With the high demand for more sustainable practices in manufacturing, businesses are seeking to use more environmentally friendly and responsible packaging, to drive their plans for long-term efficiencies and carbon reduction. The issue of plastic packaging is huge and remains important and universal within the FMCG market. Cardbox Packaging is at the forefront of this issue, committed to reducing the production of plastic packaging by exploring solutions for its diverse range of FMCG products.
A market-leader in the production of high-quality carton packaging, Cardbox Packaging of Austria supplies a large and high-profile customer base with packaging solutions for everything from diary and confectionary to pet food, pharmaceuticals, and cosmetics packaging. Its values are based on high quality standards, customer satisfaction, flexibility, and innovation, which form the building blocks for its continuous growth. Established in 2011, Cardbox Packaging’s production sites in Austria, the Czech Republic, United States, and a new upcoming site in Serbia, operate with the latest, cutting-edge technology and innovations to support its goals. In addition, the investment in a technical center is currently being analyzed in order to be able to implement product developments for barrier coatings even more quickly and in a more targeted manner, detached from operational production.
Klaus Hockl, Managing Director of Cardbox Packaging, explains, “Cardbox Packaging is focused on delivering unique solutions to meet our customers’ evolving requirements for sustainable, innovative but effective packaging. To fulfil our objectives, we need to not only equip our facilities with an advanced production line, but partner with the like-minded, forward-thinking companies that produce the technology and solutions we use. Coatings specialist, ACTEGA, and Cardbox Packaging have enjoyed this partnership approach for many years, and this enables us to overcome challenges, continually reach and set new goals, and achieve great results for our customers.”
Finding New Routes to Sustainable Packaging Requires a Sustainable Partnership
Hockl continues, “Being a company focused on innovation in sustainable packaging is not an easy choice. There are many complexities to ensuring your new solution will replace the existing ones on the market and, even when you believe you have found a solution, you need to test it for every conceivable application.” Even the same food stuff, such as greasy chicken fat, behaves differently depending on its use. In pet food, it is very hard to contain effectively, however, if it is frozen in a microwavable meal, for example, it is easier to manage. Of course, then you have the added complexity of the product needing to be effective under a variety of temperature conditions (from freezer to oven).
“Once you have overcome these challenges and are satisfied that your new solution can be used to package a variety of products successfully, you then have to ensure that it fulfils all of the appropriate regulations and laws, can be used on a global scale, doesn’t affect the product shelf life, interfere with the food itself… the list goes on.”
With such a long and complicated process involved in creating new packaging solutions, the close collaboration between Cardbox Packaging and ACTEGA is invaluable. Both companies work at a similar speed, have the same innovative approach, and ensure that the lines of communication are always open. This enables the two companies to work together to continually push boundaries, test new products and find new solutions.
“Large companies can be faceless teams but working with ACTEGA is not like that. Markus Locher (ACTEGA) and Michael Scheiber (Cardbox Packaging) have been instrumental in our latest development projects and are always in communication. As such, they can act quickly and efficiently, a huge advantage when working on developments for this fast-paced and highly competitive industry.”
With this successful, long-term partnership in place, it is not surprising that the majority of coatings and varnishes Cardbox Packaging uses are from ACTEGA and the company is keen to test and incorporate new products when ACTEGA launches them.
Impressive Results with ACTGreen® Barrier Coatings
One of the challenges that packaging producers like Cardbox Packaging face is finding a solution to replace the plastic laminates in packaging with a more sustainable alternative. Traditionally, packaging has been laminated with plastic polyethylene (PE) to protect the product and packaging from the effects of oils, fats, water, as well as external substances. However, the complicated, costly and challenging recycling process resulting from their use has led to increased pressure on finding a new solution.
So, when ACTEGA launched its range of ACTGreen® Barrier Coatings, Cardbox Packaging was quick to see the opportunities this new product line presents for its solutions, as well as the benefits it would provide its customers.
“The ACTGreen range makes it possible to recycle products, offering the effective and sustainable alternative we have been searching for. This is a big step forward for companies like ours, not only for the clear and valuable environmental advantages it provides, but eliminating PE significantly streamlines the production process. We can, therefore, benefit from time and cost efficiencies and our customers can take advantage of quicker delivery times as a result,” says Hockl.
ACTGreen® Barrier Coatings range comprises barrier coatings and TPE dispersions for coating and binding which are all water-based. Depending on the product, barrier coatings from ACTEGA are able to provide effective protection from water vapour, water, oil and fat, with additional barrier effects against alcohol, alkaline and acidic liquids and dairy products. Further to this, its novel aqueous TPE dispersions with YUNICO® technology make it possible to combine these different properties within a single dispersion – for example, specific barrier properties; tactile effects (e.g. smooth, soft, silky, rough); heat sealability in high and low temperature ranges; and certified recyclability.
“As you would expect from ACTEGA, the product quality is not compromised with these increased sustainable benefits and the brands we work for have been very impressed”, continues Hockl. “We have had numerous enquiries for new projects and products as a result - a few customers even ask specifically who supplies the coatings and want to ensure these are used in their own packaging.”
Continuing to Think Outside of the Box
Despite this latest success, Cardbox Packaging, like ACTEGA, is not a company to sit still. Hockl recognises that finding an alternative to PE laminates is a fantastic achievement but the company still wants to find an alternative to PET laminated boards. Hockl knows that it will be a long process, but it is one of his ultimate goals.
Hockl adds, “Meanwhile, we have many other innovations in development that will support our vision for increased use of sustainable packaging solutions. For example, we have created a carton board spoon for yoghurts that replaces the plastic one now in use and a 100% recyclable sealable tray. This product is really unique and can be used for a variety of foods, such as herbs, cakes or vegetables.”
Cardbox Packaging is so dedicated to innovation that it is installing a new coating system to facilitate a production line that can be used for testing new solutions, as well as expand production capacity. These innovations include new products being developed by ACTEGA, such is the mutual partnership and commitment to progress that these companies share.
Hockl concludes, “As our customers’ needs evolve and we continue to push ourselves to stay ahead of the competition, ACTEGA and Cardbox packaging are all at the same table, talking about the next advances in sustainable packaging. We are very fortunate to work with such an agile, innovative partner.”
