Ken Zaval

Ken Zaval, senior R&D technical manager of Ocean Spray Cranberries, Inc. (Lakeville-Middleboro, MA), and his colleagues will return to PACK EXPO International, November 3-7, 2002 in Chicago to investigate new packaging machinery developments.During his last PACK EXPO International visit, Zaval purchased a state-of-the-art pouching system to launch the company's popular Craisins® Sweetened Dried Cranberries.In addition, he also increased packaging efficiencies by 30 % through the purchase of a new corrugated tray and shrink packaging system for the company's beverage products.

"To successfully launch Craisins®, our first entry into the retail snack food market, a high impact re-sealable stand-up pouch was designed to extend shelf life and generate strong point of sale appeal," said Zaval."To automatically form, fill and seal such pouches on line, we had to find the appropriate equipment.We knew PACK EXPO would present us with a variety of potential solutions."

Team of Eight

Zaval and a team of eight engineering and R&D colleagues, went to PACK EXPO to search for form, fill and seal equipment to efficiently package small servings of dried cranberries.

After viewing several live machine demonstrations on the show floor, Zaval selected a horizontal form/fill/seal pouching system RPM 100 from Klöckner Bartelt, Inc. (Sarasota, FL).The new unit, an investment of approximately (USD) $150,000, allowed Ocean Spray to form pre-printed film into stand up "Delta" pouches, that are filled with

6-ounces of dried cranberries and then automatically sealed.The Klöckner RPM 100 operates at 100 pouches per minute, depending on weight, and features multihead scales to ensure accurate weights.

"Stand up pouches were the ideal alternative to boxes and rigid packages," said Zaval.

"In addition to being lightweight and reducing manufacturing, storage and shipping costs, the pouches can be colorfully designed and printed, providing a competitive edge at point of sale.The resealable zip lock closure adds additional value to our consumer friendly package."

Adding Flexibility and Reducing Waste

While at PACK EXPO, Zaval also investigated alternatives for using regular slotted carton (RSC) systems to pack Ocean Spray's filled PET and glass juice bottles."We were seeking environmentally friendly packaging alternatives that would use less material, minimize storage room, and waste," said Zaval.
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Zaval is always seeking new developments to improve Ocean Spray's plant efficiencies."Improvement is an ongoing process and requires knowledge about new technologies and trends," says Zaval.

Ken Zaval, senior R&D technical manager of Ocean Spray Cranberries, Inc. (Lakeville-Middleboro, MA), and his colleagues will return to PACK EXPO International, November 3-7, 2002 in Chicago to investigate new packaging machinery developments.