Things that matter. Sharing what we know and who we are.
At BMG, we like to share, be it our perspective on the thermoforming world, technology tips that will help the masses or just some insight into the days and lives of our employees. Take a moment every quarter to see what we are up to and see if you don’t gather some interesting or entertaining content that will help you better understand who BMG is and what we stand for.
A view from the top.
BMG is revolutionizing the future of thermoforming.
Dear Valued Customers,
At BMG, we’ve always believed that true innovation is about anticipating our customer's needs and delivering solutions that not only meet those needs but also push the boundaries of what’s possible. Today, I’m thrilled to share some exciting developments that are setting the stage for the future of packaging technology.
First, I’m proud to introduce our latest breakthrough, the NXT Thermoforming Platform. This new platform is designed to revolutionize the industry with cutting-edge advanced controls and the integration of articial intelligence (AI) to optimize performance in realtime. The NXT platform is the first of its kind to offer access from both the left and right-hand sides, providing unparalleled operational flexibility and improving operator ergonomics. With the NXT platform, we’re delivering greater control, precision, and efficiency while reducing downtime through AI-powered predictive maintenance.
But our commitment to innovation doesn’t stop there.
Tooling continues to be a cornerstone of our business, and we are constantly refining our processes to produce high-precision tools that enable our customers to maximize their production capabilities. Our Fremont, Ohio, facility is at the forefront of tooling development for paper and plastic thermoforming and form-fill-seal applications. We are proud to offer customized solutions that ensure seamless integration with our machines and meet the highest quality and performance standards.
On the sustainability front, we’ve made signicant investments in our paper product manufacturing capabilities. With the recent “SQF Quality Certification” of our paper-forming manufacturing suite and our QuadPro paper-forming lines, we are well-positioned to lead the transition to fiber-based packaging. Our innovative paper products are designed to offer a sustainable alternative without sacrificing performance, ensuring that our customers can meet both their environmental and functional goals.
Lastly, we are excited to continue advancing our expertise in end-of-line automation. Our Knoxville, Tennessee, facility specializes in designing and producing cutting-edge automation solutions that help streamline packaging processes and drive efficiency. Whether it's reducing labor needs, improving throughput, or ensuring consistency, our automation systems are tailored to meet the specific demands of today’s high-speed production environments.
At BMG, we are driven by a singular goal: to be the partner you can rely on for innovative packaging solutions. From our breakthrough NXT Thermoforming Platform and industry-leading tooling to our sustainable paper products and advanced end-of-line automation, we are committed to helping you stay ahead in a competitive and ever-evolving market.
Thank you for your continued partnership. We look forward to working with you on the exciting opportunities ahead.
Sincerely,
Jake Kowalewski
CCO, CIO, BMG
Employee Spotlight: A little bit about those who make us great!
Steffen Brown - Fremont, Ohio, USA
Steffen is a traveler who lives to discover the unknown, which ties in nicely with his pursuits at work as a Senior Engineer Lead here at BMG, working on design engineering and R&D while overseeing the tooling and engineering departments. He also likes to cook, is an avid sports watcher, and loves to travel with his wife every chance he gets. Having started at BMG eighteen years ago, he has made a name for himself as a key contributor on thermoforming and paper tooling projects that keep him asking, “Where will this take us?” His inquisitive nature is his baseline, and he likes to think of himself as an inspirational leader, a quality he has gleaned from his 98-year-old grandfather, who is still around to give him advice.
Having once dreamed of being a roller coaster designer, he spends some of his time with his wife of eighteen years in what he refers to as their “Rent a Kid” program. In these family-focused adventures, they take their nieces and nephews out to experience the roller coaster of life on trips high and low to celebrate their graduations, birthdays, and milestones of life. Every excursion is a unique experience and creates lifelong memories for everyone.
Billy Schwartz - Knoxville, Tennessee, USA
Billy grew up dreaming of a career as a Major League Baseball Player and went on to enjoy the study of the intricacies of physics, joining the ranks at BMG in his current career as a system sales manager. It may not be the MLB, but he loves to solve intricate problems for his customers. He also likes to cook and is a big fan of southern fried chicken and collard greens. Did we mention that he loves to smoke meat on his pellet smoker? Well, that's the start of the conversation. We also want to let you know that his favorite aspect of his job is integrating automation solutions that assist clients in improving their production processes. Many of his situational solves have involved complex and complicated tasks that lead to a customer's ultimate custom solution. He likes those the best and credits his mother for that quality, who he looks up to as a well-educated, logically-minded individual who always kept a level head and looked at things with a unique perspective.
As he looks to the future, he wants to play an integral part in helping with the growth of the BMG sales team and creating a work-life balance that keeps him on track with tackling specic DIY jobs around the homestead. First on the list are a few raised garden beds to grow seasonal vegetables for the family. He enjoys spending time with his wife and three children doing just about anything as long as they are all together.
European Spotlight: What’s happening across the pond.
The European packaging industry is continuing to undergo a transformation as environmental awareness and government regulations are reshaping the landscape. The demand for sustainable solutions is influencing the plastics and paperboard thermoforming sectors alike. We would like to explore key developments in Europe’s plastics thermoforming, plastic packaging, and the growing focus on paperboard alternatives.
Sustainability Driving Change in Plastics Thermoforming
Plastic thermoforming remains a signicant part of Europe’s packaging industry, but its future is being shaped by new environmental regulations and shifting consumer sentiment. The European Union (EU) is spearheading efforts to reduce plastic waste, primarily through:
- EU Plastic Strategy and Single-Use Plastics Directive (SUPD): These regulations are forcing companies to reduce or eliminate the use of certain plastic products. Plastic trays, cutlery, and beverage containers, especially single-use variants, are under increasing scrutiny.
- Recycled Content Requirements: Europe mandates the inclusion of recycled material in packaging, with ongoing targets to meet circular economy goals. This has led to innovation in the use of rPET (recycled PET) and other recyclable polymers in thermoformed trays and clamshell packaging. Lightweighting and Monomaterial Solutions: Companies are developing thinner, lighter thermoformed products that reduce resource consumption. Monomaterial designs, like PET-only trays, are becoming a focus to improve recyclability.
These shifts are motivating packaging producers to invest in advanced thermoforming platforms capable of processing new polymers and ensuring energy efficiency.
The Rise of Paperboard Thermoforming and Packaging
The pressure to move away from traditional plastics is accelerating the adoption of paperboard-based thermoforming technologies. Many packaging manufacturers are exploring or expanding their paper-forming capabilities to meet consumer demands and align with regulatory goals. The key drivers for this trend include:
- Fiber-Based Packaging Demand: With consumers favoring eco-friendly alternatives, fiber trays, paperboard lids, and compostable solutions are becoming prominent. Major players are exploring innovations in paperboard thermoforming to address needs in QSRs, ready-meal markets, and bakery packaging.
- Technological Advancements in Paper Forming: New forming lines, such as BMG’s QuadPro platform, are making large-scale paper packaging production more feasible. Innovations allow for more intricate designs and improved strength, addressing one of the key historical weaknesses of paper packaging.
- Recyclability and Compostability Focus: Paper-based trays align well with Europe’s focus on recyclability, but companies are also exploring coatings and barriers that make packaging suitable for food applications while remaining compostable.
Consumer Trends Shaping Packaging Decisions
Consumer behavior in Europe is another major influence on packaging trends. Several noticeable developments include:
- Plastic-Free Movements: Consumers are increasingly choosing products with minimal or no plastic, fueling growth in paperboard packaging and bioplastics. Supermarkets and QSRs are following suit by switching to paper-based alternatives for their packaging needs.
- Transparency and Eco-Labeling: Shoppers are demanding more information on the sustainability credentials of packaging. Certifications and eco-labels such as FSC (Forest Stewardship Council) for paper products and the European Plastics Pact for plastics are becoming key differentiators.
- Convenience and Ready Meals: While sustainability is a primary focus, demand for ready meals and convenience packaging remains strong. As a result, companies must balance sustainability goals with consumer convenience, creating hybrid packaging solutions—such as paper trays with thin plastic windows—that meet functional and regulatory requirements.
Innovation in Machinery and Automation
In response to changing market needs, Europe’s packaging industry is witnessing an increase in automation and smart manufacturing investments. The latest advancements include:
- AI-Enhanced Production Lines: Platforms such as BMG’s NXT thermoforming systems, which offer both AI-driven controls and multi-directional accessibility, are making it easier for manufacturers to optimize their operations.
- Integrated Recycling Systems: Machinery that integrates on-site recycling and production is gaining traction, helping companies close the loop on waste and meet circular economy objectives.
- Paper Thermoforming Expansion: With growing interest in paperboard solutions, new automation technologies are being developed specifically to enhance the speed and efficiency of paper forming lines, helping companies reach higher production capacities.
Future Outlook: A Hybrid Approach to Packaging
Europe’s packaging future will likely feature a hybrid approach, where both plastic and paper-based materials coexist but with distinct roles. High-performance plastic packaging will remain essential for certain applications, especially where food safety and barrier properties are crucial. However, paper-based alternatives will continue to grow, especially for short-life products and sectors that prioritize sustainability.
The key challenge for manufacturers will be balancing these materials while remaining compliant with regulations and satisfying consumer preferences. Investments in innovation—whether through AI, material science, or new forming technologies—will be crucial for companies to remain competitive in this evolving landscape.
Conclusion
The European thermoforming and packaging industry is at a critical juncture, with sustainability and innovation leading the way. The interplay between plastic reduction initiatives and the rise of paperboard solutions presents both challenges and opportunities. Companies that can adapt to regulatory pressures, integrate sustainable materials, and invest in advanced machinery will position themselves as industry leaders in this rapidly changing environment.
This transformation marks not just a shift in materials but also a fundamental change in how the industry operates—moving toward a future where innovation, efficiency, and environmental stewardship go hand in hand. Emerging Trends in Europe’s Thermoforming and Packaging Industry: A Shift Toward Sustainability and Innovation.
Tech Talk & other interesting tidbits.
BMG/GN machines: Inspecting or replacing transport drive sprockets and chains.
In the process of day-to-day manufacturing, clients sometimes inadvertently overlook precautionary inspections of items on their equipment. Wear and tear on drive sprockets and spike chains can lead to problems with transport accuracy, damage to rails, misfeeds, or sheet jamming. We highly recommend that clients set reminders to inspect the sprockets and chains for tension, damage, and proper lubrication. It’s also a good idea to check the chain for tension to prevent excessive wear. It is also a smart service inventory idea to keep these wear items on hand at your facility so that when replacement is needed, your downtime is minimized.
Simplifying setup with recipe management
It’s always good to keep consistency top of mind when transitioning between jobs by using the unique recipe storage feature in our UI to save and load machine settings for different jobs. This can dramatically reduce setup time and prevent operator errors during tool changes. Be sure to check that each recipe has all the necessary settings, such as pressure, tool heights, oven positions, and other key parameters, to ensure operational success.
General Tips:
- Maintenance Checklists: Create a detailed, step-by-step checklist that sets a timeline for routine and preventive maintenance. Keep this checklist/timeline easily accessible near the machine. A well maintained machine will last longer, have less unscheduled downtime, and provide better ROI.
- Organize Tools and Spare Parts: Set up a well-organized maintenance station near your machine with commonly used tools, lubricants, filters, and necessary spare parts.
- Training: Ensure operators are well-trained in basic maintenance procedures, including daily checks, cleaning, and using the HMI for diagnostics.
Working together towards a sustainable future!
In an ever-changing and unpredictable global marketplace, BMG continues to create category-leading sustainable renewable thermoforming solutions, providing best-in-class engineering and manufacturing enhanced by unparalleled support — all provided to a worldwide market from our/your backyard!
If there is anything that you would like to see us address in our Tech Talk section in the next edition of Trade Trends, drop us a note here. We will certainly put your suggestion into action and thank you in advance for helping us provide important information to those who find it useful.