26 BEST PRACTICES // JUNE 2014 www.PackagingDigest.com

Automated shrink labeling opens new markets for wineWith demand increasing for its stacked single-serve wine “glasses,” Stack Wines automated its multipack shrink labeling operations TO GAIN THE NEEDED HIGH-VOLUME OUTPUT.

Dean Peters, Contributing Writer

Don’t look now, but there is an emerging trend afoot in which conveniently packaged wine is �nding its way into the consumable consciousness of imbibing sports fans, concert goers, boaters, hotel and resort guests and other outdoor enthusiasts.

�is trend has been fed and accelerated by the commercial o�ering of pre-packaged wine products that o�er individual servings in “glasses” (actually food-grade PET), already �lled with your favorite varietal and sealed in a sterile and tamper-proof package. �ere is an emerging market for these beverages in places where disposed or broken glass could cause logistical or safety problems.

Stack Wines of California entered this market in March 2013 with shrink-wrapped packages of four individual servings in pre-�lled, un-stemmed glasses. �ese are sealed and stacked four high into a tower. A shrink-sleeve label is placed around this and processed through a steam tunnel, unitizing the �lled glasses into a single unit. �e subtle graphics of the shrink-sleeve label help de�ne the brand and attract potential consumers.

At venues in which it would be unsafe or unseemly to be carrying and disposing of real glass containers (not to mention the attendant need for cork screws), pre-�lled individual wine servings in recyclable plastic packaging are catching on in a big way. �ese products may not appeal initially to the wine savants among us, but oenological sophistication doesn’t generally prevail at the venues in which these products will �nd their greatest demand. �e real bene�ciaries of these products will be casual wine drinkers who enjoy sipping the occasional glass as they attend a sporting event, work the room at a convention or relax poolside at a resort.

Packaging challenges�e four varietals o�ered by Stack Wines are Cabernet Sauvignon, Charisma, Chardonnay and Pinot Grigio. Whether a wine savant or casual wine drinker, consumers may not appreciate the labeling and packaging challenges that had to be overcome to enable the mass distribution of single-serving wine.

In the early days, �lled and sealed serving glasses from Stack Wines were stacked four high in a tower and hand-sleeved for labeling by a co-packer. To meet growing demand, though, automation was required to stack the cups and apply labels at higher speeds.

�ere are two steps to the shrink labeling operation. �e �rst is the labeler, which applies shrink sleeves from rolls. �e sleeved pack is then passed through a steam tunnel where it shrinks tightly and uniformly around the stack of wine glasses. Having considered the options to automate the shrink labeling operation, Stack Wines decided to purchase equipment from PDC Intl. Corp., a Connecticut-based supplier of packaging machinery that is known as a manufacturer of tamper-evident banders and shrink-sleeve labeling systems. Stack Wines selected

PDC’s Model R-250 Evolution shrink labeler and Model KST 55-712 single-zone steam tunnel, through which sleeved stacks are passed and the shrink occurs.

Stack Wines had this equipment installed at Varni Brothers of Modesto, CA, a bottler of 7UP, spring water and other beverages. First, the stemless PET glasses are �lled with wine and proprietarily sealed with a peel-back foil lid. �e glasses are then automatically stacked four-high and transferred to the shrink labeler, which processes up to 90 stacks per minute.

When demand for Stack Wines reached a certain critical mass, Stack Wines CEO Matt Zimmer realized he “needed a higher level of automation to package and label our product. We used a line-integrator to help us design the high-volume Stack Wines packaging/labeling system, and they steered us toward PDC Intl.’s equipment. It has been working great for us.”

The shrink labeler�e R-250 Evolution shrink labeler, introduced in 2010, was developed jointly by engineering teams from PDC’s U.S. and French facilities. It is primarily mechanical in design, and was engineered for continuous operation in packaging operations that run 24/7.

The four-pack of Stack Wines is held together with a shrink sleeve label, applied at speeds of 90 stacks per minute.

After the shrink labels are dropped onto the stack of four single-serve wine glasses, units move into the shrink tunnel.