Gampack Group is a renowned multinational firm, headquartered in Italy, that specialises in secondary and tertiary packaging as well as end-of-line solutions for the food and beverage industry and beyond.
What does the dairy business demand from packaging system manufacturers?
For this reason, we met with Giovanni Anzani, Gampack Group’s Commercial Director. He described to us what the expectations of a manufacturer dealing with the milk and dairy industry are, as well as how these needs are addressed throughout this specific production phase.
From large quantities to small batches: the most suitable and sustainable option
“Efficient and versatile high-performance machines are ideal solutions for the dairy industry production requirements. Furthermore, specifically designed green packaging can eliminate or significantly minimise the use of plastic in the packaging of these products,” says Giovanni Anzani.
“When we design a new plant, we first listen to our customer carefully to understand what their production needs are. If we are dealing with large-scale production, the priority will be on the plant’s high capacity, maximum efficiency and few size changeovers. If, on the other hand, the numbers in production are limited, perhaps because they are linked to the production of small batches, greater flexibility will certainly be necessary, as in the case of a recent application where a solution for small batches with a flexible, custom-made, semi-automatic system was chosen for the packaging of portioned cheese in slices of various sizes and weights.”
Choosing the best system for production demands is extremely important particularly considering the speed with which the dairy industry is evolving. “When building a packaging solution, current manufacturing processes must be considered with an eye towards the future, as variations in the market might be a very sensitive aspect to deal with. Large production quantities or small batches are extremes in which to plan production with some degree of flexibility. A proper cost-benefit analysis makes it easier to assess the economic return of a packaging solution. Our dairy industry machines are tailored-made and can be modified to meet the following future production needs: low environmental impact, specific materials such as stainless steel for dairy products hygiene, and protection of electrical and electromechanical parts during washing operations”.
Customized packaging for rigid or flexible containers
The use of different materials to pack food goods can frequently be determined by the nature of the product itself, the market, or consumers’ preferences.
Innovation produces more sustainable, efficient, and affordable alternatives. Rigid materials such as glass, metal, and rigid plastic can be compared with soft products packaged in flexible packaging such as doypacks, bags, or other soft paper packaging.
“The Gampack Group has the skills of packaging both rigid and flexible items. For hard product packaging, such as cans or bottles or beverage cartons, we are using automatic division machines, capable of producing up to 50-60 wrap around cases, American cases or shrink-wrapped bundles each minute,” explains Giovanni Anzani. “When we have to pack soft products such as doypacks or bags, the robotic division machines form the cardboard cases that are then filled by our robotic systems.”
From primary packaging to end-of-line: complete integration and traceability
The Gampack Group handles the complete production line, from primary to secondary packaging to end-of-line, a complex system that includes multiple operational steps and integrated technologies to assure efficiency, quality, and sustainability in production.
“Integrating the complete packaging production line improves the general effectiveness and control over quantity. Giovanni Anzani says that “Gampack Group produces software that integrates the lines for monitoring, enhancing, and maintaining each aspect of the process, hence increasing productivity and lowering downtime. We can give the customer with a complete turnkey system, with the undeniable benefit of having a single supplier taking care of the entire line.”
Product traceability is a vital step in the integration of a complete packaging process since it helps the customers to pinpoint the source of any issues, easing product recalls and non-compliance investigation.
“We have recently designed and built a case packing system which can receive traced products from three different upstream production lines to create cases containing a mix of such products based on manufacturer needs,” Giovanni Anzani says. “Product traceability not only ensures regulatory compliance and product quality, but is also a key factor in operational efficiency, cost reduction and building trust with end customers.”
Gampack Group’s Green Solutions
“From primary to secondary packaging, sustainability ties together our green solutions,” begins Luna Ughini (Sales/Marketing dept. of Gampack Group). “They were initially designed to create multipacks of beverage cartons, but today they cover applications with different types of containers, including bottles, and the same beverage cartons, ranging from mini sizes for children to larger ones for families.”
Innovative secondary packaging with sustainability in mind.
“Mini trays are an example of sustainable packaging,” explains Luna Ughini. “It’s a blank that puts together the beverage cartons by covering only half of their bottom and leaving the rest of their design visible. It gathers the products together in regular sizes, such as three by one or three by two, rather than in different combinations. The blank is developed with graphics which coordinate with the product design thanks to a partnership between the marketing and sales departments. This is a practical and sustainable approach to secondary packing of products. In fact, the individual items of the multipack can be easily torn away thanks to the pre-cuts of the blank; the beverage carton is not graphically damaged, and after usage, it can be thrown away all together because the material used is paper only. Furthermore, for more effective sales processes, the blank includes a bar code that can be acquired at the cash counter. The environmental label serves as an alternative to the small tray system. “In this situation, we are referring to an adhesive paper label that is placed halfway up the products. It eliminates the use of plastic and enables for the construction of multipacks with visuals that correspond to the items and include the required consumer information.”
Gampack Group’s green solutions are not limited to multipacks for the end consumer. “We have also designed sustainable solutions for large-scale distribution, discount stores and shopping centres. The trays, quarter and half pallets in recyclable cardboard, protect the products during transport and upon arrival at the point of sale and are already ready to be displayed on the shelves with graphics coordinated with the contained products. These solutions enable to save money and improve the efficiency of your point-of-sale staff members. The manufacturer may have a valid question: is a specific machine required for these larger sizes? Gampack Group provides the appropriate solution, successfully responding to its customers’ needs with an ALL-IN-ONE machine that is exceptionally versatile in managing a wide range of sizes. This one-of-a-kind approach enables straightforward packaging from the smallest to the bulkiest shapes, such as 1/4 and 1/2 pallets, allowing producers to easily adapt to the market’s diverse expectations,” concludes Luna Ughini.
