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Stand-up pouch stands out on the shelf

Canadian marketer of coffee, nuts and spices jumps ahead of the competition by installing a versatile pouching system for nuts and coffees. Private-label packaging beckons.
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FILED IN:  Sustainability  > Strategy
     
Stand-up pouch stands out on the shelfThe horizontal form/fill/seal machine is stationed beneath the mezzanine-level auger filler in this photo. It can also be rolledIn the pouch machine (above), the tool on the left makes the bottom seal and applies the recloseable zipper. The tool on the rigThe ability of the pouch to stand up makes for good visibility in displays like thisIn the pouch machine (above), the tool on the left makes the bottom seal and applies the recloseable zipper. The tool on the rigThis scissors-like tool cuts finished pouches from the webZipper profile is turned and fed between the front and back panels of the packaging material

If the effectiveness of a packaging operation is measured by its versatility then Quebec City's La Chien D'or has every reason to be pleased with the nut and coffee packaging operation that it's been running since August of 1996.

The workhorse of the new system is a Bossar Model B 1600 S pouch machine distributed in North America by Hayssen (Duncan SC). La Chien D'or's machine is among the first Hayssen/Bossar systems installed in North America.

Mounted on wheels this horizontal form/fill/seal system moves smoothly beneath a mezzanine structure. Mounted above are an auger filler and a 14-bucket combination weigh scale. To package ground coffee the Hayssen/ Bossar is stationed beneath the auger filler. For whole-bean coffee or nuts the machine is rolled into position beneath the combination scale.

Ancillary equipment-a zipper applicator a pressure-sensitive tamp labeler that applies a special degassing membrane to coffee packages and a metal detector-is also mounted on wheels so it moves right along with the Hayssen/Bossar.

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Chiefly responsible for specifying the equipment was Alain Beaulieu La Chien D'or's director of production who attended packaging exhibitions from Chicago to Toronto to Dsseldorf to evaluate equipment. When he specified the Hayssen/Bossar system it was not only its versatility that appealed to him. It was also priced competitively and says Beaulieu it has a footprint considerably smaller than comparable systems he evaluated. The entire machine is just 11.92' long x 5.6' high x 4' wide.

Other criteria in Beaulieu's equipment search were speed and durability. The Hayssen/Bossar says Beaulieu delivers on both counts. Running typically two shifts five days/week the machine cranks out 170-g (6-oz) coffee packs either ground or whole bean at a rate of 60 to 80/min. Nuts in 227-g (8-oz) stand-up pouches are produced at the same rate.

Started with bulk packs

The arrival of the Hayssen/Bossar 1600 is the latest stage in a significant evolution the 87-year-old company has undertaken. For many years its only nut and coffee business with supermarkets was exclusively in bulk. Consumers would scoop as much out of a bin as they wanted and pour it into a tin-tie bag. These consumers believed that bulk product was fresher than the same products prepackaged in the grocery aisles. These shoppers often buy in small quantities and return for a fresh supply when they need it. Another draw at least where coffee is concerned is that some people like to mix varieties and grind their own blends into tin-tie bags.

However these consumers are caught up in today's fast-paced lifestyles which don't always allow them time for weighing grinding or blending. Store managers are sometimes bothered by a bulk program too because they worry it requires too much time and attention from store workers.

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These marketplace dynamics led La Chien D'or to install three Hayssen Ultima vertical form/fill/seal machines to package coffee in foil-laminated flat-bottom bags in several sizes. These bags of either whole bean or ground coffee are delivered to individual supermarkets on a store/door basis just as the bulk shipments were. They're even merchandised right beside the bulk bins so they retained the "unpackaged" aura and made it possible for consumers to buy the kind of gourmet coffee they were accustomed to in a more convenient format. Nuts too are packed in the flat-bottom bags.

As this pseudo-bulk packaging established itself right beside La Chien D'or's products in bulk management began to wonder if it might be able to get a foothold in yet a third format: brand-name nut and coffee packaging merchandised from the grocery aisle. The only way to pull it off the company reasoned was by avoiding a "me too" look. The company sought to break away from the Maxwell House and Folgers crowd with a completely different style of package. The Hayssen/Bossar 1600 produces just such a package. As La Chien D'or's Michael Wilson puts it "The stand-up pouch is the package of the future."

Private label too

In addition to using the stand-up pouch for its own brand La Chien D'or sees great potential in the private label business. Supermarket companies in particular are showing keen interest in having their store brands packaged by La Chien D'or.

The material used for nuts packed on the Hayssen/Bossar 1600 is supplied by Filpac (Terrebonne Quebec Canada). It's a 48-ga polyester reverse-printed in six colors with an extrusion coating of low-density polyethylene for heat-seal purposes. A different structure supplied by Winpack (Toronto Ontario Canada) is used for coffee. To prevent oxygen from entering and diminishing the coffee's freshness the adhesive lamination incorporates a 1.75-mil foil layer between an inside layer of 3.5-mil polyethylene and an outer layer of 48-ga polyester. The polyester is reverse-printed on a gravure press in eight colors. The inner layer of PE is modified with ethylene vinyl acetate to enhance heat sealability.

Also applied to coffee packages produced on the Hayssen/Bossar 1600 is a special one-way degassing valve that allows carbon dioxide to escape but prevents oxygen from entering. The CO2 is naturally given off by coffee beans after roasting. For its coffees in flat-bottom bags La Chien D'or packages only after the gassing-off period has ended. Some freshness and aroma are sacrificed but at levels that are considered acceptable in a coffee selling for $8.03 Canadian/lb ($5.80 U.S.). The Classic line of coffee sold in the stand-up pouch however is a premium variety selling for $9.84/lb ($7.11 U.S.). For this coffee La Chien D'or aims to preserve all the freshness and aroma it possibly can. Thus the application of the one-way degassing valve. (For a more detailed look at how the valve works see sidebar p. 22.)

Despite its use of a valve and a reclosable zipper the upcharge for the stand-up pouch compared to the flat-bottom bag is minimal says Beaulieu. "A stand-up pouch uses less film than a flat bottom bag for the same amount of coffee" he points out. "And the zipper material sells for less than two cents per foot."

In the plant

On the day Packaging World visited La Chien D'or ground coffee was in production on the Hayssen/Bossar 1600. Shortly after the roll-fed flexible film leaves the unwind station an