The company will install state-of-the-art equipment in the new plant and bolster its production capacity. The new plant will supply packaging materials for food and toiletries, as well as for other fields where future growth is predicted such as healthcare products, which require a high level of functionality.

Toppan Printing will put in place a clean production environment and advanced quality control system at the new plant. The plant will provide high barrier flexible packaging materials that use Toppan’s original clear high barrier films, GL Film (*1) and Prime Barrier (*2), to sectors such as food, healthcare, and industrial materials. Toppan will also strengthen the production of the main base materials of composite containers that combine materials such as flexible packaging, paperboard cartons, and plastics. By actively developing new technologies and products, the new plant will proactively supply products to cultivate both domestic and overseas markets. In the future, Toppan Printing plans to create a highly efficient production structure combining R&D and production by establishing an R&D facility within the site of the new plant.

Background
There is a high level of interest in consideration for the environment in advanced nations in Europe and North America. In the field of packaging materials, there are growing needs for CO2 reduction through reduction of material volume and for aluminum-free solutions, and this means increased demand for highly functional packaging.

In emerging nation markets such as China and Southeast Asia, the packaging material market is expanding due to economic growth. With improvement in the quality of life, higher quality products are in demand, and this also gives rise to new markets in the field of packaging.

By constructing the new plant, Toppan Printing will strengthen its production structure in the Kanto area of Japan and enable the stable supply of packaging materials with the new plant as a "mother factory" for all its packaging material production plants. The company will also aim to expand its packaging material business by providing new technologies and products to growing overseas markets.

About the new plant
Construction of the new plant is scheduled to be completed in the spring of 2014. With a clean production environment and advanced quality control system, the plant will produce flexible high barrier packaging materials and other cutting-edge packaging materials for various products and uses including foods, and medical and pharmaceutical goods. The plant will respond to the needs of consumers and manufacturers for higher levels of hygiene and protection functions, and put in place a structure for prompt and stable supply.

As equipment to drastically reduce the environmental impact of business activities, Toppan will install a state-of-the-art VOC (volatile organic compound) recovery and reuse system with an original design. Environmental impact will be significantly reduced by recovering and reusing the VOCs produced in production processes. The plant will also have efficient energy equipment such as cogeneration systems, which enhance overall energy efficiency by using exhaust heat to generate power. By using this as a source of thermal energy, it will be possible to reduce electricity consumption and therefore significantly reduce the volume of CO2 emissions and amount of energy used.

Details of the new Gunma plant

• Location: Owa, Meiwa-machi, Ora-gun, Gunma Prefecture, Japan (within Meiwa Industrial Park 3)
• Site area: 154,000m2
• Total floor area: 69,577m2
• Commencement of construction: November 2012
• Planned completion of construction: March 2014
• Items manufactured: Packaging materials
• Investment: Approximately 27 billion yen

*1 GL Film
This is a collective term for clear vapor deposition high barrier films developed by Toppan Printing. These films enjoy an excellent reputation in Japan, Asia and other overseas markets due to a wealth of variations and the world’s highest level barrier performance, which is achieved using original vapor deposition technology. As a top brand in the clear high barrier film market, GL Film is used for approximately 10,000 products by around 1,000 companies in 30 countries and regions (as of December 2012).

*2 Prime Barrier
This is a collective term for Toppan Printing’s new brand for highly functional clear high barrier films that have excellent barrier performance and functionality, which has been achieved through further development and evolution of GL Film, one of the world’s leading brands in the clear high barrier film market.