Keller Crescent Meets Demand For Security Features And Green Solutions

OTC packagers are incorporating lower-cost security features into paperboard packaging and more and more are favoring recycled content and green materials, says Bob Papa, vice president, operations, Keller Crescent Co. (Portland, CT).
 
Paperboard packaging solutions converted at Keller’s Portland facility include cartons for OTCs, blister cards, wallets, and display cartons for ethical drug sample packaging, and packaging for medical devices. “In OTCs, we do a lot of our business with contract packagers with large drug chain clients. These are carton structures that can run at very high speeds on automated filling lines,” Papa says.
 
“The chains are looking for inexpensive brand protection devices. We will incorporate security/anticounterfeiting features such as microprint and wave rule,” Papa says. The wave rule process creates minute patterns on cartons’ edges. Inconspicuously located in areas such as a carton glue seam, the markings are often not discoverable unless the package is torn apart. “You won’t find this on the spec sheet. Oftentimes, the production people don’t know about it,” Papa says.
 
Keller has developed processes for minimizing print defects in recycled paper board. Customers are favoring the recycled materials to support environmental programs and achieve material cost reductions of 5 to 10%, Papa says. “Customers want the print to look as good as with high-quality SBS board. Traditionally, you are more prone to print defects on recycled board due to the lack of cosmetic smoothness,” Papa adds.
 
Particulates, for example, will stick to the printing plate, creating a “fish eye” or “hickie” on the printed surface. “We use a specialized set of tack-adjusted inks that reduce these defects without compromising very high print quality,” he says.
 
“Customers are asking if we can reduce volatile organic compound (VOC) emissions. Basically, we already do this with all product whether it is required or not. All of our vegetable-based inks and water based coatings are very low VOC,” Papa says.
 
In moving to recycled board, customers in some instances accept slower packaging production speeds. “Many of our smaller private labels runs are more accepting of sub-speed issues. It becomes a lot easier for many of these OTC drugs to move to recycled packaging and maintain a green initiative,” Papa says.