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Automated Filling for Innovative Pack

Once The GFB had established that its hybrid paper/paperboard package was a hit with consumers, an automated rotary bagger became an absolute must.

The rotary filling machine has two volumetric fillers and lets The GFB run about 25 packs/min.
The rotary filling machine has two volumetric fillers and lets The GFB run about 25 packs/min.

Dedicated to gluten-free bars, bites, and other gluten-free products and in business now for a decade, The GFB of Grand Rapids, Mich., may be something of a new kid on the block. And with about 50 people on the payroll, it’s not exactly a food-making juggernaut. But one thing the firm’s management is not afraid of is innovative packaging and new equipment to fill it.The rotary filling machine has two volumetric fillers and lets The GFB run about 25 packs/min.The rotary filling machine has two volumetric fillers and lets The GFB run about 25 packs/min.

Exhibit A is the collapsible cup that The GFB (acronym for Gluten-Free Bar) uses for its gluten-free oatmeal. This format is an alternative to round cups with flexible film lidding commonly used in this category of products. Such cups are certainly functional enough, but from any sort of cube or space utilization perspective, they’re a bit suboptimal. Not only because a round package doesn’t cube out well, but also because the container needs to be designed with a considerable amount of head space between the dry product and the lid. Inherent in such a design is the need to ship a lot of air.

These shortcomings are neatly addressed by the cup used by The GFB because it’s collapsible. This makes it uniquely suitable for on-the-go consumers who crave portability and convenience. Consumers can easily tuck the slim pack in a purse or brief case. When it’s time for breakfast, just pinch the left and right sides toward the middle and, thanks to clever scoring and die cutting, the paper package turns itself into a squared-off bowl. Just add hot water and stir. Microwaving isn’t really necessary, but for those who prefer oatmeal that’s really hot, instructions for microwaving are included on the package.

Photo shows a package paused as it receives its charge of oatmeal.Photo shows a package paused as it receives its charge of oatmeal.Essentially a hybrid package consisting of one flexible material (paper) and one rigid material (paperboard), this collapsible cup comes from Graphic Packaging International. It was born out of GPI’s IntegraFlex™ technology, a broad hybrid platform where the common denominator is finding ways to marry the advantages of flexible packaging materials with those of more rigid packaging materials.

Until now, GPI has produced these unique packages in an R&D facility. But the firm is now in the process of finalizing a decision on which of its converting plants will house what might be called an IntegraFlex Version 3.0 machine. Unlike the beta units currently in operation, this next-generation equipment will crank out these hybrid packages in true commercial quantities.

Fundamentally, the converting process consists of printing and coating roll-fed paper and then sending it through a slitter/rewinder. Next, the paper and individual 18-point SUS paperboard blanks with offset printing are joined by adhesive in a purpose-built IntegraFlex machine. In the case of the package used by The GFB, the paper is a 25-lb weight with an unnamed coating for barrier purposes.Shown is the filled hybrid package in its slender collapsed state.Shown is the filled hybrid package in its slender collapsed state.

Conveying Innovations Report
Editors report on distinguishing characteristics that define each new product and collected video demonstrating the equipment or materials as displayed at the show. This topical report, winnowed from nearly 300 PACK EXPO collective booth visits, represents a categorized, organized account of individual items that were selected based on whether they were deemed to be both new, and truly innovative, based on decades of combined editorial experience in experiencing and evaluating PACK EXPO products.
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