Stick-packs break barriers

Breaking new ground is nothing new for Unette Corp. (www.unette.com); in fact, it's what the company was built on. In 1955, engineering inventor and company founder Frank Brown developed the first tear-top plastic tubes—also known as unit-of-use tubes, squeeze tubes or portion-pack tubes. Today, the company is a leading supplier of single-use packaging and contract filling services for the cosmetic, pharmaceutical and personal care industries.

The tubes were formed using plastic rollstock slit into various widths, which was then hot-stamped, formed, filled and heat-sealed in one operation on specialized equipment developed by Unette. Speed of production and a relatively low material cost enabled Unette to package customer-supplied liquids and pastes, often at lower costs than other packaging methods. The tubes provided a flatter decorating area than round bottles or tubes, while the narrow tip channel offered more dispensing accuracy than foil pouches. In addition, the tear-off top made the package tamper-evident and ensured that the recipient would dispense the correct portion of the product for the intended application. The small size, low cost, fast turnaround, quality appearance and convenience of the tubes made them a favorite among consumer product manufacturers wishing to sample, as well as sell, single portions of liquid and paste products.

Since then, Unette has made further inroads in tube production and decoration and has added bottle filling, labeling and safety sealing services to its portfolio.

However, Joseph Hark, president of Unette, knew the company hadn't finished growing. After making several trips overseas to handle business for Unette's European Operations (based in Manchester, England), Hark noticed an increase in the use of the stick-pack format for products like condiments, sugar and other powdered products. An attractive, cost-conscious alternative for single-use applications, the format offers powerful brand distinction from standard foil pouches. The stick-pack style also provides the ultimate in consumer convenience by enhancing portability, opening easily and dispensing precise amounts of product.

Unette’s new stick-pack machinery can handle liquids, without leaking.

Having discovered a powerful growth opportunity for Unette, Hark returned to the U.S. and began researching machinery suppliers that could produce the stick-pack format. Over the next five years, Hark met with several companies offering technology for powdered applications, but could not find a system capable of manufacturing stick-packs for liquid products without leaking.

Hark finally turned to the PACK EXPO Intl. (www.packexpo.com) tradeshow for a solution. Once there, he met with every supplier that offered stick-pack packaging systems. When Hark visited the Ropak (www.ropak.com) exhibit, he knew he had hit the jackpot. In the booth was the company's StikPak system running a liquid application—and the package did not leak.

“I had met several suppliers at that point, and all of them told me they could package liquids with no trouble,” says Hark. “However, having someone say they can do something and seeing it is completely different. I was able to examine the packs for myself and ask detailed questions about the equipment. Seeing really is believing.”

After visiting the last show, Unette purchased a new stick-pack packaging system that enabled the company to become a pioneer in a new market segment and become more competitive. Ideal for single-use applications, the stick-pack offers brand owners an alternative to standard foil pouches for products like shampoos, conditioners and gels. Since the investment, stick-pack products continue to increase Unette's market share.

Hark was also pointed in the direction of a material supplier at the show. Ropak was running stick-packs constructed from Curwood's (www.curwood.com) SlimFlex® high-barrier film technology. Engineered specifically for single-serve tube packaging, the film can be printed by gravure or flexo with eye-catching graphics to enhance visual appeal.

“Being able to examine materials and machinery in one location is very beneficial,” says Hark. “Both elements have to work in harmony with one another for the best result. Seeing the material running right on the system we were considering purchasing proved they were compatible and saved a significant amount of time.”

The Ropak StikPak is a multiple-lane, continuous-motion, vertical form/fill/seal packaging system. Production speeds can be as high as 720 sticks/min (120 cycles/min for all five lanes), depending on product flow characteristics, packing materials and fill temperatures.

Unette had the system delivered a few weeks after the show. Ropak's team of technical experts made some modifications to the system to ensure a smooth integration with Unette's existing equipment and meet the company's requirements for flexibility.

The vf/f/s equipment can reach production speeds as high as 720 sticks/min, using all five lanes.

“We package several different types of products at Unette and need to be able to switch between brands efficiently and quickly,” says Hark. “Ropak sent a technician to our facility to make sure we got up and running and could achieve the changeover required.”

Today, Unette uses the system to package a variety of haircare products such as shampoos, conditioners and gels. The tube-like foil-laminate packets are available in sizes from 1 to 30 mL.

“The system has served us very well. It is easy to maintain and offers the versatility we need,” continues Hark. “In fact, we're considering purchasing a second system to meet growing demand for this style of packaging.”

Extending its product portfolio to include the stick-pack format has allowed Unette to offer its customers a unique, value-added packaging solution. Customers have been very responsive to the new style; the number of stick-packs manufactured and filled by Unette increases each year.

Hark will make the trip back to Chicago and PACK EXPO Intl. this fall with a buying team consisting of plant management, machine fabricators and mechanics to examine the latest automation technology trends. “As a contract filler, it's essential for us to maintain the high-quality service our customers have grown to expect,” says Hark. “That means seeking new ways to enhance efficiencies, staying on top of industry trends and learning new ways to help our customers grow their businesses.”