1. Package Manufacturers & Printers Package for Success
Presented by Paul Nieuwenstein
Farnell Packaging Limited, Dartmouth NS

2. About Farnell Packaging
Who We Are
Flexible Packaging manufacturer located in Dartmouth, NS
In business for over 50 years since 1961
ISO 9001:2008 certified
HACCP/PACSecure certified
Employ 185 full-time staff
Operate 24 hours a day, 7 days a week

3. About Farnell Packaging
What We Do
Manufacture leading-edge flexible packaging materials
Extrude clear and coloured polyethylene films for conversion into bags and rollstock
Print up to 8 colours in 4 colour process and Pantone and 7 colour opaltone process print
Various laminated films structures
Specialized packaging
Cryovac polyolefin and polyethylene shrink films
Cast co-extruded palletwrap
Provide guidance with related equipment solutions

4. Sample Review What’s New? Trends? Options? Stand up pouches
Handle bags with closures (zipper, velcro, etc.)
Expanded gamet printing (Opaltone)
High-Definition printing plates
Resealable lidding films (e.g. cheese containers, cookie bags)

5. Getting Started Initial Steps – Preparation and Checklist
What type of product do you want to package?
Food grade or non-food?
How will it be packaged – using bags or rollstock?
Is it frozen or dry, etc.?
How many packages do you need for your initial order?
Are there any regulatory considerations?
Type and size of bag and gauge of plastic needed?
Automatic filling equipment? – if so, provide specifications
Quantities – minimum orders vs. larger run economics
Design considerations - number of colours, size?
Quotation – allow 1 day, if scope of work is clear

6. Ordering Process Next Steps
Initial placement of order - submit PO# to begin process
Allow up to 3 weeks for initial credit application review
Prepaid orders can expedite this process for rush deliveries
Supply artwork to printer
Printer’s proof created and supplied to customer
Printer’s proof reviewed and approved by customer
Once approved, plate materials are ordered
Production of bags - allow 4-6 weeks
Shipping of bags or rollstock to customer

7. Production Process Printing Plates
A photopolymer printing plate is used to transfer ink onto plastic film
A different plate is required for each colour in your design
In pre-press, artwork is adjusted to include ink bleeds and other tolerance requirements of flexographic printing
Once these adjustments have been approved printing plates are then ordered
Printing plate
viewed at 200x

8. Production Process Printing Dielines
A dieline is an outline used to show the artwork designer the live printable area on a bag or a rollstock impression. It will also point out areas where test is not recommended (e.g. In the tie off and seal areas)
A dieline can be provided to you art designer once the package size has been confirmed.
In some cases, a standard dieline may be available which can expedite the process (e.g. 5 lb potato bag)
look for die line

9. Film Extrusion
Your Film is Custom Made to Order

10. Production Process Resin Adding and Blending
Plastic resin pellets, colour concentrates and other additives are blended to ensure that desired film properties are achieved

11. Production Process Blown Film Extrusion
Molten film is extruded, cooled and then wound onto rolls in the size and specification required by the customer
Break these photos out and lighten some of the pictures

12. Production Process Rolled Film
Rolled film being prepared for printing and/or further processing

13. Production Process Final Step in Manufacturing the Film
Extruded flattened bubble being slit into Sheeting
Gussetted tubing can be made into Bags on Rolls

14. Production Process Recycled Pellets
Any out of specification film can be re-pelletized and re-used

15. Production Process Ready to Print!
Printing dieline was created, or existing one was chosen
Prepress - artwork was completed and approved
Printing Plates were created
Film is manufactured while plates are being produced
Now we’re ready for Printing to begin

16. Printing Options
6 Colour Stack Press

17. Printing Options
8 Colour W & H Central Impression Presses

18. Additional Options Lamination and Winding Options Laminator
Slitter/ Rewinder

19. Finishing Process
Bag Converting Machines

20. Finishing Process
Finished Bags – On Wickets

21. Finishing Process
Bag Sealing
Bottom seal or
side-weld options

22. Ready for Shipping
Loading the Truck!

23. Summary Steps to a Successful Process Understand your needs
Explore and discuss options with your printer
Allow 1 business day for quotation, if scope of work is clear
Allow 4-6 weeks for production, from time of approval of printer’s proof to shipment of your finished product

24. Package Manufacturers & Printers Package for Success
Presented by Paul Nieuwenstein
Farnell Packaging Limited, Dartmouth NS