Form and applied graphics aside, successful fibre-based packaging solutions require using the right stock to match the product and the demands of the retail environment. As this is such a critical consideration, we asked Brett Keen from New Zealand’s Whakatane Mill to shine some light on their Formakote range of specialist packaging boards.
Packaging Small-Medium Sized Goods
Small-medium goods is a general term meaning; retail products that a consumer buys over a counter, off a shelf, from a website, or out of a chiller. Of course, this encompasses a wide range of products, including dry, fried or frozen foods, beverage packs (such as beer & soft drinks), confectionery, cosmetics, toys, clothing & footwear… the list is long. The stocks used for packaging these products are generally quite different from those used for oversized and heavy goods (like power tools or electrical appliances)—which tend to be corrugate-based solutions.
Packaging – The Four Ps
Packaging small-medium goods need to be multi-purpose, covering the four ‘P’s’— protect, preserve, perform and promote. In a practical sense, this means that the stock is robust enough to protect the product during handling and to survive the rigours of on-shelf display and storage. For example, some food & beverage products spend long periods in a chiller or freezer, meaning; the stock must be moisture resistant. Nobody wants to discover the packaging board isn’t up to the job when they lift a six-pack of beers out of the fridge on a Friday night.
And, for food goods where the board comes into direct contact with the product— the stock needs to be ‘food safe’, ensuring the board will not leech and taint the taste. Packaging intended for hot foods— such as chip and burger boxes—also need special consideration as these need to be made grease resistant. This will slow the fat or oil seeping through the stock—which looks unsightly and presents the danger of the packaging coming apart. No one wants hot chips in their lap.
Specialist packaging boards also need to be suitable for cutting, folding, constructing, and provide a quality printing surface. And lastly, but becoming increasingly crucial for businesses wishing to promote themselves as a sustainable brand of choice, are any environmental considerations—do they make the board stock ethically, using sustainable materials?
The Whakatane Mill – Formakote
Located in the Bay of Plenty region of Aotearoa, New Zealand, Whakatane Mill is the only paperboard mill in Oceania. Initially founded in 1939 to convert nearby central North Island pine forests into export grade paperboard— today the mill directly employs some 180 personnel. Whakatane Mill Limited has committed to operating in an environmentally responsible manner, caring for the environment for the benefit of future generations. To manufacture the folding box board range, Whakatane source virgin fibre largely from well-managed, sustainable forests located in the central North Island. They also supplement their supply with a small volume of imported pulp from Chile. The mill is both Forest Stewardship Certified (FSC) and ISO14001 certified —meeting the strict guidelines set by the FSSC 22000 food contact safety standard.
The Formakote Range of Packaging Boards
This brings us to the Formakote range of packaging boards made in New Zealand by Whakatane Mill. Whakatane Mill happens to be one of the only carton board mills in operation in Australasia. Most recently, with the ongoing Covid-related supply issues affecting many imported goods—including paper & board—being local has had distinct advantages. First, clients are significantly reducing their carbon footprint through much shorter freighting distances, and second—Whakatane Mill can fulfil most orders within 6-8 weeks, as opposed to waiting 4—6 months for many imported boards. And, as BJ Ball and Ball & Doggett are the exclusive merchant suppliers in Australasia for the four Formakote carton board grades— it’s welcome news for our clients.
There are four Formakote products:
01. FORMAKOTE WHITE—white folding box board
Formakote White is a coated, double-sided, high white board, suitable for a wide range of packaging applications. This stock has a double-coated ‘top side’ for best print reproduction—plus a single-coated reverse side (which is also suitable for printing).
Key features:
- High White print surface
- FDA-approved for direct contact with both dry & fatty foods
- Manufactured under the strict ISO9001 & ISO14001 quality management systems
- Available as Forest Stewardship Certified (FSC) upon indent request
Suitable for:
- General packaging for retail products
- Cosmetic & pharmaceutical goods
- Dry food products & fast foods
- Fast-Moving Consumer Goods (FMCG)
0.2 FORMAKOTE NATURA—manila-back folding box board
Formakote Natura is a versatile multi-layered board with one-side doublecoated white and the other uncoated, bleached pulp manila coloured. This stock is suitable for various packaging applications, offering the same benefits as Formakote White—with a more natural, organic finish on one-side.
Key features:
- White double-coated print surface
- Natural Manila-coloured uncoated reverse
- FDA-approved for direct contact with both dry & fatty foods
- Manufactured under the strict ISO9001 & ISO14001 quality management systems
- Available as Forest Stewardship Certified (FSC) upon indent request
Suitable for:
- General packaging for retail products
- Cosmetic & pharmaceutical goods
- Dry food products & fast foods
- Fast-Moving Consumer Goods (FMCG)
03. FORMAKOTE SPECTRA—kraft-back folding box board
Formakote Spectra has a double-coated white top side for best print reproduction; the reverse side is a non-coated kraft which is printable. In addition, Spectra offers exceptional tear and puncture resistance. It is specifically designed for applications that require high levels of strength or need to be able to withstand the demanding environments of freezers and chillers.
Key features:
- Moisture resistant
- Suitable for freezer or chiller use
- FDA-approved for direct contact with both dry, fatty and aqueous foods
- Manufactured under the strict ISO9001 & ISO14001 quality management systems
- Available as Forest Stewardship Certified (FSC) upon indent request
Suitable for:
- Boxes/carry trays for all types of frozen or chilled foods
- Carry packs/trays for chilled beverages
04. FORMAKOTE SHERPA—wet strength carrier board
Formakote Sherpa has a double-coated top side for best print reproduction— plus an unbleached kraft reverse which is printable. In addition, Sherpa has been specifically developed to survive the demanding conditions of wet and chilled environments and is perfect for refrigerated applications.
Key features:
- Enhanced wet-tear resistance
- Suitable for freezer or chiller use
- NOT suitable for direct food contact
- Manufactured under the strict ISO9001 & ISO14001 quality management systems
- Available as Forest Stewardship Certified (FSC) upon indent request
Suitable for:
- Boxes/carry trays for refrigerated beverages
- Carry packs/trays for refrigerated multipacks & canned foods
CHOOSING THE RIGHT BOARD STOCKS FOR PACKAGING
This information has highlighted some of the practical considerations when it comes to choosing the right board for packaging. Board selection may even extend to include constructing and testing prototypes. For these reasons—we recommend consulting with an experienced packaging print and production specialist early in the project.
WEIGHT VS THICKNESS
Paper & boards can be measured using either weight or thickness (or a combination of both). Paper, is more commonly specified using weight, whereas boards tend to use thickness.
It is easy to confuse these two things and think they are the same.
However—they are quite different:
- Weight: is measured in Grams per Square Metre (GSM). So literally, if you took a one square metre sheet of stock and weighed this—you would have the GSM measurement.
- Thickness: measured in Microns (μm)—short for Micrometre, or one-millionth of a metre… which is pretty thin! Microns are used mainly for specifying boards—particularly in the world of packaging.
Where it gets a little complicated is; two stocks of the same weight (GSM)—can have different thicknesses (μm). This is due to several factors, such as fibre density and the make up of different types of fibre within a board. Both of which affect these measurements. The two main reasons thickness is more relevant in packaging is due to foldability & strength:
- Foldability: thicker stocks may not fold as easily— especially in small constructs. It should be noted, however, that grain direction is also a factor in determining foldability.
- Strength: rigidity is critical in three-dimensional forms such as boxes. In this manner, thickness is very important.
However, that is not to say that weight is not a consideration in packaging. For example, weight becomes a factor when thinking about freighting. All ‘made’ products need transporting in mass from somewhere to somewhere at some point. Saving five grams per unit on packaging stock across 40,000 products equals 200 kilos of weight that doesn’t need shifting—reducing carbon emissions and costs. Now, that’s a lot to weigh up!
CHOOSING STOCK
BJ Ball and Ball & Doggett offer a variety of resources and assistance to help you choose the right stock for your packaging project—this includes the recently released Packaging Boards Selection swatchbook and the Cartonboard Made Easy guide (see above).
To receive copies of both please contact your friendly BJ Ball representative or email: designline@bjball.co.nz
BJ Ball/Ball & Doggett can assist in providing swatches and/or sheet samples from the Formakote range—for more information go to:
Australian readers://ballanddoggett.com.au
NZ readers: //bjball.co.nz
BJ BALL FORMAKOTE PROMOTION
BJ Ball in New Zealand recently produced this promotional piece showcasing the Formakote range. The hexagonal box, shown here from both sides, opens to reveal four internal mini-boxes. Each hold bespoke snack foods such as cheese by Over the Moon (see giveaway on page 6).
The main box is constructed using Formakote White and printed in CMYK + Pantone PMS Black 7 + 877 Silver (used as an underlay in the dark circles). The main box also makes use of cut-away windows revealing the four internal mini-packs. Each mini-pack combines one of the four Formakote products printed using different specials— such as the holographic foil seen in the small cut-away circular window near the top of the box on the left.
Ball & Doggett recently produced this promotional piece showcasing Formakote Sherpa the perfect packaging board to contain heavy objects that are in a chiller environment.
