CardPak: Blog

CardPak Announces Senior Management Promotions

2011-06-27T13:05:00.001-04:00

SOLON, OH – June 22, 2011 – CardPak, the pioneer in developing and manufacturing environmentally sustainable packaging, announced the promotions of four senior managers. Greg Tisone, formerly CardPak’s vice president, general manager, was selected by the Board of Directors to serve as president. Jerry Lamm, previously the company’s chief financial officer, was promoted to vice president, chief financial officer. Tom Weber, director of sales, was promoted to vice president, general manager. Seth Duckworth, recently hired as the central region manager is now the company’s national sales manager. Messrs. Lamm, Weber, and Duckworth report to Mr. Tisone, CardPak president.

CardPak’s senior management team is made up of industry experts with over 100 years of sales and manufacturing experience. Their expertise has helped catapult the company’s growth and leadership position in the sustainable packaging industry.

Mr. Tisone has a Chemical Engineering degree from Youngstown State University and an MBA from Case Western Reserve University. Under his charge, the company achieved world-class excellence in several benchmarks related to safety, quality, customer service, and operational efficiency. CardPak received two EXCELLENCE awards in the 2010 National Paperboard Packaging Competition sponsored by the Paperboard Packaging Council (PPC), and three safety awards also from the PPC. In addition, the company qualified for three PPC Director’s Safety Awards in 2010.

Mr. Lamm joined CardPak as controller in 2007. He has a Bachelor’s Degree in Accounting, an MBA, and is a six-sigma green belt. Mr. Lamm has nearly 30 years of financial experience within various manufacturing and technology related industries.

Mr. Weber, a 35-year veteran of the paperboard packaging industry, joined CardPak in 2008 as Sales Director. Prior to CardPak, Mr. Weber served as Vice President/GM for Caraustar Industries and Vice President for Core Systems in Painesville, Ohio. Mr. Weber earned a business administration bachelor’s degree from the University of Akron.

The newest member of the CardPak management team, Mr. Duckworth, most recently served as Tegrant/Alloyd Brands’ Director of Sales for the Midwest region prior to joining CardPak in March. Mr. Duckworth earned a bachelor’s degree in economics management from Ohio Wesleyan University.

Mr. Duckworth had these comments in regards to his joining CardPak; “I’m thrilled to be part of the CardPak team. I’ve watched the company evolve and change over the years to be recognized as a “customer focused” leader in sustainable packaging. Clearly, there has been a major shift to more fiber-based packaging versus resin-based; Cardpak is well positioned to assist our customers in that endeavor. CardPak provides innovative design solutions with a material neutral approach. We recognize we must be flexible, reliable, and competitively priced as a supplier to help our customers win!”

Green with Envy

2011-05-17T16:06:00.003-04:00

Green with Envy
Credit: By Jamie Matusow, Editor -- Copyright © 2011 Rodman Publishing.

From Unilever to L’Oréal, Aveda to Lather, beauty brand manufacturers large and small have taken great strides to deliver the sustainable packaging consumers are asking for—but they couldn’t do it without the extreme innovation of the industry’s packaging providers. Here, we look at some who are blazing the way and why they may inspire others who wish they were as far along on the compliant path to customer loyalty and boardroom approval.

Green consumer consciousness is on the rise, and packaging—the “face” of nearly every beauty product—has become the focus for consumers’ ever-more educated eyes looking for signs that they are making eco-responsible purchasing decisions.

In Mintel’s February 2011 Green Living Report (a U.S. survey), 66% of respondents said packaging should be recycled—that it influences their purchases. Almost half—44%—said they purchase beauty products that use recycled paper.

Nica Lewis, senior analyst for the global market research firm, says, “This is a big percentage for consumer preference—even 1% would be sizable.”

In the Dumps

According to the EPA, in 2009, Americans produced about 243 million tons of municipal solid waste (MSW), or about 4.3 pounds of waste per person per day. Of this, the agency says 33.8% is recovered and recycled or composted, 11.9% is burned at combustion facilities, and the remaining 54.3% is disposed of in landfills.

The realities of packaging waste have come to bear on consumers, and they have increasingly embraced sustainability messages.

A Good Start

For manufacturers, from giant multinationals to local indie labels, building an enviable image of an environmentally conscious brand often begins with the packaging.

Michael Hughes, senior packaging manager, Unilever, explains: “We have conducted an extensive lifecycle analysis of 1,600 products across 14 countries accounting for 70% of our sales. This has given us an unparalleled insight into how we prioritize our efforts and resources across our personal care and foods brands. We purchase over two billion tons of packaging every year, so our analysis helps to ensure we focus on where we can make the biggest difference.”

Unilever’s efforts toward sustainability have also netted the company favorable public opinion. In a poll by SustainAbility and GlobeScan, Unilever ranked at the top of companies most committed to sustainability. It was chosen by 15% of respondents, and ranked as one of the top two firms in Europe.

A recent report by UK-based market research company Pira International determined that sustainability is emerging as a key trend in luxury packaging as upscale marketers look to promote their environmentally responsible credentials through their choice of packaging materials.

Seri McClendon, CEO, Clean Agency, a member of the Sustainability Consortium, an independent organization of partners who aim to “work collaboratively together, developing an approach that drives better understanding, standardization, and informed decision making” regarding sustainable products and packaging—and which claims L’Oréal as a key member—says starting with packaging materials makes good sense. “At Clean, we advise our consumer product clients to start addressing environmental impacts in three areas of their business: operations, products and packaging. Packaging is often the best place to start. There are influences in the marketplace that are driving these changes, which include retailer pressure, potential government regulation and eventually, consumer backlash. The benefits of improving packaging outweigh not addressing it at all.”

Making Claims

While Mintel’s Green Living Study focused on U.S. consciousness, Lewis emphasizes that interest in eco-friendly packaging is a global concern: “There has been a significant increase overall in claims for eco-friendly packaging in all beauty and personal care categories over the last few years.” She says there has been double-digit growth year over year for the past two years. From ’08-’09, there was a 57% increase in global claims for eco-friendly packaging. From ’09-’10, there’s been a 75% increase. In the U.S., there’s been a 78% increase—slightly more than the global average. Claims have been particularly high in Japan, increasing 313% in 2010, though their total launches of beauty products are less than 10% of the global share.

The largest increase globally has been in deodorants and fragrance, according to Mintel stats. From ’09 -’10, claims increased 143% for deodorant products touting eco-friendly packaging; 130% for fragrance.

“Claims” refer to products that use recycled components or have a package that can be recycled, but specifics are often difficult to decipher. While the EU has developed certain regulations, the U.S. lags behind.

McClendon, of Clean Agency, notes, “The EU is pretty far ahead of the U.S. because of government mandates that require companies to meet higher production standards and to be more accountable for the environmental impacts of their packaging once it’s thrown away. The U.S.-based businesses are just starting to understand the positive impact of addressing sustainability in their packaging, including cost savings and consumer appreciation, which can result in increased sales and market share.”

Customer Interest

With sustainable packaging as a growing marketing platform, suppliers report that there is increasing demand from beauty brands for eco-friendly packaging—and buyers are well-informed when making decisions.

Jonathan Dudlak, general manager, Chicago Paper Tube, says: “ I can’t remember a single cosmetics or personal-care client in the past year who has not inquired about the contents of our raw materials, the ‘greenness’ of our manufacturing process, the recyclability or compostability of our packaging, or all of the above. Five years ago it was a rarity for anyone to even ask, and as little as a year ago most people were content to take your word for it. Nowadays you better have the certifications and paperwork to back it up!”

Jessica Kimbrough, vice president, marketing, RockTenn Consumer Packaging, notes, “From a business-to-business standpoint, we are noticing a trend with our customers toward understanding forestry certifications and the benefits of having suppliers’ manufacturing processes verified externally.”

Kimbrough adds, “Our customers are increasingly interested in investigating the materials and processes used in manufacturing their packaging and developing packaging with sustainable benefits, without impacting the package’s on-shelf appeal. Paperboard packaging is well positioned for this demand as it is a recyclable packaging option that offers high print quality and graphic reproduction to promote brand equity.”

Dudlak agrees: “Almost everyone we sell to wants to know the total PCW [post consumer waste] content of their finished piece, and in most cases, it ends up on the label.” He adds, “FSC [Forest Stewardship Council] and SFI [Sustainable Forestry Initiative] certification is something people ask about all the time. Our paper suppliers and printers are all compliant with one or the other, or both.”

Materials Approach

Advancements in using eco-friendly materials from sustainable forests, or others such as recyclables, bioplastics, biodegradables and post consumer regrind board stocks, have all contributed to the recent wave of innovative, eco-friendly packaging trends in the beauty industry. But while brands may strive to emulate the successful approaches of icons such as Aveda and Method, there’s no simple formula to a very complex process, and often they start by taking small steps.

“The best way to go about creating an eco-friendly line of packaging is predicated on the product, industry, and marketplace in which the products are sold,” advises Tim Budic, marketing manager, CardPak. “There is no general solution or cookie-cutter way to go about it; each customer has their own goals and barriers that need to be addressed. Yes, material reduction, weight reduction, alternative materials are all great places to start, but it goes well beyond that and has to be reviewed on a case-by-case basis to reap the greatest success.”

Dudlak says that because Chicago Paper Tube’s products are all custom made, “We typically let the client decide how far they want to go with their sustainability efforts and present the different options, and over the past few years these options have gotten more elaborate. For some,” he says, “switching from a polybag or plastic bottle or jar to any kind of fiber canister is already a big move in the right direction. For others, they need every bit of the container down to the printing stock to be 100% recycled paperboard, soy inks, biodegradable glue, and no metal or plastic at all on the package.” He says most clients fall somewhere in-between.

Material Whirl

Often swapping one packaging material for another can make a big difference, especially if it also makes the manufacturing process more energy-efficient—but it’s not always the case.

Josh Dunn, Avery Dennison sustainability director, materials businesses—label and packaging materials, specialty materials, says, “Two key trends we’re seeing involve reducing the amount of materials in both packaging and labeling, and the development of packaging and labeling materials from bio pathways. We’re beginning to see the exact same chemical substances, PET for example, coming from plant-based sources versus petroleum-based sources. The availability of materials sourced from bio pathways will increase, as their economic viability becomes more in-line with petroleum-based sources. But lifecycle sustainability has to be part of the equation. Just because a product may come from a plant-based source, doesn’t automatically make it sustainable.”

The substitution of packaging materials, including paperboard alternatives, bioplastics and biodegradables, is a trend noted by Dudlak. “While much of our product line is secondary packaging for premium products, lately we’ve had many clients looking for creative ways to replace the primary packaging for items that have always been relegated to plastic, metal or glass with a paperboard alternative. We are already using special papers that can take the place of plastic or wax as a canister liner. Bioplastics, while they have their limitations, have emerged as a suitable replacement for applications where a non-porous, biodegradable barrier is required.”

Dudlak says most people don’t realize that simply using even a standard can liner like coated aluminum foil adds an almost negligible amount of metal and plastic to an otherwise 100% recycled paperboard package. “We’re excited about some new products we’re developing for later this year that will offer biodegradable alternatives to plastic for several different branches of the cosmetics industry,” he adds.

Lombardi Design and Manufacturing, a supplier of injection-molded components and packaging to the cosmetics and fragrance industries, has created eco-friendly packaging using Tenite, an Eastman Chemical cellulosic material made primarily from wood pulp.

Having used cellulosics in applications including the cap of the award-winning Sean John “I Am King” fragrance pack, Lombardi says, “We’re committed to offering environmentally sound alternatives for packaging needs.”

The Freeport, NY, manufacturer recently created a Tenite gift box, which is ideal for a fragrance collection. “This type of product has typically been made of general purpose polystyrene,” says Lombardi. “We’ve chosen a different material out of concern for the environment.” According to Lombardi, Tenite offers a number of advantages: “It dries faster than traditional copolyesters and is processed at lower temperatures, and also boasts excellent chemical resistance and the ability to mold thicker parts with smaller gates and better gate aesthetics.”

The classic looking, clear containers not only provide a sleek and practical way to display items at retail, they can easily be repurposed, another eco-friendly feature. The gift box design can be customized in various colors, sizes and shapes.

What’s more, Lombardi says, “All of our display cases are manufactured domestically and our products are manufactured with 83 percent renewable energy produced by hydropower.”

Viva Healthcare Packaging is another supplier that has taken a traditional product and made it more sustainable.

Darryl Laing, director of business development and marketing for the firm, explains, “Our new tube technology uses injection molding to produce a 100% polypropylene [category 5] tube.We include a multi-color label printed on polypropylene film inside the mold so that once molded, the graphics are literally embedded in the wall of the tube, making one single contiguous tube.”
Laing says the advantages of Viva’s tubes are threefold: Embedding the graphics by an in-mold labeling process avoids using glue (which contains hazardous ingredients) to apply the graphics; the entire package, including the tube, cap and in-mold label are made of polypropylene, so once emptied, the consumer can simply throw it in the recycling bin; and the manufacturing process involves only two steps (printing the label and injection molding the tube), while extruded or laminated tubes normally require at least five to six steps, with waste and buffer storage necessary between each step.

In addition, Laing says the polypropylene in Viva’s tubes contains the lowest CO2e emissions by weight compared to all other categories of plastic, and generates the least amount of CO2e emissions to both produce the raw material and process it in manufacturing. The tubes are produced in Viva’s plant in Toronto, Canada, which accesses its grid power from one of the highest proportion of renewable energy sources in North America. For distribution consideration, the tubes are made of the least dense and lightest plastic.

Lightening Up

Reduction—of both the weight and the amount of packaging materials used—has been a key factor in brand manufacturers’ move toward sustainable packaging.

Hughes says that by 2020, Unilever will reduce the overall weight of packaging used across its brands by a third. “We will do this by light weighting materials, optimizing design and eliminating unnecessary packaging. We are also actively looking for opportunities to develop re-usable packaging.” The company’s three-pronged approach to support recycling includes: 1) increasing recycling rates (partnerships with NGO, governments and industry organizations); 2) making it easier for packaging to be recycled; and 3) by 2020, increasing the recycled content of its packaging to maximum content levels.

Unilever’s Suave Professionals shampoo bottle weight was recently reduced by 17% and post consumer recycled content (PCR) is now included at 25%. Dove Men+ Care Body Wash also contains 25% PCR, and Suave Kids bottle weight was reduced by 13%.

In some cases, innovative labels are absorbing some of the weighty functions of packaging.

Renae Kulis, Avery Dennison global marketing director, Health & Beauty, Home Care, says labels are changing the face of the shelf with new printing methods, new substrates, and new closure systems all coming from the label market.

Kulis says, “As packaging transforms to lighter and compact, each component of the package is asked to play multiple functions. In labeling, the objective is not only to enable shelf appeal and communicate information, but transforming to take on the functional components traditionally covered by the other elements of the package—including container thickness/rigidity, closure, and dispensing system.

Avery Dennison’s Curve Appeal is a patent-pending system encompassing special Fasson Curvy film labels that work together in a machine application process. This system labels complex, curved surfaces far beyond other current labeling processes, says Kulis. Fasson Curvy film labels combine a wraparound look with the shelf appeal of pressure-sensitive graphics. They create up to 30% more space for primary labeling than flat surfaces, and reduce the need for two-ply label constructions by allowing larger back panels to carry more product information or multi-language information.

At RockTenn, Kimbrough says there’s been a trend toward brands’ consolidation of the packaging footprint along product lines, as well as a move toward “right-sized packaging,” where packaging is designed around the product and elements that make packaging larger are eliminated. More one-piece carton designs and/or insert card designs that limit the use of poly vac trays have been in demand.

CardPak’s Budic says that they, too, have had great success initiating the conversion to eco-friendly packaging for numerous clients. “We pride ourselves on our ability to develop sustainable packaging solutions that make sense for our customers, so they can pass along the benefits to their customer.”

One recent example was Beiersdorf’s Nivea for Men multi-package, which was originally designed as a PVC clamshell and then shipped to various club stores in slotted trays. Budic explains, “We replaced the PVC plastic with a trapped paperboard design that provided a significant cost reduction in primary package materials. In addition to cost reduction, we eliminated 80% of the overall plastic materials, increased the Walmart scorecard by 63%, and replaced the remaining plastic with RPET blisters, which led to 100% elimination of PVC usage. Also, the overall packaging weight was reduced by 30% compared to the original, full clamshell package.”

A Clear Choice

With increased focus on recycling as a key sustainability option, glass has clearly become an asset for cosmetics and skin care products as well as for fragrance.

At glass manufacturer Grupo Pavisa, Tania Castillo says, “We have seen two trends: weight reduction on glass packaging; and glass recycling, which offers savings mainly on raw materials and energy.” Castillo says there’s been an increase in demand for their products. “Glass,” she says, “has once again gained ground, and we think it is because of the special glass features that make it a unique option, and also because it’s overall environmentally friendly, since it’s 100% recyclable.”

Grupo Pavisa uses raw material as well as two types of recycled glass: external and internal. The external recycled glass is mostly domestic, used for bottles for wine, champagne, drugs and perfumes; it is recycled from 5% up to 80% depending on the color of glass the company manufactures. Over 42% of this recycled glass comes from the domestic sector, being the main production of cullet. The internal recycling is based on defective glass bottles from the company’s manufacturing lines, which are eventually crushed and stored for use as raw materials on new glass batches.

Substantial savings in terms of energy and raw materials—as well as less harmful emissions to the environment—have attracted lots of brand interest in SGD’s Infinite Glass, the first and only recyclable glass made of 100% post consumer recycled cullet, which embodies the “cradle-to-cradle” approach.

Louise de Bengy, market manager-perfumery & cosmetics, SGD, says, “Since we launched this ecological material, we closely followed the eco-design strategies of the major players in the market, and we feel the interest for ecological packaging led to two phenomenons: a tendency to switch from plastic to glass containers, and also a new interest in glass for the skin care and makeup segments.” Among the first beauty brands to launch new products in Infinite Glass in Europe are Clarins-owned Kibio, with its Gentle Exfoliating Cream, Natures et Découvertes’ Terre d’Oc, as well as a range of L’Occitane products.

The Future of Packaging

While these brands are among many who have made enviable leaps and bounds in producing eco-friendly packaging, there remains a long road to travel, with a multitude of unknowns and challenges lining the way. But it’s also a direction that shows increasing approval by consumers and increased savings by corporations, so it remains a path seemingly destined for growth.

As to the future of packaging standards, Mintel’s Lewis speculates, “It’s anyone’s guess, but probably in the way formulations have moved. Rather than mandating that products must be in sustainable packaging, to make the claim, certain criteria must be met.”

CardPak, Inc., the Paperboard Packaging Council and Solon Schools Team Up to Celebrate Earth Day

2011-04-26T10:33:00.001-04:00

SOLON, OH – April 25, 2011 – CardPak, the pioneer in developing and manufacturing environmentally-sustainable packaging, donated tree saplings to teach Roxbury Elementary school students about the natural renewability of paperboard packaging. Jerry Lamm, CFO of CardPak (www.cardpak.com), explained, “we’re thrilled to once again have the opportunity to teach elementary school kids in our community about renewable resources like paperboard packaging. The TICCIT program (Trees Into Cartons, Cartons Into Trees, pronounced “ticket”) is a great way to demonstrate how fun and easy it is to take care of the Earth.”

Fourth graders brought paperboard milk cartons from home and CardPak donated over 100 saplings and soil. The students planted the saplings in the paperboard cartons. At home, the students poke holes in the carton and plant it directly in the ground. The cartons provide protection and a natural water funnel for the new trees. As the trees grow, the cartons breakdown and provide a natural biodegradable fertilizer. This completes the trees into cartons, cartons into trees cycle. “We appreciate the warm welcome we received from the principal and teachers at Roxbury School. It’s such a great opportunity to engage the future leaders of America in a fun and earth-friendly activity”, said Mr. Lamm.

The TICCIT program celebration took place on April 20th at Roxbury Elementary School, located just 2.3 miles from CardPak’s worldwide headquarters. Roxbury Elementary School Principal, Carla Rodenbucher, was pleased to receive CardPak’s donation of over 100 tree saplings in celebration of Earth Day. “At Roxbury, we’re all about providing our students with hands-on learning opportunities like the TICCIT program. What better way to teach kids about the benefits associated with paperboard recycling and planting trees, than providing them with the materials to make it happen?” explained Ms. Rodenbucher.

CardPak’s Jerry Lamm, CFO; Gayle Wellman, human resources coordinator; and, Tim Budic, marketing manager, helped the students plant their tree saplings.

The Fine Print of Contract Packaging

2011-04-07T21:46:00.026-04:00

The Fine Print of Contract Packaging
Credit: Written by Steve Katz, Associate Editor -- Copyright © 2011 Rodman Publishing.

Contract packaging takes on a variety of definitions, but one thing is agreed upon: As brands look to streamline their operations, suppliers that offer a diverse set of capabilities repeatedly sign on the dotted line.

It’s been said that it’s not easy to pin down a definition of contract packaging. And while the phrase means different things to different people, one thing is clear: Those that offer these services in the beauty packaging industry are innovative and versatile suppliers, capable of meeting a portion—or all—of a brand’s packaging requirements.

Tim Budic, marketing manager for CardPak, discusses why contract packaging’s definition is difficult to articulate, noting that it changes depending upon if you are in the business of contract packaging, or just a supplier to the process or industry. “It is in general hard to define because there are so many levels to the process and those levels are always in flux... the definition could seemingly change from project to project,” he says. “Contract packaging could be synonymous with contract manufacturing, but I think that most supply chain people view the two as different.”

The consensus in the beauty industry echoes Budic’s thoughts. It seems that contract manufacturing companies are often thought of as those that handle the product itself, like formulations and blends, for example. Meanwhile, contract packaging is all about the primary and secondary packaging, as well as the assembling of gift sets, samples and other components.

The Contract Packaging Association website defines contract packaging, or more accurately, the types of services provided by its members, as follows: “Association members perform all packaging functions from the simplest to the most complex and from the glamorous to the hazardous. Members’ packaging services range from manual and semi-automatic to full-speed, high performance packaging lines.”With that said, contract packaging covers a diverse set of capabilities.

Tara Abraham, owner and co-CEO of Accel Inc., says there is a general perception that contract packaging companies focused on manual to semi-automatic solutions are small, “mom and pop” type establishments generally doing business on a project-by-project basis, and this, she adds, isn’t always the case. She says, “Over the 15 years Accel has been in business, it has tried to change how it is perceived by offering a wide range of services and technologies that showcase its ability to meet client demands.”

Accel offers a variety of packaging specialties that include hand- and semi-automated assembly, shrink wrapping/banding, thermoforming, glue tipping and flow wrapping.

And what about contract manufacturing? “We believe that manufacturing really implies primary components of the product,” Abraham says, “while packaging is a secondary process that comes after manufacturing. For example, we put together gift sets with a variety of personal care components for a client. Contract manufacturers manufacture the bottles and the various lotions and also fill the bottles with the lotion. Accel Inc. takes the filled bottles and puts together the gift sets. Once the gift sets themselves are complete, we are responsible to ensure they can withstand the rigors of shipping; our goal is to have the gift set look the same on the store shelf as it did coming off our line,” she adds.

Regardless of how exactly it’s defined, the contract packaging sector has dramatically changed over the past few years. “From a factory-driven business organized by type of commodities, it has evolved into a full-service business driven by design, innovation and supply chain management,” says Greg Mager, co-chairman and founder of Maesa.Maesa envisions the contract arena as being just one part of a more holistic approach to beauty category management. “This is a more innovative approach for an industry known to need at least 15 different factories to make one fragrance. An increasing number of beauty brands and retailers are looking for turnkey supply partners that function as an extension of their own business. This more progressive approach necessitates a fully integrated organization that can manage and control the entire process from conception to completion,” Mager says.

Brent Burdick, director of operations for Paragon Packaging, points out that contract packaging is often used for secondary packaging, whereby customer-approved components are packaged into finished products—and quality is held to the highest standards.

“This is accomplished through uniform workmanship standards utilizing the precepts of skillful examples, specifications and procedures. The concept of secondary packaging can be priceless to a variety of companies by providing the finesse of line packaging, which can extend productivity and eventually lower costs. The end result allows the customer the chance to reach their target market,” he says. For Paragon, most of its contract packaging work relates to cosmetic and personal care products such as hair care products, powders, brushes, gift set and display assembly, among others.

Strong Relationships
Strong relationships with brand owners, as well as being equipped with the right knowledge, are integral to working successfully with a contract packaging company.

“Contract packaging companies typically have a strong relationship with the customer, simply due to the understanding that they are providing multiple elements on any given project, if not the entire project,” says CardPak’s Budic.

A single supplier may have a relationship with a customer, but the scope and reach is limited to that one item being produced and supplied. “Contract packagers are not typically limited to the narrow confines of a single item, product line, or customer contact. Contract packagers also have a greater general knowledge of the customer and the project,” says Budic. “They may not be experts at any one specific aspect of the project, but their general expertise is the foundational base for a project’s success.”

Logan Wertkin, marketing and sales for Cosmetic Solutions, points out that the right partnership goes a long way in putting a brand owner’s mind at ease. “The biggest advantage of working with a contract packaging supplier is minimizing your risk. By taking the ‘manufacturing’ component away from most clients, they are free to focus on their areas of expertise while knowing their goods will be delivered,” she says.

Bringing Fresh Ideas
As is so often the case in the beauty packaging space, innovation is everything. Contract suppliers gain business when they bring fresh ideas to the client.

“The vast majority of innovations and advances in the packaging world are developed by independent contract packagers as they compete in an open, free-market,” states Margery Woodin, VP of marketing and sales for Identipak. “This is a tremendous advantage for outsourcing companies, for they are routinely presented with innovative, out-of-the-box ideas.”

Identipak is growing its services to include manufacturing of stick packs and fill of powder and larger size liquid pouching. “Although known for our detailed die-cut sachets, we have recognized there is a need for high-speed filling of larger fills, usually over 1oz. These new production lines are great for resale sachets of hair treatments, face masks, and any other beauty item that requires a multiple use dosage,” Woodin says.

Accel’s Abraham says that when a client involves Accel up front by providing initial project packaging specs, Accel will explore ways to improve upon the initial design quality, assembly speed and overall cost. “This really allows us to be proactive through innovation—rather than reactive at the end of the process without input into the design. We have engineers on staff that review the packaging and make recommendations to reduce overall packaging costs. By making the simple recommendation to move from bubble wrap to a shrink band in a pack-out, we decreased the amount of material (and environmental impact) by over 100,000 cubic feet and reduced the time at the store to unwrap finished goods for display by over 4,100 hours,” she says.

Whip Smart is a contract packaging company that is differentiating itself in the market with its ability to test and prototype products, using a state-of-the-art in-house design studio. “Smart Studios can allow a consumer to test packaging concepts with prototypes before committing to the manufacturing process,” says Mark Mondello, Whip Smart’s director of operations. The company’s capabilities in 3D renderings is making it possible for customers to bring uniformity and image consistency to their product images regardless of the end use. “Our engineering department allows clients to customize all components for manufacturing, and it can also produce models for inspection,” he says, adding, “the greatest advantage of working with a contract packaging supplier is that—as a customer—you get to be involved in the process without having to worry about the fine details. A customer can spend more time driving the bigger picture.”

CardPak showcases its green capabilities to brands, offering a wide array of paperboard packaging products and formats that include blister cards, folding cartons, clamshell inserts, sleeves, skin board, and specialty displays. The company’s primary service, however, has become its EcoLogical Line of Packaging, which Budic says is “helping to guide contract packagers to sustainable packaging concepts and solutions for their customers and to address the concerns of major retailers regarding source and material reductions, as well as recyclability requirements.”

The line consists of ClubPak, SustainPak, and ShelfPak, which offer what Budic says is breakthrough design and sustainable material usage for a variety of industries.

Versatility
The nature of contract packaging—when a brand relies on an outside supplier—makes being versatile an all-important trait. And this versatility can manifest in a number of ways: speed, cost and capabilities.

“Due to the lean company structure of most contract packagers, production lines can be set up rather quickly, additional qualified personnel can be hired within 24 hours, and processes and procedures are easily adapted,” Identipak’s Woodin says.

Turnaround time is another aspect of the supply chain that brand owners hold in high regard. With versatile, streamlined production lines in the area of experience and expertise of the contract packager, additional shifts can be implemented when necessary to increase production output to meet a specific deadline.

Woodin also emphasizes that with the experience of the contract packager in a specific style and market of manufacturing, production efficiency is usually high, thus leading to lower costs. “The overhead costs of a contract packager are significantly lower than the outsourcing company. If the contract packager is located in a geographical location where labor costs are lower, such as South Texas, this factor will show through in the bottom line,” she says.

Many contract packaging companies promote their variety of services as a major asset. “The many services that we offer are the benefit itself. In other words, what we provide can allow a critical mistake such as a canceled or delayed launch, to be corrected in a timely fashion and returned quickly to the market,” says Paragon’s Burdick.

“An Accel strength is the variety of services we offer clients,” states Tara Abraham. “Manual and semi-automatic assembly is our primary capability. However, as we worked with our clients, we began to expand those capabilities to custom thermoform trays, automatic gluing, shrink wrapping/banding and flow wrapping. Additionally, we expanded our ‘value add’ services such as package design/engineering, drop and vibration tests, shipper/inner pack design, ribbon tying, gift wrapping, as well as sourcing/procurement.”

Maesa’s Mager emphasizes the benefits of a one-supplier situation. “One vendor means one company is responsible for timeline and quality. Fully integrated design and package development greatly increases speed to market and efficiency,” he says, adding that Maesa is known for its expertise in turnkey beauty and fragrance for specialty stores.

Maesa offers the full array of services required to successfully launch a beauty brand or product. Its capabilities include branding, design, comp creation, marketing, product development, packaging development, quality control, testing, and manufacturing. “Maintaining all of these talents, expertise and services under one roof allows us to streamline the development process for our clients,” Mager says.

Educating Clients
The sometimes vague, muddled definition of contract packaging can sometimes be a roadblock to potential customers. “Perhaps the greatest notable challenge is educating customers on how wide a range of services exists within contract packaging,” says Whip Smart’s Mondello.

Abraham notes that for Accel, it can be hard to communicate its end-to-end capabilities and break away from the perception that contract packagers only provide value at the end of the process…the packaging. “Because contract packaging is so diverse, when clients think of us, they often have differing perceptions. One client may think, ‘They are that company that does our gift sets,’ while another client thinks, ‘They flow wrap our kits.’ It’s up to us to cross sell those capabilities to both current clients and potential clients; if we don’t, they won’t see the benefit of our diverse offerings.”

Communicating is critical to contract packaging success, and it’s paramount that suppliers and brand owners are on the same page.

“One challenge that we run into quite often is the unrealistic expectations of clients, which is due in part to poor planning on their end,” says Wertkin of Cosmetic Solutions. “The challenge becomes trying to align the reality of the situation with the customer’s needs and wants. And this mostly relates to lead times.

Woodin concludes, “It is very important to conduct detailed contract reviews to avoid misconceptions or assumptions that can lead to poor quality results.”

Despite the Recession
In light of the economic downturn, the contract packaging space has continued to grow. In fact, it’s been suggested that—for some—the recession’s effects have perhaps provided a boost.

“As businesses continue to look to streamline their operations, the growth of outsourcing will continue,” says Wertkin. “The recession kind of fragmented the industry a bit, as we found that many large-scale contract packagers hit tough times when their clients began to scale back their runs below MOQ (minimum order quantity). Many of the small- and medium-sized players in the industry reaped huge benefits from this and were able to experience serious growth.”

“A recession actually benefits contract packagers and manufacturers due to the fact that larger companies tend to slim down in all areas possible and in turn, increase their outsourcing to leaner companies,” says Woodin. “Simply put, in today’s economy everyone is thinking about ways to save time and money; this benefits companies like ourselves.”

If anything, the recession has forced CPG companies to reevaluate their breadth of influence, operations, and cost. “And that,” Budic says, “is where the contract packaging companies can become extremely valuable and primed for growth.”

Sustainable Management Expert Presents at Pack Expo 2010

2010-11-15T20:46:00.003-05:00

Sustainable Management Expert Presents at Pack Expo 2010

Dr. Ron Nahser, Senior Wicklander Fellow at DePaul University, addresses 200 at packaging and processing industry’s annual conference.

SOLON, OH – November 15, 2010 – Two hundred consumer packaged goods executives, suppliers, contract packagers, educators, and trade association personnel gathered at Chicago’s Adler Planetarium on November 1st to attend the 4th Annual Environmental Expo sponsored by CardPak, Inc., a leading supplier of sustainable packaging for consumer marketers.

The keynote speaker, Dr. Nahser, a Senior Wicklander Fellow at DePaul University’s Institute for Business and Professional Ethics, Managing Director for CORPORANTES, Inc., an outgrowth of the Nahser Agency/Advertising, and Provost Emeritus of Presidio School of Management, San Francisco, offering the first accredited MBA in Sustainable Management, urged the audience to consider what sustainability challenge or opportunity faces them; why it’s important; and what action they’ll take now.

Tony Petrelli, CardPak president, kicked off the evening by reaffirming the industry’s responsibility to identify environmentally friendly alternatives to traditional packaging. CardPak, a leader in the development of sustainable packaging concepts, has created the EcoLogical Line of Packaging to remove significant amounts of packaging materials from the waste stream and use 100% recycled materials when possible.

-- CardPak, Inc.

NextLife Packaging Group Announces Partnership with CardPak to Provide Sustainable Paperboard Packaging Solutions

2010-10-31T22:20:00.011-04:00

NextLife Packaging Group Announces Partnership with CardPak to Provide Sustainable Paperboard Packaging Solutions

CardPak is the First NextLife Packaging Group Paperboard Packaging Manufacturing Partner

Press release from NextLife - Boca Raton, FL, November 01, 2010: NextLife, a leading provider of sustainable solutions for the consumer packaged goods industry, announced today a partnership with CardPak, a leader in custom engineered packaging designs and solutions for merchandising strategies that utilize carded packaging and specialty paperboard converting. Through the partnership CardPak will become the first carded packaging converter to promote NextLife Packaging Group’s 100% PCR PET blisters for club and warehouse retail packaging.

Through a select network of manufacturer partners, NextLife Packaging Group provides a unique range of sustainable packaging solutions to consumer product companies, retail brands and retailers. The NextLife Packaging Group network provides branded packaging, resins and materials containing up to 100% post-consumer recycled (PCR) content for both food and non-food applications, backed with life cycle assessments and a wide range of marketing support.

“We are pleased to expand our roster of preferred partners committed to offering high quality, substantiated and practical sustainable packaging solutions,” said Marc Goldenberg of NextLife. “CardPak is well established, has built a positive reputation in the marketplace and has been committed to offering sustainable paperboard packaging for many years. We are confident they will be a valuable addition to our portfolio of best-in-class providers throughout the packaging supply chain.”

“Our clients have been very satisfied with using NextLife’s 100% PCR PET for blisters and clamshells with no change in performance, quality and consistency when used in conjunction with our cards or ClubPak™ products,” said Tony Petrelli, president of CardPak. “We see great value in forming this partnership, which will allow us to offer a range of solutions encompassing more than just materials. Our clients can take advantage of the unique strengths that both NextLife and CardPak have to offer.”

CardPak is exhibiting at Pack Expo 2010, in Chicago, IL the week of October 31, 2010. The company is located at booth #5939, in the Lakeside Upper Hall. On display will be their wide range of sustainable products including the ClubPak™ and SustainPak™ products, part of their award winning Ecological Line of Packaging™.

-- CardPak, Inc.

Worldwide leader CardPak places order for KBA Rapida 106 41" ten-color press

2010-09-23T12:05:00.008-04:00

Worldwide leader CardPak places order for KBA Rapida 106 41" ten-color press

Press release from the issuing company

KBA North America, a global press manufacturer based in Dallas, Texas, announces that CardPak, Inc., a leading supplier of packaging products to consumer brand companies across the globe, has placed an order for a new KBA Rapida 106 41-inch ten-color perfecting press with coating tower and twelve-foot extended delivery. The new KBA press is currently being built and will be installed at CardPak's headquarters in Solon, Ohio in mid-November of this year.

"In the past three and a half years, we have completely transformed our company," says Tony Petrelli, president of CardPak. "We've established a strategic plan that has improved our operations so that we can practice lean manufacturing and produce environmentally sustainable packaging products. This plan has taken us to our full manufacturing capabilities and the installation of our new KBA Rapida 106 41-inch ten-color press will open up 20% to 25% more capacity in our facility."

The new Rapida 106 41-inch ten-color perfecting press being installed at CardPak, which made its debut at DRUPA 08, features a high press speed of 15,000 sph output, ultrafast makeready times, and expanded automation and productivity. The press provides a wide choice of automation options, including the KBA DriveTronic dedicated drives, as well as the DriveTronic feeder, with its presetting capabilities. The press also features the GATF InterTech award–winning sidelay-free infeed, DriveTronic SIS. Its KBA Logotronic system allows for presetting of ink fountains. New technology on press also includes the KBA Densitronic Professional closed-loop color management scanning spectrophotometric system and Qualitronic In-Line Color Control. The substrate range runs from lightweight papers to heavy board, from plastic films to corrugated-all without adjusting any grippers. At DRUPA and PRINT 09, the Rapida 106 continued to execute the fastest make-ready times for multiple jobs in front of the show crowds.

Before CardPak chose to purchase its new KBA press, the firm performed diligent review of all of the press models on the market. As part of this year-long evaluation process, Greg Tisone, CardPak's vice president and general manager, and Mike McDonald, CardPak's printing department manager, spent countless hours researching all the press manufacturers. They made multiple trips to demo centers watching their jobs run on presses; checking make ready times, run speeds and perfecting tolerances. "All of the manufacturers had very good products. This made the decision even harder to make," states Tisone. "We took our pressman to see the KBA press in action. We talked to field operators and observed actual manufacturing environments. We could see and discuss the KBA Densitronic and Qualtronic inline quality control system at work. All of the KBA customers that we visited gave high marks to KBA, their presses, the technology, and their service packages. It made us feel very comfortable purchasing the KBA Rapida 106."

CardPak, Inc., a pioneer in developing sustainable packaging solutions, is a leading supplier of packaging products to consumer marketing companies across the globe. The company is committed to creating new innovative products and practicing lean, environmentally-friendly manufacturing. CardPak's world headquarters are located in Solon, Ohio.

KBA North America is a member of the KBA Group, a leading global supplier of sheetfed, webfed, and digital offset presses located in Dallas, Texas. KBA is dedicated to excellence in printing technology. The company's greatest satisfaction comes from helping its customers succeed by building presses that enable their businesses to prosper. From engineering through production, KBA's focus is on people, providing flexible technology, customized printing solutions, and personal service to help its partners differentiate themselves and be successful today and in the future.

-- CardPak, Inc.

CardPak Increases Versatility, Capacity and Efficiency with New Bobst VISIONFOLD

2010-07-23T07:59:00.018-04:00

CardPak® Increases Versatility, Capacity and Efficiency with New Bobst VISIONFOLD

Solon, Ohio – (Press Release) – Printer/Packaging manufacturer CardPak, Inc. (www.cardpak.com) has added a new Bobst VISIONFOLD 110-A2 folder-gluer giving themselves greater capacity and versatility, while further streamlining and enhancing the efficiency of their manufacturing operation.

Specializing in creating paperboard alternatives to plastic packaging, CardPak provides their customers with creative packaging solutions that not only give them an advantage on the shelves, but help them meet their goals, and demands of retailers such as Costco and Wal-Mart, of creating “greener” packaging and reducing their carbon footprint.

“With products such as our ClubPak®, SustainPak®, and ShelfPak® providing sustainable alternatives to plastic clamshells, we can typically reduce the plastic materials used by 85%. That makes a significant environmental impact on the sustainability and packaging scorecards.” says CardPak President Tony Petrelli.

In addition to seeking creative, environmentally friendly packaging solutions, CardPak’s customers, like virtually everyone today, are concerned about turnaround times and price. “Efficiency is very important to the sustainability of both our and our customers’ businesses. We put a great emphasis on lean manufacturing in our continual quest to improve the efficiency of our operations,” says Petrelli. “I like to say, ‘We want to do more with less until we are doing everything with nothing.’ While no one can do everything with nothing, my point is that we are continually working to improve the efficiency of our operation. When we think we’ve eliminated all the waste we can, we step back and start looking for more ways to save without jeopardizing the quality of our services or the products we produce.”

The pursuit of optimum efficiency, the desire to offer brand owners additional marketing options and to further diversify their own business were a few of the driving forces behind CardPak’s decision to add the new Bobst VISIONFOLD. “Blister cards were about 90% of our business, now they’re only about 50%. Not because we’ve reduced that business sector, it continues to grow, but because we’ve expanded and grown into other markets by adding capabilities and increasing our manufacturing capacity. Folding carton is one of the areas we’ve expanded into. Adding the VISIONFOLD allowed us to eliminate a bottleneck and allows us to perform more complex folding. The installation also gave us greater versatility within the operation and allowed us to open 20-25% of additional capacity. In addition to letting us put more through the plant, it gives us the ability to respond to our customers’ requests faster."

As well as their environmental packaging products, CardPak provides a wide range of products to their customers including blister cards, clamshell inserts, folding cartons, skin boards, specialty printing and much more.

Because efficiency and lean manufacturing are major focuses of CardPak, the VISIONFOLD’s fast and easy setup and ability to fold a wide range on materials including carton or solid board, up to 8 point stock, as well as mircoflute corrugated paperboard, and other materials, at speeds up to 1,150 ft/min made it the perfect addition to CardPak’s finishing department.

CardPak’s VISIONFOLD is configured to fold a wide a range of products including straight-line and crash-lock cartons, CD/DVD sleeves and much more. CardPak also performs other value-added services with their VISIONFOLD such as the inline application of Electronic Article Surveillance (EAS) devices and insertion operations. “The more we can do in a single pass in any operation, whether it’s manufacturing, material handling or even sales, the more efficient we become overall. Then we can share this efficiency gain with our customers in the form of sustainable pricing and shorter time to market which provides additional savings for customers by reducing products in stock and work in process.”

The addition of the VISIONFOLD is part of a capital investment program which includes the addition of a new state-of-the-art 40 inch, 10-color sheet fed press which will be installed later this year.

-- CardPak, Inc.

CardPak + TICCIT Program on Earth Day

2010-04-27T11:00:00.015-04:00

CardPak, Inc., The Paperboard Packaging Council and Solon Schools team up on Earth Day

Organizations sponsor TICCIT – the trees into cartons, cartons into trees program for 4th graders at Roxbury Elementary School.

Solon, Ohio – (Press Release) – CardPak, the pioneer in developing and manufacturing environmentally-sustainable packaging, donated tree saplings to teach Roxbury Elementary school students about the natural renewability of paperboard packaging. Tony Petrelli, President of CardPak, and the Chairman of the Board of the Paperboard Packaging Council, explained “we’re thrilled to once again have the opportunity to teach elementary school kids about paperboard as a renewable resource and its recycled potential.

The TICCIT program (Trees Into Cartons, Cartons Into Trees, pronounced “ticket”) is a great way to demonstrate how fun and easy it is to take care of the Earth.” Fourth graders brought paperboard milk cartons from home and CardPak donated over 100 saplings and soil. The students planted the saplings in the paperboard cartons. At home, the students poke holes in the carton and plant it directly in the ground. The cartons provide protection and a natural water funnel for the new trees. As the trees grow, the cartons breakdown and provide a natural biodegradable fertilizer. This completes the trees into cartons, cartons into trees cycle. “It’s a great opportunity to engage the future leaders of America in a fun and earth-friendly activity”, said Mr. Petrelli.

The TICCIT program celebration took place on April 21st at Roxbury Elementary School, located just 2.3 miles from CardPak’s worldwide headquarters. Roxbury Elementary School Principal, Carla Rodenbucher, was pleased to receive CardPak’s donation of over 100 tree saplings in celebration of Earth Day. “At Roxbury, we’re all about providing our students with hands-on learning opportunities like the TICCIT program. What better way to teach kids about the benefits associated with paperboard recycling and planting trees, than providing them with the materials to make it happen?” explained Ms. Rodenbucher.

As a follow up to the TICCIT activity, students in the 4th grade advisory council are visiting CardPak’s printing and manufacturing plant to see, firsthand, how environmentally sustainable packaging is made.

-- CardPak, Inc.

CardPak Wins Local Awards

2009-12-22T13:20:00.008-05:00

CardPak Wins Local Awards

Recognized for Commitment to Workforce and Community

Solon, Ohio – (Press Release) – CardPak, Inc., a supplier of innovative packaging products to consumer marketing companies, invests a great deal in its workforce, and it’s not all about capital improvement. The company is consistently recognized for its commitment to being a great place to work and a strong member of the local business community.

“Our business philosophy at its core creates a culture that develops top performers and recognizes community needs. CardPak believes that each employee contributes directly to our business growth and success, and our responsibilities in the community.” said Tony Petrelli, president. “By providing career opportunities, rewarding performance and creating a pleasant working environment, we encourage people to excel for the company, the industry and the city in which we work. The future of CardPak has people at its core.”

The company also is committed to a program of environmental responsibility, along with a strategic commitment to sustainable practices and products. These were key components of CardPak’s business model for many years prior to the rise of today’s “Green” movement. CardPak felt it critical to develop an organization that would establish policies and objectives that would protect the environment, benefit its employees’ health and safety, and provide a more efficient way of manufacturing.

As a result of all these initiatives, CardPak recently was named to the “NorthCoast 99” Best Places to Work in Northeast Ohio for the 10th straight year, and was also named 2009 Business of the Year by the Solon, Ohio, Chamber of Commerce.

NorthCoast 99 is a recognition program sponsored by the Employers Resource Council (ERC) that honors 99 great workplaces annually. Since 1999, the program has recognized over 400 organizations for their ability to maintain great workplaces that support the attraction, retention, and motivation of top performers.

“We are honored to receive this prestigious award in our home market, and we thank the ERC for recognizing our efforts to be one of the top workplaces in Northeast Ohio,” said Petrelli. “This award validates everything we strive for everyday.”

CardPak also was named 2009 Business of the Year by the Solon Chamber of Commerce, which cited the company for ably handling many challenges, including responding to natural disasters and developing manufacturing practices and products that address environmental concerns and objectives.

“We couldn’t have done any of this without the dedication and commitment of our valued employees,” Petrelli added. “They are at the heart of everything we do each day.”

-- CardPak, Inc.

Apple highlights packaging reduction efforts in green report

2009-10-22T08:14:00.004-04:00

Apple highlights packaging reduction efforts in green report
Simeon Goldstein, packagingnews.co.uk, Sept 2009

Computer manufacturer Apple has released details of its work to reduce packaging in a report looking at the environmental impact of its products.

The life-cycle analysis show all greenhouse gas emissions associated with Apple products including raw materials, manufacturing, transportation and a three- to four-year period of consumer use and subsequent recycling.

Apple has reduced the packaging for its MacBook Pro laptop by 40% since 2006, meaning 50% more products can be shipped in each airline shipping container, the equivalent of using one less jumbo jet for every 32,000 units shipped.

"These reports help educate our consumers about how Apple products affect their own environmental footprint and track out progress to reducing greenhouse gas emissions with each new product," Apple said in a statement.

Each report breaks down the packaging into its component parts. So, for instance, the iMac desktop retail box consists of 1.7kg of corrugated and paperboard, 415g of expanded polystyrene and 18g of LDPE.

An iPhone in the US is packaged in 136g of paper packaging and 17g of thermoformed polystyrene. It is now 28% lighter and 23% smaller than last year.

For more on the product environmental reports, click here to visit the Apple website.

-- CardPak, Inc.

Sustainability Leader Discusses Innovation at 2009 Environmental Expo

2009-10-16T12:08:00.002-04:00

SOLON, OH – (Press Release) Nicholas Rumanes, vice president of development for the Las Vegas Sands Corp., spoke at the 2009 Environmental Expo: An Education in Sustainability dinner during CardPak Inc.’s annual Pack Expo event at the Palazzo Resort in Las Vegas, Nevada. CardPak is a leading manufacturer of environmentally sustainable packaging products, headquartered in Solon, Ohio.

The dinner attracted nearly 125 attendees, representing some of the pre-eminent retailers, consumer packaged goods companies, packaging manufacturers, contract packagers, educators, media and packaging trade associations nationwide.

“We chose the Palazzo for our annual dinner because the Las Vegas Sands Corp. has led the way in sustainability,” explained Tony Petrelli, president of CardPak. “Its dedication to the environment echoes our standards and mission here at CardPak, and we couldn’t have selected a better place to discuss the future of sustainability in our daily lives.”

Rumanes spoke about founding and operating Las Vegas Sands Corp.’s sustainable development practice, which achieved a Silver LEED rating for the Palazzo Resort. Rumanes is an expert on sustainable building practice and has worked on similar projects for clients such as GE, Equinox, ABC, Disney, Omnicom and SAP.

The Palazzo is not only the largest LEED-certified building in the world, but it is more than four times bigger than the second largest. More than 41.6 million gallons of water are conserved annually, which is enough to fill 63 Olympic-sized swimming pools. Enough electricity to power more than 700 homes a year is also conserved at the Palazzo. And perhaps the most impressive statistic is the facility’s waste conservation: approximately 42,000 tons of construction waste is diverted from landfill to recycling, which is the equivalent to a stack of cars 23-miles high.

-- CardPak, Inc.

5 Secrets of My Success: Tony Petrelli

2009-09-06T08:55:00.001-04:00

5 Secrets of My Success: Tony Petrelli
Secrets of my success from legacy winner Tony Petrelli, president and COO of CardPak.
By Eric Broder

When Tony Petrelli joined CardPak in 2006, the company was facing plenty of financial challenges.

During its 44-year history, the paperboard packaging firm had weathered much adversity, including a flood in 1994 and a 1996 fire that destroyed the company’s equipment and forced it to temporarily close. CardPak was rebuilt in 1998, moving from Cleveland to its current Solon digs.

But the company was deep in debt. Something had to change. The owners knew that operating changes and procedural efficiencies on the floor had to be made to save the company — and then to keep it competitive.

Enter Petrelli. Under his leadership as president and COO, CardPak returned to profitability in one year.

“Even through difficult times, this was a culture that grew up as a family,” says Petrelli. For many workers, CardPak was their first job out of school. Many had been working together for more than 20 years. They weren’t just co-workers, they were an extended family to one another, Petrelli explains. It made for a good workplace: When he arrived, CardPak had already nabbed six NorthCoast 99 awards. And Petrelli didn’t want to break that streak.

* Don’t come in guns blazing. Petrelli, a packaging industry veteran, had worked primarily with larger companies of 6,000 or more employees. The team of 125 at CardPak was much smaller and carried that friendly, family atmosphere. Floor shop employees needed to work “faster, smarter, better” to make packaging products more efficient, so Petrelli introduced new, lean manufacturing processes. But “I had to make sure I didn’t come in as a gunslinger. I realized I had to change the culture without changing the people. This was a strong group that worked hard even in tough times. I didn’t tell them to change,” Petrelli says. “I asked.”

* Communicate with care. Be careful what you say and how you say it in a more intimate environment. Written memos and e-mails don’t get the point across like a message delivered personally, and it helps to avoid misunderstanding. “Tell them what you’re going to tell them — then tell them what you told them,” says Petrelli. Tell them as many times as it takes to make sure they understand the message clearly and completely. “You can never overcommunicate to a group.”

* Safety first. Accidents will happen in heavy machinery plants — back strains, cuts, tripping over cords, electric shocks. But with Petrelli’s introduction of new manufacturing methods, along with retooling work areas and keeping them clear, safety has greatly improved at the plant. The change is highlighted by a traffic light on the CardPak shop floor. A green light indicates no workplace incidents the previous day, yellow denotes a near miss, and red means an accident occurred. No one’s seeing red now: After upping safety measures, CardPak has gone from double-digit annual incidents to the top five in safety for facilities its size in the nation. That is good for both morale and business. “It’s singularly impacted the profitability of the company,” says Petrelli.

* Nurture confidence. Company stability, especially now, is important for maintaining employee morale. Compelling new products provide the opportunity for profitability, and CardPak’s sustainable alternatives to clamshell packaging fit with the ecological demands of large retailers such as Costco and Sam’s Club. The company had a record year in 2008 and is ahead of the pace in 2009. “The bad economy is no excuse,” says Petrelli. Competitors are waiting for the clouds to pass, he says. “We set out fans to push ’em away.”

* Learned behavior. Petrelli has learned something about himself in his time at CardPak. “I find myself taking more pride in seeing an employee develop,” he says. “I’ve learned to give credit to those who help me reach my conclusions. And people have responded. The key is passion and enthusiasm.”

-- CardPak, Inc.

Recycled-paperboard symbol gains with sustainability popularity

2009-07-10T12:55:00.002-04:00

Eighteen major consumer product goods companies sign on to use RPA-100% logo in first half of 2009.

PRESS RELEASE -- Converting Magazine

The 100% Recycled Paperboard Alliance announced that a record number of new licensees have signed up in the first 6 months of 2009.

During the period January 1st through June 30th, 18 of America’s best known brand owners ave chosen to sign a license agreement with the RPA-100% granting them the right to display the RPA-100% symbol on their packaging. In making the announcement Paul Schutes, Executive Director of the RPA-100% commented that, “this puts our organization on a pace to add 40 new licensees by the close of 2009, exceeding any previous year’s total new licensees and exceeding our goal for this year.”

These new licensees include companies such as Harland Check, Nestle’ Purina Petcare and Snyder’s of Hanover. New licensees are using 100% recycled paperboard to package organic foods, pet food, snacks, office supplies and even to manufacture coffee cup insulating sleeves. Mike Kiepura, Chairman of the Board of the RPA-100% noted that, “this high number of new licensees proves that today’s brand owners are increasingly interested in communicating to their customers that the products they are purchasing are packaged in 100% recycled paperboard. We are encouraged by this level of activity and are confident that 100% recycled paperboard and the use of the RPA-100% symbol will continue to play a key role in the drive for more sustainable packaging and the education of consumers with regard to the value of recycled paperboard packaging.”

The 100% recycled paperboard symbol is owned by RPA-100% and is reserved exclusively for licensed use on products and packaging made with 100% recycled paperboard. Use of the symbol is free for licensees of RPA-100%. Currently more than 150 companies have signed licensing agreements to display the symbol and become RPA-100% partners. More information on licensing the symbol is available on the RPA-100%. Website at www.rpa100.com.

Consumer packaged goods companies have used 100% recycled paperboard for more than 100 years. Recycled paperboard plays a pivotal role in making fiber based packaging one of the most environmentally beneficial and sustainable packaging substrates. Today, 100% recycled paperboard is used to package a wide range of goods including food (dry, frozen, ready-to-eat, microwave and fast food), beverages, pharmaceuticals, electronics/software and other consumer products. Nationally known names such as FedEx Corporation, Kraft, General Mills, Kellogg’s, Procter & Gamble and Reynold's Consumer Products, a division of Alcoa Consumer Products, are just a few of the companies using 100% recycled paperboard for their products.

The 100% Recycled Paperboard Alliance (RPA-100%) is a non-profit, independent trade group representing the leading manufacturers in the recycled paperboard industry since 1995. Based in Washington, D.C., RPA-100% serves as an information resource on the benefits of recycled paperboard and provides assurance of the recycled content of consumer packaged goods through its 100% recycled paperboard logo licensing program.

-- CardPak Inc.

Debunk five eco-packaging myths

2009-06-26T07:21:00.001-04:00

The following thoughts can help you correct some of the commonly quoted inaccuracies for your packaging-material customers and their consumers.

By The Benson Group -- Converting Magazine

In these days of environmental focus, nothing seems to arouse the passions like food and medical packaging. Unfortunately, much of the "bad news" that circulates on the topic is based on myth and hearsay. Maybe some of the following thoughts will help to correct some of the commonly quoted inaccuracies for your packaging-material customers and their consumers.

Myth 1: Food Packaging is filling our landfill sites
Publicly available information suggests that the total volume of waste produced from all sources in the UK per year is about 300 million tons. Only some 10% of this is accounted for by household waste - about 27 million tons. Building sites, as one good point of comparison, produce about four times as much rubbish as households. Packaging of all types represents some 4.5 million tons of household waste, and the amount actually due to food packaging is likely to be no more than 1 million tons. The weight of food packaging per person is less then 44 lbs per year.

Compare that 44 lbs of packaging with the 220 lbs per person per year of food waste that is put straight into the wastebin, and you begin to see that packaging is actually the least of our worries. The environmental impact of the food waste is compounded by the fact that the vast majority of this is also dumped into landfills. Food going to landfills will gradually rot and produce methane - a gas of significantly greater concern regarding global warming than CO2.

Myth 2: Everything is over-packaged
While there may be some mileage in this statement in certain sectors, food is unlikely to be one of them. The protection offered to food products by packaging provides a significant benefit, as illustrated by statistics from the World Health Organisation, which suggest that food waste in the Third World can be as high as 50%, while in developed economies as low as 3%. Much of this difference is due to good quality packaging. Under-packaging is 10 times worse for the environment that the same amount of over-packaging, as 10 times more energy and material resources go into the production of goods and food than into their packaging.

Additional fuel in favor of sensible packaging is provided by the Cucumber Growers' Associated, which showed that unwrapped cucumbers are unsaleable after three days. Plastic wrapping keeps them fresh for 14 days and untouched by dirty hands.

Cleaner and fresher produce and foodstuffs less likely to be damaged during transportation equals product less likely to be thrown straight into the wastebin. Smarter shopping and cooking, and more focus on producing less food waste is far more likely to provide the answer to environmental issues than simply reducing packaging.

Myth 3: Cardboard packaging destroys trees
An unfortunate perception of the print and packaging world is that it "eats trees." In fact, of the world consumption of wood only 12% is actually used for the manufacture of paper and board, and of this, just one tenth is used for cartons. Over half the cartons used in Europe are manufactured using recovered fiber from waste paper.

In Europe, over 90% of the wood needed by the paper and board industry comes from European forests, and responsible packaging producers ensure that their purchases are made from FSC- and PEFC-certified suppliers, which means that any new wood used has come from responsibly managed forests. Overall there are more trees planted than felled in Europe, and as forests absorb CO2 they combat greenhouse gases, and therefore have a positive effect with regard to climate change.

Myth 4: Burying plastic is harmful to the environment
OK, time for a bit of a controversial thought now. Anything that is taken to landfill and rots will give off methane - fact! Methane, as already mentioned, is a significantly harmful gas in environmental terms, and is the probably the weakness of the argument for so called "degradable packaging." While no one likes the idea of burying plastic, it will not rot, and therefore represents less of a climate-change issue than burying food waste or even paperboard and paper (which will also rot, but should, of course, be recycled instead). This text is not advocating burying plastics - just pointing out that actually in some ways it's not as bad for the environment as burying other things.

Myth 5: Not enough packaging is being recycled
This might appear to be another controversial comment to describe as a myth, but the statement does require further analysis to extract the real truth. Some packaging materials are more difficult to recycle than others, and some are particularly expensive or energy-inefficient to recycle. Generally speaking, cartonboard is easy to recycle, and an ever increasing percentage of the population is doing so on a daily basis. Boxes and cartons are easy to disassemble and place into the recycling bin for collection, as is probably typical across much of the country. Paperboard that is not recycled will at least compost easily. More cartonboard/paper is recycled than any other packaging material. Once recent claim suggested that recycled waste paper represented around 63% of the fiber used to produce paper and board in the UK.

Summary:
Food packaging represents a small fraction of UK waste
Food waste is significantly higher in terms of volume
Food waste is also significantly more damaging to the environment
Good packaging helps to prevent more waste
Paperboard packaging is produced from sustainable resources
Paperboard packaging is easy to recycle, and is being recycled

-- CardPak Inc.

Shifting to Sustainable Packaging

2009-06-10T12:15:00.008-04:00

PMMI VP Industry Relations, Ben Miyares, kindly agreed to participate in a Q&A with packagedesign.com on sustainable packaging materials, energy-saving equipment and the upcoming PACK EXPO trade show (October 5-7; Las Vegas Convention Center).

Q: What attributes define a sustainable package?
A: Sustainability is often misunderstood and can be confusing when applied to packaging. In essence, it is having the tools in place to continue operating into the next generation. I like to use the following definition for sustainability: Resource, Conservation and Replenishment.

It is sometimes easier to think of sustainability in terms of farming and fishing. For example, salmon are at risk of being fished out in the Northwest, so the government has imposed a moratorium to give the fish time to breed and replenish themselves. The idea is that you control the eco-system so that it has time to replenish itself.

However, when you apply the concepts of sustainability – resource, conservation, and replenishment – to packaging, it becomes a different matter. Packages and systems themselves do not have a regenerative capability. And the term “sustainable” has been applied to packaging without precise definition and guidelines. It has evolved into a discussion of the environmental friendliness of packaging. That is, people equate “green packaging” with “sustainable packaging” and as a consequence, some in the packaging supply chain believe – mistakenly we feel that this will be a transient movement.

Q: Is there a governmental or industry organization that supervises or regulates sustainable packaging to assure consumers of the integrity of sustainability claims?
A: Currently, there is no official government arbiter of sustainability in the U.S. The Environmental Protection Agency (EPA) would be the default regulator of environmental issues. The Federal Trade Commission (FTC) monitors market claims, including sustainability claims. If you say a product is made of recycled content, the FTC takes the position that it must be made of 100% recycled content. If it is anything less than that, you better spell out the percent.

In Europe, there is a clearer definition of what they consider sustainable packaging. They equate “sustainability” with “environmentalism,” so certain materials are perceived to be better than others because they are intrinsically less harmful to the environment in the minds of those who issue the guidelines.

Q: If there are no regulatory institutions overseeing these procedures, what’s to prevent manufacturers from abusing the term “sustainable” for marketing purposes while their procedures could be far from it?
A: The introduction of the Wal-Mart scorecard at PACK EXPO in 2006 has been the greatest change agent and driver of interest in packaging sustainability. The company has become the de facto regulator or standard setter simply because of its enormous impact in the marketplace. Wal-Mart accounts for a very large percentage of Fortune 500 CPG sales and figured out how to develop a distribution system that is more efficient than its competition. The company’s goal is to reduce packaging of products sold in its stores by 5% by 2013.

With the establishment of the scorecard and its various components, Wal-Mart has been able to encourage suppliers to reduce the size of their packages. From a design standpoint, one of the early success stories that Wal-Mart points to is the introduction of Unilever’s All® Small & Mighty™ triple-concentrated detergent. The concentrate in the 32-ounce bottle cleans as many loads as 100-ounces of unconcentrated liquid detergent, but in a more compact package that's easier to pour, store and carry. The bottle also uses less plastic in its packaging, less water in its formula than regular detergent and fits into smaller cases, saving on corrugated. And, more of these smaller cases can be stacked onto a conventional pallet for improved cube efficiency throughout the distribution pipeline.

Wal-Mart instructs its category buyers to use scorecard scores as an element in purchasing decisions. Still, Wal-Mart makes it clear that the scorecard will not be used to make bad purchasing decisions. At the end of the day, that suggests that a ketchup package with a better scorecard score but lower consumer preference will probably not push off Wal-Mart’s shelves the brand/package that the market prefers, and get a high rate on the scorecard, would I replace the category leaders on the shelf? Probably not.

Q: When people think of sustainability, they often think of the material itself. How does packaging machinery contribute to the sustainability equation?
A: In the discourse about packaging sustainability, you don’t hear much about packaging machinery. And that is really a major omission. Greenhouse gas counts for 15% on the Wal-Mart scorecard and a company’s energy footprint and emissions are seen as contributing to environmental damage. The package sitting on the shelf is not emitting much GHG. It’s the MANUFACTURING process of that package and the distribution system that contributes significantly to the package’s sustainability imprint.

Sustainability is part of the DNA of packaging operations managers. Typically at inception they will over-package a product, often protecting it more than it requires. But once a product begins to succeed in the marketplace, the first initiative that the packaging department is challenged with is, “how can we reduce the weight of that package without compromising its impact on the shelf?”

That is the type of message that will resonate at PACK EXPO in October. Technology advances will vary, ranging from let’s say a machine that can bundle a 6-pack of product with a thinner film that won’t break or one that reduces the amount of material needed, to systems that demonstrate a much longer Mean Time Between Repair (MTBR) so that they don’t break down as much. These are all important messages to decision-makers because in some categories, a minute of lost production can equate to tens of thousands of dollars per line.

Q: How will the sustainability trend be reflected at PACK EXPO this year? What resources can designers, CPG’s and retailers expect to find that will help them achieve sustainability goals?
A: At PACK EXPO, attendees will find many machinery and materials exhibitors highlighting technologies that use fewer resources and some that may in fact replenish them.

Hartness International (Greenville, SC) is a good example. The company has evolved into a machinery manufacturing company from a traditional packaging manufacturer and has numerous sustainability messages, such as remote diagnostics for repair of downtime and damages. The company has determined that 90% of the problems that occur can be addressed and repaired remotely over the phone and Internet. That reduces the time, cost, fuel consumption, etc. of a repair technician being there in person. Additionally, Hartness has a dry lubrication system that uses ounces of water in the course of production instead of the thousands of gallons traditionally used to lubricate a conveyor line in a can/bottle line.

Companies exhibiting materials at PACK EXPO will have the classic sustainability stories to tell in terms of lightweighting, increased use of recycled material, reusable palletization and tertiary packaging. For example, CHEP, started in Australia after WWII, is now global and provides a much more robust wooden pallet and service program to reuse that pallet. There are alternatives, including plastic or metal pallets that because of the nature of their composition can make a lot more trips. The initial cost may be higher, so on the surface, one may not want to invest more for these materials. However, if that metal pallet will make a lot more trips, you get into a concept that is sustainable without ever mentioning the environment, and that is considering the total cost of ownership of a technology.

Q: What are some of the newest packaging materials that you’ve seen and are excited about?
A: There are four core materials used in packaging – paper, metal, glass and plastic – where advances continue to be made.

In the plastics area, we have seen the emergence of biopolymers, or plastics derived from plants vs. geologically derived plastics. They have created a lot of buzz but are not quite ready for prime time. The principle biopolymer material that is currently being used in packaging is a PLA formulated by NatureWorks. It is derived from corn right now, although the company is talking about going from the corn we eat to “cellulosics,” the leaves and stalks of the plant.

The Dow Chemical Company also makes a monopolymer polyethylene and copolymer of polyethylene, used for milk bottles and laundry detergent respectively, from sugar that chemically functions as an equivalent to traditional petrochemical derived polyethylene. So they break down sugar to its chemical component and from there build a polyethylene that is chemical and functional equivalent of petrochemically derived polyethylene, virtually the same. From there we would potentially have a source of renewable plastic, which is really exciting.

I recently saw a thermoformable structure that looks like plastic but is made of “stone” where they take geologically derived components and press them in a form that is usable for packaging. Additionally, Cornell University has started a company called NOVOMER that is introducing eco-plastics or eco-polymers, as opposed to biopolymers. These plastics are not derived from plants, but instead from carbon monoxide and carbon dioxide. While still in early development, this approach could help address the greenhouse gas problem and create a source of feedstock for these polymers.

In the metal area, what is “new” are ever-lighter structures and shaped cans for added shelf appeal. For example, compared with 20 years ago, aluminum beverage cans are 28% lighter, steel food cans are 33% lighter and tinplate aerosols are up to 18% lighter – without sacrificing performance. In addition, new printing technologies result in photographic quality graphics or engage the senses, such as thermo-chromic inks that change color based on temperature, or feel soft to the touch.

In glass, the typical bottle is produced by a “blow and blow” blow technology that results in an irregular wall thickness, the thinnest part being the weakest. When breakage occurs, it breaks at its thinnest part, whereas a newer technology called “press and blow” does what it suggests: presses the mold so that there is a more even wall thickness and the result is a thinner yet stronger glass bottle.

Q. Do you think consumers have been over-hyped with the sustainability message by marketers?
A: Absolutely. To date we have seen a rash of certifications, brands and logos put on packages that are pretty meaningless to consumers. Some early studies indicate that the consumer has very little understanding of sustainability. The average consumer equates sustainability to recyclability. Further, they still prefer packages that are “recyclable” to those that are recycled.

There are probably 30 or 40 “green” or “sustainable” certification brands in the marketplace today. Most are pretty meaningless to the consumer due to lack of knowledge. They pick up a package and see chasing arrows with a number in it and they say “this is recyclable.” Unfortunately the industry has not done a good enough job clarifying for consumers that the numbers “1–7” are not recyclable codes, but rather resin identifiers.

About PMMI
PMMI is a trade association with more than 550 member companies that manufacture packaging and packaging-related converting machinery, commercially-available packaging machinery components, containers and materials in the United States and Canada. PMMI’s vision is to be the leading global resource for packaging, and its mission is to improve and promote members’ abilities to succeed in a global marketplace.

PACK EXPO will be held October 5-7, 2009 at the Las Vegas Convention Center. To register for the show or obtain more information, visit www.packexpo.com or contact PMMI’s Show Department at 703.243.8555 or expo@pmmi.org.

Posted on Monday, June 8, 2009 at 10:36AM by packagedesign.com

-- CardPak Inc.

Forming Green

2009-06-04T08:58:00.001-04:00

'Green thermoformer' - that is becoming an increasingly common label (or at least a popular goal) as the packaging industry continues to adjust to the market's demand on environmental awareness.

With films such as Eco-therm, distributed by IPF Inc., (a biodegradable, 100% Post Consumer Content, Recycled PET Film that is thermoformable) available and currently being used in the marketplace, thermoformers can now join in on the 'sustainable packaging' revolution and have a key ingredient to offer, instead of trying to fight the trend, and the inevitable.

Innovative Plastics South, located in Nashville, TN., is one company that has embraced this opportunity, with the directive of being recognized as one of the industry leaders... take a few minutes and check out their video below:

-- CardPak Inc.

Walmart joins GreenerPackage.com in new product database

2009-05-07T12:26:00.008-04:00

Walmart joins GreenerPackage.com in new product database
Posted by Anne Marie Mohan, Managing Editor, GreenerPackage.com

Walmart Stores, Inc. and its Packaging Scorecard software provider ECRM have tapped GreenerPackage.com to serve as the entry point for packaging material suppliers wishing to add their sustainable product data for use in Walmart’s Packaging Scorecard Modeling software. Upon launch of the Greener Package Database, product information submitted to the site will not only be available to GreenerPackage.com visitors, but it will also feed ECRM’s MarketGate™ application suite, maintained for Walmart’s private use with its modeling software.

In the following exclusive interview with GreenerPackage.com managing editor Anne Marie Mohan, Sam’s Club director of packaging Amy Zettlemoyer-Lazar discusses the agreement and the new Greener Package Database in more depth.

GP: Why did Walmart decide to ask ECRM to merge its database with Greener Package?
AZL: ECRM initially created MarketGate as a virtual trade show to support our Sustainable Packaging Expo by housing the packaging suppliers’ sustainability information. Greener Package has a broad audience of packaging professionals who may find this information useful, and therefore, merging the two seemed like a good fit of information and an audience.

GP: What are the benefits of this database to packaging suppliers?
AZL: With the Greener Package Database, packaging suppliers will have one place to post their company information, and it establishes a uniform way to talk about their packaging materials, their components, and any environmental claims associated with both.

GP: What are the benefits of this database to your product suppliers, i.e., consumer packaged goods companies?
AZL: CPG companies can use the database as a source to find more sustainable materials and packages, which ultimately provides our customers and members with more choices. Walmart Stores, Inc. holds an annual Sustainable Packaging Expo in Rogers, Arkansas, and this database allows suppliers who can’t travel to the exposition access to the same information year-round. Because it doesn’t require travel, the virtual trade show also provides an opportunity for us as a company to provide low-cost innovation.

GP: Can you explain how the data in the Greener Package Database will link to the Walmart Packaging Scorecard Modeling software?
AZL: The modeling software is currently used to compare packages for multiple environmental metrics. When the user makes material selections for comparison within the software, the product information is visible. So the system provides suggestions for packaging suppliers that can help improve their modeling score. For those product suppliers that are interested, when they compare their packages, they have a direct link to those packaging suppliers who can help them make that improvement.

For Walmart, it’s really important right now to push better packaging and more sustainable choices because Americans are being very thoughtful about the purchases they make. It’s really important to make sure that we are continuing to drive waste and inefficiencies out of the business, which is why more sustainable packaging plays a good role in that goal for us as a company.

At Walmart, efficiencies and sustainability go hand-in-hand. So our motto is really “Save money. Live better.” At Walmart, we are providing value through our products, and that value translates into quality and more sustainable products and more sustainable packaging. So we are driving more efficient products and more efficient packaging, and making better material selections, and that has a direct link into more choices and better-value products for our customers and members.

GP: The Greener Package Database will provide suppliers with the opportunity to have their product claims reviewed by a third party. Can you explain why this is important?
AZL: The Document Review process will verify that the information that the packaging supplier is sharing is being reported using industry-standard terminology, making sure that claims are being made in a similar manner across multiple suppliers. So when a CPG company looks at the site, they understand what’s being claimed, and there is no confusion between the way one supplier may make that claim versus another supplier making that claim. It’s important to verify what statements are being made or what claims are being made and how they could be interpreted by the CPG customer or a retailer. Then ultimately, those claims can be passed on to our customers or members. So we want to make sure that at the start
they are accurate.

GP: Can you talk about the how the Document Review process will address greenwashing and bogus claims by suppliers?
AZL: We found that some of the guidelines out there may be confusing to packaging suppliers. There is potential for misunderstanding that the Federal Trade Commission Green Guides pertain to all marketing claims. They are not only marketing claims to the consumers paying for a product that’s in a package, but they are also meant for business-to-business marketing claims.

And so, the Document Review process will ensure that when the product supplier makes an environmental claim, they have done the tests to back that claim up. Or, that they can prove that the material is being recycled as per the FTC guidelines. There has been a lot of confusion in this space in the last couple of years, and it has the potential to lead to greenwashing. Greenwashing is a concern because we really want to make sure that we are communicating accurate information to our customers and members, and we want to be sure that they have better information to make better purchasing decisions.

In general, we are basing the Document Review on the FTC Green Guides and strict interpretation of those guidelines.

GP: Can you give some examples of how claims of biodegradability or recyclability might be reviewed?
AZL: Sure! The claim of compostability would actually need to have a test report from a lab stating that it has actually been tested and meets the requirements of the testing outlined in ASTM D6400 or D6868 pending the material. For recyclability, that would be based on the package type.

Some things in order to be claimed for recyclability must be able to be recycled or collected in a significant majority of municipalities. That doesn’t mean that it’s capable of mechanically being recycled. So that’s where there has been a big difference. If a supplier is making a claim that their package is recyclable, then they must talk about the actual packaging components that are being collected. There are several studies and reports that show what is being collected across the United States that are going to be used to verify that claim.

So suppliers need to talk in detail if they are using a PET bottle. Does it use color or not? If it’s glass, what type of glass is it? Based on the packaging components and the FTC guidelines and several reports, a decision will be made whether that really meets being able to be collected in a significant majority of municipalities.

GP: Do you know what a significant majority is?
AZL: I have heard some numbers, but it would need to be above 51% and around 60%. But that is not outlined, to my knowledge, in the FTC guidelines.

GP: Originally the Greener Package Database was going to focus on questions pertaining more to the environmental impact of a product, but the merger with ECRM brings far more data points with extensive performance data. Can you explain what the benefits are of having one database for both performance and environmental data?
AZL: The benefit is that suppliers don’t make decisions based on one or the other. If you have a packaging material or a packaging component that is more sustainable but doesn’t perform, then it really doesn’t meet all the requirements of the marketplace. It’s very similar to when our customers and members come to Walmart and Sam’s Club; they are looking for a more sustainable product that meets all of their expectations in performance. So it’s important to have both together because decisions cannot be made on one area without considering the other. Walmart is recommending that when you look at performance data, you also look at environmental areas of the product and vice versa.

GP: What is the benefit to suppliers who pay to have their data reviewed? How will it affect how their data is displayed in the database?
AZL: Packaging suppliers who pay the fee to have their data go through the Document Review process will have the benefit of having it clearly identified in the database that they have gone through the review process and that their packaging material or packaging component meets the requirements to make all the claims. Whereas, if the supplier does not go through the audit, it will be clearly identified in the database that they have not provided documents to prove this claim. It doesn’t mean that the packaging does not meet the claim, but that those claims haven’t been verified. And so it will be clearly identified if the product has been reviewed or not reviewed in the database.

As a result, after August 1, 2009, the modeling software will not show a link to any packaging suppliers that have not gone through the Document Review process.

GP: I would think that the Document Review process is something that packaging suppliers would almost need to have done anyway if they are going to be selling their products based on environmental benefits. What are your thoughts?
AZL: The Document Review helps to substantiate their claims and helps to give them credibility. I think it will be a benefit to those packaging suppliers in that they won’t have to worry about establishing credibility with every product supplier that they are trying to sell to. They will have been able to do it once in the database and can refer to that Document Review to show that they have provided the compostability claims or the recyclability claims, and that it has been reviewed by a third party. Instead of every one of their customers having to verify that information, they can double-check on the Web site themselves and feel confident on the level of Document Review.

It’s also due diligence to make sure that the application the CPG is selecting meets the requirements, but it is a nice first pass to make sure that it is by starting with the verification. Definitely every package is customized for the product and for the customer. So it’s important that after that customization, any claims that they are making on the label are also verified.

GP: Any final thoughts on the new agreement and on the future of the Greener Package Database?
AZL: In my opinion, the database is nice because it takes the Sustainable Packaging Expo every year and makes it year-round. It also helps our product suppliers, our customers, and our members find better products and better options. It makes that information more accessible, and it is not going to require as much travel or as much investigation upfront. So it opens innovation to a whole new group of people.

GP: Although Walmart is gearing the database information toward its suppliers, the database can help move everyone ahead. It isn’t only available to people who are working with Walmart. It’s available to anyone who is interested in making positive changes in their packaging, correct?
AZL: Right! To make packaging more sustainable, in many instances, you need economy and scale. So having a package that only works for one retailer may not be the right solution for a more sustainable package. So it is important that other retailers, even our competitors, have the visibility to these suppliers as well. While Walmart wants to lead with innovation, it is definitely important to have other competitors have access to the same information.

-- CardPak Inc.

Green Jobs: Chief Sustainability Officer

2009-05-06T10:15:00.001-04:00

How important is the title, and more importantly the role of, Chief Sustainability Officer?

That is the question I find myself asking as I read about how more and more Fortune 500 companies are naming or hiring - and in some cases creating the position of - a Chief Sustainability Officer (CSO).

Chief Sustainability Officer, sometimes known by other titles, is the corporate title of an executive position within a corporation that is in charge of the corporation's "environmental" programs. Several companies have created such positions in the 21st century to formalize their commitment to the environment. Normally these responsibilities rest with the Facility Manager, who has provided cost effective resource and environmental control as part of the basic services necessary for the company to function.

Is this another 'green' marketing ploy to attract other large companies to do business?

Is this a way to match the perceived 'environmental awareness' of a competitor in one's industry?

Or is it the realization that the sustainability standards of a company can only exist on their own merit for a short time before they deserve the same attention and focus as the other foundational aspects of business?

Wherever the origin of the position, I hope that it is not a wasted post. I fear the seriousness of the position may be overlooked by a company and, even worse, taken for granted by the person in the actual position.

Even in the current economic climate, the environmental movement is strong in its development and is close to breaking through to become a standard aspect of day-to-day business. So, with that reality in mind, companies need to be prepared and designate a leader to handle this segment of a company's DNA.

Coupled with the trend of hiring a CSO... lower level 'green jobs' are on the rise as well. Colleges and universities are reacting to the trend as well and are now incorporating 'environmental' and 'sustainable' focuses into their undergrad and graduate business curriculum.

It is very apparent, the environmental movement has been one of innovation and action. The trailblazing companies are reaping the benefits now, but they also understand that long term, leadership has to be in place within the organization to continuously monitor the pulse of the green movement within their industry, and throughout other industries.

In the past, some companies were content to follow the trailblazers and let the success spill over so they too could achieve. But with the economy and the detailed scope of the environmental and sustainable movement, it is not a safe bet to count on that theory or approach to keep a company healthy and successful.

Bottom line, what is your company doing to acknowledge the changing paradigms of organizational structure? Where does your company's awareness level rate when looking at 'green jobs' from the top down? Is this lack of recognition affecting your business?

-- CardPak Inc.

CardPak Leads in Environmentally-Sustainable Packaging

2009-05-01T22:56:00.002-04:00

CardPak Leads in Environmentally-Sustainable Packaging
As the printing and packaging industries adopt green initiatives in manufacturing processes, CardPak leads in its initiatives.

CardPak Inc., a manufacturer of environmentally sustainable packaging products, was an early proponent of the "green" movement, and offers a complete line of packaging solutions that reduce the amount of total materials and plastics used in retail packaging, thereby reducing the company's, retailers' and end-users' carbon footprints.

"We are very dedicated to the growing movement to protect the environment," said Tony Petrelli, president, CardPak. "Aside from manufacturing our products with recycled renewable and/or sustainable materials, CardPak also has adopted a lean manufacturing strategy which reduces manufacturing waste and recycles scrap fiber waste, while reducing energy consumption in our manufacturing processes."

Taking that a step further, CardPak is joining with the Solon schools and the National Paperboard Packaging Council in sponsoring the Trees Into Cartons, Cartons Into Trees Program. TICCIT (pronounced "ticket") is an outreach and education program highlighting the natural renewability and sustainability of paperboard packaging. And at the center of TICCIT is a mainstay of the typical school day: the milk carton.

As part of TICCIT, milk cartons are collected out of schools' waste streams and re-used for planting new trees. Seeds and saplings are planted in the cartons, and then the new "carton-and-tree units" are planted in the ground. The cartons provide protection and a natural "water funnel" for the new trees. As the trees grow, the cartons break down, completing the trees into cartons, cartons into trees cycle.

The company's environmental efforts have not gone unnoticed. CardPak recently received an "Evolution of Manufacturing" Award from Smart Business Cleveland magazine. The magazine recently honored 15 innovative Northeast Ohio companies who have adopted "green" initiatives in their manufacturing processes.

"We are very proud to receive this honor, and we are grateful that our efforts in environmental manufacturing processes and products are being noticed," Petrelli added.

-- CardPak Inc.

Fluorescent Lightbulb Packaging & Recycling Program

2009-04-29T08:13:00.009-04:00

Waste Management Introduces Fluorescent Lightbulb Packaging & Recycling Program: First product for recycling compact fluorescent lightbulbs also reduces mercury risks

Waste Management, Inc. announced that it will provide Earthmate(R) compact fluorescent lightbulbs (CFLs) in recyclable packaging that also doubles as a CFL recycling kit.

This new product includes Earthmate CFLs packaged in a resealable box lined with Waste Management's patent pending Mercury VaporLok(TM) technology, which is designed to reduce the risk of airborne mercury exposure and environmental contamination from lamps broken during storage and shipping. The box is suitable for storing used CFLs and is approved for shipping by the United States Postal Service. Consumers return used CFLs in a postage paid shipping container to the Waste Management lamp recycling center simply by mailing them from home or any one of over 34,000 United States Postal Offices across the country.

The recycling kits are available at www.ThinkGreenFromHome.com, Waste Management's streamlined online service for the recycling of universal household waste, including CFLs, batteries, and household electronics.

"We are excited to be the first company to offer this innovative product, designed to help consumers properly dispose of household universal waste as safely and conveniently as possible," said Rick Cochrane, senior business director of Waste Management's LampTracker(R) program.

"We are offering consumers the first 'cradle-to-cradle' solution for CFL usage," said Jim Ouellette, vice president of Earthmate. "Now consumers can purchase and recycle their CFLs in one package and from the convenience of their home. The kit is the simplest and most convenient solution for the disposal of CFLs."

CFLs have gained popularity because they provide a quick and convenient way for households and businesses to reduce their electricity consumption. According to the U.S. Department of Energy's ENERGY STAR program, CFL shipments have grown from 21 million lamps in 2000 to nearly 400 million lamps in 2007. Aided by the new National Energy Plan, which phases out certain incandescent models in the coming years, it is projected that over 4 billion CFLs will be in households by 2012.

CFLs are up to 75% more energy efficient than traditional incandescent bulbs, but because CFLs contain trace amounts of mercury, the U.S. Environmental Protection Agency (EPA) recommends they be recycled and some states have passed mandatory recycling laws for CFLs. Earthmate CFLs contain an average of only one milligram of mercury - a 75% reduction compared to the four milligrams of mercury in standard CFLs.

"With the increasing popularity of CFLs, it is important to develop a recycling solution that is easy for consumers to use," said Matt Hale, director of EPA's Office of Solid Waste. "EPA applauds Earthmate and Waste Management for taking the first steps to expand recycling options for CFLs, reduce the amount of usable materials going to landfills and make recycling a CFL as easy as mailing a postcard. EPA encourages other companies to follow this example."

This new product, along with the other recycling options at www.ThinkGreenFromHome.com, is part of Waste Management's sustainability initiative committing the company to nearly tripling the amount of material it recycles by 2020.

Source: Waste Management, Inc.

-- CardPak Inc.

Picture perfect

2009-04-15T16:00:00.000-04:00

Nikon has releases a new product - Ecobins 'green' binoculars, where all components; the binoculars, the carrying case, and the retail packaging are all 'green', sustainable, and environmentally friendly.

This comes off as one of the best examples of what is possible when going to market with a vision of what is truly important... and believing in the environmental movement within the consumer market.

Below are the specs of the packaging... click here for the specs of the binoculars and carrying case as well.

Green Packaging Features:
* Nikon Ecobins binocular packaging is constructed from 85% recycled material
* Printed on recyclable and waterproof FiberStone™ paper
* FiberStone™ paper is TREE-FREE and created from post-consumer limestone collected from existing quarries
* FiberStone™ paper is made with a clean production process that does not utilize water or emit toxins into the air
* FiberStone™ paper is photodegradable after a period of about one year!

-- CardPak Inc.

Want True Sustainability? Then Design to Seduce

2009-04-13T14:30:00.006-04:00

Want True Sustainability? Then Design to Seduce
By Gadi Amit

Sustainable design is a hot topic. While most people applaud the idea of designers using ecofriendly materials, others insist that that's missing the point--that by designing for mass consumption, designers are still part of the problem, not the solution. I disagree.

The Designers Accord, the global initiative that unites designers, engineers, educators and others around the idea of incorporating sustainability into all practices and production, is a remarkable achievement. Yet, before I signed on, I wanted to have a talk with Valerie Casey, the founder of the movement.

I told her that it bothers me that almost invariably, sustainability is framed as an 'anti' movement. It mostly tells us what not to do. While that's often right, I would add a caveat. For true sustainability, we need to make a more profound culture change--one that involves more than the right standards, specs, or agreements. We should harken back to design in its classical sense, in which an object is so beautiful or functional or otherwise pleasing that it elicits an emotional reaction.

Here's an example. Remember GM's EV1? Introduced in 1996, it was first modern production electric vehicle from a major automaker. After problems developed with its batteries in hot weather, the cars were discontinued and crushed. The EV1 was not the first electric vehicle, and it was not the first vehicle to be 'killed' either. However, it was the first loved EV to be 'killed'. It became a symbol--of the promise of what-could-have-been and a demonstration of what-GM-couldn't-be. As I drove it back in the '90s, I vividly remember thinking, "This is one cool car… I want one!" And that's the role of design in our era: Encouraging people to change, by making products so beautiful that they're tools of seduction to a new, better world. Design in that classical sense is missing in many sustainability discussions.

Seduction is not design's only power. Designers also can create long-term commitment. Think of it this way: if the average car buyer holds on to his car for six years instead of the usual three, we can change the auto industry overnight. Regardless of the car's carbon footprint, any car designed and built for a six-year ownership cycle will be good for our planet. Despite its good intentions, even recycling is not really sustainable. By shipping short-term products, we squander energy, natural resources and public goodwill. Reliability of cars is so high today (yes, even American cars) that the real reason cars are traded in sooner than sx years is lack of love. Loved cars are not given away easily.

The same is true for any other product. A great dress you keep for years is sustainable. A great sofa passed from one generation to the next is sustainable. By this measure, things that might not otherwise be deemed 'sustainable' may actually be more so than less endearing products made with more ecofriendly materials. Take Apple's latest MacBook. To create its aluminum case, engineers take a sheet of aluminum 15mm thick and machine away 90% of its mass. They then regrind and smelt the leftovers up to 20 times to make 20 more notebooks--hardly a 'sustainable' practice from an energy use and dematerialization standpoint. However the resulting product is beautiful and solid as a rock. I will keep mine for a long time--unless they force its obsolescence through software--because I simply love it! And that's the most sustainable point about it.

Gadi Amit is the president of NewDealDesign LLC, a strategic design studio in San Francisco. Founded in 2000, NDD has worked with such clients as Better Place, Sling Media, Palm, Dell, Microsoft, and Fujitsu, among others, and has won more than 70 design awards. Amit is passionate about creating design that is both socially responsible and generates real world success.

-- CardPak Inc.

"Green" packaging sales top $37 billion

2009-04-03T08:34:00.003-04:00

US demand for recycled-content, biodegradable-plastic and reusable packaging is increasing 3.4 percent annually. Total sales to reach nearly $44 billion in 2013.

Converting Magazine (Press Release) - US demand for green packaging -- comprised of recycled content, biodegradable and reusable packaging -- is projected to increase 3.4 percent annually to $43.9 billion in 2013, using 59 billion pounds of material. Growth will outpace overall packaging but will remain modest due to the maturity of many products and the fact that recycled content packaging has a large existing presence in paperboard and metal packaging.

The fastest gains are anticipated for biodegradable plastic packaging and plastic recycled content packaging. Biodegradable plastic packaging is forecast to climb nearly 13 percent per year through 2013, driven by increased price competitiveness with conventional resins, rapidly expanding capacity and lower pricing volatility than petroleum-based plastic packaging materials.

Additional stimulants include enhanced performance properties brought about by more sophisticated polymerizaton and blending techniques; efforts by brand owners to improve the environmental footprint of their packaging; and legislative bans on polystyrene foam foodservice disposables in some parts of the country. These and other trends are presented in Green Packaging, a new study from The Freedonia Group, Inc., a Cleveland-based industry research firm.

While recycled content packaging demand is expected to increase in line with the overall green packaging average, robust growth for plastic recycled content packaging will be aided by more concerted efforts to boost collection volume, an increased focus on the development of food-contact approved resin grades, and further sustainability initiatives by plastic processors and brand owners. Gains will be moderated by slow growth for paper recycled content packaging, which is dominated by the large but mature corrugated and paperboard box segment.

Reusable packaging is forecast to expand more slowly, held back by marginal growth for drums, which face competition from larger formats such as intermediate bulk containers (IBCs). More favorable prospects are anticipated for reusable plastic containers, IBCs and other reusable packaging types. In general, value gains will decelerate sharply from the 2003-2008 pace due to an expected moderation in raw material prices, especially for plastic and steel. The relatively long service life of most reusable packaging also limits the need for replacements, a factor that restricts growth in demand for new units.

-- CardPak Inc.

Sony DVD packaging goes green

2009-03-24T09:10:00.001-04:00

Sony DVD packaging goes green
- Suzanne Ault

Paul Blart: Mall Cop has a new job, as Sony Pictures Home Entertainment's green ambassador.

The title, releasing on DVD and Blu-ray May 19, will kick-off a launching a massive green packaging initiative at the studio.

From Mall Cop on, all of Sony's single-disc standard-definition DVDs will incorporate ultra-light cases that feature 20% less plastic than Sony's previous single-disc standard DVDs and will be covered with plastic shrinkwrap that is 20% lighter. The printed artwork that wraps around boxes will use paper that contains 30% post-consumer waste. Previously, Sony had been using 100% virgin paper.

The studio's goal is to reduce carbon emissions associated with its DVD manufacturing and distribution by 2 million pounds in North America by the end of 2009.

"What we were looking to do was be efficient and over time, deliver cost savings," said Lexine Wong, senior executive VP of worldwide marketing for SPHE.

The lighter cases also should help the studio trim both packaging costs and freight charges.

"For the last couple of years, we have been looking at ways to be sustainable and make a difference," said Wong. "I think our industry and our studio is really committed to environmental issues. All the studios are."

The Mall Cop box has walls that are cut out to use less plastic. The DVD also will be packaged without a cardboard outer sleeve, saving more than 2,200 trees, or 322 tons of wood, according to Sony.

Several studios have been using greener packaging solutions, following Wal-Mart mandates that vendors both clamp down on carbon emissions and reduce packaging.

Already studios have worked to meet Wal-Mart's goals, slimming average DVD packaging weight by about 30% between 2006 and 2008. The carbon imprint for a title (encompassing emissions from manufacturing, packaging and transportation to retail) dropped to 0.98 lbs. in 2008, down from 1.1 lbs. in 2006, according to the Digital Entertainment Group.

-- CardPak Inc.

Consumers Still Buying Green...

2009-03-16T12:10:00.009-04:00

Consumers Still Buying Green Despite Economic Downturn
Research shows that 82 percent of shoppers continue to seek eco-friendly products - Packaging Digest

Four out of five people say they are still buying green products and services today—which sometimes cost more—even in the midst of a U.S. recession.

A new study commissioned by Green Seal and EnviroMedia Social Marketing and conducted by Opinion Research Corporation reveals peoples’ opinions and behaviors about products that claim to be environmentally friendly.

Half of the 1,000 people surveyed say they are buying just as many green products now as before the economic downturn, while 19 percent say they are buying more green products. Fourteen percent say they are buying fewer environmentally green products.

Other key findings in the new research conducted by telephone in a random-digit-dial sample:

Brand Reputation Matters More Than Ads
Twenty-one percent (21%) of consumers say a product’s reputation is the biggest factor they weigh when making purchasing decisions followed by word of mouth (19%) and brand loyalty (15%). Just 9 percent say green advertising is their primary influencer.
More “Green Claims” Education Needed

About one in three say they don’t know how to tell if green claims are true.

One in 10 consumers blindly trusts green product claims.

Consumers are verifying green claims by reading the packaging (24%) and turning to research (going online, reading studies; 17%).

What Consumers Say Versus Do
While 87 percent of people surveyed say they recycle, the Environmental Protection Agency reports just 33 percent of our waste is diverted from landfills.

The other things people do are look for minimally packaged goods (60%) which is statistically tied with buying green cleaning products (58%). Buying green personal-care products came in at 31%.

"This research suggests that consumers are buying green products second only to participating in recycling,” said Arthur Weissman, Ph.D., Green Seal's President and CEO. "This increased consumer demand sends a signal to manufacturers to produce products that are truly green.”

Green Seal, an independent nonprofit product certification organization, and EnviroMedia Social Marketing are releasing the research today from the first-ever Greenwashing Forum in Portland. The forum, hosted by the University of Oregon, was inspired by the Greenwashing Index, which was launched in January 2008 by EnviroMedia and the UO School of Journalism and Communication. Since the popular watchdog Web site was founded, consumers in 138 countries have been posting and rating ads to “out” greenwashers and showcase companies that employ sound environmental marketing efforts.

“There’s a real opportunity for authentic green marketing, despite the tough economy,” said Valerie Davis, EnviroMedia Principal and CEO. “This research proves people want to do what’s best for the environment, but it needs to be easy and accessible. Companies should be clear about the environmental benefits of their products and services and make sure what they claim in the TV ad is backed up consistently on product packaging and on the Web site.”

Sources: Green Seal, EnviroMedia Social Marketing

-- CardPak Inc.

Product captivity & security

2009-03-02T11:40:00.002-05:00

It is well known (and old news) now that Wal-mart, Target, Amazon, and Sears, among others, have all jumped on the sustainable bandwagon and have taken a public stance in regards to the use of PVC, most commonly in a clamshell design, for the packaging of retail products.

But with the 'negative' perception to clamshells comes the one main point of backlash that there is a the lack of product security when switching to a more sustainable package.

Well this has been debunked, as it has been noted by many of the major retailers that regardless, whether the product is in a traditional clamshell, a tear-resistant replacement (Natralock), or a sustainable micro-flute clamshell replacement (ClubPak)... the security is equal because the method of stealing the item remains the same.

* With a box cutter, slice the lip of the blister, pull the product out, and then stash the remaining package somewhere else in the store.

Below is a photo from a recent trip to Costco. This item was found on the complete opposite end of the store, stuffed into a toolbox that was on display. Clamshell, tear resistant... it wouldn't matter, this would still happen.

So with that in mind, the retailers have made the choice to be more 'environmentally friendly' knowing that they will continue to deal with the same thief issues.

In this same vein, sustainable micro-flute clamshell replacement packages are typically marketed as more 'user friendly' and easier to open... so for some humor, I threw a few key words into youtube, and the search yielded an incredible amount of 'clamshell rage' videos.

Below is just one of hundreds, and this is definitely one of the more 'civil' ones, as many had clamshells getting backed over by cars and shredded open by a gas powered chainsaw.

Yes, without a doubt or argument, there are products out in the retail environment that require a clamshell package. But for a majority of products on the shelves of the mass retailers, that is not the case.

In the end, the key is to know both sides of the story when talking security and sustainability, it is an advantageous position to be in when dealing with the mass retailers that are controlling the climate of retail packaging.

-- CardPak Inc.

FTC's Green Guides need update sooner than later

2009-02-24T08:36:00.001-05:00

FTC's Green Guides need update sooner than later
John Kalkowski, Editorial Director - Packaging Digest

Recent articles show that “natural” and “environmentally friendly” messages resonate with consumers, as thousands of new products introduced in 2008 rely on those attributes in both product and packaging marketing to help boost sales.

With the proliferation of this message, many marketers skate dangerously close to what might be considered misleading or even false advertising. One study done by TerraChoice Environmental Marketing finds that 99 percent of 1,018 “green” advertising claims for everyday consumer products could be misleading.

The industry needs an up-to-date set of guidelines on what are acceptable marketing practices, taking into account new packaging materials, new technology and the changing perceptions of today's consumers. The U.S. Federal Trade Commission (FTC), which is charged with protecting the American public from misleading environmental marketing messages has established its interpretation as to what are deceptive environmental marketing claims in a document known as the Guides for the Use of Environmental Marketing Claims or “Green Guides.”

The Guides originally were published in 1992 and were updated in 1998. To its credit, the FTC launched a new review in 2007 and held three workshops in 2008 to solicit public input on what should be included in a revised set of guidelines. However, new Green Guides have not been issued. At this point, the FTC says it wants any new guidelines to be “done right,” but the agency does not have a target date for release. The commission's staff must prepare recommendations to the five commissioners who make the ultimate decision. When the new guidelines are written, they likely will be subject to a final round of public comment before a final decision is made. The new federal administration also may want to put its own stamp on the direction any changes might take.

A sustainability study done late in 2008 by Packaging Digest and the Sustainable Packaging Coalition, shows that 77 percent of the respondents feel minimum standards should be set before packagers can market themselves as “green.” When asked who should set the standards for sustainability claims, 42 percent said they believe the federal government should do so, followed closely by either a third-party program or trade associations.

It appears the industry wants stringent guidelines that remove ambiguities. This is important because local and state jurisdictions increasingly rely on the Green Guides for direction on enforcement, even though the FTC does not pre-empt regulation of environmental claims by individual states.

For more information, click here.

-- CardPak Inc.

Case Study: Paul Mitchell - sustainable & elegant

2009-02-23T11:24:00.003-05:00

A great case study involving Paul Mitchell Systems and JohnsByrne (Graphic Technologies) in regards to meeting a client's needs and desires from an sustainable aspect, as well as providing the 'look' that is demanded, expected, and customary in the marketplace.

Click on photo below to enlarge and read the case study...
-- CardPak Inc.

New CardPak website

2009-02-18T11:53:00.009-05:00

After a period of redesign, the new www.CardPak.com is now live!

There are still more additions & features coming soon to the website, so visit frequently, but this is a great upgrade and reflects the corporate direction and sustainable focus that CardPak continues to integrate.

-- CardPak Inc.

Smart Business Cleveland - Sustainable Manufacturing

2009-02-13T08:30:00.007-05:00

CardPak president, Tony Petrelli, was featured for the cover story, 'Sustainable Manufacturing', in this months Smart Business Cleveland...

A care package for the future
How Tony Petrelli keeps CardPak Inc. focused on practicing sustainability
Smart Business Cleveland | February 2009

Tony Petrelli is proud of the awards that CardPak Inc. has received for producing packaging that is both durable and environmentally friendly. But it’s not accolades that Petrelli seeks through the company’s commitment to sustainability.

Rather, Petrelli hopes employees, clients and any other stakeholders who come into contact with CardPak see the company’s passion for doing what it feels is right and applies that to its actions.

CardPak has developed numerous sustainable packaging concepts that address the concerns of major retailers regarding source and material reductions as well as recyclability requirements.

The company’s EcoLogical Line of Packaging has been created to remove significant amounts of packaging materials from the waste stream and use 100 percent recycled materials when possible.

Petrelli believes it is his responsibility, as well as that of his employees, to carry on the company’s history of finding the safest and most efficient way possible to manufacture its products.

CardPak is able to create products that reduce the amount of total materials used while providing consumers with a better package for protecting and dispensing the products they buy.

It’s not just the products that CardPak manufactures, however, that reflect the company’s commitment to sustainability. By using more efficient lighting in the company’s plant, energy consumption and carbon dioxide emissions were trimmed by more than half, saving a potential 600 barrels of oil per year.

The company also has adopted a lean manufacturing strategy that reduces in-plant manufacturing waste by more than 2 percent per month, reducing the amount of paperboard waste going to the landfill or having to be collected for recycling by close to 350 tons annually.

At the same time, the company is able to collect and provide more than 2,700 tons of fiber waste per year for use in the manufacturing of recycled paperboard for future packaging products.

So when the company was honored at the Environmental Printing Awards in Toronto last February, CardPak employees were gratified at the recognition. But the awards do not so much represent a goal achieved as much as a reinforcement of the company’s commitment to the future stake-holders of a community we are all a part of: the Earth.

-- CardPak Inc.

Field Guide to Sustainable Packaging

2009-02-11T07:43:00.002-05:00

"The Field Guide to Sustainable Packaging is a meaningful and motivating source of information that is filled with real-life examples and success stories. A 'must read' for both veterans and newcomers to the packaging development process." --Brad Menees, Vice President--Technology and Development R&D, Campbell Soup Company

"One of the greatest challenges facing companies looking to advance the sustainability of their packages is the absence of guidance and inspiration. Steve Sterling's Field Guide offers a practical resource for better understanding the fundamentals of sustainable packaging and learning from the experiences of others. Whether you're starting out or you're a seasoned veteran on the journey to sustainability, this book is a valuable read." --Scott Vitters, Director Sustainable Packaging, The Coca Cola Company

"Sustainability is a dynamic force in the packaging world--it cannot be ignored. As a catalyst for change, sustainable packaging will serve as a new and exciting source of innovation for all of the constituents in the packaging value chain for years to come. Sterling's Field Guide to Sustainable Packaging serves as an excellent information source for both the novice and the experienced practitioner." --Jay L. Gouliard, Vice President--Global Packaging, Unilever

From the publishers of Packaging World - Field Guide to Sustainable Packaging:

Now in its second printing, this acclaimed resource explores the origins and definition of sustainability and offers actionable strategies, inspirational success stories and essential resources for your company to begin or continue your journey towards sustainability. Inside this 70-page volume you’ll find:

* interviews with high-level professionals who have successfully realigned their corporate goals to integrate sustainability

* practical case histories offering real world models

* timely insights into the Wal-Mart Scorecard, including an exclusive Packaging World interview with Sam's Club's Director of Packaging

* a wealth of resources to use, as you develop or improve your company’s environmental stewardship strategy.

-- CardPak Inc.

Consumers Still Buying Green...

2009-02-09T07:49:00.005-05:00

Consumers Still Buying Green Despite Economic Downturn, Says Study
Research shows that 82 percent of shoppers continue to seek eco-friendly products

Four out of five people say they are still buying green products and services today—which sometimes cost more—even in the midst of a U.S. recession.

Other key findings in the new research conducted by telephone in a random-digit-dial sample:

About one in three say they don’t know how to tell if green claims are true.

One in 10 consumers blindly trusts green product claims.

Consumers are verifying green claims by reading the packaging (24%) and turning to research (going online, reading studies; 17%).

What Consumers Say Versus Do
While 87 percent of people surveyed say they recycle, the Environmental Protection Agency reports just 33 percent of our waste is diverted from landfills.

The other things people do are look for minimally packaged goods (60%) which is statistically tied with buying green cleaning products (58%). Buying green personal-care products came in at 31%.

Green Seal, an independent nonprofit product certification organization, and EnviroMedia Social Marketing are releasing the research today from the first-ever Greenwashing Forum in Portland. The forum, hosted by the University of Oregon, was inspired by the Greenwashing Indexsm (www.Greenwashingindex.com), which was launched in January 2008 by EnviroMedia and the UO School of Journalism and Communication. Since the popular watchdog Web site was founded, consumers in 138 countries have been posting and rating ads to “out” greenwashers and showcase companies that employ sound environmental marketing efforts.

Sources: Green Seal; EnviroMedia Social Marketing

-- CardPak Inc.

What’s the Score?

2009-02-05T12:54:00.005-05:00

What's the Score?
As they say, you can't tell the players without a scorecard!
By Tom Polischuk (PackagePrinting.com)

Wal-Mart has clout—there’s no doubt about that. When Wal-Mart speaks, people listen—especially its suppliers.

The company created a real buzz for RFID a few years ago, when it announced that it was mandating the use of this technology from its suppliers. Although this effort has faded from the limelight and has been largely redefined in scope, RFID technology received more attention during a two-year period than it would have gotten in a decade. RFID technology still has a ways to go in terms of reliability and cost, but Wal-Mart’s initiative probably did a lot to advance its development.

Before the dust had a chance to settle on its RFID efforts, Wal-Mart took on another noteworthy initiative—sustainability. In September 2006, the company announced that it would institute using a Packaging Scorecard with its suppliers to help the company meet its commitment to reduce the use of packaging materials across its global supply chain by 5 percent by 2013.

The Scorecard, unveiled at Pack Expo 2006, is based on metrics for how packaging impacts sustainability factors throughout many aspects of the entire supply chain. They were developed over many months by the Packaging Sustainable Value Network, a group of 200 suppliers, experts, and other Wal-Mart stakeholders. These metrics and their Scorecard weighting factors are: greenhouse gases/CO₂ per ton of production (15 percent); material value (15); product/package ratio (15); cube utilization (a measure of storage efficiency in warehousing and shipping trailors/containers, 15 percent); transportation (10); recycled content (10); recovery value (10); renewable -energy (5); and innovation (5).

The Scorecard has been in various stages of use and implementation since its introduction. Even before it officially went online in February 2008, Wal-Mart reported that more than 97,000 products had been entered into the Scorecard by more than 6,300 vendors.

Diamond Packaging and CardPak are just two package printers that have been actively involved with the Scorecard and have been experiencing its impact firsthand.

Diamond Packaging has been proactive on the sustainability front for a number of years now, having committed to the use of renewable wind energy, and started a program called the greenbox initiative to develop and implement sustainable packaging solutions for its customers.

Dennis Bacchetta is director of marketing for -Diamond Packaging. Although he believes that sustainability has gained a great deal of traction from “a confluence of legislative, corporate, and consumer interest,” he also says that the Wal-Mart Scorecard has done its part in raising the stakes.

“Wal-Mart’s Packaging Scorecard tool has helped put the concept of sustainable packaging in the forefront of many companies’ and consumers’ minds, and thus been a key driver in trying to understand what sustainability truly is,” he says. “As a result, many consumer product companies [CPCs] have requested information on sustainability, including our efforts to design more eco-friendly packaging, and our experience with the Wal-Mart Packaging Scorecard tool. We anticipate that as sustainability continues to grow in the public and corporate awareness, it will become ingrained in our corporate and social structure.”

David Himmelein, regional sales and marketing manager for CardPak, also recognizes the impact that the Scorecard has made and the opportunities that it presents to his company and others. “The Packaging Scorecard is one of the first tools of its kind to judge the entire package that hits the Wal-Mart shelves,” he notes. “This has been beneficial to CardPak because our EcoLogical Line of Packaging eliminates the harmful PVC plastic clamshells from the waste stream. The scorecard now gives us an opportunity to measure the differences in the original packaging and our solution.”

The ability to provide a tangible measurement system lies at the heart of the Scorecard’s value to its users. When something can be measured, it can be improved. “The value we get from the Wal-Mart Packaging Scorecard is that it provides measurable evidence that our designs have increased a package’s sustainability,” says Bacchetta.

CardPak uses the Scorecard as an additional sales tool in its arsenal, and performs mock-Scorecard analyses to show the impact that its packaging system has when compared to traditional clamshell alternatives. “This information is then presented to our customers for them to use in making their decisions on the engineering of each product package. They are well aware of Wal-Mart’s objectives for the Scorecard, so will want to have the best possible score for each package,” notes Himmelein.

It is not surprising that Himmelein reports all of CardPak’s customers that sell to Wal-Mart are involved with the Scorecard in some form. To provide a value-added service to its customers, CardPak hosted an exclusive training event early in 2007 with ECRM and Mars Packaging that allowed its customers to get answers to their questions concerning the Scorecard.

Bacchetta notes that even companies that do not directly supply Wal-Mart have been impacted by the Scorecard due to increased sustainability awareness. “They see it as an opportunity to support a sustainable use of resources and cultivate a positive emotional connection to their brand,” he says.

Diamond Packaging has used the Scorecard for many customer projects. One in particular—done for a well-known personal care company, says Bacchetta—rated various products and developed a plan for redesigning their packaging based on weight, environmental impact, and material. “We then scored the new packaging to ensure that, when compared to the existing packaging, it resulted in a score improvement,” he explains.

CardPak successfully implemented a redesign for the packaging of GE’s compact fluorescent lamps (CFLs) that are carried in Sam’s Club stores, says Himmelein. “The original package was in a PVC clamshell, and scored a 3.5. By switching to the ClubPak™ style, we were able to more than double the scorecard value to a 7.5.”

Of the Scorecard’s nine metrics, both Himmelein and Bacchetta agree that a package printer can have the greatest impact on the product/package ratio.

In CardPak’s case, the traditional PVC clamshell is a prime target. “Oftentimes, the overall weight and size of the clamshell is too much,” says Himmelein. “We have reduced the footprint of the package and removed up to 85 percent of the plastic materials, resulting in a better score for this particular metric.”

According to Bacchetta, reducing the weight of a package can impact several areas in the Scorecard’s metrics, including conserving raw materials and energy, reducing greenhouse gases, and minimizing discards. “This can be achieved through careful material selection, reduced board usage, and the elimination of components (e.g., thermoform and shrink wrap).”

Another area of focus for package printers is cube utilization, says Baccetta. “However, this requires a higher level of collaboration with other partners throughout the supply chain (marketing/sales, distribution, retailer, etc.) in an effort to reduce material and energy usage, and maximize shipping efficiencies.”

Going forward

Since it was first announced in 2006, Wal-Mart’s Packaging Scorecard has made a significant impact throughout the consumer products arena. Last November, Wal-Mart again used Pack Expo as a forum to announce evolutionary changes to the system.

In a keynote presentation, Amy Zettlemoyer-Lazar, packaging director, Sam’s Club and co-manager of Wal-Mart’s Sustainability Value Network, reported that the Scorecard’s metrics would be adjusted to increase the focus on greenhouse gas and packaging weight reductions. She also said that in 2009, Scorecard implementation would begin to move beyond the U.S. and include other countries such as Canada, Mexico, Puerto Rico, and China.

For many North American package printers, the Scorecard’s impact has already been felt. Himmelein attributes some of CardPak’s success with its EcoLogical Line to the Wal-Mart Scorecard. “Wal-Mart is the driving force in sustainable package leadership,” he says. “Our customers know this and we, in turn, want to be able to meet our customers’ needs. This is a growth opportunity for us as a company. Two years ago the EcoLogical Line of packaging did not exist at CardPak, and today it is almost 50 percent of our total product mix.”

“The Scorecard has had a positive impact on how we approach our business and our customers,” adds Bacchetta.

With the focus that the Scorecard is receiving from the packaging arena, it appears that Wal-Mart is well on its way to achieving its 2013 goal of a 5 percent reduction in packaging throughout its supply chain.

-- CardPak Inc.

Clamshells Made With Ingeo Prove Sustainable

2009-02-03T12:00:00.004-05:00

PackExpo.com / Business Wire (Press Release) - A first-of-its-kind lifecycle analysis finds that clamshell packaging made from Ingeo, a unique biopolymer derived from plants rather than oil, emits fewer greenhouse gases and uses less energy when compared to clamshells manufactured with petroleum-based rPET (recycled polyethylene terephthalate).

The Institute for Energy and Environmental Research (IFEU), Heidelberg, Germany, conducted the head-to-head lifecycle comparison on more than 40 different combinations of clamshell packaging made from Ingeo natural plastic, PET, and rPET. Both Ingeo and rPET clamshells outperformed PET packaging in terms of lower overall greenhouse gas emissions and lower overall energy consumed. Ingeo clamshells clearly offered further advantages over the petroleum-based rPET in numerous comparisons.

"Brand owners and converters will lower the carbon and energy footprint of clamshell packaging by moving away from PET and rPET to Ingeo polymer," said Marc Verbruggen, president and CEO of NatureWorks, the manufacturer of Ingeo. "This is true with today's virgin Ingeo and, in the longer term, recycled Ingeo will decrease that footprint even more. Furthermore, the high performance of Ingeo biopolymer in clamshell applications means that less material may be required to manufacture them " on average 25 percent less."

Representative results of the lifecycle analysis:

The study showed that clamshell packaging consisting of 100 percent rPET emitted 58.6 kilograms of CO2 equivalents per 1,000 clamshells. Ingeo 2005, a representative grade biopolymer in the study, emitted 49.2 kilograms " an overall 16 percent reduction in CO2 equivalents. The Ingeo clamshell was lighter, yet functionally equivalent in terms of top-load strength.

Energy consumed over the lifecycle for 100 percent rPET clamshells was 1.1 gigajoules. This compared to .93 gigajoules for the lighter, yet functionally equivalent, Ingeo 2005 packaging " an overall 15 percent reduction in energy consumed.

"The study found that Ingeo compares favorably with rPET even when a producer chooses not to lightweight a clamshell," said Steve Davies, NatureWorks director of Communications and Public Affairs. "The study also showed that the next generation of Ingeo biopolymer, which will be available in 2009, offers further improvements in eco-profile and clearly outperforms 100 percent rPET in head-to-head comparisons."

Clear plastic clamshells, like the ones analyzed in the study, are often used for fresh produce and foodservice packaging " for example, lettuce, tomatoes, sandwiches, or deli salads. Currently this packaging is not recycled in either the U.S. or Europe. In the U.S. clamshell packaging typically goes to landfills after use, while in Europe this packaging may be incinerated for waste-heat recovery. The lifecycle study took both end-of-life scenarios into account.

For a copy of the full IFEU lifecycle analysis comparing rPET and Ingeo natural plastic clamshells, click here. Brand owners and converters in Europe, the Americas, and Asia who are looking for greater sustainability and performance in bottles, clamshells, labels, and other packaging should visit NatureWorks website to locate the nearest sales office.

-- CardPak

LEED or follow...

2009-02-02T09:34:00.008-05:00

This is from this past April, but I thought it was another relevant example of how creative projects can get when an environmental angle is factored into the equation. Lo and behold, sometimes that 'green' aspect takes over and steals the show.

The Santa Monica Civic Center parking garage is the first LEED certified parking garage in the US. The garage provides 900 parking spaces throughout six above ground levels and 1 ½ below ground levels.

Of the 900 spaces, 2% are reserved for electric/hybrid vehicles, and come equipped with public electrical outlets. There is also free bicycle storage available to “encourage alternate transportation modes.”

The structure features roof top solar panels, a storm drain water treatment system, recycled construction materials, and energy efficient mechanical systems.

For more details & photos - click here.

-- CardPak Inc.

Packaging Design Insight from XO Create!

2009-01-29T21:43:00.008-05:00

This is the main body from an interview conducted by Packaging Digest (David Bellm) with Jim Stringer, the Creative Director for XO. Jim provides some great substance and insight into packaging, branding, creativity, design, as well as client relations... the whole gamut.

Packaging Design Insight from XO Create!
Packaging Digest, David Bellm

Jim, Do you feel that packagers are getting more sophisticated about branding?
Yes and for good reason. We have all read the statistics about in-store purchase decisions, how long it takes a consumer to make one and so on. These are all true but the real reason packagers have to become more brand savvy is that their product (the package) is on the front line of their client’s battle - the store shelf. The package has for many become the first touchpoint, the first interaction with a brand and it had better speak the right message in the right voice to its audience or they may never interact with it. We are talking about more than slapping a logo on a box as big as you can and calling it branded. These days the shape, the color, the material all must align to tell one concise, succinct story - the brand promise - and we must do it in way that captures our audience and provides a real value in their life. Quite a role for packaging, but one that can be achieved with the right team and the right framing of the project.

What do you feel is the biggest (missed?) opportunity clients have with their packaging?
Telling their story. Delivering on the brand promise or at least starting to clue the consumer in on what the brand represents. Also it's the experience after the consumer gets the package home. Does it store the product well? Was it easy to open? Properly childproofed? What post-purchase value can be designed into the package? Also packaging can be a source of tremendous savings when approached from the right point of view. Can we use less material, fewer inks? different substrates? There are so may variables that go into a package it's no wonder that the right packaging firm can assess the situation and often find ways to shave production costs without sacrificing on the brand or the experience.

What do you see as the most important design trend in packaging in the next five years?
Reduction of materials and sustainability, so start doing your homework! Honestly, these areas are going to continue to be hot and there are a lot of misconceptions out there about what's green and what's sustainable. This leaves us, the packagers and package designers, to learn more and lead the way for our clients in these areas including educating them on the facts.

What do you see as the most worrisome design trend happening in packaging?
Moving packaging design overseas. I certainly understand the reasons behind outsourcing, but often any savings realized is spent on production management (are the colors right, is the substrate correct?) and time getting things back and forth. The bigger issue is if your actual design is outsourced, because more often than not these designers have no concept of our varied cultures and emotional triggers. This often leads to very alien looking design and messaging that leaves the consumer more confused than informed. If you are going to outsource your packing production that's fine as long as you have a qualified person representing the project and it's objectives dedicated to the outcome of the work.

What do you have to educate your clients about the most when it comes to packaging design?
Production. Many of our clients are new to the world of manufacturing, conversion, printing and fulfillment of packaging. It can be quite intimidating when you have no idea where to start or what's involved, but over the years we have become very good at bridging the gap between client and production processes. Of course many times the client has never budgeted for this type of education or production management. Yet when it's all said and done most feel it was worth the extra investment to avoid production pitfalls which can quickly drain a budget.

Describe your approach to redesigning a clients packaging
We first begin by asking the client to write a creative brief describing the general reasoning and objectives that are driving the project. We often help with this brief in areas the client is unsure of or may have difficulty articulating. From this brief we begin to ascertain what areas of the existing packaging may or may not be supporting the desired outcomes. Many times we discover disconnects not necessarily with the packaging but with the product or it's presentation. For example, a client may have a game aimed at adults, yet the colors of the product itself and/or it's packaging may unknowingly cause consumers to see it as a child's product. The copywriting could have the wrong voice, the images could have the wrong art direction, or the client may just being trying to brilliantly solve the wrong problem. This is why we constantly question and circle the project from so many viewpoints; to discover these hidden issues and then design for or around them in order to more clearly articulate the brand or product message.

Is there any kind of packaging that your firm specializes in?
Not particularly since we approach package design as an extension of a brand. We design almost any type of packaging that achieves the client’s objectives, whether it's glass, plastic, toys or appliances. We have a very talented team here at XO Create! and I personally feel there isn't much they can't accomplish. If we were forced to niche I would say most of our work lends itself to the unusual or atypical type of packaging solutions.

What packaging design are you the most proud of?
We are quite proud of all our packaging work, so it's hard to pinpoint any one project. Just about everything we are really proud of is featured on our website - www.xocreate.com under the portfolio section.

What types of projects are the most exciting to you?
Any project that has a genuine objective to reach or problem to solve. For XO Create! packaging is not a form of decoration, it's a real opportunity to communicate on may levels and solve some real issues on both the client and consumer sides of things. When we have a defined goal or objective and are allowed the creative freedom to discover solid solutions, we always get excited!

What kind of packaging would you love to design if you had the chance?
Cosmetics packaging would be exciting! Beauty and style products always seem to have a very high aesthetic and this team could really sink their teeth into those values and produce something exceptional!

Do you work remotely often? (email, web, phone, etc.) Or do you prefer working face-to-face with clients?
We work in any capacity that provides the level of detail and responsiveness the client or project desires. This is often a marriage of all forms of communication and we make sure anyone assigned to a project can communicate with a client about the work.

Which package has more fun – a box of fruit or a bag of candy?
A bag of candy! It's far easier to carry around a bag of jelly beans than a box of kiwi!

If you could be a package for one day, what would you be?
A bottle of high-end liquor - it would be a celebration everywhere I went!

Is there anything you’d like to tell prospective clients?
Hire a good packaging firm, one that can assist with everything from budget and production constraints to branding and emotional touch point creation. Choose them not on the work they have done for others in specific product categories, but on the ground breaking work you believe they can achieve for your unique product or situation. Also, clearly define what you hope to achieve with your packaging and bring your chosen firm in early on in the game, it's their unique problem solving perspectives and experience that you hired them for, not their software skills, so utilize it and allow them the room to do something you would have never thought of. After all, isn't that the reason for hiring professionals?

How can clients get in touch with you?
You can contact me via email at - jim@xocreate.com.

Complete article/interview can be viewed by clicking here.

-- CardPak Inc.

Coke Teams with MSU School of Packaging

2009-01-26T21:01:00.002-05:00

Coke Teams with MSU to Create Packaging Innovation & Sustainability Center

Michigan State University (Press Release) - Improving the global sustainability of product packaging took a meaningful step forward with a new collaboration proposed by The Coca-Cola Company and Michigan State University. Coca-Cola awarded $400,000 to MSU’s College of Agriculture and Natural Resources to helpestablish a new Center for Packaging Innovation and Sustainability.

The planned center, to be housed in the MSU School of Packaging, will serve as a think tank for packaging innovation and sustainability and a research and education hub to measure and reduce packaging’s environmental impact. The Coca-Cola grant represents the initiating gift in a campaign to establish the global center.

"The Coca-Cola Company is honored to collaborate with Michigan State University in its quest to bring corporate, academic and packaging professionals together to foster new ideas in sustainable packaging,” said Ingrid Saunders Jones, senior vice president of global community connections for The Coca-Cola Company, “Our company has set ambitious environmental goals to not only deliver quality products, but to also have minimal impact on the environment. Research and work generated through this collaboration with MSU will assist us in reaching our goals.”

The center will involve the MSU colleges of Agriculture and Natural Resources (School of Packaging), Engineering and the Eli Broad College of Business (Department of Supply Chain Management). It will provide a platform for both collaborative, non-proprietary research and proprietary work conducted by industry partners, both in partnership with and independent of MSU researchers, to develop innovative packaging solutions that reduce production costs and improve sustainability.

“The center will offer an entry point for industry to have easy access to MSU expertise. It will serve as a bridge between corporate and packaging industry professionals and university scientists in engineering, packaging, business, the environment and other areas,” said Satish Udpa, dean of the MSU College of Engineering.

“The center will be a clearinghouse that disseminates information and encourages action that speeds the adoption and implementation of sustainable practices.”

“By bringing together university and industry resources in supply chain, packaging and engineering, this center will be able to effectively address issues of sustainability, discover environmentally and economically operative solutions and consider new ways to manage environmental impact throughout the value chain,” said Elvin Lashbrooke, interim dean of the Eli Broad College of Business.

The center will include state-of-the-art technology for bench research and testing of packaging materials and will offer academic, outreach and continuing education programs. It is anticipated to eventually expand its reach internationally through research, development, education and training facilities in Dubai and Shanghai.

“Packaging is ubiquitous throughout the food system and a critical component to the quality, safety and sustainability of the products we buy and eat,” said Jeffrey Armstrong, dean of the MSU College of Agriculture and Natural Resources.

“Coca-Cola’s funding commitment to establish the Center for Packaging Innovation and Sustainability will move us toward an unprecedented level of industry collaboration that will have global implications for improving packaging performance and sustainability.”

Scott Vitters, group director, Global Sustainability for the Coca-Cola Company, will speak during the luncheon program of the Packaging Executives Forum II being presented by the School of Packaging on Jan. 27 at the MSU Kellogg Hotel and Conference Center. A discussion of the Center for Packaging Innovation and Sustainability is also scheduled for the afternoon program. This will be the first opportunity for packaging professionals to meet with the deans of the involved colleges and the acting director of the School of Packaging to learn more about the center and discuss its launch.

Details are available at http://www.packaging.msu.edu.

Established in 1952, the MSU School of Packaging is the first and largest packaging program in the U.S. The school supports the packaging industry through education, research and outreach focused on solving problems and developing improved technology.

Source: Michigan State University / Packaging Digest

-- CardPak Inc.

Sustainability Highlight: EcoHangers

2009-01-22T09:00:00.004-05:00

This Sustainability Highlight showcases how a company can make an environmental difference, and yet, in the vein of good business, use innovative marketing and advertising to put a new spin on a 'commoditized' item.

The environmental aspect of this is great, and should be honorably recognized, but it speaks for itself... there is much more to this than just the 'green' side of it.

Despite the higher cost, EcoHanger has been able to change the dynamic and usage of the 'generic metal hanger' by offering a valuable and vibrant billboard to offset the extra costs of being environmentally friendly. A win-win all the way down the line: EcoHanger, advertisers, dry cleaners, and customers of the dry cleaners.

And of course, the environment.

The following was taken from the EcoHangers website:

No new trees are used in making them! They are constructed from 100% recycled paper and are 100% recyclable. And unlike wire hangers, our EcoHangers Media are made from a renewable resource. One that is not depleted when used by people.

In fact, we use tons of recycled paper and create a large demand. This demand actually helps recyclers create programs to reclaim even more consumer waste paper.

In addition, unlike the cheap wire hangers made outside of the United States in low wage factories, our EcoHangers Media are made in EPA regulated plants here in the USA. And those plants conform to OSHA standards as well as local wastewater discharge standards.

Made from 100% recycled paper and recycled plastic bottle caps
100% recyclable and durable enough to be used over and over again
Produced with our proprietary 4 color printing process and aqueous coating on a special formula of moisture resistant EcoPlyBoard™

Click here for the EcoHangers website
Click here for the article in Packaging Digest

-- CardPak Inc.

Growth predicted for packaging

2009-01-19T07:31:00.001-05:00

High Visibility Packaging, a new study from Cleveland-based industry research firm The Freedonia Group, Inc. shows US demand for high visibility packaging is projected to expand..

Cleveland, OH (Press Release) - US demand for high visibility packaging is projected to expand 4.0 percent yearly to $8.5 billion in 2012, exceeding 33 billion units and generating demand for 1.1 billion pounds of plastic resin.

Gains will reflect rising disposable personal income levels, the influence of mass market retailers, and the cost and performance efficiency of high visibility packaging. Low cost, market aesthetics and consumer convenience will remain the main drivers of high visibility packaging demand. Food will continue to account for more than half of the high visibility packaging market in 2012 due to opportunities in fresh produce; meat, poultry and seafood; and prepared and frozen food. These and other trends are presented in High Visibility Packaging, a new study from The Freedonia Group, Inc., a Cleveland-based industry research firm.

Clamshell packaging and carded blister packs together accounted for 56 percent of high visibility packaging demand in 2007. Clamshells will present the best opportunities and expand 5.0 percent annually through 2012 due to ebullient gains in food markets such as fresh produce and prepared foods. Clamshell demand will also benefit from their upscale appearance; thick, rigid construction; clarity; and ability to deter theft and tampering. Current efforts focus on making clamshell packages easier to open. Blister pack demand is expected to rise 4.4 percent per annum, fueled by healthy gains for pharmaceutical packaging.

Windowed packaging demand is expected to increase only 2.1 percent annually to $2.0 billion in 2012. Advances will reflect opportunities in areas such as fresh produce, and cosmetics and toiletries. Nonetheless, below-average growth is anticipated as a result of subdued demand in major markets such as baked goods, and intense competition from imported products.

Skin packaging will register the slowest growth based on diminished demand for carded skin packs, due to their higher production cost and growing offshore production of toys, hardware and other goods. Strong growth is forecast for the niche segment of high visibility tubs, cups and bowls, due to opportunities in the packaging of baked goods, produce, snacks, candies and other foods.

-- CardPak Inc.

Data for American Forest and Paper Assoc.

2009-01-13T22:00:00.003-05:00

Data for American Forest and Paper Association
Zogby International
Online, 3385 voters in 2008 +/- 1.7%

Of the following six major industries, which two do you believe devote the greatest effort toward improving the environment? (CHOOSE TWO)

Paper/Forest Products Industry 33%
Automobile Industry 29%
Oil and Gas Industry 28%
Plastics Industry 9%
Mining Industry 8%
Steel Industry 3%
Other 8%
None of the above 23%
Not Sure 17%

When purchasing products that are made with paper (for example, coffee cups, napkins, etc . . .), how often do you look to see if the paper material is recycled or environmentally-friendly?

Always 19%
Sometimes 42%
Rarely 18%
Never 20%
Not Sure <1%

Please tell me whether you strongly agree somewhat agree, somewhat disagree, or strongly disagree with the following statement: “When purchasing paper products, I would be willing to pay more for an environmentally-friendly product like recycled paper.”

Strongly Agree 19%
Somewhat Agree 41%
AGREE 60%
Somewhat Disagree 18%
Strongly Disagree 20%
DISAGREE 38%
Not Sure 3%

How active do you believe the forest and paper industry has been in working to improve the environment through programs like reforestation, recycling and water and air quality improvement efforts?

Very active 26%
Somewhat Active 41%
ACTIVE 67%
Not Very Active 16%
Not At All Active 3%
Not Active 19%
Not Sure 15%

Using your best guess, how many of the paper and forest products you purchase would you say are made from recycled paper or other environmentally friendly sources?

Less than 25 percent 28%
25 – 50 percent 36%
50 – 75 percent 17%
More than 75 percent 7%
Not Sure 12%

Which is more important to you – plentiful, inexpensive energy or clean, safe and renewable energy?

Plentiful/inexpensive 35%
Clean/safe/renewable 58%
Neither 3%
Not Sure 4%

-- CardPak Inc.

Interview: CardPak's Tony Petrelli

2009-01-10T14:40:00.005-05:00

Posted below is an interview of CardPak President Tony Petrelli, featured in the December issue of Paper, Film and Foil Converter Magazine. This interview focuses in on Tony's particular management style and philosophy.

Click on photo below to enlarge and read the interview...

-- CardPak Inc.

Post-Election Poll... voter insight.

2009-01-08T07:00:00.002-05:00

Here's an article recapping a Post-Election survey commissioned by the National Wildlife Federation...

Zogby Post-Election Poll: 78% Believe Investing in Clean Energy Is Vital to Boosting U.S. Economy

Survey finds supporting candidates who favor reducing global warming pollution is important to most voters.

UTICA, NY - More than three in four voters - 78% - believe investing in clean energy is important to revitalizing America's economy. Of those, 50% said they strongly agree clean energy investment is vital to the nation's economic future, a new Zogby Interactive post-election poll shows.

Support for clean energy investment is particularly strong among younger voters - 87% of those age 18-24 and 80% of those age 18-29 believe this type of investment is necessary to help improve the U.S. economy. African American voters (94%) and Hispanic voters (84%) also showed overwhelming support for clean energy investment.

While the vast majority of Democrats (96%) and independent voters (77%) view clean energy investment as a key means to boost the U.S. economy, more than half of Republican voters (58%) also said the same.

The Zogby Interactive survey of 3,357 voters nationwide was conducted Nov. 5-6, 2008, and carries a margin of error of +/- 1.7 percentage points. The survey was commissioned by the National Wildlife Federation.

"While the economy was the top issue in the 2008 election, clean energy clearly emerged as part of voter expectations for getting the economy back on track," said John Zogby, President and CEO of Zogby International. "Support for action on global warming, already strong in the 2006 election, was even stronger in 2008, particularly among young voters that are the future electorate."

This post-election survey also found that most voters want their elected officials to focus on global warming - 61% said they agree their elected officials should make combating global warming a high priority, an increase from 58% of voters who said the same in 2006. Among young voters age 18-24, 69% want a greater emphasis put on combating global warming. The desire for a greater political emphasis on global warming has increased to 88% among African American voters from 78% in 2006 and to 73% among Hispanic voters from 64% two years ago. This post-election survey also shows independent voters are increasingly likely to want their elected officials to make sure combating global warming is a high priority.

More than half of voters (57%) said voting for candidates who support reducing global warming pollution was important to them in this election, up from 50% of voters in 2006. This was particularly significant to younger voters and has increased in importance from two years ago - among those 18-24, 70% said a candidate's support for reducing global warming pollution was important to their vote, up from 56% who said the same in 2006. This issue also has also increased in importance among independent voters, African American voters and Hispanic voters in since the election two years ago.

For content, contact: Miles Grant, National Wildlife Federation Communications Manager, 703-864-9599 (cell) or grantm@nwf.org

For methodology, contact: Fritz Wenzel, Zogby International Communications Director, 315-624-0200 ext. 229 or 419-205-0287 or fritz@zogby.com

-- CardPak Inc.

Packaging Sustainability Emphasized at Industry Keynote Event

2009-01-06T21:39:00.008-05:00

Chicago, IL (Press Release) - More than 100 key packaging brand executives, suppliers, trade association and media personnel gathered at Chicago's Shedd Aquarium November 10th to attend the 2nd Annual Environment Expo sponsored by CardPak Inc., a leading supplier of sustainable packaging for consumer marketers.

The event was held in conjunction with Pack Expo 2008 held at Chicago's McCormick Place Exposition Center. The evening's focus was on the packaging industry's role in addressing the sustainability needs of the retailer, the consumer and the environment.

Attendees dined in the Shedd Aquarium's rotunda among reef sharks, manta rays and an actual scuba diver. Tony Petrelli, CardPak president, spoke of the importance of environmental sustainability being the future of the packaging industry - and the future of our planet.

The keynote speaker, Michelle Jost, Director of Sustainable Practices at the Shedd Aquarium, highlighted the sustainable practices in place at the Shedd Aquarium and provided a fascinating insight to the different freshwater and saltwater exhibits. In closing, she challenged all guests to adopt small conservation habits to help protect and conserve water, one of our most precious natural resources.

Hi-Res photos and additional photos of the event - click here.
Word document of this release is available at - click here.

-- CardPak Inc.

Case Study: Beiersdorf Nivea ShelfPak

2009-01-05T08:30:00.006-05:00

The following is a case study featured in the December issue of Package Design Magazine. The case study focuses in on the Beiersdorf Nivea for Men ShelfPak design as an alternative to a stand-up clamshell package.

Click on photo below to enlarge and read the case study...

-- CardPak Inc.

Sustainability story telling

2008-12-31T21:41:00.002-05:00

'Sustainability' still has some growing up to do as a concept and label. It brings about many opinions and debates... some see it as a marketing ploy, while others see it as a sincere and legit foundation of doing business. Either way, 'sustainability' success stories need to be shared with hopes that these stories will help other ideas and initiatives to be developed and fueled. Plus, the more success that is being reported, the less negative connotations will be linked to the term.

For example, GE has been telling such a story on the back of their CFL light bulb packaging. GE backed up the talk by reducing the amount of plastic used in the packaging and replacing the plastic with recycled and recyclable materials.

Wal-Mart scorecard proof aside... this package is one of the best on-the-market examples of what is possible when considering and developing sustainable packaging.

As we look ahead to 2009, GE was ahead of the times with this sort of 'story telling' approach.

As the new year approaches, consumers will be seeing more and more 'green stories' being told on the packaging of products they buy. Sustainability labels will also become a common sight, with major retailers like Wal-Mart hoping to standardize and require such information.

The labels, which some companies have already starting using (hoping for a competitive edge) will have information on the various categories like: carbon footprint, an index measuring recycled content, what raw materials were used to produce the product and/or package, and how sustainable those materials are.

Sustainability labels will soon become as common as nutrition labels on food, especially since it will be driven by the retailers, which is great for the everyday consumer looking to make a difference.

-- CardPak Inc.

Paper bag or the whole tree?

2008-12-26T12:26:00.009-05:00

The Panera phenomenon:

Order:
one whole sandwich
one 1/2 sandwich
one side salad
one cup of soup

Packaging/bagging:
one large carrying bag
one medium bag
three small individual bags

All companies can strive towards a better carbon footprint, but in this day and age, for a high profile company to create this amount of excess waste and pass it on directly to the end consumer is mind-boggling. Environmental consciousness is not that hard of a concept... in the case, the picture speaks volumes.

-- CardPak Inc.

Rethink Hybrid capabilities

2008-12-19T16:22:00.006-05:00

A hot and relevant topic to environmental awareness is to learn and discuss more about the true capabilities of hybrid cars.

Johnathan Goodwin can get 100 mpg out of a Lincoln Continental, cut emissions by 80%, and double the horsepower. Does the car business have the guts to follow him?

Goodwin leads me over to a red 2005 H3 Hummer that's up on jacks, its mechanicals removed. He aims to use the turbine to turn the Hummer into a tricked-out electric hybrid. Like most hybrids, it'll have two engines, including an electric motor. But in this case, the second will be the turbine, Goodwin's secret ingredient. Whenever the truck's juice runs low, the turbine will roar into action for a few seconds, powering a generator with such gusto that it'll recharge a set of "supercapacitor" batteries in seconds. This means the H3's electric motor will be able to perform awesome feats of acceleration and power over and over again, like a Prius on steroids. What's more, the turbine will burn biodiesel, a renewable fuel with much lower emissions than normal diesel; a hydrogen-injection system will then cut those low emissions in half. And when it's time to fill the tank, he'll be able to just pull up to the back of a diner and dump in its excess french-fry grease--as he does with his many other Hummers. Oh, yeah, he adds, the horsepower will double--from 300 to 600.

"Conservatively," Goodwin muses, scratching his chin, "it'll get 60 miles to the gallon. With 2,000 foot-pounds of torque. You'll be able to smoke the tires. And it's going to be superefficient."

He laughs. "Think about it: a 5,000-pound vehicle that gets 60 miles to the gallon and does zero to 60 in five seconds!"

"You can feed it hydrogen, diesel, biodiesel, corn oil--pretty much anything but water."

Goodwin's feats of engineering have become gradually more visible over the past year. Last summer, Imperium Renewables contacted MTV's show Pimp My Ride about creating an Earth Day special in which Goodwin would convert a muscle car to run on biodiesel. The show chose a '65 Chevy Impala, and when the conversion was done, he'd doubled its mileage to 25 mpg and increased its pull from 250 to 800 horsepower. As a stunt, MTV drag-raced the Impala against a Lamborghini on California's Pomona Raceway. "The Impala blew the Lamborghini away,"

You can read the rest of the article here... Motorhead Messiah - great stuff; converting Hummers, Escalades, 1960 Lincoln Continentals, 1965 Chevy Impalas, you name it - into highly fuel efficient, monstrously powerful vehicles.

Don't limit your ability to make an environmental difference. Think outside of the box and don't just assume that things are 'just the way they are'... this is a perfect example.

-- CardPak Inc.

Pack Expo press release from Winterborne

2008-12-04T15:07:00.003-05:00

LOS ANGELES, CA (Press Release) - Armed with fresh information from end of year shows and conferences, including Pack Expo success, growing interest in EnviroShell® and excitement about the CardPak Winterborne alliance, Winterborne’s confidence that the New Year will bring ever more demands for environmentally compatible packaging remains strong.

Winterborne is urging brand owners to examine their current packaging with an eye to sustainability. When a package does not measure up now is the time to redesign and reengineer a new approach to product presentation.

Winterborne’s proven ability to design award winning sustainable packaging and the company’s investment in the tools to follow through with energy frugal production practices makes Winterborne a must consult option for brand owners looking to refresh their image while making an exponential improvement in sustainability scores.

A Reliable Shortcut to Successful Sustainability

“We are a reliable shortcut to successful sustainable packaging. We know the mass market landscape and know how to upgrade a brand’s presence in big box stores, club stores, large discount department store environments and any other retail outlet where the competition for distinguished brand presence is fierce. Our expertise includes exceptional knowledge of sustainable materials, highly creative graphics capabilities and proprietary engineering and state-of-the-art production,” Mallen said.

Winterborne is a full service packaging supplier of thermoforming, corrugated and paperboard packaging and displays. Winterborne is widely known for the invention of the exceptionally successful, award winning EnviroShell®, made from recycled RPET and recycled corrugated, now widely used by a variety of internationally recognized brand owners in both retail and warehouse club marketplaces.

Winterborne is fortified by a recent agreement with Ohio based CardPak to join resources to bring sustainable packaging products and services to the clamshell and blister packaging markets. By combining efforts the partner companies become the dominant force in sustainable replacements for traditional plastic clamshell and blister type packaging. Both companies have a strong presence in the warehouse club channel as well other major retail outlets.

-- CardPak Inc.

New Partnership Agreement Advances Sustainable Packaging

2008-09-02T11:30:00.007-04:00

SOLON, OH (Press Release) - Sustainable packaging powerhouses, Ohio based CardPak®, Inc, and Los Angeles based Winterborne, Inc have agreed to join resources to bring sustainable packaging products and services to the clamshell and blister packaging markets. By combining efforts the partner companies become the dominant force in sustainable replacements for traditional plastic clamshell and blister type packaging. Both companies have a strong presence in the warehouse club channel as well other major retail outlets.

Winterborne is widely known for the invention of the exceptionally successful, award winning EnviroShell®, made from recycled RPET and recycled corrugated, now widely used by a variety of internationally recognized brand owners in both retail and warehouse club marketplaces. Winterborne offers brand owners turnkey services, including custom sustainable product packaging design development and production.

An early innovator of sustainable packaging, CardPak® has a long held commitment to development of sustainable products and practicing lean, environmentally friendly manufacturing. CardPak® has brought to market an award winning ecological line of clamshell replacement packaging that eliminates up to 85% of plastic and reduces harmful contaminants from the waste stream. Included in their line is SustainPak™ and ClubPak™ - the preferred warehouse club packaging used by major brands such as Oil of Olay®, General Electric®, and Kirkland Signature®.

Tony Petrelli, CardPak® President said, “This partnership allows both CardPak and Winterborne to present a more robust offering to retailers and brand owners and break new ground in the world of sustainable packaging. I have no doubt the combined resources of our two companies will significantly and positively impact the sustainable packaging industry. The geographic spread between our manufacturing facilities also gives us mutually beneficial, sustainable shipping advantages.”

Howard Mallen, Winterborne Executive Vice President said, “The partner companies are remarkably similar in culture and focus on sustainability. We have complementary market strengths and products and expect this agreement to give us, jointly, a dominant presence in the market while offering our customers seeking sustainable packaging the convenience of using a single source supplier.”

-- CardPak Inc.

CardPak Sustains Its Future Growth

2008-08-01T11:53:00.005-04:00

This Ohio converter adapts its traditional blister card business to capture a piece of the retailers' sustainability pie.

The shift by major U.S. retailers Wal-Mart, Costco and Target away from polyvinyl chloride (PVC) packaging and towards recyclable packaging will have a huge environmental impact, which is long overdue, critics say. Solon, Ohio-based CardPak, Inc. is helping influence that impact all the while sustaining its own future.

Click here to read the entire article from : Paperboard Packaging Magazine

-- CardPak Inc.