Danaflex Opens Factory in Kazan for Nano-enabled Flexible Packaging

11 November 2011

Photo: R. Kadyrov

On the day of its 10th anniversary, the Kazan-based Danaflex group of companies has opened a new factory where Danaflex-Nano, a RUSNANO project company, will use a proprietary nanotechnology process to manufacture improved flexible packaging material. RUSNANO is co-investor in establishing the new facility. Total budget for the project is 2.45 billion rubles.

President of the Republic of Tatarstan Rustam Minnikhanov, RUSNANO CEO Anatoly Chubais, Danaflex General Director Airat Bashirov, and Danaflex-Nano General Director Viktor Molokin were among dignitaries taking part in gala opening ceremonies.

Opened a new factory Danaflex-Nano

Photo (from left to right): President of the Republic of Tatarstan Rustam Minnikhanov, RUSNANO CEO Anatoly Chubais, Danaflex General Director Airat Bashirov

 

The high-barrier polymer film and related flexible packaging material that the new company will produce is intended mainly for packaging foodstuff, household chemicals, cosmetics, and pet food. Danaflex-Nano’s new factory has design capacity of 46,000 tons of packaging material per year. Income from sale of goods in 2015 is forecasted at more than six billion rubles. Danaflex-Nano has already filled 320 new jobs and in the future that number will rise to 600.

Opened a new factory Danaflex-Nano

Photo (from left to right): RUSNANO CEO Anatoly Chubais, Danaflex General Director Airat Bashirov, President of the Republic of Tatarstan Rustam Minnikhanov

The advantages of the flexible packaging material are its low weight, greater safety, and lower consumption of energy in manufacturing. The film’s barrier properties prevent oxygen and other gases, household chemical compounds, moisture, oils, fats, microorganisms, and ultraviolet radiation from penetrating the package. The material requires considerably fewer preservatives to keep foodstuff and other products fresh, and the shelf life of the goods using the packaging is considerably longer. It needs less warehousing space, and the cost for shipment of the goods is less than other types of packaging. Finally, this latest advance in flexible packing uses no foil, so packaged goods may be heat processed and then reheated in a microwave oven without opening.

Opened a new factory Danaflex-Nano

Photo (from left to right): RUSNANO CEO Anatoly Chubais, Danaflex General Director Airat Bashirov, President of the Republic of Tatarstan Rustam Minnikhanov

“Every producer is interested in lengthening the useful life of his goods, whether on a shelf in the store or in the consumer’s home,” said Danaflex Gneral Director Airat Bashirov

“Danaflex has held the lead in the Russian flexible packaging market for many years. We took notice of the project when its team proposed using nanotechnology to improve characteristics of the packaging materials, a product with a growing market,” RUSNANO Managing Director Dmitry Pimkin explained.

Danaflex-Nano and its backers have outfitted the new factory with the latest equipment from German company Windmoeller & Hoelscher. The Filmex flat-slit extruder for production of high-barrier polymer films, for example, produces film using nanotechnology that contains 17 layers. As a result the physicomechanical properties are enhanced and films may be obtained with unique qualities. Two machines for deep printing have been installed in Danaflex-Nano’s print shop; the machines are able to print using 10 to 12 colors. This is the only equipment in Russia with technology for applying cold glue in a single pass, inline lamination, and reverse-side printing. Danaflex-Nano also leads the industry in Russia with the country’s fastest flexorgraphic printing unit. And the company’s shop for blown film extrusion uses high-performance three- and five-ply extruders for production of polymer films.

Structure of polymer film with the addition of nanocomposites, particularly silicate nanoclay, that improve the barrier properties of the packaging materials

Structure of polymer film with the addition of nanocomposites

Comparison of traditional flexible packaging with packaging based on a nanocomposite

Comparison of traditional flexible packaging with packaging based on a nanocomposite

Competitive advantages of the new packaging material: 

  • Replaces traditional tin cans
  • Permits thermal processing and reheating in a microwave oven without opening the package
  • Reduces the amount of preservatives in foodstuff
  • Extends the shelf life of products
  • Simplifies the composition of packaging material
  • Reduces the production cycle from 14 days to two days
  • Lowers cost of a single package in comparison with traditional analog
  • Lowers the weight of packaging material
  • Improves the environmental parameters of the material and makes possible its recycling

 

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Opened a new factory Danaflex-Nano Danaflex Opens Factory in Kazan for Nano-enabled Flexible Packaging
From left to right: President of the Republic of Tatarstan Rustam Minnikhanov, RUSNANO CEO Anatoly Chubais, Danaflex General Director Airat Bashirov
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Opened a new factory Danaflex-Nano Danaflex Opens Factory in Kazan for Nano-enabled Flexible Packaging
From left to right: RUSNANO CEO Anatoly Chubais, Danaflex General Director Airat Bashirov, President of the Republic of Tatarstan Rustam Minnikhanov
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Opened a new factory Danaflex-Nano Danaflex Opens Factory in Kazan for Nano-enabled Flexible Packaging
From left to right: RUSNANO CEO Anatoly Chubais, Danaflex General Director Airat Bashirov, President of the Republic of Tatarstan Rustam Minnikhanov
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Danaflex was established in Kazan in 2001. Production of flexible packaging materials is the company’s primary focus. With market share of 12 percent, Danaflex is the largest producer of flexible packaging in Russia. In 2010 the company reported income from the sale of finished goods of 2.46 billion rubles and growth in income compared with 2009 of 11 percent.
Danaflex has developed and brought to market innovative types of packaging that have become leaders in their market segments and that have won awards from leading international and domestic competitions.
The company is developing its business with a strategy of flexible relations with clients, high-quality products, and technical and product innovation. Considering the latest trends in the packaging market and Danaflex’s development of proprietary technology for the production of barrier materials, the company has chosen the most promising areas for growth—nano-enabled high-barrier flexible packaging. Its advances include better barrier and physicomechanical properties and lower cost of goods.
Output from the RUSNANO-Danaflex joint project company is expected to replace imported materials in the domestic market. Danaflex-Nano will supply Russian and foreign customers, most of whom will be producers of packaged products.

RUSNANO was founded in March 2011 as an open joint stock company through reorganization of state corporation Russian Corporation of Nanotechnologies. RUSNANO’s mission is to develop the Russian nanotechnology industry through co-investment in nanotechnology projects with substantial economic potential or social benefit. The Government of the Russian Federation owns 100 percent of the shares in RUSNANO. Anatoly Chubais is CEO and chairman of the Executive Board of RUSNANO.
Work to establish nanotechnology infrastructure and training for nanotechnology specialists, formerly conducted by the Russian Corporation of Nanotechnologies, has been entrusted to the Fund for Infrastructure and Educational Programs, a non-commercial fund also established through reorganization of the Russian Corporation of Nanotechnologies.