In agricultural technology, precision and innovation are key to superior and effective products. In a collaboration with Netafim, Aran has achieved a remarkable feat – manufacturing the smallest bag they ever made, a crucial component of the revolutionary PULSAR system. This exceptional bag plays a pivotal role in providing precise and efficient water coverage for specific segments of Netafim’s agricultural products to protect crops from extreme weather events.

Aran’s Commitment to Innovation

At the core of Aran’s philosophy lies a commitment to pushing boundaries and designing solutions that meet the unique needs of their clients. The journey to create the PULSAR bag was not just about manufacturing a component; it was about understanding and addressing the specific challenges faced by growers in orchards, vineyards, and various plantations worldwide during extreme weather conditions

Yoram Engel, Netafim’s product manager, approached Aran with a unique idea – to develop a spring-like bag that could withstand pressure and function flawlessly in the PULSAR system. Aran embraced the challenge, displaying its ability to translate conceptual ideas into tangible, high-performing products.

The PULSAR System: Revolutionizing Agriculture

Netafim’s PULSAR system is a testament to agricultural ingenuity, providing growers with precise water distribution and efficiency. This innovation caters to diverse crop applications, offering protection against both extreme heat and frost event conditions. Aran’s contribution to this system is embodied in the specially crafted bag that plays a crucial role in the thermodynamic protection of crops. The bag’s role in the PULSAR system is to disperse water through controlled pulses, creating a protective coating of ice during frost event to prevent the plant from freezing and aiding in cooling through evaporation during heat waves. Agriculture in different climates requires this unique functionality.

Crafting the Perfect Bag

The journey to create the PULSAR bag was not without its challenges. Aran’s team, led by Yehuda Nahir, meticulously examined various options, materials, and structures until they found the perfect solution. “We are experts in developing bags that can keep the liquid inside, the challenge was to figure out what kind of bag can withstand prolonged water exposure and constant mechanical stress, it had to have high resistance to flex cracks”, says Yehuda. The final solution was based on the multi-layer composition and the same materials as Aran’s bag “SuperFlex”. Six layers, combining plastic and metallization, were combined to achieve the necessary flexibility and durability. This small yet mighty bag, measuring just 4 cm in width and a 20 cm in length, undergoes millions of pulses before replacement is necessary.

The Collaboration’s Success

The collaboration between Aran and Netafim exemplifies the power of innovation and industry collaboration. Aran’s expertise in plastic engineering and material science, coupled with Netafim’s precision agricultural prowess, has resulted in a game-changing product that benefits growers worldwide. The PULSAR bag is a crucial component in Netafim’s mission to provide water and energy-efficient solutions for sustainable agriculture and preventing crop damage during extreme weather events.

Aran’s journey with Netafim displays the company’s ability to rise to challenges, innovate, and create specialized products that have a profound impact on the agricultural landscape. The PULSAR bag stands as a symbol of Aran’s commitment to excellence and capacity to contribute to transformative solutions in diverse industries.

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Everyone knows the simple mathematical rule that if you multiply two negative numbers you get a positive one. However, in real life, finding two disadvantages giving a distinct advantage is rare. Such a case can be found in recycling. This case illustrates a way to take two types of post-consumer waste, which require a significant effort to recycle alone and create high-quality, innovative raw materials, that reduce landfilling and support a circular economy.

The challenges in PCR of plastic films for agriculture waste

The Roded company specializes in recycling agricultural plastic waste. “Post-consumer agricultural waste is one of the most difficult plastic wastes to recycle.  These greenhouses cover and mulch PE films, exposed to dirt, sand, and dust. Changes in the temperature, during day and night, winter and summer, also contribute to the polymer’s cycles of shrinking and expanding and the penetration of microscopic-level pollutants into the polymer. In addition, the films undergo prolonged exposure to pesticide materials as well as to solar radiation. These cause unwanted phenomena in the polymer such as degradation, cross-linking, loss of elasticity, and making the polymer brittle. This damage reflects on the polymer MFI: the original MFI values are 4-6, while the PCR material reaches much lower MFI values, 1 or less.

Washing and mechanical dry-cleaning improve the results, but it is still necessary to add flow enhancers or lubricants in the form of paraffin oil or PE-based wax to the recycling process. Despite that, the recycled material remains with a problematic melt flow that limits its applications, especially in pressing and injection manufacturing. It is possible to increase the temperature to improve the melt flow, but recycled materials are more thermally sensitive, and tend to degradation.

The challenges in recycling laminate waste that contains various polymers as well as metallization

Another waste that is difficult to recycle is laminate. These films consist of a combination of different polymers, PE and PA or PET, which are not compatible, and recycling them together is challenging. The addition of an aluminum layer to the film will cause it to end up in landfills or energy recovery as an end-of-life solution. “These films are part of the BIB (Bag In Box) that we manufacture at Aran”, says Lior Mor, CEO of Aran Group “We reduce their use, but for some food products, they are necessary. As part of our commitment to recycling and circular economy, we invest efforts to find an environmentally friendly end-of-life solution for these types of films, whether it is industrial waste from the production processes of organizations, or post-consumer waste.”

What happens when you combine agricultural plastic film waste with metalized laminate waste from the BIB processes?

An innovative collaboration between Aran and Roded led to finding a creative solution to the challenges faced by each of the companies individually. Significant development work has revealed that combining the two different types of waste and recycling them together produces an improved raw material. An in-depth study revealed that the low-level aluminum from the metalized films has a positive effect on the melt flow of the material and acts as a flow enhancer as well as a reinforced material that contributes to the final product. It is in patent-pending processes and initial pilot facilities already exist at Roded’s factory in Israel. It relies on unique cleaning, shredding, processing, and manufacturing technologies, including mold design with release mechanisms of volatile materials generated in the recycling process.

From agricultural waste and laminates to industrial pallets

“Reusable plastic pallets, produced by pressing, are an ideal application for these recycled materials”, says Eitan. “They replace the wood pallets which are commonly used in the industry. They are less susceptible to contamination and the fact they are produced from recycled material is a significant advantage.”

Compared to wooden pallets the plastic ones are lighter and more durable. “Thanks to the use of recycled raw material, we manage to maintain the same price level. This is the first pallet that presents a negative carbon footprint. This product presents advantages even when comparing it to pallets made of virgin plastic. The recycled material contains inherent foaming which lowers its density and enables more energy-efficient logistical transportation. Moreover, the product has improved mechanical strength, and it does not require metallic reinforcement.”

The carrying capacity of the pallet is 4 tons when placed on the ground and 1.2 tons when stored on high shelves. Thus far, thousands of pallets have been produced. All are safe for secondary packaging of food products.

What does the future hold? Establishing a reverse logistics system to collect post-consumer BIB waste. The next step of this project is to recycle post-consumer BIB waste. “We intend to collect the outer bag of the packaging, which does not come in direct contact with the food. This layer is the massive one, and it’s about 70% of the weight of the entire plastic packaging,” says Luis Hernandez, CEO of Aran Europe. “Aran group will lead the establishment of a reverse logistics system for collecting PCR BIB from its customers. We are submitting the project to the European Union’s Horizon program and hope to bring positive change in the field of sustainable BIB”, he concludes.

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Come summer, the time for harvesting the “Love Apple,” better known as tomatoes, arrives. This beloved fruit takes hold of our kitchens in all forms and is an ingredient in many recipes. Aran, a company specializing in the production of aseptic bags for liquid packaging, plays a crucial role in supporting this culinary phenomenon. These bags are precision-crafted solutions specially tailored for packaging tomato products. Let us discover the innovative measures taken by the company to ensure the freshness and quality of tomatoes from field to table.

The Global Tomato Processing Calendar

Tomato processing is a global affair, with different regions engaging in the activity at various times of the year. In the northern hemisphere, particularly in Europe, California, and the East, the tomato-processing season starts in July. Across the equator, countries like Chile, Argentina, and Brazil harvest and process their tomato in mid-February. This seamless rotation ensures the year-round availability of tomatoes worldwide, and it is within this continuous cycle that Aran’s expertise in tomato product packaging becomes indispensable for maintaining the global supply of this beloved fruit throughout the year.

Diverse Customer Base

Tomatoes operate in a fast-paced world where harvesting, processing, and packing occur within a single day. Many tomatoes are not destined for fresh consumption; instead, they undergo processing to meet the demands of the culinary world, transforming them into diced, minced, crushed, and pastes. Aran caters to a diverse clientele, offering bags tailored for industrial use (55 and 300 gallons) and the food service industry (varying from five to 20 liters). Renowned brands like MUTTI, Heinz, KAGOME, Campbell’s, and others actively seek Aran’s packaging solutions.

In the food service sector, Aran provides a wide variety of options to meet the needs of end customers. These options include different types of fitments and seals, such as screw caps and temper evident seals, as well as barriers with varying permeability levels—ranging from standard barriers to enhanced barriers, ensuring less than 0.5 CC per m³ for 24 hours.

For industrial use, the end application varies, Aran’s range includes mechanically reinforced bags suitable for extraction from the barrel while full, as well as thinner bags that can be emptied without pulling them out of the barrel. Aran’s unique products, Super Flex and Premium Flex, offer varying levels of oxygen resistance and can endure significant logistics transport distances — 6000 km and 8000 km respectively — without succumbing to flex cracks, addressing diverse industrial needs.

Adapting to Environmental Demands

Aran has seamlessly integrated sustainability into every facet of its operations. The company introduces 300-gallon products with adaptations that align with recycling requirements. Through a strategic transition from recycling code 7 to code 4 and increased utilization of less than 5% EVOH layers over traditional metalized layers, the use of mono materials and fewer colors Aran actively contributes to a more environmentally friendly approach.

Aran’s Global Presence and Impact

In the realm of tomato processing, Aran stands as the third-largest packaging manufacturer globally, serving clients on every continent and distributing tens of millions of aseptic bags annually. Collaborating with 11 of the largest tomato manufacturers worldwide, the company provides a significant portion of the packaging solutions, contributing to a market share that has notably grown in the last five years. With local production capabilities in Spain and the USA, proximity to customers ensures enhanced availability and service.

In a world where the love for tomatoes transcends borders, Aran’s commitment to innovation and environmental sustainability in tomato product packaging is truly noteworthy. As the company continues to grow its market share and adapt to changing demands, it remains a key player in shaping the future of tomato processing.

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In a noteworthy move towards sustainability, Aran Group, a prominent manufacturer of bag-in-box solutions, is delighted to announce the successful acquisition of a majority stake in IBA Germany from Liquid Concept GmbH (LC). This strategic venture not only signifies a pivotal moment in Aran’s growth trajectory but also underscores their commitment to sustainable packaging solutions. The focus of the acquisition lies in furthering the development of 1000-liter IBCs (Intermediate Bulk Containers), aligning with Aran’s dedication to eco-friendly practices.

Managing Director Dan Abraham, together with Sascha Siebel, COO & Chief Engineer, leads the Aran-IBA operation. Siebel, a global expert in bag-in-box (BIB) and sustainable food packaging, brings innovative solutions to the forefront of the fruit preparation industry.

A leap toward sustainable practices

Lior Mor, CEO of Aran Group, expressed his enthusiasm about the acquisition: “This marks a tremendous leap forward for Aran and IBA in terms of sustainable practices. With the board’s unwavering support, we are poised to achieve significant milestones in responsible packaging solutions. IBA is now officially part of the Aran Group, and we anticipate this move will further strengthen our sustainable footprint in Europe.”

Dan Abraham, elaborating on the acquisition’s sustainability advantages, stated, “This strategic move positions Aran as a significant player in 1000-liter aseptic packaging solutions for transporting sensitive food products. Our partnership with IBA not only solidifies our presence in Germany but also offers an environmentally friendly alternative to traditional stainless-steel containers.”

Sustainable aseptic packaging solution for sensitive food products

The cornerstone of this collaboration is IBA’s flagship product, the IBA Tainer aseptic IBC. This patented 1000-liter container, designed for liquid food transport, incorporates a protective cage and a disposable flexible bag. Not only does it present a cost-effective substitute to conventional containers, but it also ensures an aseptic environment, eliminating the need for resource-intensive washing and sterilization processes. Beyond its economic advantages, the IBA Tainer significantly reduces energy consumption throughout the entire value chain, aligning with Aran’s commitment to sustainability.

The acquisition marks Aran as a key player in the European market

The Aran-IBA partnership, spanning a decade, has been instrumental in mutual growth. The acquisition of IBA positions Aran as a key player in the European market, specifically Germany, where the bag-in-box market generates substantial revenue. This move enables Aran to export IBA’s sustainable products beyond Germany, leveraging its global network and the innovative IBA Tainer.

As Aran and IBA’s combined capabilities and sustainable technology converge, the industry can anticipate substantial growth in the years to come. This acquisition not only advances the fruit preparation sector but also underscores the collective commitment towards sustainable packaging solutions.

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In a world where innovation constantly shapes industries, the wine sector has seen a transformative packaging solution that is redefining convenience, sustainability, and taste preservation: Bag-in-Box (BIB) packaging. The BIB format offers an array of benefits that are becoming increasingly apparent to both producers and consumers. It ensures wines maintain quality, reduces environmental impact, and provides consumers with a user-friendly and cost-effective way to enjoy their favorite vintages.

Challenges in Wine Filling with Bag-in-Box

However, the adoption of any packaging method comes with its own set of challenges, and the BIB approach is no exception. The process of filling wine into these bags necessitates specialized equipment and materials to ensure that the product remains untainted and fresh. Maintaining the integrity of the wine during the filling process, particularly for premium and delicate varieties, demands meticulous attention to detail to prevent oxidation, contamination, and other factors that could compromise the wine’s characteristics.

Innovative Solutions by Aran: Pioneering the Future of BIB for Wines

Amid the complexities of BIB packaging for wines, emerges Aran, leveraging a rich history and expertise that spans 25 years in the industry. From its roots in Israel to the heart of Spain’s wine country, Aran has been producing wine bags that exceed traditional standards. With a strategic factory in the Valladolid region, Aran’s presence in the wine industry took a leap forward in 2010, enabling it to cater to Portugal, Spain, France, and Italy – the classical heart of European winemaking.

Aran’s commitment to innovation is highlighted by two products that set new benchmarks in the realm of BIB for wines. The first, a wine bag fortified with Superflex film, elevates durability and ensures wines can withstand the rigors of transportation and storage. The bag’s high resistance to wear and tear enables it to endure journeys exceeding 4,000 kilometers without any compromise in quality.

The second product, oxygen scavenger-infused wine bags, showcases Aran’s dedication to preserving the freshness of wines. By minimizing the dissolved oxygen content in the wine, these bags extend shelf life, enhancing the overall drinking experience. Notably, Aran’s oxygen scavenging technology can add two extra months to a wine’s shelf life compared to standard bags. This innovation not only retains the wine’s characteristics but also prevents oxygen from infiltrating the bag and affecting the wine’s flavor profile.

As Aran forges ahead, it continues to work closely with its customers, including esteemed wineries like Delicato in California. With its operations spanning across the Atlantic, Aran USA in South Carolina contributes to its global reach. The company’s dedication to delivering high-quality, efficient, and sustainable packaging solutions has firmly positioned it as a market leader and a key driver of the future of wine packaging.

Beyond Bottles: Aran’s Bag-in-Box Redefines Wine Packaging

The evolution of Bag-in-Box packaging for wines epitomizes the fusion of tradition and innovation. Aran’s steadfast commitment to pushing the boundaries of this packaging format has propelled the wine industry towards quality, convenience, and sustainability. As wine enthusiasts around the world seek ever-more exceptional tasting experiences, Aran’s innovative solutions stand ready to meet and exceed their expectations, redefining the very essence of how wines are packaged and enjoyed.

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Flexible packaging made of plastic offers numerous advantages, such as its lightweight nature, cost-effectiveness, and versatility in design. However, these packages are typically made from a blend of polymers, which makes their after-use recycling difficult in most cases, or highly challenging. As a leading producer of flexible packaging solutions, Aran is committed to sustainability and taking tremendous steps toward providing end-of-life solutions to face this situation.

Downgauging for Reduced Plastic Usage

One of the most important solutions that Aran employs is downgauging of the flexible packaging. This process involves reducing the thickness of the film while ensuring it maintains the necessary properties to be efficient and withstand storing and transportation. “Our extensive knowledge of polymer materials enables us to achieve this without compromising the packaging’s mechanical properties. We utilize alternative materials made from renewable sources and recycled materials with food-grade standards. All of our product range is available using this bio-polymer alternative, thus providing packaging solutions with a lower carbon footprint to protect the environment”, says Aran R&D manager Yehuda Nahir.  

Mono Materials for Enhanced Recyclability

Aran has also made significant strides in designing mono materials packaging. By simplifying the composition of the material, Aran has departed from traditional packaging that relied on multi-layers and metalized polyester. “Previous film structure incorporated a thick EVOH barrier layer with or without nylon, which made recycling not possible. Now we focus on the development of co-extruded products containing only PE and a thin layer of EVOH (less than 5%). This composition enables the bags to be recycled at the PE recycling stream, which can be found almost everywhere on the globe”, says Gil Yanai, Plastics Engineer and Sustainability Implementation manager at Aran Products. This move aligns with market demands for recyclable products and opens new possibilities for recycling facilities. Aran has also taken steps to reduce the use of colors and eliminate carbon black from its packaging. Preference is given to transparent or light colors, as carbon black poses challenges for waste sorting facilities, and causes failure in identifying types of polymers. Another important change to promote sustainability is regarding not the film design but the attached tap. Aran has transitioned to using only low and high-density PE for all taps. In addition, we eliminate the use of artificial colors and use the polymers’ neutral colors. This change facilitates easier recycling as both bags and taps are made of the same material and can be recycled together.

Compostable Additives and Recycled PET

A groundbreaking project was done in collaboration with Midori Bio. Aran Incorporated an additive in the PE formula of their bags, enabling composting of the traditional polymer. This additive, distinct from OXO, allows bacteria in compost environments to break down the material and turn it into bio during landfilling. This project is currently undergoing testing to ensure both bag quality and bag compostability. Aran is also actively exploring the use of recycled PET through chemical recycling methods in its bags.

Recycling PIR and PCR with Roded

Efforts to minimize factory waste get priority. Starting in 2023, in collaboration with Roded, a company specializing in creating pallets through press molding that developed a technique to clean both post-industrial and post-consumer waste. Aran began the process of recycling all of their laminates post-industrial waste. Trials for this project have proven successful and thus Aran has introduced this innovative solution to one of their clients for testing. If successful, Aran plans to offer this end-of-life treatment solution, promoting sustainable practices and recycling options for its products. With Roded, Aran has found recycling solutions for both post-industrial and post-consumer waste.

Incorporating Chemically Recycled Materials

Despite the higher costs involved, our company offers a sustainable approach to manufacturing by utilizing films made from food approved chemically recycled material. While this might not be the conventional choice for liquid food manufacturers, we are committed to environmental responsibility and reducing our carbon footprint. By using films from recycled materials, we can provide a greener solution for the majority of our products. Although it comes at a premium, we believe that investing in eco-friendly practices is essential for a healthier planet and a better future.

Aran’s Sustainable Initiatives

We are dedicated to decreasing our carbon footprint through all of the value chains and improving overall sustainability. By implementing innovative solutions such as downgauging, mono materials, compostable additives, incorporating recycled materials, and actively reducing the use of disposables in our logistical department by reusing cardboard boxes, utilizing reusable plastic boxes, and gradually shifting to non-disposable materials for packaging and transportation. Aran strives to be at the forefront of sustainable packaging practices. Aran displays its commitment to minimizing environmental impact and fostering a more sustainable future through these initiatives.

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Ensuring food safety and security is crucial in today’s world. To achieve this, it is important to focus on three main goals when distributing food: freshness, color, and avoiding spoilage. Freshness and color are essential indicators for consumers while avoiding spoilage is necessary to prevent potential health risks.

Food processing and transportation methods are key in maintaining both food safety and security. Continuous advancements in these areas aim to improve the overall quality of food products, preserving nutritional values and prolonging shelf life. Various methods, such as hot filling, ambient filling, and aseptic filling, can help preserve freshness and increase the shelf life of food items. Each method offers specific benefits that contribute to maintaining the quality and safety standards of the food. There are various packaging methods from rigid packaging made of metal, glass, or plastic to flexible packaging. Comparing the environmental impact of different packaging solutions shows that flexible packaging is a more sustainable and eco-friendly solution. Aran manufactures bags in box solutions, suitable for each of these methods and thus provides liquid packaging solutions to plenty of different sectors in the food industry.

Food Packaging Methods

Some food products are highly formulated with natural preservatives like salt, sugar, alcohol, or vinegar, making sterilization and chemical preservatives unnecessary. These products are packaged using Ambient filling at room temperature, a process that requires less energy and allows for efficient transportation. Aran’s bags are used for ambient filling of various products, such as wine, ketchup, post mix, and more, they arrive in a variety of sizes ranging from 3 liters to 20 liters, 55-gallon, and 300 gallon

Other foods require sterilization to keep up with the goal of food distribution, Hot filling or Aseptic filling is used to package them. Hot filling entails heating the food product to a high temperature before filling it into the bag, the heat from the product heats and sterilizes it, when the filling is done; the bag and content are cooled together quickly. One of the benefits of this method is that it eliminates the requirement for pre-sterilization treatment of the bag. However, a drawback of subjecting the food to high temperatures during this process is that it results in a reduction in nutritional value. Moreover, for some foods, such as tomato concentrate, the color of the product is adversely affected.

Aseptic filling is the most advanced and effective process method today. In this process, the food product is heated for a period, to a temperature that will sterilize it. Then it is cooled to approximately 10 Celsius. The fast cooling helps to maintain the food’s nutritional values, color, and freshness. At the same time, the bag undergoes radiation treatment, which thoroughly eradicates all microorganisms in the bag. The filling is done in a controlled sterilized environment. The advantage of aseptic filling is that it allows for a longer shelf life and does not require refrigeration while also preserving the color, flavor, and nutritional value of the food product. Aran’s flag products are aseptic bags in sizes ranging from 3 liters to 1000 liters, these are complex bags made of special formulations and Aran has all the knowledge and experience needed to manufacture them in high quality. 

High-Pressure Processing (HPP)

Another food processing technology that is gaining popularity is high-pressure processing (HPP). This method uses high pressure to neutralize harmful bacteria, mold, and other contaminations while also increasing the shelf life of the products. It offers exceptional sterilization, making it an ideal choice. However, due to its high energy consumption and low production rate, HPP can be quite expensive. In this regard, Aran stands out as a reliable manufacturer of suitable bags for HPP. With their extensive experience and knowledge in the field, Aran is well equipped to produce co-extruded bags that effectively prevent flex cracks, ensuring optimal results for this innovative food processing method.

Bag Compatibility and Structure in Food Processing

The bags used in each method must be compatible with the process demands in terms of temperature resistance. Moreover, the structure of the bags and layers must fit the process and the products it stores Different film combinations to match the process. Each product is categorized for its need for a barrier and its acidity, the process and the bags are chosen accordingly.  Aran can understand the process as a whole and listen to the customer  In conclusion, food-processing technologies play a crucial role in ensuring food safety and security. The continuous development of these technologies has resulted in methods like hot filling, ambient filling, aseptic filling, and HPP that can help to keep food products fresh for longer and increase their shelf life. As technology advances, we can expect to see even more innovative methods for processing and transporting food products in the future.

Contributors to this article: Food Packaging Specialist Flavia Takahashi-Flores and Elhanan Hameiri.

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We are excited to introduce the Premium Flex bag, part of the sustainable products family, our newest product designed specifically for long-distance transportation of liquid foods.

Developed after two years of intensive research, this bag offers unparalleled sustainability advantages and practicality.

The Premium Flex bag is engineered to prevent Flex Crack while minimizing its environmental impact.

By replacing Nylon with internal PE layers, we have enhanced durability and ensured that the bag can be 100% recycled.  Its vibrant green color and yellow fitment (SLY) ensure easy recognition and handling. This product reflects our unwavering commitment to sustainable development and social responsibility.  It aligns with our ESG strategy and demonstrates Aran’s dedication to environmental protection. We sincerely thank you for your continued trust in us. Together, let’s make a positive impact on our world.

Our customer service team is ready to assist you with any inquiries about the Premium Flex bag.

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The popularity of Bag-in-box (BIB) flexible packaging solutions has increased due to their convenience, versatility, and cost-effectiveness. The production of flexible film is a crucial aspect of BIB technology, and it can be achieved through various methods: Co-extrusion, Thermo-lamination (TLT) or Adhesive lamination, and a combination of both. Each of these technologies has its advantages and disadvantages. This article will delve deeper into these three BIB technologies, analyzing their distinctive features, benefits, and limitations, with a particular focus on mechanical properties, visibility, sustainability, and functionality as gas transmission barriers for extending shelf life.

Moving toward thermo-lamination technology

All three BIB film manufacturing methods are common. However, in recent years, due to sustainability considerations and the desire to preserve packed food for longer shelf life and extended transportation distances, it seems that the equation has changed. When considering these factors, the thermo-lamination method presents significant advantages over other methods. This led companies in the industry to adopt this technology and make it their main manufacturing method. It is important to note that this is not a black-and-white issue, as there are applications where other methods have advantages. Thus, it is essential to maintain flexibility and adapt the appropriate technology to the desired application.

Seal the Deal: The Advantages of TLT

The lamination stage is critical for Bag in Box plastic bags as it determines the final properties of the film. This process involves combining different films produced using various techniques to create a single film that incorporates the unique features of each film. Lamination can be accomplished through chemical adhesives or Thermo-lamination, which uses only heat and pressure to combine the films.

Thermo-lamination has significant advantages, especially in terms of the environment. Adhesive lamination has major environmental drawbacks, such as the use of chemicals and solvents, which have a highly negative impact on the environment and pose a risk to workers on the manufacturing floor. These chemicals and solvents can also leave residues in the final product and contaminate packed food inside the bag. Additionally, the drying tunnel’s solvent evaporation consumes a significant amount of energy.

In contrast, Thermo-lamination requires less energy and is safer for the workers on the production floor, the final product, and the environment. Adhesive films are less flexible, which makes them more susceptible to flex cracks phenomenon and pinholes.

Another advantage that TLT bags present is their high oxygen barrier; the metalized layer has excellent performance, preventing oxygen from entering the bag and extending the product’s shelf life. Aran’s bags reach a level of less than 1 (cc/m2/24 hr), which is an outstanding performance from the bags.

Aran recognized the advantages of Thermo-lamination 30 years ago and produces their Bag in Box bags using this technology ever since. With our experience, we can design and provide all our products, including custom-made ones, in sizes ranging from three to 1500 liters.

Beyond Ordinary Bags: Advantages of Aran’s Co-Extrusion Bag in Box Bags

Co-extrusion is another technology to create multi-layer films for BIB applications. However, the barrier layer is usually based on EVOH, which is sensitive to moister. For better barrier and higher oxygen protection, the thickness of the EVOH layer must be more prominent, but doing so will cause the flexibility to diminish.

To address the drawbacks, Aran adopted unique co-extrusion technology that modifies the structure of the polymer matrix and enhances the flexibility of BIBs made with Co-extrusion films.

A Whole is Greater Than the Sum of its Parts

Both Thermo-lamination and Co-extrusion techniques have their respective advantages and disadvantages. However, Aran’s “Super-Flex” and Premium Flex product line utilizes a combination of these techniques to achieve superior properties, particularly in terms of durability against flex cracks. This solution outperforms all other available solutions on the market. The high mechanical durability provides an excellent oxygen barrier. This enables the BIBs to be transported for a longer distance without affecting the quality of the product inside.

Thermo-lamination vs Co-extrusion: Bonding Tech Showdown                                                           

When choosing a suitable BIB technology, it is important to consider optical factors as well. Contrary to transparent co-extrusion bags, TLT bags are opaque, block light and allow better protection for the product inside. In terms of mechanical properties, TLT laminates are more durable during shipping and less prone to pinholes than co-extrusion laminates. On an environmental level, the co-extrusion film can be fully recyclable if the EVOH content is limited to under 5% of the total film thickness. However, the metallization of the laminates poses a recycling challenge. Aran is currently developing metalized laminates made from recycled materials to address this issue, which will significantly reduce the environmental impact of this solution.

ARAN’s Expertise in Hot Lamination for BIB Applications

Many companies in the industry are only now discovering what ARAN has known for many years: Thermo-lamination is the preferred lamination method for BIB applications, both for sustainability reasons and for functional considerations. ARAN’s years of experience as a pioneer in the field are reflected in advanced developments and solutions that utilize all the advantages that heat lamination technology has to offer. We would be happy to collaborate and explore the benefits thermal lamination can provide for your product.

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