Steady metal

3 May 2012



Figures released by the European Aluminium Foil Association in March showed a “modest decline” in overall production levels in the sector for 2011. David Longfield reports


Despite the annual aluminium production figures reflecting a “cautious outlook” throughout European markets, exports from Europe remained “steady”, the industry organisation EAFA said. Total production fell back by 5.2% to 801,900 tonnes – compared to 846,300 tonnes in 2010 – with thinner gauges declining by 7.9%. The figures for thicker gauges looked better, however, registering only a 2.4% drop from 2010 levels. At 0.7% down, exports from the region covered by EAFA membership held up somewhat better.

EAFA’s Roller Group chairman Manfred Mertens commented: “Most retailers and fillers are placing orders on a ‘just in time’ basis and in lower volumes. As the longer-term outlook for aluminium is positive, we are cautiously optimistic for the next few months.”

In February this year, the EAFA became a full member of the UN-backed Save Food initiative, launched in May 2011 at the Interpack expo in Düsseldorf. A joint campaign by the UN Food & Agriculture Organisation (FAO) and the show’s organiser Messe Düsseldorf, Save Food provides a platform for the promotion of initiatives to reduce food waste.

Ready to cook

Nicholl Food Packaging has added five new smoothwall variants to its existing range of aluminium foil trays for the fresh and convenience food sector. Available in rectangular and round designs with different depths and a variety of design enhancements, including ribbed sides and embossed squares on the base, the new trays are said to be ideal for a wide selection of applications.

“The introduction of these latest variants underlines our pro-active new product development programme and our commitment to offering our customers the widest choice of tray types and designs in order to be able to tailor a solution to their precise requirements,” says Nicholl Group CEO John Griffiths.

Smoothwall trays offer a robust construction that enables sleeves and cartons to be lightweighted, reducing total pack costs. Their smooth rims allow each tray to be hermetically heat sealed with standard film on high speed machines, while gas flushing techniques can be incorporated into the filling and sealing process for extended shelf life.

Smoothwall aluminium foil container supplier i2r Packaging Solutions reports exceptional growth of 50% over the past year, including a rise in exports to 25% of total sales, now operating directly in more than 20 countries where ‘ready to cook’ products are becoming more popular.

In September 2011, the company – a subsidiary of Italian aluminium packaging producer Contital – completed a £2.5 million move to a new manufacturing site in its home town of Telford, Shropshire.

Plans for 2012 include a further half million pounds of investment to specifically grow the range of wrinklewall products now offered by the company, increasing choice for i2r customers, while also increasing capacity at the firm’s new 5,500m² premises.

“Our new premises mean we will be able to retain our focus on technological innovation and customer care while having the space to grow in the future,” says commercial director Jon West.

In 2009, Contital became a major investor in the company, established only two years previously, allowing i2r to add wrinklewall products to its range and bringing new opportunities in the UK for its parent company. The combined group converts more than 8,500 tonnes of aluminium a year with an annual turnover exceeding €45 million worldwide.

Aiming to fulfil the needs of chilled meat packers who need an absorbent capable of being heated by conventional ovens within the tray, Lancashire-based Elliott Absorbent Products has launched its Dryline Duo Ovenable Pad. Available in pad or reel format in 1700ml and 3000ml absorbency, the Dryline Duo oven range uses a food contact aluminium heat-resistant top coat and a proprietary bonding capable of withstanding temperatures in excess of 200°C for more than two hours.

“Dryline Duo offers multiple application use across a variety of ovenable trays in the growing ready meal sector at an attractive saving when compared to existing metallised polyester coated options,” says the company’s MD Matt Hankins.

Canned activity

The improved BRE+ (Ball resealable end) from Ball Packaging is due for its first branded launch in the middle of the year, the Germany-based company says. The BRE+ beverage can resealing system can be used with all drinks that need pasteurising, including fruit juice flavour energy drinks, teas and ice teas. A new plastics mixture makes BRE+ resistant to higher temperatures, while the laser-perforated label has the added function of conducting condensate formed during pasteurisation on the inside of the plastics elements (not inside the can) to the outside.

At this year’s Anuga FoodTec show in Cologne, Ball exhibited its new aluminium 33cl Sleek Can. April saw the start of production of the new version at the company’s plant in Oss, Netherlands, where the conversion of an existing line to a ‘swing line’ allows flexibility between producing standard and sleek cans. With a diameter of 58mm and a height of 145mm, the Alu Sleek Can is thinner and higher than the 33cl standard can, closing the gap between the currently available Ball 30cl and 35cl aluminium cans.

France-based metal packaging manufacturer Massilly Group has acquired Linar, a producer of tinplate aerosol cans based in the Stavropol region of Russia, from its former owner Lindal group. Linar was founded in 2002 and serves the cosmetics and industrial markets.

The company says the acquisition will “increase the size of Massilly’s aerosols industrial footprint and enable a closer relationship with its customers”. A family owned company producing metal packaging for most of the world’s leading food, beverage and consumer product brands, Massilly operates 14 factories, generating sales of €275m in 2011.

US-based metal packaging manufacturer Crown has this year announced some major advances in its markets in the Asia-Pacific region. The first commercial application of 202 neck (2 and 2/16th inch) diameter cans recently hit store shelves in the Chinese market. Currently being produced at the company’s Hangzhou facility, Crown says production of the smaller size cans will be supported in all new Crown plants being built in China.

“The launch of 202 neck diameter cans in China is just the latest example of how fast the market is maturing and the growing interest in beverage cans,” says Robert Bourque, Crown’s vice president of beverage cans Hong Kong/China.

The 202 neck cans are easily adaptable to existing canmaking equipment and are suitable for the filling of beer, carbonated soft drinks, energy drinks, teas and other beverages. The smaller diameter brings environmental savings by reducing the amount of metal used in production.

Scheduled to come on stream early in 2013 will be Crown Asia-Pacific’s second two-piece beverage can line at its existing facility in Bangi, Malaysia, bringing the total capacity of the plant to more than 1.2 billion cans. And beginning operations in the second quarter of next year, will be Crown’s fourth beverage can plant in Vietnam, in the major port city of Danang. The plant’s initial capacity of 750 million two-piece 33cl cans will be supported by a long-term contract with a major brewer.

2012 Alufoil Trophy awards

Judges at the EFEA Alufoil Trophy this year were particularly impressed with “the original thinking that had gone into some traditional items, which took them to a new level of performance and technical innovation”.

Packaging products among the 13 winners included, for ‘Overall Excellence’, Canny (pictured) from Amcor Flexibles – a premium quality, wrinkle-free aluminium thin wall bowl, 30% lighter than traditional ring-pull cans and nestable when empty, offering up to 90% savings on space during transportation and storage.

In the Consumer Convenience category, Plus Pack, Danapak and Tibon Technology won a trophy for the TIBON coating for aluminium food trays – a multi-layer technology that allows the heat transmission per cm² of the tray to increase by up to 400%, allowing frozen food to jump over the ‘water-phase’ and go directly from frozen to baked.

And in the Product Preservation category, a trophy went to Guala Closures for its patented Roll On TE aluminium screwcap with tamper evident, coloured plastics ring incorporated into a standard 30x60mm roll on cap.


Alufoil provides convenience and hygiene Alufoil Wrinkle wall food trays from Contital i2r Contital i2r Oven pads from Elliott Absorbent Products’ range Elliott Absorbent Products The latest BRE+ resealable end development from Ball Packaging is set for launch this summer BRE+ Crown is launching 202 neck diameter cans in China Crown Canny Alufoil Trophy winner Canny 2

Canny 2 Canny 2
Alufoil Alufoil
BRE+ BRE+
Crown Crown
Contital i2r Contital i2r
Canny Alufoil Trophy winner Canny Alufoil Trophy winner
Elliott Absorbent Products Elliott Absorbent Products


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