Juice Multipack Wins Product Of The Year Award

The Association of Industrial Metallizers, Coaters and Laminators (AIMCAL) bestowed its Metallized Product of the Year Award* on Graphic Packaging International (GPI), Marietta, Georgia, for a 10-count multipack carton for Disney brand juice pouches from Pouchsmart Inc., Santa Monica, California/Langer Juice Co., Inc., City of Industry, California. GPI served as both converter and metallizer and supplied the 100% recycled paperboard substrates for the reverse-printed, metallized Composipac Z-Flute folding carton. DuPont Teijin Films, Hopewell, Virginia, supplies the 48-gauge polyethylene terephthalate (PET) film for the Composipac structure. The carton, designed by Bryan Schuttinger, Concord, New Hampshire, consists primarily of 24-point clay-coated solid unbleached sulfate (CCSUS). To eliminate the need for corrugated shippers and reduce material requirements, GPI laminates 18-point uncoated, recycled board reinforcement strips to load-bearing areas of the CCSUS. The thinner profile of the Z-Flute carton versus a traditional B-Flute shipper doubles the number of multipacks per pallet and thereby reduces the number of pallets and truckloads needed to ship product. In addition, the reverse-printed, metallized film imparts scuff and moisture resistance to the Composipac structure and provides eye-catching shelf impact with its high gloss finish and use of transparent and spot opaque white inks. Gravure-printed graphics for four Disney brands -- Fairies, High School Musical, Hannah Montana, and Cars -- were designed by Diane Brewer, Lawrenceburg, Tennessee. Contract packaging takes place at Langer Juice Co.

The marketing, environmental and productivity advantages sold the judges on the reverse-printed, metallized Composipac Z-Flute folding carton. Eliminating the need for corrugated shippers not only reduces material costs and waste, but also simplifies handling for retailers. "This application expands the use of metallized material into the juice pouch multipack category," commented one judge. "Definitely new and innovative for the category," noted another member of the judging panel.

The award was presented at an Awards Banquet on Sunday, March 21, 2010, during AIMCAL's annual Management Meeting, March 21-24, 2010, at the Hilton La Jolla Torrey Pines in La Jolla, California. It's the second year in a row that GPI has taken home Product of the Year honors.

The judges also awarded marketing and technical awards in several categories. GPI also captured the Technical Award in the Food Packaging Category for a dual-susceptor package it converts for WeightWatchers Smart Ones microwavable flatbread from Heinz North America, Warrendale, Pennsylvania. The Focus Inset susceptor lamination covers most of the interior of the carton. Pattern metallization done by Rol-Vac, Dayville, Connecticut is tuned to deliver a crisper product on one side and a softer product on the other side. Billed as the first package of its kind, the structure consists of OPV/ink/solid bleached sulfate (SBS)/adhesive/pattern susceptor/48-gauge PET. International Paper, Texarcana Texas, supplies the SBS, and DuPont Teijin Films supplies the PET. A special adhesive bonds the polyester film to the paperboard. An extrusion system ensures proper delivery of the glue and increases line speeds without compromising the integrity of the seal. For a softer flatbread, the consumer opens the carton, unwraps the flatbread and places it on the grid pattern part of the susceptor and sets the hinged carton top back in place. For a crisper flatbread, the consumer tears off the perforated carton top, removes the flatbread and flips the carton over so it serves as a platform, places the carton top on the platform, metallized side up, and sets the unwrapped bread on it. Package design credit goes to JoAnna Terhune of Heinz North America.

"The dual-susceptor concept takes susceptor technology to the next level," noted one judge. The panel was impressed with the ability of the carton to enable preparation of a soft or crispy product and the simplicity of the directions. The judges also noted the dual-susceptor design simplifies inventory requirements by eliminating the need to stock different cartons for soft or crispy products.

The Marketing Award in the Food Packaging Category goes to Taghleef Industries SpA, San Giorgio di Nogaro, Italy, for a stand-up pouch package for Werther's Original candies from August Storck KG, Halle, Germany. A matte lacquer applied to some areas of the film provides an eye-catching contrast with the glossy areas. Taghleef supplies the 48-micrometer TSS biaxially oriented polypropylene (BOPP) and 20-micrometer ZSF metallized film that is laminated to create the pouch, converted by Constantia Hueck Folien, Pirk, Germany. In addition, the PP/metallized film lamination represents a source reduction compared to an aluminum foil lamination.

The judges found the combination of matte and gloss finishes exceedingly appealing. "There's a three-dimensional quality," noted one member of the judging panel. "The graphics have a rich feel, and the candy really stands out," added another.

In the Nonfood Packaging Category, Hazen Paper Co., Holyoke, Massachusetts, captured the Marketing Award. Hazen Paper served as the converter for a holographic folding carton for Caribou Crossing Single Barrel Canadian Whiskey from Sazerac Co., Inc., Frankfort, Kentucky. Hazen Paper laminates Ultracure lacquered Rainbow 80-gauge OPP to the coated side of 0.024 SBS using a water-based adhesive. The holographic rainbow material provides a backdrop for the subtle nighttime scene pictured and imparts a multi-dimensional appearance. Hub Folding Box, Mansfield, Massachusetts, designed the package and also performs contract packaging duties.

The judges loved the Northern Lights effect the holographic material provides. "It's a very effective use of the image and film underneath," noted one judge. "Great design and execution," concluded another.

Unifoil, Fairfield, New Jersey, earned the Technical Award in the Nonfood Packaging Category for converting an ultraviolet-printed, acrylic-coated, holographic rainbow polyester film/paperboard used for the covers of TinkerBell DVDs from Walt Disney Studios, Burbank, California. Special features include raised printing on the front panel to provide a tactile feel of a leaf and a raised sparkle coating on TinkerBell's wings. To heighten contrast, the rainbow is dropped out in some areas. The acrylic coating helps achieve a superior lamination and ink bond and also provides the flexibility for fault-free scoring and gluing. Other participants in the project included the metallizer, ITW, Newburyport, Massachusetts, and the paperboard substrate supplier, MeadWestvaco, Atlanta, Georgia. Package design and contract packaging services were performed by AGI/MeadWestvaco, Melrose Park, Illinois.

Attention to detail and tactile effects convinced the judges of the merits of the TinkerBell DVD covers. "There's a lot going on - embossing, varnish, glitter, printing, all tightly registered - to create an attention-grabbing package," explained one judge.

In the Healthcare, Cosmetics & Toiletries Packaging Category, Hazen Paper received a Marketing Award for a "gem-studded" gift box for Elizabeth Taylor White Diamonds products from Elizabeth Arden, New York, New York. As metallizer and converter for the box, Hazen metallized 48-gauge polyester coated inline with Ultracure acrylic lacquer and laminated it to 0.018 SBS using a water-based adhesive. The silver film provides a brilliant base for the final rich gold background color and holographic stamping.

The judges concluded the combination of embossing and holographic "jewels" projects the image of White Diamonds. "Registration is extremely precise, and the box is really striking from a distance," noted one judge.

In the Decorative Display Category, the Marketing Award went to Vacumet Corp., Franklin, Massachusetts, for a holiday promotion for Presidente and Presidente Light Beers from Cerveceria Nacional Dominicana, S.A., Santo Domingo, Dominican Republic. Vacumet supplies substrates and metallization services for the holographic bottle label, multipack carton, point-of-sale poster, and shelf-talkers. A custom HoloPRISM holographic pattern ties the various media together and features glittering snowflakes showcasing the P of the Presidente logo. Converting services are provided by Editorial Padilla, C. por A., Santo Domingo, Dominican Republic.

Judges liked the family look of the sparkling holographic label, multipack, and promotional materials and acknowledged the challenge of applying the same hologram to different media. "Execution was superior," concluded one judge. "The poster actually looks wet," he explained.

In the Other Category, Unifoil took home the Marketing Award for souvenir cups for the New Moon movie from Summit Entertainment, LLC, Santa Monica, California. The in-mold-labeled cups proved so popular with moviegoers, the entire production run sold out. In-mold labeling made it possible to reproduce glistening metallic graphics at a low unit cost. To produce the labels, Unifoil converts 3-mil EWR 57 gloss/matte white PP from Treofan America, LLC, Winston, Salem, North Carolina, using its Ultralustre Silver transfer-metallizing process. Metallizer for the project is Crown Roll Leaf, Paterson, New Jersey. IGH Solutions, Inver Grove Heights, Minnesota, provided package design and contract packaging services.
Judges noted the in-mold labeling results in a more durable souvenir cup. Although metallized material has been used for in-mold labels, this application extends the technology to promotional cups.

The Technical Award in the Other Category went to JDSU, Santa Rosa, California, for HoloFuse polycarbonate security film. Used for identification cards and passports, the substrate combines high-security demetallized holography with clear polycarbonate in an adhesive-free construction. Available in sheet or roll form, the HoloFuse film replaces the clear layer of polycarbonate currently used as the top layer in identification document construction. Eliminating the adhesive layer simplifies the structure, reduces costs, eliminates hot-stamping or patch-lamination production steps, and reduces waste. Compatibility with laser engraving makes it easy to add other security features.
Judges viewed the simpler, yet harder-to-counterfeit construction as a significant advance. "This material accomplishes a security goal at a reduced cost," explained one member of the panel.

The judging panel for the Sustainability Awards Competition included Vince DiTrolio, vice president/owner of DiTrolio Flexographic Institute, Broadview, Illinois; Travis Funk, senior packaging engineer, Diageo, Plainfield, Illinois; Jeffrey T. Weber, research principal, Kraft Foods, Glenview, Illinois; Stan Kopecky, principal, SJK Packaging Associates, Prospect Heights, Illinois; Mark Spaulding, editor-in-chief, Converting magazine, Chicago, Illinois; and Yolanda Simonsis, associate publisher/editor, Paper, Film & Foil Converter magazine, Chicago, Illinois. AIMCAL Awards Committee Chair Steve Sedlak, sales manager for ESK, Ceradyne, Inc., Costa Mesa, California, moderated the judging session.