No. 92 – 2nd Quarter 2014

Water

BOX

Both of our paper-producing facilities have their own water treatment plants. The one in Weinfelden cleans the water so thoroughly that it can be released straight back into the River Thur. In Niedergösgen, meanwhile, the water is pre-cleaned before being fed to the munici-pal treatment plant.

We look forward to meeting the continued challenge of handling our resources carefully and sustainably. Best wishes

Andreas GalloHead of Model PaperModel Group

16

02–03 model box

EDITORIAL

DEAR READER

Water is a fascinating natural resource. It is thought to have made life possible, and life cannot go on without it. It plays an important role for everything – animal, vegeta-ble and mineral – as a key ingredient in almost every aspect of metabolism, as well as in fundamental geo-logical and ecological processes. Water is the only chem-ical compound on Earth that occurs naturally as a solid, a liquid and a gas.

Its importance for our paper production is second only to that of cellulose (wood fibre), and it is equally vital to other industries. Put simply, manufacturing paper in-volves wetting cellulose, and then drying it again.

It takes around 100 litres of water to prepare a single kilo-gramme of cellulose for the production line. Our two fac-tories in Weinfelden and Niedergösgen produce more than 1,000 tonnes of paper a day, which translates to over 100 million litres of water. This vast quantity is, of course, reused many times, but some 900,000 litres are lost as steam each day, while roughly 3 million litres go into wastewater treatment. We use water about 25 times before it leaves the production loop.

Water treatment plant in Weinfelden With its Weinfelden site, the Model Group is one of the few European companies in the packaging industry to have a closed paper cycle: from its own water treatment plant, to containerboard manufacture and onward pro-cessing, through to professional recovery and disposal.

Water treatment plant at Model AG, Weinfelden

03 Editorial 04 Thurpapier – fire protection solution 05 Model ICC – transport protection 06-08 Finishing 09 Interview – Yves Kübler, Distillerie BLACKMINT, Kübler & Wyss 10-11 Interview – Raphael Maier, Lekkerland (Schweiz) AG 12-13 Efficient shelf-stocking 14-15 Hygiene certification 16-17 Interview – Dominik Gmünder, La!Creme GmbH 18-19 World of Cardboard/Model RSS feed/Publication details

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Sustainability is a particular priority at Model. The paper needed to make corrugated board is produced using environmentally friendly methods from recycled cardboard and paper at the Group’s Thurpapier and Aare-papier factories. Producing one kilogramme of paper consumes 3.7 litres of water, but about nine tenths of a litre per kilogramme of paper are also lost as steam (some 450 cubic metres a day). Most of the energy that Thurpapier in Weinfelden needs to dry its paper is generated by the nearby household waste incineration plant. The waste heat is fed into an energy recovery system. However, sustainability at Model also means keeping fire risks to a minimum, and these are especially high in the paper drying process, at temperatures of around 115 degrees Celsius.

Closing a safety gapThurpapier has installed FibroLaser, a state-of-the-art solution that has proven highly effective around the world as a fire warning system for

road tunnels. It detects hot gases and heat radiation using linear tem-perature measurement with a glass fibre sensor cable that can with-stand temperatures of up to 400 degrees.

Following a pilot phase, the tried-and-tested system was adapted to suit the factory’s special environment. The sensor cable, for instance, had to be encased in a steel jacket to cope with the heavy shocks to which it is subjected in the paper machines. The cable measures temperatures to an accuracy of one degree at nine fixed points along the two paper machines, each of which is roughly 80 metres in length. The heart of the FibroLaser heat detection system is the OTS30xx Controller, which con-tinually analyses the sensor data. If the predefined temperature limit is exceeded, an alarm is immediately triggered via the Sinteso warning system, with flashing lights and acoustic signals, as well as by phone.

Innovative fire protection solution

THURPAPIER

The drying process in containerboard manufacturing requires temperatures of around 115°C to en-

sure that the paper is sufficiently dry. Model has identified an innovative solution from Siemens –

FibroLaser – that minimises the risk of fire inside the drying.area.

Atom cushion packagingDamage as a result of inadequate transport protection costs the manufacturing industries seven-figure sums every year. The developers at the Model Innovation and Competence Center (ICC) have sought to deal more effectively with the stress experienced in transport, and thus avoid damage, by devising some novel shock and impact-resistant packaging solutions. Some of these sys-tems are based on Model’s patented Atom cushion prin-ciple, whereby a 360-degree cushion is built into the packaging to absorb impacts. The cushion allows the contents to “float” inside the packaging, and effectively dissipates the energy of a fall or bump.

Every postal delivery package created by Model is the result of a special engineering process. This tests various prototypes for their intended function, and optimises them by means of iterative development. The ideal trans-port package not only protects the product inside,

but also prevents complaints and the costs they entail, thus contributing to sustainability through the efficient use of resources.

Online shops need better packagingE-commerce has grown by more than 40% in recent years*. In some retail segments, notably books and elec-tronics, more is sold online than in traditional shops. Even products that were considered impossible to sell on the Internet years ago – groceries, for example – are now anything but. The rapid expansion of this sales channel has encountered many pitfalls, especially in terms of logistics. Most goods are delivered as individual parcels, meaning that their packaging must be more robust than would be the case with conventional pallet delivery.

*According to the German E-Commerce and Distance-Selling

Trade Association (bevh)

mODEL Icc

Transport protection

Stress:medium

low

high

Protective box:inner

outer

Creative die cutsDie cuts are often used as a creative feature, for example to produce three-dimensional motifs or completely cut-out designs. There are many types of die cut and lots of ways to use them. When correctly designed and con-structed, laser die cuts can give an air of high-end exclu-sivity. Folding boxes, packaging and presentation folders are die cut by a machine that exerts high pressure onto the printed sheet to stamp out the end product in its final form.

f InIsHIng

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Pre-pressThe majority of the folding boxes produced in Au (SG) are sales packaging – mostly printed and finished to a high standard. We attach a great deal of importance to pack-aging design, because it is a key marketing tool that often plays a significant role in the customer’s decision to buy or not to buy. Pre-press is an essential stage in the man-ufacturing process for folding boxes. We offer our cus-tomers the following services:

«We dress to impress»Special finishes achieve impressive printing results using light and shade. Various embossing and varnishing tech-

niques and a range of materials are employed to create unique products that are as good to touch as they are to

look at. Sophisticated die cuts allow a tantalising glimpse of the contents inside. Model PrimePac manufactures

individual, creative packaging solutions that can be combined with an almost limitless choice of finishes.

ÃÃ constructive collaboration with the customer’s graphic design department or advertising agency

ÃÃ provision of dielines in a variety of file formats

ÃÃ preparation of print data for the various printing and finishing processes

ÃÃ professional online data and project management

ÃÃ simplified online sign-off

ÃÃ efficient composition of the entire printed sheet

ÃÃ reliable archiving of customers’ print data.

Varnished finishesDo you prefer glossy, matte, or perhaps scented? With varnishing, the possibilities are virtually endless. Partial or full-surface varnishing can make the printed product nicer to touch, look at and smell. Protective varnishes are used primarily to preserve the printed design through the later processing, making-up and transport stages. How-ever, varnished finishes are usually a deliberate design feature to make the product look more expensive, and attract attention. A soft-touch varnish lends a particularly smooth, rubbery soft feel. Special inks and Iriodin® coat-ings containing metallic-effect pigments are the ideal way to make the printed product shimmer and shine over part or all of its surface. The pigments refract and reflect light to create the desired effect.

UV varnishing is another option. It is applied in the print-ing machine and then dried and cured using ultra-violet light. UV varnishes can be used across the whole surface or just part of it to add a special flourish, for example by producing matte or gloss effects. Relief varnishing can create a 3D feel, while microstructured varnishing is suited to very intricate designs. The UV varnish is applied using printing plates or photopolymer plates. It even works with non-porous substrates such as PET lami-nates and litho-laminated foils.

EmbossingBlind embossing shapes the printed material without the use of an embossing foil. The interplay of light and shade creates a three-dimensional image. A distinction is made between embossing and debossing, both of which can be multi-level or structured.

Embossing: The embossed design is raised.

Debossing: The debossed design is recessed.

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InTERVIEW

The perfect finish

time, a high standard of quality must be ensured without compromising the understated design of the packaging.

Would you say this packag-ing is a stroke of genius?It really is quite complex, as Model has employed a combination of different printing and finishing tech-niques. The box gets its unique style from offset printing, silver hot-foil em-bossing and conventional embossing, as well as matte and UV varnishes.

How did you find out about Model?When a contract came up for renewal, I asked a num-ber of Swiss cardboard packaging makers to ten-der, and Model Emballag-es, as well as Model Prime Pac, offered just what I was looking for.

What has been the particu-lar challenge in producing Kübler absinthe?The main challenge for us has been to spread the word about the quality of authentic absinthe, a spirit made from wormwood ex-tract, a special blend of ar-omatic herbs and the purest alcohol, around the world. We’re now number one on the Swiss market and among the leading ab-sinthe brands in Europe and the USA.

You have created very elegant packaging together with the specialists at Model. What was the most important aspect for you?Getting the colours exactly right on the Swiss cross. This is because the red sits on top of the silver hot-foil embossing. I also wanted the colours on the label and on the box to match perfectly. At the same

Mr Kübler, what has been the biggest change since you took over the distillery?One big change was per-mission to distil an absinthe-based product (Kübler ab-sinthe extract, 45% alcohol by volume). This opened the way to the legalisation of absinthe in Switzerland on 1 March 2005.

Kübler is a family business that has been producing authentic absinthe in Môtiers in

the Val-de-Travers region, known as the spirit’s birthplace, since 1863. After the

fourth generation took charge, the company was renamed Blackmint, Kübler & Wyss

in 1990.

Yves Kübler, owner

Distillerie BLACKMINT,

Kübler & Wyss

How long have you been working with Model?We placed our first order in 2012.

What advantages does Model offer?The decisive ones from my point of view are quality, responsiveness, competi-tiveness, and proximity.

What hopes do you have for the future of your working relationship with Model?Continued technical devel-opment, attractive packag-ing concepts, and informa-tion on the latest trends in packaging.

Model PrimePac AG is more than just a state-of-the-art printing firm. Our packaging specialists are adept at taking customer’s wishes on board, providing expert advice, developing individual packaging solutions and im-plementing them with technical precision.

The very heart of what we do is the production of crea-tive, tailor-made packaging that ensures a multi-sensory experience thanks to special printing and finishing pro-cesses and thus stands out from rival products at the point of sale.

Model PrimePac - your partner for:ÃÃ Individual project analysis and consulting

ÃÃ Project management and product development

ÃÃ Pre-press

ÃÃ Online porject and print data management

ÃÃ Colour management

ÃÃ Data archiving

ÃÃ CTP printing plate production

ÃÃ Colour mixing

ÃÃ Printing technology

ÃÃ Print finishes.

If you had to pick out one aspect of your partnership with Model, which would it be?Model has delivered what it promised.

What finer points of your relationships with your suppliers and partners are particularly important to you?It is very important to foster a real partner-ship with suppliers and partners which is focused on finding and implementing solutions. In other words, we don’t want to optimise our business at our partners’ expense. We want partners who like working with us, and thus make their con-tribution to the value-generation chain through to our customers. We’ve got off to a very good start with Model.

What communication resources or tools do you use nowadays to encourage dialogue with your supplier companies?I prefer to talk to people directly, and try to do that as often as possible. I’m also very open in stating when we think we need to look at something more closely, and when

not. This is directly linked to the develop-ment phases which we are always going through in the company. I also like to take a broader view of issues, and that means that I’m open to creative approaches and solutions.

How important is recycling to you and your customers, now and in the future?Our customers’ need for recycling solu-tions is growing steadily. As a supplier, we offer our customers the best system for collecting and consolidating waste, so that it can then be passed on to the recy-clers themselves.

Do you have any other projects on which you could envisage working with Model Recover?So far, we have concentrated on larger depots, but we’re working with Model on expanding our recycling expertise at smaller depots too. Here, too, I want an efficient solution for our environment.

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InTERVIEW

Recycling

What do you think are the benefits of the partnership? Is there room for improvement?Model exudes a high innovative drive, and that is exactly what we need of our part-ners. It guarantees that they will always be up to speed on developments in the markets along our value chain. There is always room for improvement, as that is how a genuine partnership grows.

The pressure to innovate is a topical issue. How do you find the need to bring new ideas to market ever more quickly? What is your approach?For me, the challenge isn’t so much in the ever-quicker implementation of new ideas, but in maintaining a high level of quality, because there is a fine line be-tween standardisation and change. We tread this line by modularising our pro-cesses.

Is Model Recover meeting your expectations?Model showed that it knew exactly what it was doing when we did the internal changeover. That confirmed that we had made the right decision.

How did you find out about Model Recover? The quality standards we set for our inter-nal processes prompted us to start look-ing for a new partner. We found out about Model Recover through our existing ties with Model, as we already use the com-pany’s packaging. In view of the fact that Model Recover gives us an optimised full product cycle, the decision was an easy one.

How does the partnership work?Our small-outlet retail customers don’t have the space to collect waste. We already deliver to them very frequently, so we are able to collect much of that waste on our rounds. At the same time, food is our core business, so we need a partner that will keep our logistics facilities free of the tonnes of cardboard that otherwise accumulate. Model made two compactor containers available, which we use on an alternating basis. This ensures that we always have a container to fill. Model monitors, and manages, the container ex-change remotely.

Lekkerland is an interna-tional wholesaler, systems partner and logistics expert in one. In addition to a needs-based range of products, Lekkerland offers its convenience store customers all they need to succeed from day to day, developing customised shop, logistics and all-in solutions that go far beyond the products themselves.

Mr Maier, you have part-nered with Model Recover for recycling since autumn

2013. What were your key reasons for entering into this alliance?Every day, we set ourselves the challenge of providing highly efficient support to small-outlet retailers, so that our custo-mers can perform at their best. We are always on the look-out for solutions that will help us do that. Model Recover is a direct link between us, on the waste dis-posal side, and waste recycling.

Convenience stores supplied by Lekkerland offer any-

one wanting to grab a quick, easy and delicious bite a

whole array of food, fresh produce, drinks, tobacco

products, value electronics, non-food items, and much

more. Lekkerland makes convenience a pleasure.

Raphael Maier,

Head of Logistics

Lekkerland (Schweiz) AG

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Eff IcIEnT sHELf-sTOck Ing

Shelf-ready packaging Packaging solutions that can be used for presenting goods, in addition to their transport and protection, fulfil one of the core elements of the shelf-ready concept.

The primary focus here is on optimising resources and processes. Such packaging can be placed directly on the shelves, thus removing the need to unpack products from their transport cartons. When developing the pack-aging, care is also taken to ensure that no tools (knives, scissors) are needed to open it later, and that the result-ant waste cardboard can be disposed of quickly and with-out taking up a lot of space. Pictograms on the packaging help ensure that they are easy to open and manage.

Adding value for retailersAdvertising effectivenessGreater creative options in packaging design open up enormous marketing potential. Added to this, shelf-ready packaging has a large printed area that can be used for communication purposes and better product recognition. Better product availability is another positive result of the simplified stocking that shelf-ready packaging makes possible.

Bespoke shelf-ready packaging solutions, manufac-tured with precision for reliable downstream processingModel manufactures shelf-ready packaging in one, two or three parts. This wide range of options allows Model to offer clients individual solutions that are more closely focused on their needs.

Further informationModel AGTel. +41 71 626 71 11, or send an e-mail to info.mag@modelgroup.com

Model’s shelf-ready packaging has proven to be an ideal means of ensuring simplified handling and neat presenta-tion.

Advantages at a glance:1. Simple shelf-stocking

2. Simple product removal

3. Easy to identify

4. Easy to open

5. Simple cardboard waste disposal

The aim of the BRC/IoP audit is to check cleanliness and the technical set-up in the production of food packaging and packaging materials, with a view to optimising their safety and hygiene. Packaging also has an influence on the safety of our foodstuffs. This relates not just to the hygienic conditions, but also the possible transfer of sub-stances to food.

The BRC Standard is based on five fundamental requirements:ÃÃ A comprehensive risk analysis

ÃÃ Intensive quality management (documentation, hy-giene and quality, traceability, organisation of internal audits, evaluation of suppliers)

ÃÃ Hygienic conditions in production (order and mainte-nance of premises, organisation of goods flows, equipment maintenance, disposal and treatment of waste)

ÃÃ Staff hygiene

ÃÃ Control and prevention of contamination, be it physi-cal (foreign bodies, glass, pests etc.), chemical or bio-logical.

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HYgIEnE cERTIf IcAT IOn

All in all, there was high praise for positive findings such as the good audit atmosphere, excellent tools, the re-fined Model Top system, and various sets of documenta-tion.

Other positive aspects were good order and cleanliness throughout, practical process models, data manage-ment, and detailed reporting.

The audit also revealed areas with room for improve-ment, however, for example with regard to training and

Successful bRC/IoP auditThe Model AG plant in Weinfelden and the Model PrimePac AG facility in Au (SG) received top marks (grade A)

in their recertification audits, while the Model Emballages SA plant in Moudon successfully completed its initial

certification.

progress checks, and evaluating the effectiveness of measures that are implemented. This gives rise to fresh objectives for the future, including more stringent inter-nal audits and more consistent line clearance in produc-tion.

At the same time, the Model Emballages SA plant in Moudon successfully completed its initial certification. The final report also highlighted good order and cleanli-ness in the production halls, as well as complete and well structured documentation.

These successes are down to the outstanding commit-ment and efforts of all Model staff. This dedication will also be needed in the future to identify and implement further improvements and optimisations.

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InTERV IEW

Appenzell blossom face creamfrom the butter crock

The outer “jars” are made of hand-turned “butter crocks” in maple wood, with a distinctive grain that makes each one unique. An artisan-made container for a high-quality product. What do you expect from the packaging solutions from Model? It was important to us to have a high-quality product from the Eastern part of Switzerland. All the “ingredients”, if you can call them that, are sourced in the region, from the cream with more than 20 flower essences, through the printing to the final butter crock and are of the highest quality and purity. It was clear to us that the packaging should also reflect the same high standards. We there-fore created a packaging solution with Model that meets these requirements in every way. Our quality standards were confirmed when the producer of our cream was awarded the international “Beauty Oscar” in Hamburg this year, beating out the international competition.

How did you find out about Model?Our business partner Martin Müller studied together with a Model employee, and so knew at first hand about the services that the company has to offer. It was clear to us that, as far as quality and reliability are concerned, Model was the packaging producer best suited to us.

As a start-up company, what is the deciding factor for you in your choice of supplier?As the provider of a smart ageing cream that embodies Swissness and nature, we work exclusively with top sup-pliers from our own local area. By buying our brand, each of our La!Creme customers supports the production chain for our local economy. We see our suppliers not simply as “suppliers”, but as partners in the same suc-cess story.

Extremely high quality, well-known products such as our cheese, “Biberli” cakes, beer, liqueurs and “Mostbröckli” meat, etc. are produced here. But what was missing was a high-quality face cream that would do justice to the name of Appenzell – no mean feat!

Mr Gmünder, how and when was the idea of creating a high-quality face cream made of natural essences born?The idea was first raised in December 2012, over a glass of wine with Dr. Menno van Rooijen, a dermatologist. Appenzell stands for tradition, local customs and nature.

From Gais, Canton Appenzell, La!Creme GmbH was born on 10 October 2013. The eponymous pro-duct stands for

a unique, rich, feel-good cream. It has earned a fan-like following among men and women alike, and fulfils its

promise as sustainable skincare. Model PrimePac AG developed the presentation packaging for this extraordi-

nary product, and Model AG the box for six units.

La!Creme has so far been available in a few outlets in German-speaking Switzerland, and it is also available via an online shop. Through which markets and channels will it be possible to buy La!Creme in the future?In the future, La!Creme will be available in certain care-fully selected pharmacies and cosmetics stores, as well as in wellness hotels throughout Switzerland. In addition, we are planning a production line for export to Russia and Asia. Moreover, the original in the butter crock is an ex-cellent gift idea for companies and their valued custo-mers. It doesn’t always have to be wine!

Dominik Gmünder,

CEO La!Creme GmbH,

Smart-Aging

The rigid box has a transparent

glued-in window. A cardboard

insert ensures that the butter

crock is set off to perfection.

18-19

Many thanks to the following for their contribu-

tions and images:

Fabienne Schumacher, © Siemens Switzerland Ltd,

picture credits to Felix Wey

COLORFUL LICENSES

Nestlé Suisse S.A.

Yves Kübler, Distillerie BLACKMINT, Kübler & Wyss

Raphael Maier, Lekkerland (Schweiz) AG

swiss export, LABOR AG, Zurich

Dominik Gmünder, La!Creme GmbH

B+G & Partners SA

Marta Mielcarek, Federation of Migros

Co-operatives

Stefan Leemann, Unilever Switzerland Ltd Liab. Co

L’Oreal

Model Box

Model Group customer magazine

Volume 25, published quarterly

© Model Management AG, 2014

modelgroup.com

Editors

Iris Brugger, iris.brugger@modelgroup.com

Stefanie Schawalder,

stefanie.schawalder@modelgroup.com

Model Management AG, CH-8570 Weinfelden

T +41 (0) 71 626 71 11

Design

cocomu m.stähelin, CH-4502 Solothurn

www.cocomu.ch

Printing

Heer Druck AG, CH-8583 Sulgen

www.heerdruck.ch

model box

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mODELgROUP.cOmWORLD Of cARDBOARD

This unusual and eye-catching display, manufactured entirely from corrugated board, was created to convey a distinctive and authentic Italian air at the point of sale.

Each shelf can carry up to 20 kg, and the spacing is fully adjustable.

The deep metallic blue background of this packaging line creates associations with a stimulating dip in crystal-clear waters, a revitalising morning shower, and the com-forting feeling of post-shower skincare. The effect is further enhanced by the use of brilliantly reflective silver PET film lami-nation, paired with a glossy UV varnish.

This finest micro-flute presentation pack was created for two typical Vaudoise products (wine and Mont d’Or cheese). The additional glued-in window reveals the contents of this one-piece packaging. Following its initial launch, the presenta-tion pack continues to be sold as a pre-mium product in selected stores.

Packaging solution for eight different sur-prise package options, with different fill volumes, for Migros branches. This offset-laminated packaging solution was developed and produced to the tightest of deadlines. A triple tab system to open the box perfectly guarantees the desired sur-prise effect.

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