Colegate Calls for Recyclable Packaging

Colegate-Palmolive has recently announced new commitments to recyclable packaging. In particular, the company has spoken out against the increasing adoption of non-recyclable flexible packaging.

More and more products are now being sold in flexible, non-recyclable plastic packets. Raisins were once commonly packaged in little cardboard boxes, but now they use flexible packaging. Likewise, drinks traditionally come in bottles, which are usually made of glass or PET, or else in aluminium cans. All of these can be economically recycled. But now, some products such as Capri Sun, which is immensely popular with children around the world, come in flexible packaging that is difficult or impossible to recycle. All in all, 2012 saw sales of products in such flexible packaging reach levels of over US$26 billion in the US alone.

So what has made companies invest in the formers, forming tubes and other packaging machine accessories necessary to completely change their packaging to a non-recyclable option?

Cost, of course, could be one factor. Flexible packaging is often cheaper to produce, offsetting that initial investment in new forming sets and packaging machine accessories. Nonetheless, it is surprising in these days of environmental awareness and increasing corporate responsibility to see such a large shift away from recyclable materials.

However, some companies may have made the change with genuinely good eco-intentions. In the short term, manufacturing this packaging generates lower levels of emissions and uses less material. However, while this makes sense in the short-term, the fact that these products cannot be easily recycled offsets the initial advantages. There are few disposal options available except for incineration or landfill, and then the manufacturing process for new packaging begins again from scratch.

Indeed, misguided views on the eco credentials of flexible packaging are making their way to the very heart of the packaging industry. In a recent interview, green design advisor and sustainability architect William McDonough said “I see packaging awards being given to these pouches as more efficient containers of, say, a cereal.” He then pointed out that this product, traditionally placed in an easily-recycled cardboard box, is now “wrapped in seven plastics with undefined inks and metallized polymers. It doesn’t have a recycling symbol on it because you could never recycle it… And yet it’s being put forward as a more efficient package.”

Now Colegate have taken their stance against this non-recyclable packaging, they seem to mean business. For three out of four product categories in the company’s portfolio, they have committed to making all packaging recyclable by 2020. For their remaining product category, oral care, they are working on development of a recyclable toothpaste tube, or a new kind of recyclable packaging to serve the same purpose, so that the remaining products can follow suit.

The Debate over Recyclable Packaging


More and more companies are making the shift towards packaging their products with recyclable materials. While it is certainly a more environmentally-responsible approach, many companies continue to use non-recyclable packaging. So, why haven’t all companies made the switch yet?

Even though we are seeing plenty of companies using forming sets to package products in recyclable materials, there has also been an increase in the number of products that are being packaged in flexible, non-recyclable materials. A prime example of this is Capri Sun, the popular kids’ drink packaged in materials that are virtually impossible to recycle.

Cost is the major factor behind the use of flexible packaging, since it is often cheaper to produce due to the materials required. There are also some short-term ecological benefits, as this type of packaging generates fewer emissions and uses less material overall.

However, on a long-term scale, recyclable packaging is more beneficial. Flexible, non-recyclable packaging may be cheaper for manufacturers to produce and more convenient for consumers to use, but it is a major drawback that the material cannot be recycled. This type of packaging can only be disposed of in an incinerator or landfill.

One company that has taken up the cause is Colgate, as the company has taken a stand against non-recyclable packaging. For three of four of their product categories, the company will make all of its packaging recyclable by the year 2020. Oral care is the remaining category, and Colgate aims to develop a new recyclable toothpaste tube in coming years.

When making the switch to recyclable materials, brands may require different forming sets to ensure the efficiency of the packaging process. At Kenray, we work with our customers to understand the different issues relevant to your food processing needs, such as recyclable packaging, product flow, bag quality and sealing issues – as well as temperature, material and volume requirements. As such, we can advise you on the ideal type of forming set or even build bespoke formers to suit your packaging needs.

KENRAY can help you find the ideal forming set for your recyclable packaging. For more information, visit our Forming Sets page or call us at: +44 (0)1530 400 100.

Packaging trends 2014: Predictions

With 2014 still in its infancy, now is the right time to consider what the year ahead holds for the packaging industry. Expert predictions have indicated some interesting potential developments, so it’s important to take note of these ideas and plan accordingly, in order to ensure that you are a leader in your industry. Taking advantage of advanced predictions in terms of machinery, health and safety, and the environment are just some of the considerations when studying the upcoming trends over the next 12 months.


Environmental considerations

More and more people are tuning in to the importance of environmentally friendly manufacturing processes and the need for materials to be recyclable and sustainable. For a growing number of people, sustainability is cited as an integral factor when they choose which products to buy or use. This rise in awareness and interest in sustainability is reflected across all business sectors, and it is therefore becoming increasingly important for packaging manufacturers to focus on environmental issues. In terms of packaging, one way to become more environmentally friendly is to reduce packaging sizes to as small as possible. As a result, formers and machinery like forming collars and similar pieces of packaging machinery need to be able to manage and cope with reductions on package sizes. Forming tubes and shoulders can, when used correctly, also reduce wastage and aid sustainability.


Health and safety

Concerns over the safety of products continues to loom large within society, and it is therefore important for packaging manufacturers to consider this. In particular, food packaging must be able to provide safe and healthy consumption. As awareness rises regarding diet, people are taking more and more interest in nutritional information. The packaging industry has recognised this by incorporating key nutritional details on packaging. Meanwhile, demand grows for smaller portion sizes, and many packaging companies are now looking to include such products, for example 100 calorie snack packs. Reducing pack sizes again calls for the correct packaging machine accessories, machinery and equipment such as forming tubes and forming collars.



As brands grow, they not only look for localised growth, but in maintaining a global presence with a recognisable character. As a result, design is as important as ever in terms of packaging. While slight changes to packaging design may continue to occur to match localised tastes and trends, consistency is becoming more and more key to keep up with the demand for instantly recognisable brands. Creating packaging that includes colour, shape, and logos (along with layout) can be important to establishing and developing a recognisable brand.


Retail relationships

The demand for packaging from the retail sector continues to grow. Many retailers are now looking to provide own brand alternatives to established brands, and as a result require professional and engaging packaging. Manufacturers therefore have an onus upon them to justify the premium prices that they command. In order to cope with the demand of high quality packaging from retail groups, packaging machine accessories and machinery must be correct. Forming tubes and forming collars are a vital step in offering structural improvements to retailers through packaging.

Decades of Development in the Packaging Industry

With over 30 years of experience in the food packaging industry, KENRAY has seen many changes and developments to the way that food is packaged. While it originally started out as a way to protect food and keep it fresh, packaging has developed to serve a number of other purposes, including branding, environmental-sustainability and reducing food or material wastage.


Food Packaging Design

One of the most crucial aspects of food packaging today is design. Companies aim to ensure that their packaging is designed in a way that captivates and impresses customers. As such, there has been an increased need for advancement in food packaging technology.

If manufacturers want to sell their products in interesting ways, they require vibrant colours and designs. New technological advancements make colourful packaging more viable and allow for unique shapes to be made. Forming sets and shoulders help to create this type of packaging, which simply would not have been seen on grocery store shelves twenty years ago.



In the past, studies showed that an alarming amount of food packaging material was being wasted both during and after the manufacturing process. Today, innovative sealing jaws help reduce leakage, which keeps food fresh and prevents wastage. They also run on a low temperature to save energy and production costs.

To further reduce waste, more and more refrigerated products are being sold with re-sealable packaging. Subdivided packages also help in this respect, as they allow you to use some of the product now and save the rest for later without opening the package.


Environmental Concerns

In the packaging industry, we are also seeing a shift towards sustainability. Manufacturers want to keep food and material wastage to a minimum, so many foods are packaged in materials that have been recycled or can be recycled in the future.

In turn, this has had an effect on the physical design of packaging, as products are printed with clear instructions about disposing the material in environmentally-responsible manner. Many brands even use their sustainable packaging as a selling point.


Nutritional Information

Over the course of the past few decades, we have also seen the addition of nutritional information to food packaging. New health regulations have led manufacturers to include information about calories, protein, fat, sugars and carbohydrates on their products. This has also become a part of the marketing strategy for many companies, as their packaging helps them promote their commitment to providing healthy foods to customers.

For more information on how KENRAY’s innovative technology can benefit your products, visit our Packaging Solutions page or contact us.

Choose the right forming set to reduce packaging costs

One of the major considerations faced by packaging businesses is the selection of an appropriate forming set. Ensuring that you choose the correct forming set is of paramount importance to the running costs of your business. It’s not just the initial price that defines the cost-effectiveness; after all, it becomes an essential part of the packaging process, and using appropriate forming tubes and forming sets that are of high quality can ensure your business isn’t wasting money.
Less material wastage

Nobody likes to lose money through production faults, so using the correct forming shoulders is vital. This ensures that packaging materials are used more efficiently, and as a result means that fewer materials are wasted. Less waste means less time and money is lost to a final product that is unusable, and also means that precious time is not spent producing a flawed product.
Fewer blockages

Another common drain on time resources in the packaging industry is caused by blockages in forming tubes and collars. Many product types are prone to these blockages, which has a negative effect by slowing the production process and rendering the machine useless until the blockage is cleared.

Using higher quality, purpose-built forming tubes, which offer intricate designs to reduce the severity and frequency of blockages, can be a beneficial way to minimise this kind of setback. These tubes will be designed with wider inlets to reduce the chances of a blockage, along with unique shaping of the tube. This helps by allowing the machine to do its job; producing the profitable products.

Despite this, it is not always necessary to buy purpose-built forming tubes that prevent blockages. While some are prone to blockage, there are some product types that do not commonly suffer such fate.
Optional features

High quality forming sets are often tailored to suit the particular needs of a company, with many suppliers offering a host of optional features to increase efficiency and functionality. This can allow your company to increase the volume of output. Such features are intended to provide a balance between cost and the running of the business, which improves the optimum outlay level and maximises business profits.
Longer lifespan

It is an inevitable circumstance that forming collars and tubes will fall victim to wear and tear as time passes, and will eventually need replacing. Using higher quality forming sets, which are much more tough and durable, means that they will need to be replaced much less often than cheaper and more flimsy alternatives. In the long run, this means that although the initial outlay may be higher, money will be saved by the infrequency at which the tubes need to be replaced.

In summary, the selection of the right forming set is a vital factor in the running cost of a packaging business. While higher quality sets may be more expensive initially, their lower repair and maintenance outlay over time makes them much more cost-effective than basic sets. Additionally, a high quality forming set and collars allow your business to maximise productivity and consequently increase profits.

Andrew Bridgen MP opens new KENRAY ANCILLIARIES production plant in Coalville

Andrew Bridgen MP for North West Leicestershire recently opened Kenray’s second factory in Coalville. The second factory will be for KENRAY ANCILLARIES and will be the global hub for servicing food packaging customers in need of maintenance and spare parts.

On 23 May 2014, MP for North West Leicestershire Andrew Bridgen officially opened the new KENRAY ANCILLARIES production plant at Telford Way, Stephenson Way Industrial Estate, Coalville.

With over three decades of experience, KENRAY is the global leader in the design, problem solving and manufacture of forming solutions. Having delivered large bespoke orders as well as complex one-off projects to blue chip organisations like FritoLay North America, Pepsico Europe, KP, Kellogg’s, Nestle and Intersnack, KENRAY has become the partner of choice for companies around the world. The company attributes its success to its investment in research and development, coupled with its philosophy to innovate. KENRAY’s experienced and skilled team members pride themselves on finding efficient solutions for customers regardless of the ingredients that they are packing or the temperatures required.

KENRAY ANCILLARIES is the company’s latest expansion, which provides alterations and full refurbishments for forming sets, as well as the manufacture of single shoulders and tubes. The ancillary company will also deal with customers’ needs for any accessories such as spreaders, block bottoms and roller assemblies.

Andrew Bridgen MP commented: “Businesses need to innovate. Small and medium sized enterprises like Kenray will be the companies that will provide the growth this country needs. It’s great to hear that Kenray exports all over the world. Today, we have seen what investment in equipment, training and staff who speak multiple languages can do for a company like Kenray. Having come from the food industry myself, I am aware it is a major part of UK manufacturing, enhanced by specialist companies like Kenray who have been able to build their international reputation in this sector”.


“The benefit to our customers is simple. The new facility will mean we can offer a much faster turnaround on jobs with less impact on the downtime of our core production line,” comments Mark Evans, Commercial Director. “The new production plant allows us to offer small repairs and accessory items at a quicker rate, in turn offering a better service and aftercare support to our new and existing customer base”

Additionally, KENRAY ANCILLARIES consists of a new storage facility, which will stock spare part such as jaws, knives, belts and tape. This is set to be the hub for servicing food packaging customers all over the globe who are in need of such products and solutions.

The company has come a long way since its humble beginnings as a metal fabricator in Syston 30 years ago. Today, KENRAY provides bespoke forming solutions to clients all over the world. With an international presence in the packaging industry, over 60% of KENRAY’s sales come from outside of the UK with more than 20% originating from the USA.

KENRAY Heads to Interpack in May 2014

From 8-10th May, KENRAY will be exhibiting at the Interpack exhibition in Düsseldorf, Germany, displaying our range of forming solutions in Hall CS at stand 410.

As the world leader in the manufacture of forming solutions, KENRAY develops custom forming sets to help clients pack various food products with greater efficiency and reduced downtime – regardless of their size, temperature or ingredients. We work closely with customers from all over the world to develop bespoke forming solutions that are right for them. Our multi-lingual staff members will be on hand at stand CS 410 to understand more about customer requirements and discuss KENRAY’s forming products in English, Russian, Polish, Mandarin, French, Italian and Spanish.

“It is really important for us to make the trip from Leicestershire, UK to Dusseldorf to stay current with the latest developments in packaging and processing. We like to be on hand for our customers so that we can understand current issues they are facing and determine how we can to help them,” says Mark Evans, Commercial Director at KENRAY. “Interpack is a great opportunity to network with leaders in the industry while learning about cutting edge technology and products”.

Interpack welcomes more than 2700 delegates from 60 countries. Industry professionals will gather at the Düsseldorf Messe to present products, innovations and recent trends in the market. The exhibition welcomes all members of the packaging and processing industry – from companies involved in producing packaging equipment to those that provide industry-wide services and materials.

Register for Interpack here, and be sure to visit KENRAY at in Hall CS at stand 410 to learn more about KENRAY’s packaging solutions.



Du 8 au 10 Mai, Kenray sera présent au salon Interpack, à Dusseldorf en Allemagne, pour présenter ses conformateurs et solutions d’emballage au HALL CS STAND 410

En tant que leader dans la fabrication de conformateurs, KENRAY développe des solutions d’emballages adaptées à tous les produits de nos clients – peut-importe leurs tailles, température, ou types de produits emballés. KENRAY travaille en collaborations avec ses clients dans le monde entier pour leurs proposer des solutions adaptés à leurs besoins. L’équipe KENRAY prendra place au stand 410 pour parler de solutions qui vous conviendront et discuter des Tubes Formateur aussi bien en Français qu’en Anglais, Espagnol, Italien, Polonais ou encore Mandarin.

“ Ce déplacement depuis notre région du Leicestershire jusqu’à Dusseldorf est particulièrement important pour être au courant des nouveautés du marché du packaging et des process. Nous souhaitons aussi être aux côtés de nos clients pour mieux comprendre leurs besoins et savoir comment nous pouvons les assister au maximum”, nous explique Mark Evans, le directeur commercial de KENRAY. « Interpack est une opportunité d’agrandir notre réseau avec les leaders de l’industrie tout en se mettant au courant des innovations qu’ils préparent en matière de technologie ou de produit ».

Interpack accueillent plus de 2700 entreprises qui viennent de 60 pays différents. Les professionnels de l’industrie seront présents à Düsseldorf pour présenter leurs produits, leurs innovations et les futures tendances du marché. Ce salon regroupe toutes les personnes liées aux Packaging ou au Process – allant des entreprises produisant le film plastique jusqu’à celles fournissant les machines.

Enregistrez-vous pour Interpack ICI, et venez visiter KENRAY à son stand dans le HALL CS STAND 410 pour connaitre toutes les solutions que KENRAY peut vous apporter.



Del 8 al 10 de mayo KENRAY participará como expositor en la feria internacional del embalaje Interpack en Düsseldorf (Alemania), donde mostrará su gama de tubos formadores en el Stand 410 (Hall CS).

Reconocido como líder mundial en la fabricación de tubos formadores, KENRAY diseña sus productos a medida para ayudar a sus clientes a envasar sus productos alimenticios con mayor eficiencia y un período de inactividad reducido, independientemente del tamaño, temperatura o ingredientes. Nuestro personal multilingüe podrá asistirle en el Stand CS 410 para conocer mejor sus necesidades de envasado y hablar sobre nuestros tubos formadores en inglés, ruso, polaco, mandarín, francés, italiano y español.

“Es muy importante para nosotros viajar desde Leicestershire (Reino Unido) a Düsseldorf para estar actualizados sobre las últimas innovaciones en el sector del envasado y procesado. Nos gusta acercarnos a nuestros clientes para entender los problemas que tienen actualmente y determinar cómo podemos ayudarles,” dice Mark Evans, Director Comercial de KENRAY. “Interpack es una excelente oportunidad para conectar con los líderes del sector y al mismo tiempo conocer la tecnología más avanzada y los nuevos productos.”

Interpack da la bienvenida a más de 2700 delegados procedentes de 60 países. Los profesionales del sector se reunirán en Messe Düsseldorf para presentar los productos, innovaciones y tendencias más recientes en el mercado. La exhibición da la bienvenida a todos los miembros del sector, desde empresas de maquinaria de envasado a consumidores de las mismas.

Regístrese aquípara asistir a Interpack aquí y visite KENRAY en el Hall CS en el stand 410 para saber más sobre las soluciones de KENRAY.