RETAL Baltic Films, which manufactures food-grade APET film and closures at the Klaipeda Free Economic Zone, has completed a €1m laboratory expansion investment project. The renewed lab allows the company to imitate the food and beverage packaging processes of its brand-name customers while utilising the packaging elements it produces, helping to bring innovative packaging solutions to market sooner.
The company has been pursuing scientific research and production testing projects in Klaipėda since 2016, during which time its laboratory has been certified by one of the world’s largest beverage producers. The current R&D capacities of the company have allowed it to successfully perform tethered cap research and to create and test the product, in turn contributing to a greater quantity of packaging elements being returned for recycling and meeting the EU Directive on single use plastics.
Believing in the lab’s importance and its contribution in developing more sustainable products for the market, the company decided to expand its R&D capacity, prompting the completion of the expansion of the laboratory’s premises and purchasing new laboratory equipment this year. The company will transport a full set of equipment to Klaipeda and install it by the second quarter of 2021. Currently, the laboratory premises and equipment have drawn €1m investment, and since 2016, €800K has been allocated for purchasing the equipment. The company plans to purchase a further €700K worth of laboratory equipment. General Manager at the company Viktorija Grižienė notes that the new laboratory will allow the company to expand its research into closures and will open up totally new opportunities in the food film segment. “In terms of bottle closures, we already are a research centre for our global group, and we have also established firm partnerships with third parties. The entire world is keen to use more recycled and sustainable materials in bottle caps and bottle preforms, and in our new lab we can test every idea and possibility by imitating the entire packaging process, replicating the conditions and technologies of our clients. Today, most of the food packaging on the market is comprised of components supplied from various manufacturers, which does not ensure optimal compatibility, functionality, sustainability and opportunities to improve the packaging. We can create products for our customers which are more optimal, more sustainable and easier to recycle,” V. Grižienė says.
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Brands overlook the importance of innovative closures to their detriment, as clever caps deliver protection of product as well as convenience. Yet with the latest EU directive regarding tethered closures making stay-connected caps a need not a want, manufacturers are highlighting how their particular expertise can bring value to this crucial part of packaging design. Emma-Jane Batey speaks to design engineer Andzejus Buinosvskis and marketing manager Mariya Ushakova from RETAL to learn how this global plastic packaging manufacturer is exceeding its brand-owner customers’ requirements.
The impact of the EU Single Use Plastic Directive on tethered closures sees a ruling that all beverage containers of up to three litres must have lids that ‘remain attached’ is not only set to be positive from an environmental perspective, but also in terms of packaging innovation.
With the crucial yet often underplayed role of closures in the performance and, to a lesser extent, brand awareness, this SUP directive brings closures into the spotlight. And now that closures have been given their chance to shine, they seem to be rather enjoying it! For global caps and closures manufacturers, their work has long been somewhat in the shadow, yet for those involved in the creatively technical aspects of the design of closures, their deep understanding of how the closure literally allows the product itself to be protected, this is not news. For carbonated beverages in particular, the role of the closure is driven by the pressure of the fizzy drink within, so understanding how that performance influences the engineering elements is key. The additional demands of tethered closures is bringing an additional challenge to those who create what consumers take for granted.
Andzejus Buinosvskis, design engineer for RETAL, a global plastic packaging manufacturer that works with many of the world’s leading food and beverage brands, explains how the EU’s SUP directive is influencing his work. He says, “In the early days of tethered cap development all packaging manufacturers were working in our own bubbles, but as the regulations and their impact have become more clearly understood and, particularly, now we have more specific requirements from our household-name brand owner customers, we are able to develop solutions that are unique to us.”
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Despite the unforeseen difficulties of 2020, global plastic packaging manufacturer RETAL continues to actively invest. The RETAL Baltic Films plant in Klaipeda officially opened its modern production R&D laboratory and additional 4000 sq.m warehouse for storage of finished products in October, thanks to a EUR4.5 million investment.
The new laboratory is fully equipped with the latest machinery, opening new opportunities for the company to quickly create and produce higher volumes of sustainable packaging films. The expansion of the administrative and warehouse premises will improve the company’s operational efficiency, as greater stocks of finished products will mean faster deliveries.
RETAL Baltic Films General Manager Viktoria Griziene notes that the new laboratory, which has already been certified by one of the world's largest beverage producers, will allow the company to expand its research on caps and maximise completely new opportunities for the film segment. “Now we can test every idea and opportunity; simulating the entire packaging process, reproducing the conditions or technologies of our customers, including filling and capping, which will allow us to optimise all the parameters of our product, including being more environmentally friendly and easier to recycle.”
The combination of high professionalism and the striving of the RETAL team for continual development guarantees the company a competitive advantage, and ensures a trusting relationship with customers, who are primarily global food and beverage brands. Ms Grisiene emphasises: “The new RETAL Baltic laboratory, equipped with the state-of-the-art equipment, is ready to conduct in-depth analysis of the technical and consumer properties of our customers’ products and any changes in their formula, including new additives, design modifications or new materials. We can test both prototypes and the products themselves - films, preforms and closures. The laboratory has installed Zeiss coordinate measuring machines, a Zalkin pilot capping line, and equipment for testing the strength of the closure in accordance with the requirements of leading global brands."
Alexander Grinko, head of the quality department at RETAL, is confident that the use of its own testing equipment, combined with the high technical knowledge of its specialists, assures stable product quality. Mr. Grinko notes: “The new laboratory will provide an even higher level of product quality control for all RETAL factories. Active communication and sharing experience within the company adds to the continual improvement of the testing process and guarantees the supply of high-quality products to our customers in the shortest possible time."
Customers will also benefit from the new warehouse facilities, which are equipped with a software-based racking system and an increased number of shipping bins, as the additional storage volumes and efficient inventory management will ensure faster and more flexible deliveries.
Employees can enjoy more comfortable conditions too, as the investment in the administrative facilities includes a new canteen, a larger changing area, and considerably more space throughout the offices on site.
In 2021, RETAL Baltic Films expects to maintain and boost production processes and the expertise of its employees, which, together with the upgraded facilities, will provide an excellent basis for its continued success.
In all the best success stories, it is not one person that makes the difference, but rather a motivated team of like-minded individuals that come together to achieve a big goal. This is certainly true of RETAL Cyprus, the Limassol-based plastic packaging factory, part of RETAL Industries, which celebrated its fifth anniversary on 9th October this year.
The story first started with a big inauguration in 2015. The importance of RETAL opening and operating a successful factory in Cyprus, where it is headquartered, was clear from this event, as it was attended by the President of Cyprus Mr. Anastasiadis, senior local government officials, the President of RETAL Anatoly Martynov, all of RETAL's board of directors, and its global customers. The event was widely publicised as it highlighted the importance of opening such a modern factory in Cyprus.
RETAL's plans in this strategically important region - the south part of Europe - have come true. Today it is a successful and dynamically developing business that contributes to the Cyprus economy. The company’s president Mr. Martynov notes, “RETAL has over 20 years of experience in the production of plastic packaging. It is the synergy of our deep understanding of the industry and significant investments in our modern plant that are key to the achievements of RETAL in Cyprus.”
Read the story online on Cyprus Times
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In all the best success stories, it is not one person that makes the difference, but rather a motivated team of like-minded individuals that come together to achieve a big goal. This is certainly true of RETAL Cyprus, the Limassol-based plastic packaging factory, part of RETAL Industries, which celebrated its fifth anniversary on 9th October this year.
The story first started with a big inauguration in 2015. The importance of RETAL opening and operating a successful factory in Cyprus, where it is headquartered, was clear from this event, as it was attended by the President of Cyprus Mr. Anastasiadis, senior local government officials, the President of RETAL Anatoly Martynov, all of RETAL's board of directors, and its global customers. The event was widely publicised as it highlighted the importance of opening such a modern factory in Cyprus.
RETAL's plans in this strategically important region - the south part of Europe - have come true. Today it is a successful and dynamically developing business that contributes to the Cyprus economy. The company’s president Mr. Martynov notes, “RETAL has over 20 years of experience in the production of plastic packaging. It is the synergy of our deep understanding of the industry and significant investments in our modern plant that are key to the achievements of RETAL in Cyprus.”
Beyond the facility’s impressive equipment and investment, is the unquantifiable advantage of RETAL Cyprus – its engaged, enthusiastic, and highly trained staff. General manager Mr. Hagai Golan shares: “We started from practically a greenfield site. There were almost no specialists in our industry in Cyprus. We recruited people with technical skills, trained them and together we are achieving our goals. We have enjoyed great support in training from our colleagues in other RETAL plants, bringing their expertise to us here in Cyprus. Our team certainly helped us a great deal during coronavirus crisis; our plant operated without interruption and the demand for our products has remained stable. All of this allows us to look confidently to the future."
RETAL global key account manager Nedko Nedev concludes, “RETAL Cyprus is a game changer - one of the leaders in the region. In our first five years we've established high quality standards and reliable business relationships with our local and global customers. Today, about 95% of PET packaging for water, beverages and dairy products in Cyprus is produced by RETAL. Also, our products are in demand outside Cyprus, being exported to Greece, Israel and African countries. RETAL Cyprus plans to expand our product range and sales geography in the near future.”
RETAL Cyprus pays great attention to environmental issues, with extensive investment in solar panels currently providing around 25% of the factory's electricity requirements. The company produces sustainable plastic packaging and utilises its R&D capabilities to offer lightweighted products with a design-to-recycle approach and tethered closures. Promoting the principles of a circular economy, RETAL Cyprus is actively involved in projects related to rPET usage, carries out plastic pollution awareness initiatives, and takes part in cleanup activities to improve the ecology of the island.
RETAL Cyprus also takes part in the social life of the country, sponsoring the Apollon Ladies football team, with both groups participating in environmental activities aiming to raise public awareness in Cyprus on plastic usage.
In its first five years, RETAL Cyprus has become an integral part of the global RETAL company. In the early months, specialists from other RETAL facilities came to Limassol to share their experience. Today, RETAL Cyprus is a hub for key business decisions, strategic planning sessions, and analysing results for the whole group.
The team has ambitious goals, and we hope that by the next anniversary we will have even more to share about the latest achievements of RETAL Cyprus.
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Sustainability Director Emmanuel Duffaut is actively ensuring RETAL engages with suppliers that also perform highly in their CSR actions, as well as systematically guaranteeing quality and food-safety procurement across the company's facilities worldwide.
Duffaut says, “It is crucial that we buy raw materials, good, and services in the lowest impact, most responsible manner possible and we must have a formalized and credible way to evaluate and report our suppliers’ CSR performance to meet our customers’ needs and protect their reputation. Along with our Procurement department, we are implementing a systematic, structured and standardized evaluation of our suppliers regarding CSR to ensure to our existing customers and potential customers that they work with a responsible company.”
RETAL provides to its suppliers subsidized licenses of the 7 Toolkit that RETAL uses, which is based on the ISO 26000 standard, and was created by the CSR Company International Ltd, whose owner Martin Neureiter was the global chair for the ISO 26000 standard development.
With formalised CSR increasingly integrated across RETAL's global facilities, the company is delighted to reflect its multi-stakeholder appreciation for partnering with a responsible manufacturer that practices sustainable procurement.
Effective internal communications for a global company brings many advantages but can be hard to implement and maintain. With various stakeholders and their differing needs, creating an engaging communications strategy is an opportunity for commercial and organisational goals to be met. Following their intranet launch in 2019, global plastic packaging manufacturer RETAL shares how developing its intranet has been both more difficult and more rewarding than it expected – and how they had to adapt in response to Covid.
For traditional manufacturing companies, the understanding of what effective communication is and why it’s necessary can be the first hurdle in developing a communications strategy. Different stakeholders can see the value of communications in opposite terms, with the ROI hard to quantify, especially in the short term. Yet the cost of poor internal communications may only be seen when it’s too late, so proposing, agreeing to, and, crucially, getting the budget for, a corporate intranet is the first hurdle.
RETAL develops and manufactures plastic packaging solutions to customers in over 60 countries worldwide. The business was founded in 1994 and currently employs around 1,500 employees. Today, RETAL has locations worldwide including Eastern and Western Europe and the US, so its wide range of cultures both internally with employees and externally with customers and other stakeholders means that communication is key. Having historically relied on separate communication within each of its locations, the company realised that integrated internal communication could add considerable value to both its employee engagement and its bottom line – as long as it was done right.
In 2019, the organisation invested in a new corporate O365 intranet. The project was focused on delivering enhanced communication across its 15 factories.
Using an Attollo Intranet out-of-the-box package, RETAL built its internal communications platform to allow for closer cooperation between colleagues and departments in a more efficient and effective manner.
However, the unprecedented changes that the spring of 2020 brought meant that the dedicated communication platform has more than earned its keep, highlighting how staying closely connected even when colleagues are working from home around the world supports a profitable modern workplace.
In this article, RETAL explains how its newly designed intranet had to quickly evolve to meet the needs of its employees in the face of Covid.
Socially-distanced celebrations are still possible at RETAL Baltic thanks to the official opening of its new premises.
The new space is dedicated to an updated central group laboratory to maintain the company’s international-standard quality assurance and testing, as well as expanding working and auxiliary spaces for administration and production employees. It sees the previous 700sqm site now doubled to 1400sqm, in addition to its production facilities.
On 19th June, General Manager Viktorija Jurevičiūtė cut the symbolic ribbon to declare the facilities open, following 12 months of construction that was delayed earlier this year due to coronavirus. The RETAL Baltic team enjoyed a small ceremony to mark the event, with the additional space allowing for plenty of room between people. Each employee was also presented with a personalised plant to match the new office.
Viktorija says, “This new facility represents our continued growth, both professionally and personally, and so we wanted to give each employee something to mark the occasion. The bright, clean design is perfectly in tune with our focus on providing high quality, sustainable plastic packaging solutions and we’re all looking forward to utilising this investment.”
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Digitalisation supports sustainable packaging thanks to adding value without adding materials or considerable costs. That value takes many
forms, from marketing and consumer engagement to raising awareness of environmental issues. Digital tools that can bring benefits to global beverage brands include laser engraving and a gaming-style recycling app, with plastic packaging manufacturers able to integrate both relatively easily and cheaply.
Laser engraving is a design tool to add value to plastic packaging, with the infrared and UV laser capabilities bringing appealing consumer
engagement opportunities right at the start of the design process. The digitalisation element of laser engraving comes from its graphic design
foundation, whereby the right files mean clear designs can be engraved on closures.
Andzejus Buinovskis, design engineer at global packaging manufacturer RETAL, developed specific files that highlight the possibility of laser
engraving for integration in the company’s portfolio of HDPE closures, which are widely used by many of the world’s leading beverage brands.
Andzejus says, “I realised the potential for laser engraving on the underside of our closures when I was Retalsent files to create engraving on our closures, but the graphic files were not suited to laser engraving. The files were prepared by a professional graphic designer as they meant to be printed, but they would not translate well in laser engraving and would not have the desired result. I worked on solutions using one or two lasers and with ultraviolet, infrared or both technologies, with my knowledge of the capabilities of the machines married with
my design skills. For example, the laser doesn’t see shapes, but rather outlines; the laser beam follows the perimeter of the shape, so the design needs to be simplified in order to create a clear image. I worked with the creators of the machine to understand in depth what is and is not possible within its existing capabilities, like can we create an infilled area and can we engrave on light, dark and coloured closures.”
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Globally-active plastic packaging solutions manufacturer RETAL is implementing a 'defined, robust' Heath & Safety project across all its 17 international factories.
The 2BSafe project sees all RETAL's worldwide factories working to the same high level international standards, rather than simply adhering to local regulations, to formalise its strict health & safety standards in every factory.
Lead by Sustainability Director Emmanuel Duffaut and project manager Marlene Riethus, the cross-facility team brings together the different legal regulations and cultural expectations in order to establish and maintain a standardised agreement for health & safety performance.
Corporate standardisation of health & safety also brings economies of scale for resources management, such as buying PPE for the whole group, as well as allowing for effective process management with standard products.
Riethus says, “We want everyone at RETAL to work within the same H&S management system; as a global company with increasingly active global communications, we need to demonstrate to our stakeholders that we are OneRETAL. It helps to protect our employees, to be more effective, to attract talent, to avoid litigation, to reduce downtime...there are so many positive aspects.”
The RETAL 2BSafe project is currently in its implementation phase and is expected to be rolled out across the company by 2021.