Pursuing a new strategy for this product category, P&G redesigned machinery as well as packaging structure to enable a switch from wicketed polyethylene bags to continuous flow-wrapping technology.
The new packaging facilitates better pallet fit, due to the tighter packaging, and reduces the energy usage required for transport of packaged products. Specific film structures and gauges vary within the Always product line and are considered proprietary.
P&G section head for R&D packaging development Ibrahim Ulas says, “The new process enables the use of less material and creation of a tighter bag, leading to a 25-percent reduction in film use. The rollstock is more compact and thus leads to an 80-percent reduction in packaging material storage space. The film, flexo-printed in a minimum of six colors, is formed into bags on-line and heat-sealed using custom flow-wrap equipment developed jointly with a proprietary partner.
“Bags are designed to allow for easy product dispensing. The package opening is parallel to product orientation to facilitate easy product dispensing. Consumer reception has been good.”