminium cans and 42 per cent tinplate

cans. The personal care segment is the major consumer of

aerosol products. Significant import of filled products is also

taking place and some of these may convert to local fill-

ing in due course. In the next five years, the Indian aerosol

market is expected to grow at a rate of about 15-18 per

cent per annum (2).

The future of the aerosol can market elsewhere looks

promising, with major growth seen in Asian markets.

SubstitutionThe aerosol can is one type of metal container that has

historically had very low level or almost no threats from

alternate packaging. This is mainly due to the fact that

it is almost impossible for another container to hold the

high pressure – up to 18 or sometimes even 20 bars – while

delivering the cost economics that an aluminium or a steel

aerosol container delivers. Only recently, we have heard

news about the development of a PET aerosol container

that potentially could be a major threat to the industry. It

is a development that should be watched closely by the

industry.

SustainabilityBeing made from steel or aluminum, an empty aerosol

can also has the same sustainability credentials as a stand-

ard metal can, as both steel and aluminium are made

from permanent materials and are infinitely recyclable.

However, if an aerosol container is full, it is recommended

to empty the container before it is sent for recycling. ❑

References:

(1) Statistics from www.companiesandmarkets.com

(2) Hindustan Tin Works

Other benefitsSafety: Aerosol cans are hermetically sealed, so their con-

tents cannot leak or spill. They are also tamper-resistant

and tamper-evident.

Efficiency: Aerosol containers are designed to deliver the

right amount of product exactly where it’s needed. Using

an aerosol package reduces waste and spillage.

Cost-effectiveness: Aerosol containers control the particle

size, the spray pattern, the volume dispensed per second

and the concentration of the spray for maximum effec-

tiveness. The hermetically sealed package protects the

product and extends its useful life; aerosol paints and finish-

es, for example, can be stored without risk of evaporation.

Clean and sanitary use: Aerosol products can be applied

without contact, protecting users from mess, germs and –

in case of burns or lacerations – with a minimum of pain.

Family members can hygienically share aerosol personal

care products. In addition, the sealed can prevents any

product contamination.

Special products: Aerosol containers give consumers the

use of products – from shaving cream and long-distance

spray insecticides to asthma inhalers and other medical

products – which would otherwise be unavailable.

Convenience: Aerosol containers are spill-proof, which is

helpful for medical and personal care products used for

travel, by children, nurses and the elderly. They eliminate

the need for mixing containers and applicators, and can

be stored and used in the same container, often for long

periods of time.

Aerosol can marketVolume output within the global aerosol market has been

forecast to increase at a compound annual growth rate

(CAGR) of approximately three per cent over the next five

years, increasing from 14.4 billion cans in 2012 to reach a

total of 16 billion cans by 2017.

Global consumer markets suffered seriously in the finan-

cial crisis in 2008. As a result, residents curtailed unneces-

sary expenses, which made market demand decline. In

return, worldwide aerosol output volume also declined.

However, since 2010, the international markets have grad-

ually recovered, with aerosol output volume showing a

rising trend.

European aerosol production figures are also looking

strong, and nowhere is stronger than the UK. European

aerosol filling figures stood at 5,535 million units in 2011,

compared with 4,676 million units a decade ago. Since

1995, production has increased by just under two billion

units – an average of just under 100 million aerosols per

year over this period.

The Chinese aerosol industry, meanwhile, has devel-

oped rapidly in recent years. The sector began in the early

1980s in China with output volume at only 30 million cans in

the mid-1980s. By 2000, volume had rocketed to 560 million

cans and hit a figure of 1.61 billion cans in 2012, making

China one of the largest aerosol producers in the world.

The demand is highly concentrated in the beauty and

home-care industries, with these two markets representing

over 80 per cent of the aerosol cans produced across the


BAMA Awards

Sustainability award winner - Reabrook Ltd“Energy savings”

Reabrook’s energy and environmental committee

focused on overall environmental impact, making three

major investments, which resulted in 26 per cent reduction

in both electricity and fuel oil usage. The improvements

were: a new compressor; replacement lighting including

presence detectors; and a new steam generator replac-

ing a boiler.

Runner Up - R&R (Midlands) Ltd“Aerosol can micro-leak detection machine”

R&R (Midlands) Ltd is marketing a series of aerosol

micro-leak detectors that use a vacuum decay principle

to identify leaking filled aerosols. The system was devel-

oped to work with the UN-approved alternative to the hot

water bath test, but can also be used in conjunction with

a standard hot water bath and is able to test for LPG (liq-

uefied petroleum gas) and compressed gas propellants.

The British Aerosol Manufacturers’ Association (BAMA) hasannounced the winners and finalists of the 2013 BAMA Awards

Consumer goods giant Unilever UK was the overall winner this year, collecting two out of four top prizes at BAMA’s awards dinner in October. With a new structure to the competition, the level as well as the

quality of entries was encouragingly high, the association

says. The finalists were announced at the dinner following

the annual forum.

The awards are open to BAMA’s members and this year

rewarded a range of projects and products for ingenuity,

innovation and sustainability. Unilever UK’s two awards

were in the Innovation and Aerosol of the Year catego-

ries. Reabrook, meanwhile, collected the top award in

the Sustainability category for its Energy Savings Project,

while Norman Clark, global aerosol technical manager at

Reckitt Benckiser, received the outstanding contribution

award.

Speaking at the awards, Dr John Morris, chief executive

of BAMA, notes, “The UK aerosol industry is a real success

story. We saw everything from examples of corporate

social responsibility to environmental sustainability; tan-

gible evidence of innovation in products, packaging

and manufacturing techniques; and examples of sound

strategic thinking in all aspects of these businesses, from

processes through to marketing.”

The results in full:Aerosol of the year - Unilever’s compressed aerosols

“Setting the trend for new sustaina-

ble deodorant aerosols”

Launched in February 2013,

Unilever’s collection of compact

aerosols within the Sure, Dove and

Vaseline brand ranges created 16

new products.

The launch of the Unilever com-

pressed aerosols range is leading

the way in sustainability, with 50

per cent less propellant gas and 25

per cent less aluminium per can, a

35 per cent reduction in transport

emissions and 53 per cent more

products on a pallet. Overall, these

changes lowers the packages’ car-

bon footprint by 25 per cent on

average.

22

And thewinners are…

Left row, back to front: Stuart Marsh (R&R (Midlands) Ltd), Dr John Morris (BAMA), Dr Phil Hammond – guest speaker, Richard Chambers (Unilever UK), Andrew Saynor (Unilever UK)Middle row, back to front: Surjit Bajwa (R&R (Midlands) Ltd), Norman Clark (Reckitt Benckiser), Javier Mateu (Unilever UK)Right row, back to front: Tony Brealey (Reabrook Ltd), Malcolm Watkins (Reabrook Ltd), Adrian McCretton (Swallowfield), Sebastian Alvarez (Unilever UK), Ian McCluskey (Avantigas)


Highly commended - Avantigas“Terminal upgrade project at Mossmorran, Scotland”

To keep pace with increased demand for the aerosol

propellants supplied from Mossmorran, Avantigas has

introduced improvements to enable it to be pre-

pared for current and future needs.

Innovation award winner - Unilever’s Rexona/Sure for Men

“Outstanding execution of a brand re-launch

(Rexona/Sure for Men) following brand principles

and incorporating key masculine insights”

Unilever, together with another BAMA member,

Lindal, the developer of the actuator for this product,

launched the new Rexona/Sure for Men aerosol in

summer 2013.

The relaunch offered an enhanced formulation

with the introduction of MotionSense. It also included

new fragrances, new design hardware designed by

Pininfarina, upgrades and package graphics, as well

as new brand positioning.

Other companies involved in the product’s devel-

opment included Plastek (actuator development

along with Lindal) and DCA for actuator engineering

development.

Runner up - Swallowfield “Dr Oetker Shimmer Spray (gold & silver)”

The company that claims to have filled the first

commercial UK aerosol in 1950 has now expanded

from its business in the beauty, cosmetics and person-

al care sectors, into the increasingly popular home

baking area.

Dr Oetker wished to create a professional-style

aerosol based cake decoration spray for the mass

consumer market. The product complies with strin-

gent food and aerosol regulations while delivering

an attractive spritz of gold or silver edible glitter spray,

which can be layered onto cakes, icing or choco-

late, in order to create different effects or intensities.

Highly commended - Albedo100 UK Ltd“Albedo 100 Reflective Spray”

Albedo 100 Reflective Spray is a range of light

reflective sprays used to enhance visibility in low light

conditions for use on animals, clothing or equipment.

It is available in four variants: light metallic, invisible

bright, sparkling grey, and horse and pet. It is also

offered in permanent and non-permanent options.

Outstanding contribution awardNorman Clark, global aerosol technical manager at

Reckitt Benckiser, has worked with BAMA for over 20

years, representing both his former employer, Unilever

UK, and his current employer at the assocation.

During that time, he has been an active member

of the technical group. He has also chaired the reg-

ulatory affairs committee, held both the vice chair

and chairman posts of the executive committee and

also represented the association as chairman of the

European Aerosol Federation’s (FEA) packaging and

contents committee. Clark is currently involved with

the revision of the BAMA Standard. ❑

Outstanding contribution: Norman Clark (centre) with BAMA chief executive, Dr John Morris (left) and BAMA chairman, Nigel Jackson (right).

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Q. Has the trend towards alternate formats (glass,

plastic) continued for aerosols? What do you think

is behind the drive towards less traditional formats?

A. There is a great interest in alternative formats, particu-

larly plastic. Producers of plastic aerosols are promoting

advantages such as lighter weight, lower process and

transportation costs, and design and texture benefits.

There are claimed environmental benefits also but these

need scrutiny. These perceived advantages are very

attractive to manufacturers and brand owners where shelf

differentiation and consumer acceptance are key issues,

and these will drive change.

Currently, European legislation limits plastic aerosols to

220ml capacity, but if the legislation changes (and there is

a consultation underway to do so) then we could see plas-

tic aerosols up to 1000ml – the same capacities as metal.

Q. Why is the UK such a strong aerosol market,

compared with the rest of Europe?

A. There are a couple of key reasons. Firstly, historically,

the UK was one of the earliest countries to fill and sell aer-

osols to the public. The demand has fuelled innovation to

remain competitive – innovation both in the processing

and marketing of aerosols – and to ensure safety was the

essential consideration. Secondly, built on this expertise

and market, major brands were established with interna-

tional and national companies, which also spurred devel-

opments in areas such as engineering, filling and testing.

There is also a thriving contract filler market supplying own

label and branded aerosols in both consumer and indus-

trial and technical applications. BAMA believes that about

65 per cent of filled aerosols are exported, making this one

of the more intense export oriented sectors, with Europe

the main recipient.

Q. What about recyclability and sustainability?

A. Most aerosols are manufactured in metal and metal is

an infinitely recyclable resource. It doesn’t lose strength or

diminish its potency with recycling, so is an ideal renewable

resource. It is also highly valuable to recover from waste

streams and through recovery; it saves up to 95 per cent

of the energy compared to producing virgin metal. BAMA

has worked with the MetalMatters programme where the

focus has been on targeting local authorities to recover

more metal, including aerosols. Wherever this programme

Aerosols

‘’

Dr John Morris is the executive director of the British Aerosol

Manufacturers’ Association. Here, he explains why the UK is such

a strong aerosol producer, and what challenges lie ahead

Innovationin a package

’There is still a lot of work to

do to convince pressure groups

and influencers of the value

of a permanently available

packaging material

has been established, the results have been excellent and

have helped to drive aerosol recovery such that 90 per

cent of all local authorities now collect aerosols at kerbside

or through can banks. Obviously we strive for 100 per cent

but we are very pleased with this latest figure, up from 87

per cent in 2012.

Our own survey at the end of 2012 demonstrated that

most consumers act responsibly by recycling aerosols from

most rooms in the house. The results surprised and delight-

ed us and we have used the data to demonstrate the

ease with which aerosols can be recycled through trade

and press releases and to industry and government.

Q. What do you predict the filling figures will look like

for the UK in 2013? What about the rest of Europe?

A. Tentatively, I am optimistic that there will be a slight

increase in 2013 in line with the general increasing opti-

mism in the manufacturing sector.

The long-term trend in Europe is for the filling numbers to

increase. The year 2012 showed a slight downturn despite

good growth for the UK. The main drivers for growth are

the personal care and household sector, which are closely

linked to the overall economic wellbeing of the European

consumer. Aerosols seem to be less affected than some

other product formats because people accept all their

positive user benefits, but they are not immune to such

influences.

Dr John Morris

November 2013 CanTech International26CanTech International June 2012

Machine vision has become an integral part of the manufacturing process for can makers. Through proper inspection, manufacturers can ensure the safety and integrity of the products produced.

They are assured consistency in the production line and

deliverables free of defects. Inspection allows can makers

the ability to keep a hand on the pulse of their manufactur-

ing processes, allowing them to correct issues before they

become potentially costly.

Multiple-unit inspection presents flaws

The industry has been following a trend of utilising multiple

cameras with a single inspection controller. While this may

work for some applications, such models tend to break

down in distributed applications.

For example, in a food-end application with four cam-

eras spread across four lines, all controlled by one central

processing unit (CPU), the lines will continue to produce

ends until the CPU fails for any number of reasons. Such

reasons can include a camera malfunction, remote system

failure, or an operator error. If this occurs, production on

all four lines must be stopped for the problem to be fixed.

Once solved, the system must be restarted, all for the

benefit of a single lane.

An autonomous solution

In a single, self-contained inspection unit, line placement

and installation become simpler and faster, and ultimately

more affordable for manufacturers. Instead of losing pro-

duction on all four lanes as in the scenario above, only

one lane would be interrupted in the case of a CPU or

camera malfunction.

Moreover, single-unit inspection offers the added benefit

of reducing the additional maintenance and space require-

ments multiple units require in limited space applications. By

combining lighting and processing into a single enclosure,

the installation, mounting, cabling, and labour are also

simplified.

35

Inspecting cans

One vision Brian Baird, director of product marketing at Applied Vision, discusses the

reasons why its single, self-contained inspection system is helping to

revolutionise can inspection

A machine with a brain

The Cyclops inspection

system from Applied Vision

combines the forward

thinking of distributive com-

puting with autonomous

processing. This results in

better return-on-invest-

ment, improved reliabil-

ity and reduced spoilage

rates for can makers.

Cyclops combines imag-

ing, lighting and processing

into one compact enclo-

sure, as opposed to running

multiple, additional cam-

eras on a single processor.

Cyclops can be placed

almost anywhere on a line,

alerting operators to potential defects as early as possible

in the manufacturing process before unnecessary cost is

added further downstream.

With its flexible optical configuration and motorised

height adjustment, Cyclops can be adjusted to accom-

modate product heights from 1” to 8” without costly disas-

sembly and downtime. Due to its modular nature, malfunc-

tions can be easily detected and quickly repaired.

“Cyclops’ dexterity and adaptability is a departure from

strictly end-of-the-line thinking,” says Amir Novini, president

and CEO of Applied Vision. “It is a significant step forward

in application-specific distributive imaging, and is an

example of the commitment to our customers to innovate

a simpler, smarter future.”

Applied Vision’s Cyclops system features one camera and can be used across a can line

Aerosols

Q. What do you believe are the key issues going

forward for aerosols and why?

A. I’ve tried to pick out a few, but these are the ones I feel

are the most pressing for the industry as a whole.

Re-labelling for ADD/CLP

All aerosol containers manufactured after May 2015 must

comply with the new legislation for labelling. This will involve

all marketers, designers, can makers and fillers to redesign

their labels to ensure compliance. There is a two-year sell

through period to mid-2017 for those aerosols already in

the market before June 2015, but companies need to be

thinking about this now. Changing the can design is not

an overnight conversion and many companies might be

chasing the same resource. For example, the pictograms

will move from two to three colours. Can you be sure this

will not add cost and complexity to your label?

Can coatings

Most internally protected aerosol cans are lacquered with

an epoxyphenolic coating. Some such coatings have

been found to contain bisphenol A (BPA) in extremely low

levels, well below levels of concern to most internation-

al health authorities. However, some countries, notably

France, have taken a stance against the inclusion of

any BPA in food containing coatings, and this has led

to companies supplying cans and components to the

aerosol sector to seek alternatives to conventional epoxy

coatings. There is a view that switching to as yet unproven

alternatives to epoxyphenolic could eventually be more

problematic for industry, and that epoxyphenolic coatings

and linings are extant throughout industry (not just the aer-

osol sector) suggesting that just changing can linings may

not remove the issue.

REACH (Registration, Evaluation, Authorisation

and restriction of CHemicals)

This is probably the most far reaching and costly (for indus-

try) piece of legislation enacted and will eventually limit

availability of chemicals that could be used in formulating

to those registered and tested for a variety of safety tests.

The eventual impact is almost impossible to gauge but it is

likely to limit choice for formulators and inhibit innovation

simply because of the cost of registering new entities.

Counterfeiting

This will become one of the most serious issues threatening

the industry if left unchecked. Already you can buy copies

of well-known aerosol brands in significant volume over

the internet. These are not copies with bad printing or silly

spelling mistakes but virtually indistinguishable from the real

article unless closely visually inspected. The big problem

of course is what is inside the can. You can be certain it

will be made with cheap, probably untested ingredients,

to a formulation likely to contain illegal or unsafe levels of

chemicals (for example substituting methanol for ethanol)

and it certainly will not be the brand experience you would

be expecting.

Environmental footprinting

Companies want to be able to say on the packaging

how environmentally friendly they believe their products

to be. The drive for this is coming from several quarters but

primarily NGOs and retailers anxious to demonstrate their

green credentials throughout the supply chain. The main

problem is one of standardisation for the footprinting. There

are several techniques available, none of which is wholly

satisfactory, and metals generally show a very positive

story. However, there is still a lot of work to do to convince

pressure groups and influencers of the value of a perma-

nently available packaging material. nently available packaging material.

Whether it’s print, online or newsletter,CanTech International has the

advertising solution for your needs.

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Aerosols

Q. What other trends are there in aerosols at the moment?A. The dry shampoo market is very interesting right now,

especially in the UK, with the sector having experienced

significant growth over the last few years. Crown recently

worked with one of the UK’s leading dry shampoo brands

at our innovation centre in Wantage. From the first market-

ing brief to discussions about shelf presentation to design of

the final package, we focused on ensuring that the brand

would maximize impact at the point-of-sale and continue

to convey the quality of the product within.

At the same time, we are continuing to use aerosol

containers for other products, such as sun care. Spraying

from an aerosol container is a lot easier than from a

plastic pump. Aerosol cans feature actuator technology

that allows the product to be dispensed from any angle –

whether upright or inverted. That offers consumers a much

higher level of convenience and flexibility.

Q. The European and North American beverage can markets would appear to be close to satura-tion, while depending on whose figures you use, aerosols are still growing. Do you think this growth will continue?A. It’s certainly fair to say that the continued innovation

in metal packaging is appealing to consumers. When it

comes to the aerosol market specifically, we are definitely

seeing growth within Central and Eastern European coun-

tries. This is partly due to the region’s developing economy

and the increase in disposable income this provides. Given

that there is greater consumer awareness of the impor-

tance of personal health, people are spending more of

their hard-earned money on health and beauty products.

As demand grows, Crown will continue its research and

development efforts and focus on delivering innovation

that responds directly to consumer needs and, in turn,

helps our customers build their brands.

Q. Crown’s Bican was a revolution 25 years ago. Are you thinking about the next step now?A. I would have to say that innovation really lies at the

heart of everything that we do at Crown. A perfect exam-

ple of this is the Bican, and it is important to remember that

this is a technology rather than a design innovation.

Our customers know that the Bican is the best way to

keep a product and propellant completely separate

and is still the most effective aerosol package to ensure

Véronique Curulla of Crown Aerosols and Speciality Packaging Europeexplains the trends driving the latest aerosol designs

Q. What is Crown currently working on in the aerosol sector?A. We’re always working with brands to

build consumer loyalty with metal pack-

aging that is functional, sustainable and

visually appealing. To offer our customers

packaging solutions, we are continuing to

invest in our decoration capabilities as well as

introducing innovatively shaped

container designs.

While aerosols are typically

associated with the beauty and

health care markets, there are

many other applications, particu-

larly in the food industry, where

we can build brands and impact

consumer purchasing habits. For

instance, aerosol containers work

extremely well with olive oils or

other condiments that need to be

applied in measured, controlled

amounts to enhance the flavour

and taste of dishes. Traditionally

spreadable foods like peanut but-

ter and cream cheese can also

now transition to aerosol pack-

aging.

With our upcoming market intro-

ductions, we are currently work-

ing on a fully recyclable solution

derived from Bican technology

that will allow our customers to fill

more products and eliminate the

need for polyamideimide (PAM)

lacquers.

Q. Smaller is bigger seems to the trend in aerosols with the ‘compressed’ Unilever products coming on the market – do you think this trend will continue?A. We know that consumers are looking for increased con-

venience and we have seen a sharp rise in mini aerosols

specifically targeted for travelers and people who spend

a lot of their time on the go. Larger, family-sized containers

may also see increased popularity down the line.

Having said that, standard size products still lead the

market due to consumers’ continued familiarity with the

more common aerosol format.

28

Compressed to thrillQ. What is Crown currently working on in the aerosol sector?A.

build consumer loyalty with metal pack-

aging that is functional, sustainable and

visually appealing. To offer our customers

packaging solutions, we are continuing to

invest in our decoration capabilities as well as


Aerosols

29

The use of colour can also be more involved, using new

finishes, like colour change basecoat to allow for a rotating

transformation of the colour. In this way, when held up to

the light, the can now changes, for example, from dark

green to lilac.

At Crown we are continually exploring new can finishes

that can elevate brands to “must have” status. We cur-

rently offer brands a wide range of different finishes, for

example, the sparkle finish that gives cans a premium yet

retro-industrial look, the soft touch for a velvety feel or the

pearlescent, which provides a soft, glowing effect.

Q. Shaping is likely to play an increased role in the aerosols. Is aluminium better suited for that or has steel still got a role to play?A. Shaping offers an ideal solution for marketers seeking to

develop an imaginatively designed package or as a com-

plement for promotional activities. Eye-catching custom

designs guarantee high shelf impact and can also offer

unique tactile characteristics.

And steel cans are actually the ideal packaging format

– Crown offers its customers an enhanced shaping expe-

rience with full body shape and asymmetrical design. At

our Wantage research facility, optimising the blend of the

shape and design using Computer Aided Design (CAD),

we can fully visualise designs in 3D and therefore give our

customers immediate feedback on concepts, allowing

them to collaborate with our teams in every step of the

design process.

Q. There is a lot of focus on the deodorant/hair spray section, but male grooming has changed and a preference for beards has hit the shaving foam mar-ket. Does Crown have any views on this?A. Trends are exactly that. It is certainly the case that male

grooming habits have changed, and we must always be

mindful of these patterns, but this is part of an ongoing

cyclical evolution. And while some of our customers are

adapting their product portfolios to suit these particular

consumer trends, other markets and applications for aer-

osols are growing in popularity, and we see a strong con-

tinued demand for innovative aerosol packaging going

forward. ❑

propellant is not emitted during dispensing. Moving for-

ward, we continue to review and evaluate opportunities

to evolve our technology lines, working with a formalised

development process so that our resources are focused

on commercially viable projects that bring real value to

our customers.

Q. What is Crown doing to keep aerosols on top?A. We are always looking at ways to improve the perfor-

mance and effectiveness of our products in order to help

our customers. To do this, our research and development

project teams combine their own scientific expertise with

a thorough understanding of consumer expectations,

the brand’s requirements and our own manufacturing

processes.

We firmly believe innovation requires the right focus

and strategic customer partnerships and we work closely

with brand marketing teams from concept design through

to manufacture and delivery, to support their short- and

long-term goals.

Crown is also pleased to announce its attendance at

ADF 2014 (Aerosol & Dispensing Forum) on 5-6 February at

the Espace Champerret, Paris. Located at stand number

A22 /A24, our packaging and branding experts will be

on hand to discuss the latest trends and to explore ways

we can collaborate with our customers to help build their

brands.

Q. The look of aerosols has come on leaps and bounds in the past few years. What is Crown doing in this field?A. With a significant percentage of

can · 2007-09-05 · editorial comment cantech international november 2013 3 ack in the summer,...

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