Top metallized packages shine in AIMCAL Awards - Uflex Ltd. awarded for its stand-up pouch for Cadbury India

The Association of International Metallizers, Coaters and Laminators (www.AIMCAL.org) bestowed its 2011 Product of the Year Award on the Consumer Packaging Div. of Graphic Packaging International (GPI), Marietta, GA, for a series of oval holiday canisters for Kleenex tissues from Kimberly-Clark Corp., Neenah, WI.

GPI, which has won top honors in this competition for the third consecutive year, served as converter on the project (shown alongside). The three-piece formed canister is designed by Kimberly-Clark to complement home décor during the holiday season. The sidewall structure consists of ultraviolet (UV) coating/UV inks/metallized polyethylene terephthalate (mPET)/0.016-inch solid bleached sulfate (SBS)/extruded low-density polyethylene. A proprietary process creates a lens pattern on the mPET. The resulting “ornaments” look so three-dimensional, the paperboard appears to be embossed. Registration marks in the film ensure the lens pattern aligns perfectly with the graphics. UV inks and coatings enhance shelf presence. The upscale, holiday-themed canisters sell for $2.99 each, a significantly higher price point than standard tissue packs.

The Holiday Ovals for Kleenex tissues impressed the judges on many levels. They loved the eye-catching oval shape, the interplay of the metallization, lens image and holiday ornament graphics, and the three-dimensional effect. “This really stands out,” said one judge. “Great execution,” added another. “This design elevates the art of packaging to something extraordinary,” summed up a third member of the panel, noting, “People aren’t going to hide this package, and they’ll pay a premium for it.”

The judges also named six category winners, which received either Marketing or Technical Awards. GPI also captured the Technical Award in the Food Packaging Category for a susceptor package it converts for Red Baron Fire Baked and Brick Oven Pizza Singles from Schwan’s Consumer Brands North America, Marshall, MN. GPI converts the overprint varnish/ ink/ SBS/ patterned adhesive/ paper/adhesive/mPET to create a functional susceptor patch lamination that eliminates warping of the front panel when it’s exposed to repeated freeze/thaw cycles. The warping not only made the package look less attractive on shelf, but also caused uneven cooking in the microwave oven. The key to preventing warping lies with the paper/mPET lamination and the adhesive pattern that attaches it to the SBS. The innovation extends package shelf life six months, presents a more appealing package, and enables more even cooking. Toray Plastics (America), Inc., North Kingstown, RI, supplies the PET film, which is metallized by Rol-Vac, LP, Dayville, CT.

Members of the judging panel were impressed by the shelf-life extension and warpage and waste reduction achieved by the pattern adhesive that attaches the suspector to the SBS. Since the adhesive creates open channels between the SBS and susceptor, humidity vents to the interior of the carton instead of passing through the paperboard, thereby minimizing warpage. The judges also cited the increase in line speed and reduction in waste as major technical achievements.

The Marketing Award in the Food Packaging Category goes to the Packaging Division of Uflex Ltd., Noida, India, for a PET/ mPET/ polyethylene standup pouch for chocolates from Cadbury India Ltd., Mumbai, India. Uflex serves as a single-source provider as the substrate supplier, printer (rotogravure), metallizer, laminator, slitter, and converter. Plasma metallization enhances the lamination’s barrier properties. Added convenience is provided by a punched hole for hanging display and a press-to-close zipper. The judges noted the package design makes good use of the metallization. “The gold really makes the product look rich,” said one judge. “The graphics are mouthwatering,” observed another member of the panel.

Category, Hazen Paper Co., Holyoke, MA, captured the Marketing Award. Hazen Paper served as the substrate supplier and metallizer for a holographic slip case for the Elvis 75th Anniversary DVD Collection from Warner Home Video, Burbank, CA. The slip case wrap consists of 60-gauge custom holographic mPET laminated to 80-pound, coated-one-side litho/label paper from Hazen. A two-/three-dimensional Holo-Lens insert adds a security feature. The custom hologram, a repeating pattern of the name Elvis, reflects the persona of the star as well as the integrity and pizzazz of the brand. The litho/label stock exhibits excellent lay-flat and stay-flat characteristics to support faster printing and die-cutting speeds. The PET helps prevent score cracking. Other participants in the project included Multi Packaging Solutions, Indianapolis, which served as the converter and shared design duties with Warner Home Video.

The judges agreed the slip case is a superior integration of metallizing, holography, and printing. Registration between printing and holography is tight, and there’s great contrast between the printed images and words. “Well done,” they concluded.

Hazen also won a Technical Award in the Decorative Display Category for a magazine insert publicizing its custom holographic capabilities and sustainable practices. Hazen served as designer, substrate supplier, metallizer, and converter for the Rose Among Thorns insert. The 10-point, coated-two-side paper features a custom, transfer-metallized hologram overprinted in four-color process plus opaque white. A UV coating protects the front and back of the page. Transfer metallizing helps the relatively lightweight insert lay flat because it permits moisture gain and loss on both sides of the sheet.

Describing the insert as “really effective,” the judges noted how transfer metallizing provides source reduction because it eliminates a metallized film layer. It also offers superior aesthetics and minimizes warping because it allows the paper to breathe. In addition, the holograms are so appealing “you want to touch the page and feel the cracks,” commented one judge.

The Marketing Award in the Decorative Display Category goes to FLEXcon Co. Inc., Spencer, MA, as the substrate supplier for indoor floor advertisements for Tecate beer from Heineken USA, New York City, Dunmore Corp., Bristol, PA, served as metallizer, and Performance Printing, Dallas, handled converting tasks. The base film consists of FLEXmark MMV 400 F Silver TC-848 A-109 94 PFW, a 4-mil, metallized silver, pressure-sensitive polyester/vinyl laminate. The metallized base film generates a shinier, more reflective metallic appearance than the previous structure, which relied on screen-printed faux metallic ink. In addition, the pressure-sensitive adhesive bonds strongly to floor surfaces, but removes cleanly for up to 180 days after installation. The surface-printed, four-color-process graphics are protected by FLEXmark OV6602, a 4-mil, clear gloss, pressure-sensitive vinyl overlaminate that resists delamination and meets industry standards for non-slip performance (ASTM D 2047).

According to the judges, the metallized floor advertising not only enhances brand recognition for Tecate beer, but encourages favorable purchase decisions and spurs sales. In addition, noted one judge, the designs “do a good job of bringing metallization to the floor.”

As its third win in the 2011 competition, Hazen Paper took home the Marketing Award in the Other Category for the holographic cover it designed, embossed, metallized, and laminated for the Super Bowl XLIV Exclusive Stadium Collection Edition program from H.O. Zimmerman, Inc., Lynn, MA. The custom hologram, featuring the Vince Lombardi Trophy, was transfer-metallized to 100-lb coated-two-side paper, which was then coated inline with Ultracure Acrylic.

The three-dimensional impact and balanced design of the cover impressed the judges. “Just enough flash,” said one judge. “Not too gaudy,” commented another member of the panel. Everyone agreed, “They did a really good job with the execution.”