Tokyo Pack reflects style-led Japan market

In a special report based on his visit to the Tokyo Pack show, which ran from 2-5 October 2012, Andrew Manly gives an insight into the packaging sector in Japan – where the majority of output is driven by domestic or near-market consumption.

Machines offer extra
Japan is one of the top five manufacturers of packaging machines in the world. Yet the peculiarities of the market means only a small proportion of these machines find their way into Western factories.

Almost 90 per cent of Japanese output is geared to domestic or very close market consumption. This is due to some of the particular demands of the supply chain and retailer formats for pack styles and materials – but also, many of the products being packed are unique to Asian markets.

Of course Europe and the USA are familiar with names such as Ishida, Yamato, Anritsu, Sanko and Omori. But, as Tokyo Pack 2012 illustrated, there are increasing numbers of companies starting to look further outside Asia, bringing with them some fresh ideas.

Eye-catching pack styles
Pack appeal is an important aspect of retailing in Japan, and ideas for pack differentiation were evident on some machine stands at Tokyo Pack. Yuma Industries, part of the Fuso International Group, has adapted one of its vertical baggers to produce a striking rice pack, using vacuum to create a cube format, which gives excellent presentational possibilities.

The HP-500 machine was already capable of producing zip, gusset and flat bags in various sizes, and thanks to new folding mechanisms and improved vacuum strength it can now produce up to eight 75x75x75mm cubes/min, weighing 200g to 250g.

Another example of pack differentiation was to be found on the Furukawa Manufacturing stand where a modified version of the company’s Old Rivers filler/sealer FF-220 N-TP was producing Super Tetrahedral packs of shell nuts at 30 bags/min. The visually impressive container uses OPP film or an aluminium laminate, depending on the application, and is 150mm along each side.

The bags, created by Pattruss, have advantages of strength and being suitable for a variety of products, including fresh salads as well as snacks, it is claimed. The automatic filler uses premade bags and enable options such as gas flushing and direct printing on the bag.

More familiar in Europe is the Box Pouch machine from Totani. The latest version, the high speed BH-60DG-F, unveiled at TokyoPack, can run, on a dual lane basis, at 240 packs/min in sizes from 90x74x200mm up to 194x114x580mm, depending on the pouch format. The diverse range of styles is achieved by utilising two separate film webs (main and side gusset), and a larger width of 294mm is available with a web extension.

The makers claim the machine uses 12 per cent less material than a stand up pouch with a similar volume and has the advantage of five printable surfaces. Applications include groceries, apparel, medical, DIY and pet food. It is particularly suitable for presentation packs of all these. A liquid fill version is also available.

Labelling difficult shapes
Label specialist Takara Pac highlighted the BA-5000 Bellows Label Applicator. Developed for challenging label applicators, the BA-5000 is a high-speed pneumatic level applicator which features elastic bellows that use air pressure to hold labels in position and apply them onto products of irregular shape and size. This includes uneven and concave/convex package surfaces, flexible packages, and soft/fragile products.

The bellows motion has a rate of 0.1sec/cycle, allowing for the continuous motion of the conveyor. The bellow stroke length is 20-30mm, and the machine can be used for pressure sensitive labels width 25-80mm, label pitch 8-10mm and maximum label size of 105mm (l) x 80mm (w).

Entry level value with extra functionality
The Ishida Company rolled out several innovations at Tokyo Pack, as would be expected on ‘home territory’. Surprisingly one of the ‘stars’ of the stand, a low cost tray sealer, is under development in the UK at the company’s European HQ. The QX-300 mini – which is still a prototype – is a simple, stand alone machine that can accommodate a single tray size of 415x270mm, two of 270x197.5mm, four of 197.5x125mm and six of 125x125mm. Able to run at 10 cycles/min, the sealer is aimed at the ‘entry level’ market, where a semi or fully automatic machine would be too costly.

In addition Ishida launched a range of low cost checkweighers. Made in China, the DACS-EL series are simple to operate and robust, says the company. Also on display were the latest combination checkweigher and X-Ray machines, offering customers a dual unit, claimed to save both space and energy.

Ishida’s second generation X-Ray inspection system was also featured. The IX-G2-4076 offers improved detection sensitivity for layered products and benefits from new technology using a Dual Energy sensor, it claims. The demonstration unit featured a non-curtain trapezoidal conveyor.

Anritsu Industrial Solutions’ latest metal detector, the duw-h, incorporates ‘self learning’ control software which makes it extremely user-friendly, and easy for a new operator to understand quickly without specific training, according to the company. The machine also incorporates a ‘high-sensitivity’ head that enables it to detect smaller metal particles, the company says.

Also demonstrated was the latest version of Anritsu’s Quicca range of quality and control management systems software. The KX9002 series provides real time monitoring and analysis for production line optimisation as well as traceability and HACCP compliance.