Increasing consumption nonwovens
-That’s a wrap
The increasing consumption of nonwovens products across the world is being accompanied by an equal amount of growth in the vital machine-made packaging sector
A key requisite for the packaging of nonwovens items in the hygiene and medical sectors is that they should have the longest possible shelf life while also ensuring that the product complies with all legally specified hygiene and sterilization standards.
Another increasingly important aspect is the sustainability of the product throughout the supply chain, from the raw material production to waste disposal.
The result of these two demands is that nonwovens are becoming more and more attractive as packaging material, both for manufacturers and users.
Throughout the world packaging manufacturers in different industries are stepping up their endeavours to ensure the best possible sustainability for the production and waste disposal of their products prompting the rise of key trends such as volume reduction and reusability
Recyclable Increasing consumption nonwovens
Recyclability is a requirement that multi-national packaging specialist Mondi is keen to address. The company has recently collaborated with Essity and Dow to create new, recyclable secondary packaging for Essity’s feminine care products, using renewable materials and post-consumer recycled content that reduces the use of fossil-based materials.
Essity’s feminine care towels were previously packed in bags that already used 50% renewable materials. Extensive research and testing by Mondi however, resulted in the recommendation of a new solution that aligns with Essity’s packaging goals – to work towards 100% recyclability and to use up to 85% biomass, renewable or recycled material in all bags where up to 25% are recycled plastics. Increasing consumption nonwovens
The new packaging contributes by using a renewable material and by-product from the paper making industry that is produced from circular feedstock based on the ISCC (International Sustainability and Carbon Certification) mass balance approach. The packaging also contains mechanically recycled content from post-consumer material. Mondi worked with long-term supplier Dow and other companies along the value chain to find the most suitable resin formulation for this solution. The end result is an extruded film that is printed on and converted into a bag.
Providing the same high-level of protection as the previous alternative, the solution prevents moisture and light damage, has strong sealing properties and delivers outstanding print quality to maintain on-shelf appeal for Essity’s European recognised brands such as Bodyform, Libresse, Nana and Nuvenia.
“The challenge was to find the best combination of renewable and recycled content that maintains product quality and the production efficiency already enjoyed by Essity said Marjo Kuisma, responsible for consumer flexibles regional sales at Mondi.
“We tested several options until we found the most suitable solution. Working in collaboration with Essity and Dow validates our EcoSolutions approach – we go back to the start and ask the right questions to ensure we create the best possible solution for our customers.” Increasing consumption nonwovens
Kraft
Recyclability was also a key consideration for American Hygienics Corporation, a global leader in wet wipes and baby diaper manufacturing, which has introduced a sustainable alternative packaging option which uses Kraft paper for its most eco-friendly baby diaper range of products.
AHC’s paper bag offers global hygiene product manufacturers an additional option to bio-based and compostable packaging and has a number of attributes that will be attractive to the end consumer. The bags are easy-to-open, recyclable and sustainably sourced, with FSC certification, significantly reducing carbon footprints. Increasing consumption nonwovens
“AHC’s long-term vision towards sustainability is driving its R&D efforts to give the world a better sustainable and eco-friendly choice,” said group directors Kalpesh Parmar. “Following tremendous demand for more eco-friendly packaging and interest in reducing the single use plastic in our products, we have been constantly looking for the right option. Finally, we came up with the paper bag for our green diaper range that has the ability to claim itself more sustainable and recyclable.
Among other targets in the years to come, AHC aims to offer more biodegradable and compostable products to reduce landfill waste while committing to carbon-neutral manufacturing operations.
Partnership
Hayat is regarded as one of the leading FMCG companies (Fast Moving Consumer Goods) based in Turkey, offering products in the hygiene, home care, tissue, and personal health categories that reach over 100 countries. With demand continuing to grow the company has recently taken delivery of its 50th Optima bundler, expanding its 18-year partnership with the packaging technology specialist. Increasing consumption nonwovens
Optima and Hayat have worked closely together since 2003, and in 2021 this culminated in the delivery of the 50th Optima bundler.
Hayat, which is the world’s fifth largest branded baby diaper manufacturer, ordered an Optima bundler for the first time in 2003 – the first model offered through the company for packaging paper hygiene products. This year the 50th bundler was supplied to Hayat – a special occasion that both companies are proud of.
“When we entered the market for baby diapers and sanitary napkins, we were looking for a world-class partner for packaging,” Ibrahim Güler, vice president Operations at Hayat, said. “Of all the potential partners, Optima stood out with its high standards and clever solutions. Today, Optima also meets the requirements of our high speed production lines, which are Industry 4.0 compatible, perfectly.” Increasing consumption nonwovens
Ivair Santos, sales director, South America at Optima do Brasil, added: “Hayat expects the best technologies to ensure maximum efficiency. With valuable feedback, Hayat has played a part in the success story of the Optima bundler over the years.” Other multipackers are already in production for Hayat.
During their 18 year partnership, Optima says it has continued to optimize the bundlers and adapt the technology to customer requirements. Today, for example, the welded seams of the multi-unit packs, which consist of PE film, are formed with a servo-controlled unit. This makes format changes significantly quicker. Hayat is also able to accommodate the almost tool-free format change. The Optima bundler can be switched to a new format in 15 to 30 minutes. Increasing consumption nonwovens
Pre-packed paper hygiene products are fed inline to the OPTIMA BD12 bundler during production. For multi-line packaging, the bundler creates single or multi-layered formations. The bags are made in the machine from the PE film roll, then the product formations are inserted into the bags and closed with a welded seam.
The multi-unit packs have a width of up to 800 mm, a length of up to 1,200 mm and a height of up to 400 mm. The output is twelve multi-unit packs per minute, which almost entirely covers the market requirements. All Optima bundlers are produced at the Brazilian site in Vinhedo and comply with the high standards of the international special-purpose machine manufacturer based in Schwaebisch Hall, Germany.
The Optima bundlers are used at various Hayat locations worldwide. The company employs over 9,000 employees across 21 plants. Increasing consumption nonwovens
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