Slitting and Rewinding
How Digital Laser Technology is Revolutionising Sustainable Packaging
By Jordi Prat, slitting technical sales director at Comexi
transparent cellulose label in a single pass. The Result: A paper-based mono-material packaging solution with an attractive design, allowing consumers to view the product through a cellulose label. This solution is not only more sustainable, but also enhances the product’s visual appeal.
A
s the world increasingly shifts toward sustainability, the packaging industry finds itself at the forefront of this transformation. Companies are under pressure to adopt eco-friendly practices that not only reduce environmental impact, but also meet the rising expectations of consumers. We are committed to driving this change through innovative solutions like our Comexi Laser System, a technology that streamlines the production of sustainable packaging by integrating seamlessly with Comexi Slitters. This system enhances the recyclability of packaging materials while decreasing packaging costs through efficient processing.
CASE STUDY 1: WINDOW PACKAGING TO OFFER CUSTOMERS EXCELLENT VISIBILITY OF THE PRODUCT INSIDE Replacing Paper + Film with Paper + Coating + Cellulose label What? To develop a more recyclable paper packaging, we replaced the conventional film with a specialised coating which offers both humidity barrier and heat seal properties. This new packaging also features a window to showcase the product inside. How? The process begins with the application of the coating using a Comexi ML2 Evolution laminator. Once the reel is coated, it undergoes a second process with a Comexi Slitter integrated with a laser inline and labelling module. The laser precisely creates the window in any desired shape and the labelling module seamlessly applies a
CASE STUDY 2: RECYCLABLE PAPER + MESH PACKAGING FOR VEGETABLES Replacing Plastic Mesh with Cellulose Mesh What? We have engineered a recyclable bag for vegetables, replacing the conventional plastic mesh and solvent-based adhesives with a water-based heat seal and cellulose mesh. How? The process involves advanced technology beginning with the application of the water-based heat seal using a Comexi ML2 Evolution machine, eliminating the need for traditional adhesives and solvent-based laminations. The coated material is then processed using a Comexi Slitter equipped with a laser module and an unwinding module featuring IR lamps. The laser module creates a window and the cellulose mesh is integrated in a single pass. The Result: An environmentally friendly fully recyclable paper-based packaging solution that is durable enough to support the weight of the vegetables while allowing the contents to breathe, thereby extending shelf-life and allowing for product visibility.
CASE STUDY 3: 100 PERCENT RECYCLABLE MONO-MATERIAL RESEALABLE TRAY WITHOUT LABEL What? A 100 percent rPET tray with a resealable PET lid designed to keep perishable foods fresh. How? The lid is constructed using a two-step process. First, two layers of PET are laminated together using a water- based PSA adhesive within a Comexi ML2 Laminator. One layer is printed for visual appeal, while the other is heat-sealable for functionality. Next, a Comexi Slitter with an inline laser system adds an easy- open feature to the inner layer of the lid, which also serves as a resealable label. The lid is then heat-sealed to the tray. The Result: This mono-material packaging solution consists of three layers of PET, all of which are recyclable. The combination of the PSA lamination with the laser application unites recyclability, consumer convenience and reduces the cost of the final packaging by simplifying the process.
CASE STUDY 4: RESEALABLE PACKAGING WITH MONO-MATERIAL LABELS What? A sophisticated BOPP packaging solution comprising a printed BOPP layer, a metallic BOPP layer laminated using a solvent-less process and a BOPP label. How? The two BOPP layers are first laminated using a solvent-less process with a Comexi SL2 Evolution or Comexi ML2 Evolution laminator. A Comexi Slitter equipped with a labelling module and an inline laser system is then used to apply the label to the laminated BOPP structure. The laser system precisely shapes the packaging without touching the label, enhancing both the protection and presentation of the product. The resulting BOPP packaging solution is multi-layered, sustainable and designed with precision to maintain product integrity.
28
September 2024
www.convertermag.com
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