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TRANSCRIPT
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No. 07+082011
25 .07 .11
PETplanet is read in 146 countries
MAGAZ INE FOR BOTT L E RS AND BOTT L E -MAKERS IN THE AMERICAS, ASIA, EUROPE AND ALL AROUND THE PLANET
MARKETsurveySuppliers of single
stage machineryPage23
Regional market repor ts
Finland Part 1
Page8
sensitiveBEVERAGESBEVERAGES
imprint
EDIT
OR
IAL
PUBLISHERAlexander Büchler, Managing Director
HEAD OFFICEheidelberg business media GmbHLandhausstr. 469115 Heidelberg, Germanyphone: +49(0)6221-65108-0fax: +49(0)[email protected]
EDITORIALDoris Fischer fi [email protected] MaruschkeRuari McCallionIlona TrotterWolfgang von SchroeterAnthony Withers
MEDIA CONSULTANTSUte Andrä[email protected] [email protected] [email protected]
phone: +49(0)6221-65108-0fax: +49(0)6221-65108-28
France, Italy, Spain, UKElisabeth Maria Köpkephone: +49(0)6201-878925fax: +49(0)[email protected]
LAYOUT AND PREPRESSExprim KommunikationsdesignMatthias Gaumann | www.exprim.de
READER SERVICESKay Krü[email protected]
PRINTChroma Druck & Verlag GmbHWerkstraße 2567354 RömerbergGermany
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PETplanet insider ISSN 1438-9459 is published 10 times a year. This publication is sent to qualifi ed subscribers (1-year subscription 149 EUR, 2-year subscription 289 EUR, Young professionals’ sub-scription 99 EUR. Magazines will be dispatched to you by airmail). Not to be reproduced in any form without permission from the publisher.Note: The fact that product names may not be identifi ed as trade marks is not an indication that such names are not registered trademarks.
3PETplanet insider Vol. 12 No. 07+08/11 www.petpla.net
Go to Brau Beviale! Our Regional Reports are proving to be a big hit both with
you, our readers, and with the companies we visit. The basis of our Regional Reports is simple: we visit PET users worldwide and invite them to tell us about the PET business in their coun-tries.
In this issue we have headed north to the Baltic for the fi rst of our reports into the PET business in Finland. It proved to be an interesting visit. Following the government’s decision to drop the tax on one-way packaging, Finnish consumers have now regained their appetite for it. Within months of the announce-ment, PET refi llables had vanished from the market whilst glass refi llables continued to lose market share. Unsurprisingly per-haps, purchases of new PET fi ller equipment showed a dramatic increase.
Our reports are authoritative and wide-ranging and we thought it would be an excellent idea to encourage readers’ participation in them. So, with the imminent opening of the Brau Beviale exhibition, we are inviting our readers to visit PETpoint to share with us all the news and views from the market.
Our Editourmobile will be setting out from Nuremberg on October 3, 2011 and will be travelling through Austria, Slovenia, Croatia, Serbia, Bulgaria, Turkey, Armenia, Azerbaijan, Romania and Hungary. In Azerbaijan, we will be interviewing the winners of the Eurovision Song Contest Ell and Nikki who will be taking time out to sample their favourite drinks in PET bottles.
There will be a regular blog to help you get really involved and – of course – you will be able to see the fi ller plants we visit. We return to base in time for Brau Beviale and, in addition to the vehicle, you will also be able to admire the bottles we have brought back and to talk shop directly with the editors.
Subsequent issues will feature a full version of our compre-hensive Regional Report as usual. Come on board with us and enjoy a trip through some very exciting PET markets.
Yours,
Alexander Büchler
EDITORIALdear readers,EDITORIALdear readers,,,
PETcontents 07+08/11
4 PETplanet insider Vol. 12 No. 07+08/11 www.petpla.net
INSIDE TRACK 3 Editorial 4 Contents 6 News33 Products36 Bottles38 Personal care40 Patents
MATERIAL / RECYCLING12 High sun protection factor Developing a new sensitive product packaging solution: A case study
BOTTLE MAKING16 A ‘sensitive’ affair Sokpol invests in growth with Sidel’s Predis FMa line18 Barriers without frontiers New coating technologies for beverage packages21 Bottle developments for sensitive beverages Suppliers offer new PET bottle solutions
BOTTLING /FILLING30 Compact and dry PET Asept D Compact - the aseptic solution from Krones for the
low output range 32 The next generation KHS launches dual-concept aseptic fi llers
PREFORM PRODUCTION14 Parting line deformation A rapid guide to perfect preforms - part 22
MARKET SURVEY23 Suppliers of single stage machinery
BOTTLE MAKING27 Single stage converters Single stage feature part 2 - A visit at PET Power, the Netherlands
TRADESHOW REVIEW35 Chinaplas, 2011
Page12
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Page27
BUYER’S GUIDE41 Get listed!
sensitiveBEVERAGESBEVERAGES
RED HOT CH I LI PET.
Our injection moulds are used to produce PET preforms with barrier properties for hot products. www.otto-hofstetter.com/pet
PETnews
6 PETplanet insider Vol. 12 No. 07+08/11 www.petpla.net
Oystar and Sacmi to cooperateThe Oystar Group, manufacturer of packaging machines,
has concluded a cooperation agreement with the Ital-ian Sacmi Group. The two companies aim to develop new market opportunities through integrated packaging solutions. The primary focus will be on the beverage industry. Above all, this cooperation will involve three core divisions. Thus plans are to combine Oystar Hamba Flexline fi lling machines with Sacmi blow moulding machines and in particular with the CBF machine (Compression-Blow Forming Technology). In the future, downstream solutions from Sacmi, such as those for labeling, palletizing or other end-of-line processes, are to be offered in combination with Oystar fi lling and packaging lines. And, fi nally, the two mechanical engineering compa-nies also want to exploit synergies when it comes to the development of new and innovative solutions while profi ting from their mutual know-how. “The portfolios of our two com-panies complement each other outstandingly,” underlined Sacmi CEO Pietro Cassani. “We will remain independent, but through this cooperation we will create genuine added value for our customers.”
www.sacmi.com www.oystar-group.com
PTI establishes new, independent closure testing lab
Plastic Technologies, Inc. (PTI), Hollands, Ohio, USA, has established a new closure testing lab. “Closure manufactur-ers have traditionally offered testing support for their prod-ucts, but up until now there really hasn’t been an independ-ent closure evaluation and analysis lab. PTI’s new capability complements its previously-established bottle testing service. This means that brand owners wanting to test the perfor-mance of the entire package now have a one-stop place to go,” explains PTI’s Greg Fisher, Ph.D, who is responsible for overseeing the lab. Closure testing capabilities will include: application, top load vent, removal torque, opening perfor-mance, secure seal, carbonation retention, impact, barrier, scavengers, lubricants and others. The lab will also include a single-head capper to test reliable and reproducible capping, as well as a vision system to measure critical dimensions and facilitate tooling evaluations. Accurate analysis also is critical to ensure that packaging materials and structures haven’t been over engineered, thereby negatively affecting cost and source reduction initiatives. The total package approach also helps reduce the number of samples required to execute the tests and eliminates the need for correlated bottle data from one lab with closure information from another. PTI’s closure lab can analyze both plastic and metal closures for a broad variety of packaging applications. These include beverage, food, personal care, household chemicals and others. Fisher, the lab’s director, offers a signifi cant amount of closure exper-tise, having previously worked for a leading closure manufac-turer for almost a decade.
www.plastictechnologies.com
Krones re-structures its Supervisory and Executive Boards
At the AGM in Neutraubling on June 15, 2011, the agenda for the shareholders of Krones AG included a vote on a revamped Supervisory Board. The following members of the Supervisory Board were re-appointed: Chairman Ernst Baumann (62), a former director of BMW AG, Norman Kronseder (48), farmer and forester, Dr. Jochen Klein (67), Managing Director of I-Invest GmbH, and Count Philipp von und zu Lerchenfeld (59), a member of the Bavarian State Parliament. The former President of Regensburg University, Prof. Dr. Erich Kohn-häuser (66), will be stepping down from the body upon conclusion of the AGM. Petra Schadeberg-Herrmann, (44) managing partner of Krombacher Finance GmbH, was newly elected to the Krones’ Supervisory Board. In the constitutive meeting following the AGM, the Super-visory Board of Krones AG decided upon the changes to the company’s Executive Board. After 15 years on the Krones AG’s Executive Board, the Deputy Executive Board Chairman, Hans-Jürgen Thaus (62), will be step-ping down from it, with effect from 31 December 2011, having reached the contractually agreed age limit of 62. His successor as Financial Director is Christoph Klenk (47). An engineering graduate, Christoph Klenk has since 2003 been a member of Krones AG’s Executive Board, where he was responsible for Research and Develop-ment and Divisions. The successor to Christoph Klenk is the former Head of Research and Development, Thomas Ricker (43). A mechanical engineering graduate, Thomas Ricker is set to be appointed to the Executive Board with effect from January 1, 2012.
www.krones.com
Orders up at EremaErema, the Austrian manufacturer of plastic recy-
cling systems, reported improved sales performance for fi scal year 2010/2011, which ended March 31, 2011. The Erema Group is comprised of Erema Engineering Recycling Maschinen und Anlagen Ges.m.b.H., Ans-felden; Erema North America Inc., located in Ipswich/MA; and 3S-GmbH of Roitham, Gmunden, Austria Con-solidated sales across the Group were €95 million, with order intake at €127 million, compared with €75 million in 2009/10. Erema attributes its growth to further devel-opments of its plant and process technologies, positive market developments, increased orders from existing accounts and the attraction of new customers. The com-pany’s headcount increased to 335.
www.erema.at
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A global player with special focus on health - 80 years of natural food ingredients
Wild was founded in 1931 as a family business, when company founder Rudolf Wild was working on the revolu-tionary idea of producing soft drinks without the addition of synthetic ingredients. In 1951, he achieved a break-through with “Libella”, the fi rst ever carbonated soft drink made entirely of natural ingredients. The product portfolio was extended to fruit preparations, fruit fl avours, and later also natural colours, herbal, tea and plant extracts. This year Wild is celebrating its 80th anniversary; the company employs around 530 staff worldwide and is one of the world’s leading manufacturers of natural ingredients for the food and beverage industries.
Products for a healthy diet
The global trend towards natural foods is on the rise. Food constituents that can improve productivity and health will play an important role in future. Around a decade ago, the company was one of the fi rst companies to introduce products offering additional health benefi ts, like antioxi-dants which, in high doses, are known to boost the immune system. Their health-promoting effects have been scientifi -cally proven in clinical tests. The company’s portfolio also includes other plant extracts and substances which support the different metabolic processes.
The gains must be measurable
In future it will be essential to convince the consumer about a healthier nutrition. It is not enough for aAny new food or drink merely to promise to be health-promoting. The company is convinced that there has to be a proven, measurable effect. Wild has come up with a new tagline “Measurable Health”, and this will serve as a basis for research and development of verifi ably healthy foods. The company is now working with researchers from various col-leges and universities to investigate the effects of prom-ising substances. In China for instance, the company is testing the high potential of “Traditional Chinese Medicine” (TCM) at its own production site.
Stevia – the natural sweetener from South America
The use of natural sweeteners which can be extracted from Stevia rebaudiana is also currently under investigation at Wild. Commonly known as sweetleaf and sugarleaf, this South American plant provides an extract that is several times sweeter than sugar. Stevia has a long tradition of use as a sweetener in Asia but in the European Union, with minor exceptions, its use is banned. However, the positive rating by the food safety authorities suggests that approval for use in the EU is on the horizon. The product develop-ers at Wild have already created various concepts based on stevia, and the company is ready to serve the market as soon as approval of the natural sweetener has been given.
www.wildfl avors.com
DAK Americas acquires Wellman PET business in USA
DAK Americas LLC has announced that it will be acquiring the PET business of Wellman, Inc. for approxi-mately US$ 185 million, including a cash payment and the assumption of certain liabilities. The acquisition is expected to complete in the second half of 2011, pending regulatory approval. The acquisition includes Wellman’s production facilities in Bay St. Louis, Mississippi, which has a production capacity of approximately 950 million lbs/a (approx 430 million kg/a) of PET resin and a workforce of approximately 165 people. DAK Americas, headquartered in Charlotte, NC, is wholly owned by Alfa S.A.B. de C.V. of Monterrey, Mexico. It is one of the largest integrated pro-ducers of PET Resin in the world and the main producer of polyester staple fi bre in the Americas.
www.dakamericas.com
Appe invests £1.5 million in Krones ProShape
Appe, the packaging division of LSB, is seeking to increase its output and fl exibility, following its investment of around £1.5m in the newly-developed ProShape pro-duction process from Krones. Appe is the fi rst operator to install ProShape. The machine is now in operation at Appe’s site at Gresford, UK, which supplies clients in the household and personal care sectors. The new ProShape module is integrated into Krones’ current Contiform series and combines its established blow-moulding technology with a new module for orientation and selective tempera-ture control of the preforms. ProShape is claimed to offer an optimised production process for oval or asymmetrical containers, as well as the potential for light-weighting of oval packs and the production of unusual designs. Krones says that ProShape’s output is around 40% higher than standard blow moulding machines. The Contiform S8 installed at Appe’s plant has eight cavities with an output of up to 2,000 bottles/hr each, depending on container design and complexity. The system can be switched from the preferential heating and neck orientation process to a standard blowing mode.
www.krones.com
Repi opens Russian subsidiaryItalian company Repi S.p.A., which produces liquid
colorants and additives for plastics and polyurethanes, has opened its own company in Moscow, Russia. The company has had a presence in the Russian market for 12 years and its own representative offi ce in the country for the past fi ve years. Repi supplies customers in Russia with colorants and additives for PET preforms, as well as promoting its basic colorant technology for the extrusion of PVC profi les and panels, and other polymer-related activities. The new com-pany will provide the growing market in Russia with local service, technical support and just-in-time deliveries from its Moscow warehouse.
www.repi.ru
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Finland
New start in 2008They call it the land of a thousand lakes. It’s also the land of the 3 big bottlers. Between them, they control 80% of the soft drinks market, including the Pepsi and the Cola licences. When the Finnish government abolished the tax on one-way bottles in 2008, all the bottling plants began investing in new PET disposable systems. The most important criterion here is fl exibility as this is where up to 50 different products are actu-ally bottled. Since the investments are rela-tively new and the logistics are adapted to suit them, the Finns are running the PCO 28 (1810). Discussions on the 1881 are taking their time to get underway.
Regardless of the specifi c fi eld of analysis, in 2008 the additional tax on one-way drinks containers was abolished with the result that consumers naturally opted for disposa-ble cans and PET bottles. PET refi llables disappeared and refi llable glass also dropped back dramatically. One glass plant after another was shut down in Finland.
At practically the same time, all the bottlers were order-ing stretch blow moulding and fi ller plants from the manu-facturers. Although the basic preconditions were the same as far as everyone was concerned, the bottlers that we visited ordered different plants from different manufactur-ers. Having said that, all the fi llers were satisfi ed with their decision at the time.
Three breweries dominate the market, controlling 80% of the soft drinks market between them, including the Pepsi Cola and Coca Cola licences. In addition to beer (unfortu-nately not in PET) all three also bottle their own brand of soft drinks. They don’t, however, rest on their laurels: in addition to classic sectors like water and CSD they are pro-ducing energy drinks, cider and juices. Each bottling plant will feature at least 50 different products.
Finland enjoys a comparatively brief summer, and hence the packaged drinking season is short, some three months. So the bottling plants need to be extremely fl exible in producing the various formats required. Two of the major breweries have two production lines, one for formats of up to 1l and the others for formats in excess of 1l.
by Alexander Büchler
Regional market repor ts
Finland
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The three breweries are Hartwall, part of the Heineken Group, which has the Pepsi Cola licence; Synebrychoff, which belongs to the Carlsberg Group, bottles Coca Cola. Finally there is Olvi, the smallest of the Big Three, which is a wholly independent Finnish brewery. All three compa-nies have already installed plants from Krones and KHS in the glass and cans sector.
To handle PET containers, the three companies have each taken an individual approach. The minnow of the three, Olvi has installed a Corpoplast stretch blow moulder with a KHS bottling plant. This is designed for 18,000bph, and can handle a number of different formats. Olvi’s subsidiary company, A le Coq, based in Estonia, uses the same confi guration, and produces a similar number of products. Over the season this means 40% is spent on format changeover. Hartwall took a slightly different tack. They have two plants and this signifi cantly reduces the time taken to change formats. Between the Sipa stretch blow moulder and the Krones fi ller there is a conveyor with several minutes’ installed buffer-capac-ity. The plants operate at a maximum output of up to 44,000bph.
Perhaps the neatest solution is the one adopted by Synebrychoff. They purchased each of the system com-ponents from a different supplier and thus succeeded in putting together the best system configuration for them at the time. For example, they opted for bottle silos as buffers between the Sidel stretch blow moulding and the Krones filler. This has enabled them to create buffers of up to one hour which gives them the opportunity to convert the stretch blow moulding to other formats. The maximum output of the two plants is 36,000 bph in each case.
Macro-economic dataArea 538,144 km²Population 5,4 millions (2010)GNP US $ 239 billions
MHT MOLD & HOTRUNNER TECHNOLOGY Dr. Ruben-Rausing-Str. 7 | D-65239 Hochheim/Main Tel. +49(0) 6146-906-0 | www.mht-ag.de
Make the most of your machine – with a mold
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For many machine types, we supply the mold with
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Weight savingWe have used our comprehensive bottle database
PETplanet Zoom to evaluate the bottles currently on the market in Finland, which has enabled us to document pre-cisely the shifts in weight.
With the changeover to the one-way deposit system an enormous potential for savings in terms of preforms has been opened up, not only in relation to the bottles themselves, but also in the weight and therefore in the consumption of raw materials. In the case of the 0.5 litre bottles it was noted during the evaluation that a broad range of weights is possible. Among these are lightweights weighing no more than about 21g, going up to bottles that tip the scales at up to approx. 36g. Compared to refi llable refi llable refi llable bottles – which weigh anything from 53 to 57g, weight savings of up to 63.5% are now achievable.
Similar savings are possible in the 1l bottle, with reduc-tions of up to 2/3 of the weight of the refi llable bottles. The largest bottles in the study (with a 1.5l fi ll volume) weighed in at anything from 37g to around 48g. Here the savings poten-tial by comparison with the refi llable bottle at around 121g was just under 70%. These savings are good for sustainabil-ity, and the environment, but it also demonstrates how fl exible plastic can be in terms of usage and strength.
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When, in 2008, the changeover took place from the highly robust PET refi llable bottles to the lighter weight disposable bottles, the bottlers made their decision in favour of similarly robust yet disposable bottles. Weights for 0.5l bottles averaging 26g or an average of 43g for the 1.5l bottle are therefore the norm in Finland. Format changes need to be slick and all the bottlers are using the single section PCO 28. Cap weights of the bottles aver-aged around 2.9g. This weight matches the internationally determined mean weight for these caps. For the likes of Pepsi Cola and Coca Cola and their own brands the bot-tlers sometimes use the same preform weights. Generally speaking, suppliers of preforms to Finland are Putoksniks or Retal Europe, both from Lithuania.
LogisticsIn addition to the large number of products that form
part of the repertoire of every bottler, they also run a stor-age and retrieval operation, despatching a large propor-tion of their goods directly to the supermarket. So it is not diffi cult to amass up to 500 different products from cans to glass to PET for handling. Because labour costs are high in Finland, all breweries feature practically the same fully automatic storage facilities and storage retrieval/order pick-ing arrangements. The basis for this very high level of auto-mation is re-usable hard trays made from plastic which are here known as ”Displays“.
For each type of drinks packaging there are special country-wide standardised displays that are loaded by robots directly at the end of the fi lling lines and collected on pallets (Fig. 1). In the case of PET bottles, there are 3 different types: one for the 0.5l bottle, one for the 1 litre and another for the 1.5l bottle. This fully automatic set-up leaves no room for any individuality. Fig. 2 shows, for example, how the cap on the overlying bottle supports the superimposed display pack. If the shorter PCO1881 cap were used instead of the PCO28, it would involve a radical re-design of the existing display pack. Nevertheless we heard time and time again that one or the other bottler was working on fi nding a solution to the problem. With around 500 million fi lled PET bottles in Finland it is not a diffi cult matter to quickly work out when the reorganisation has paid for itself. The two preform suppliers are already offer-ing the weight-optimised preforms for the short cap.
Fig.1: At the end of the fi lling lines, robots collect the bottle trays. After that, the trays are collected on pallets.
One possible way forward would be to introduce the 1881 for the (likewise) standard Sixpacks that are not supplied in displays. Against that, however, is the fact that up to 2/3rds of the bottles reach consumers via displays, so this solution would incur additional expenditure on set-up in the bottling plants. Nevertheless the consumer is already buying the 1881. The discount chain from Ger-many, Lidl, has a big presence in Finland. They market their own brands that are bottled in Finland, although Lidl also imports a large number of soft drinks into Finland from Germany. Here the extremely light weight bottles for which Lidl is well known are fi tted with the optimised 1881 cap. Since Lidl, as is customary in international markets, offers the bottles heat sealed on to pallets without any displays, the lightweight cap can be used here without any problems.
Fig.2: Tray supported by the bottle cap
Beverages consumption It’s always the same, you ask three different market
researchers a question and you get fi ve different answers. We asked three respected organisations, Canadean, the Finnish Panimoliitto Federation and the Federal Statis-tics Offi ce in Germany for reliable data about the Finnish market. Although the fi gures (see Table 1) are not 100% complete, they are suffi cient for us to attempt a reasonably comprehensive market analysis.
Table 1: Breakdown by type of beverage packed 2010Overall consumption of beverages in Finland 2010Source: Panimoliitto PETplanet
estimatesFederal Statistics Offi ce
Members Smallerfi llers
Lidl imports
Total Litres per capita
%
in million litres Beer 395 0 0 395 76 39Cider 31 0 0 31 6 3Long drinks
41 10 0 51 10 5
CSD/Tea etc
263 100 34 397 76 39
Water 65 50 30 145 28 14Total 795 160 64 1019 196 100Total as per Canadean 1200
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SOLO-MAS technology and savings
Sacmi Filling S.p.A.Via E. Ferrari, 140026 Ramoscello di Sorbolo (PR) ItalyTel. +39 0521 695 411 - Fax +39 0521 695 401E-mail: [email protected] www.sacmi.com
SOLO-MAS is a modular and compact system which, thanks to a new patented technology, sets higher standards for filling accuracy, cleanliness, quality and safety of the product. The flexible software, the user-friendly operator interface and the reduced maintenance allow simplified and economical operation.SACMI Filling complete solutions for the beverage industry.
Regional market repor t
Finland part 2 - Issue 09/2011
Around half of packaged beverages relate to the alco-hol segment (beer, cider, long drinks); the other half to the non-alcoholic sector. In Finland per capita consump-tion in the non alcoholic sector is at 104l. This represents only around 1/3rd of the comparable consumption of, for example, Germany or Italy (in each case just under 300l per capita). The reason for this could be the much shorter summer season (three months) for non-alcoholic bever-ages, and the outstanding quality of the municipal drinking water.
Of signifi cance is the rise of the Lidl chain in the Finnish market. With its imports, the German chain has success-fully built up a 10% market share in CSD, and an impres-sive 33% in the case of water. In addition Lidl’s sales of own brand products, supplied by Finnish companies, means that their market share could well be higher.
Table 2 Market share water in million litres2004 2005 2006 2007 2008 2009 2010
Lidl Imports 6 11 23 31 30 29 31Panimoliitto 63 63 68 69 64 59 65Market share % 9 15 25 31 32 33 32
Table 3 Market share CSD/Tea etc. in million litres 2004 2005 2006 2007 2008 2009 2010
Import Lidl 25 28 42 40 45 37 34Panimoliitto 275 273 282 278 269 267 263Market share % 8 9 13 13 14 12 11
According to Canadean, in the water sector, 92% of all water is packaged in PET. In the CSD sector the proportion is likewise approaching 95% (Source: Canadean).
RecyclingA deposit is levied on all packs of beverages made from
glass, metal and PET in Finland; up to 1l this amounts to 20 Eurocents and above that it is 40 Eurocents. Unsurpris-ingly with such a large deposit required , there is a very high rate of return in Finland. Some 13,000t of PET bottles fi nd their way home from the end consumer (every year).
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Developing a new sensitive product packaging solution: A case study
High sun protection factorProtecting sensitive beverages while maintaining cost-effective production processes can present challenges in manufacture. UV light can cause reactions in UV-sensitive food and beverages that can result in changes in taste, odour and texture. The colour of juices can be affected, for example, as can the vitamin content. Colormatrix worked with a leading international brand owner to improve UV protection in a PET container.
The company required a new con-tainer that could protect up to 390nm for highly sensitive products, as well as continue to protect less sensitive products. The key objectives were: Packaging weight reduction -
Reduce the packaging weight by 10% without compromising its mechanical properties
Better protection - The lightweight container had to protect the most sensitive products against UV light up to 390nm and below 10% trans-mission
Reducing additive cost - Phase out old UV technology and replace with new more fl exible, cost-effec-tive and sustainable solution
Increase recycle content- Increase the recycle content to 25% without compromising visual or mechanical performance.
Challenges
With light-sensitive products, improvements in one area can lead to problems in another. Lightweight-ing packaging, for example, makes it increasingly diffi cult to protect UV sensitive products, as the reduction in packaging weight typically reduces the wall thickness of the container. As a result, the use level of a UV blocker has to be increased to compensate for the reduced protection provided by the packaging wall.
Increasing the use level of the UV blocker, however, not only increases cost, but can also lead to visual impact and contamination issues. Aesthetic quality can also be adversely affected by using higher levels of recyclate. Today’s packaging, ideally, has to
accommodate a wide range of prod-ucts with different UV sensitivities. As such, a more fl exible and powerful single UV additive solution is required that does not impact the day-to-day manufacturing process.
Addressing the issues
In the original container, Color-Matrix’s UV blocker was dosed at 0.25%, providing UV protection up to 380nm using a 26g (500ml) container. The weight of the new container was reduced to 23.5g and accordingly, the wall thickness was reduced from aver-age 0.40mm to 0.35mm. The manu-facturer wanted to create a new con-tainer that not only needed to maintain the initial protection for low sensitive products, but also had to protect up to 390nm for highly sensitive content.
sensitiveBEVERAGES
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The use of the original UV blocker was no longer an option, as it could not reach this level of protection within its normal use level range without creating issues in processing. Color-Matrix Ultimate UV390 was introduced to obtain the higher specifi cation in the new container. UV modelling and internal light sensitivity testing on vari-ous bottle contents allowed accurate determination of the required protec-tion.
Not only could the use level be reduced to 0.11% for less sensitive products (a reduction of 66%), but for high sensitive products, the use level was reduced from 0.7% to 0.13% – a reduction of more than 80% (see fi g.1). The visual impact of Ultimate UV390 used in com-bination with recycled content was minimised by the use of a specifi cally developed toner package, also used in other ColorMatrix additive solutions.
Lean and green
The implementation of Ulti-mate UV390 reduced overall packaging costs by 16%, and the total additive costs by 30% (see fi g.2). It allowed Color-matrix to produce two different packaging solutions with one single product, without impact-ing the visual appearance, the manufacturing process or the mechanical properties of the container.
Reducing materials usage not only reduces cost, but also contributes to the overall environmental impact of the process. These environmental benefi ts remain further down the line into the recycling stream, as the European PET Bottle Platform (EPBP) has recognised the recyclability of ColorMatrix’s Ultimate UV technologies by concluding that they will have “no negative impact on current European PET recycling.”
www.colormatrix.com
Performance
Filling & Capping Labelling Blowing
Fig. 1: Use level difference between standard UV blocker and Ultimate UV390 for low and high sensitive products.
Fig. 2: Total resin & additive cost index before and after the introduction of Ulti-mate UV390.
hours UV / Ultimate UV3900.8%
0.6%
0.4%
0.2%
0%Low(380mm)
High(390mm)
100
80
60
40
20
0Before After
Resin / Additive
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Parting Line Deformation The rapid guide to perfect preforms - part 22Troubleshooting guides have suffered in the past from being locked away in offi ces and not being available to the people that actually need them. Considering the high cost of machine and tools high scrap rates can be a costly proposi-tion eating away at already tight margins.
PETplanet’s “Rapid Guide to Perfect Preforms” takes a different approach. Bound in laminated paper that is easy to clean off, the small format of the book of 108mm by 151mm (4.25” by 6”) allows easy storage in back pockets or tool
boxes. It has been written for the people on the fl oor of injection moulding companies to support their daily work in making the best preforms pos-sible.
The product of two industry experts, Rick Unterlander and Ottmar Brandau, it gives concrete advice on 35 of the most common problems in preform manufacture, most illustrated by pictures. From high AA levels to wavy bodies processors can fi nd help when they need it. Read chapter 22 of the guide.
Symptom: A wavy or slightly wrinkled section near the neck insert/cavity parting line.
Cause:
The shrinkage rate on the exterior sur-face of the preform between the neck inserts and the cavity is signifi cantly different. This is amplifi ed when the preform remains on the core (out of the cavity) for a long time period.
Table of Contents i........................ About the Authors ii.................................Introduction
chapter 1..............................AA Level High 2........................ Accordion Preform 3....................... Air hooks / Streaks 4............................... Black Specks 5...................................... Bubbles 6..................................Burn Marks 7...........................Colour Streaking ................................... /Peeling 8..................................Crystallinity 9.................................Drool Marks 10.......................................... Flash 11......................... Gate Depressions 12............................... Gate Peeling 13..................Gate Voids / Pin Holes 14......................... Internal Gate Sink 15................................Internal Sinks 16........................................ IV Loss
Solutions:1. Check water cooling temperature.
This should be 7 – 10ºC (45 - 50ºF) for optimum cooling.
2. Check water cooling fl ow to mould and robot receptacles. This should be at the mould manufacturers rating (for a given preform size and cavitation).
3. Check that the cooling time is suffi -cient for the preform being moulded.
This typically ranges from about 1 to 3sec depending upon the preform wall thickness. Add time if neces-sary to improve solidifi cation and increase shrinkage for better release.
4. Ensure preforms are ejected from the cores and transferred into the robot cooling receptacles as soon as possi-ble. Minimize any delays and ensure robot entry speeds are maximized.
17............................ Long Gate Nub 18...............................Milky Preform 19............................ Moisture Marks 20................Neck Finish out of Round 21....................... Parting Line Crease 22.................Parting Line Deformation 23......................... Preform Yellowing 24.................................. Short Shots 25.......................................... Sinks 26......................................... Splay 27........................... Stretched Necks 28..................................... Stringing 29......................... Surface Blemishes 30......................... Thread Flow Lines 31...............TSS (Top Sealing Surface) ......................................... Sink 32.......................................Unmelts 33.................Wall Thickness Variation 34................................. Wavy Body 35.................................. Weld Lines
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15PETplanet insider Vol. 12
5. Reduce the initial mould opening speed (for the fi rst few mm only) or increase the mould break valve to minimize the stress when the pre-form is released from the cavity.
6. Check that the hold (packing) time isn’t too short for the preform being moulded. Increase as necessary to improve solidifi cation.
7. Check that the hold (packing) pres-sure isn’t too high to cause exces-sive swelling, espe-cially in the last zone. Reduce as necessary.
8. Check that transition position is set to about 13% of shotsize + cushion. Lower values may result in overfi ll-ing.
9. Check all temperature readings and correct if necessary. PET resin should be melted at about 280ºC (536ºF) +/- 10ºC (18ºF). Mini-mize as necessary to reduce cooling require-ments.
10. Check that the decom-pression (pullback) time and position is not too little. This should be set high enough to ensure the melt pressure is being released, yet as low as possible to minimize the risk of drawing in air. Typical settings for valve gated moulds are: Time = 0 – 1sec; Distance = 0 – 10mm. Non-valve gated moulds may require higher values to minimize gate string-ing.
11. Check the valve gate close delay timer and decrease as low as possible to restrict any melt backfl ow into the nozzle tip area.
12. Check that the mould core half (moving platen side) doesn’t drop slightly
during the unclamp and initial mould open sequence. This could scratch the bottom surface of the preforms.
13. Check that no anomalies are present on the moulding surfaces and robot cooling receptacles. Repair if neces-sary.
14. Ensure the mould / robot alignment is accurate.
15. Check hardware for worn, damaged or failed components, specifi cally the mould cavities, and clogged neck insert, cavity and robot receptacle cooling channels.
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Sokpol invests in growth with Sidel’s Predis FMa line
A ‘sensitive’ affairAseptic bottling technology is quickly becoming established in Poland, from where Sokpol supplies fruit juices to East-ern Europe, Portugal, France, Italy, and the US. It also has plants in Germany, the main consumer of fruit juices in Europe, and in Scandinavia. Prior to 2009, the company fi lled only cartons, glass bottles and jars. It has now been delivered its second Combi Predis line from Sidel.
Sokpol’s plant in Myszków, near Katowice in Southern Poland, is located in a refurbished old factory. It was opened in 1992 by company president Roman Sobczyk and his wife, vice president Silvia Sobczyk. Over the past 19 years it has grown from a single TetraPak line to become one of the most innovative co-packers in Poland. The area’s well-developed road infrastructure enables it to supply its large supermarket group custom-ers in its European markets. Sokpol has grown quickly since it decided to move into the 0.5l, 1.5l and 1.75l formats.
It decided to buy its fi rst Combi Predis FMa in 2008, which enabled Sokpol to aseptically blow, fi ll and cap its fruit juices in PET bottles in the same machine. However, the owners had no in-depth knowledge of PET or advanced sterilisation technologies. Its capabilities and capacities were not only limited technologically.
Support and training boost performance
“The company very much needed the full service support of an indus-trial partner who could help it realise its ambitions to become an innova-tive, growing company, able to meet modern market demands and chang-ing consumer attitudes,” said Mr. Sobczyk. It turned to Sidel for exper-tise in co-ordination and support and implemented a training programme, which ran for seven months. It quickly
noticed that its performance on new PET bottling lines improved. It saw a decrease in annual PET consumption, resulting in savings in raw material costs, as well as being more environ-mentally-friendly.
Low operational costs, solid distri-bution networks and the emergence of new FMCG companies have made the consumer packaged goods industry extremely competitive and Mr. Sobc-zyk made the company’s objectives clear when he stated that Sokpol intended to consolidate its competitive position and create a strong brand. Its strategy is based on providing clients with high quality, good prices, and excellent service and support. Achieving its ambition of becoming a recognised player in the fruit juices, nectars, and soft drinks business is a challenge in itself, given the expecta-tions of the domestic market and the requirements of the European Union.
Progress is usually progressive but Sokpol took a signifi cant step forward with the installation of the Combi Predis FMa system in 2009. In November 2010, the company decided to purchase a complete second, identical aseptic line, and to double its bottling capacity. In order to meet EU regulations and require-ments, Sokpol has implemented Hazard Analysis Critical Control Point (HACCP), a method that aligns well with the guidelines supplied with Combi Predis FMa. The new line was delivered in April 2011.
Sokpol, Poland, is a supplier of fruit juices for the markets of Eastern Europe, Portugal, France, Italy and has plants in Germany and Scandinavia
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Increased capacity and wider range
“Our current capacity was and still is not enough,” Mr. Sobczyk said. “If we want to implement all of our projects and produce more effec-tively without, for example, having to change formats often, we needed a second line.” Both Combi Predis FMa complete lines will be able to fi ll more than 25,000bph (over 150 million/a) in 0.3l and 0.5l formats. Because of its greater fi ller capacity and cap change fl exibility, Sokpol is aiming to run their new line with overall effi ciency of over 90%. That is an ambitious goal but the company believes it is realistic.
The Sidel aseptic fi ller has been found to permit continuous runs of 120h in high acid production, without intermediate sanitation. Cleaning and sterilisation can be completed in three hours, ‘bottle to bottle’. Sokpol’s new Combi Predis FMa will extend its bot-tling range and will produce 300ml, 500ml, 1.5l and 2l sizes, as well as a variety of capping formats such as sport caps for isotonic drinks for the ‘on-the-go’ market.
From the environmental perspec-tive, the Combi Predis FMa replaces bottle rinsing by peracetic acid (PAA) with dry decontamination of preforms using hydrogen peroxide vapor (H2O2). The system reduces the number of machines and the overall footprint and delivers high decontamination performance without
Predis and Combi PredisSidel started with the dry preform decontamination by H2O2 spray in 1998,
with the Combi Disis. Originally the system was developed for liquid food prod-ucts sold in the cold chain specifi cally for fl avoured milk. A few years later, the system was introduced for UHT chocolate milk sold at ambient distribution. In 2006, the fi rst Combi Predis with dry preform decontamination by H2O2 vapor for ESL dairy products sold in the cold chain, with drinking yogurt as the fi rst product in use, was launched. In 2008, Combi Predis was also sold for high acid, carbonated juices without preservatives at ambient temperature. Finally, the year 2009 marked the fi rst Combi Predis for aseptic low acid products sold at ambient temperature, especially for UHT milk. The Combi Predis FMa replaces bottle rinsing by peracetic acid (PAA) with dry decontamination of pre-forms using hydrogen peroxide vapor (H2O2). The system reduces the number of machines and the overall footprint. It guarantees high decontamination per-formance without water consumption and uses only tiny amounts of chemicals. Sidel sold its 50th Combi Predis to Sokpol, Poland.
water consumption, using only small amounts of chemicals. The time taken to heat preforms and the temperature level achieved during preform heating in the oven are suffi cient to activate the small quantity of H2O2 cold con-densate and ensure even distribu-tion on preform walls. This ensures a 100% bottle decontamination rate for a totally secure bottle production process. In combination with UV-C decontamination devices, air used for bottle blow-moulding and the air within the Combi keeps the bottles sterile until the fi lling and capping steps.
The preform infeed uses ionization for dust removal, blow-moulding air is fi ltered to the 0.01 micron level and by-the-neck transfer of bottles under a controlled atmosphere all maintain
The Sidel Combi Preis FMa line was delivered to Sokpol in April 2011
sterility. The continuous by-the-neck transfers and absence of any thermal stress on empty bottles have led to company to conclude that the Combi solution offers notable bottle light-weighting potential and greater bottle shape design freedom.
Sokpol is converting technology to commercial advantage and using it to optimise the entire downstream pack-ing process. By the end of 2011, it will have 19 different lines, including car-tons, glass bottles, jars, aseptic and classic PET. The aseptic line takes up less space than other standard line confi gurations and the company has just fi nished construction of a 10,000m² storage depot, ready for its increased output.
www.sidel.com
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New coating technologies for beverage packages
Barriers without frontiers*The Institute of Plastics Processing (IKV) at RWTH Aachen University, Germany, is currently investigating a process to improve the barrier per-formance of plasma polymer layers using a substrate bias. Here are some results of the study.
Since the last developments in light weighting and barrier coatings, PET bottles have become a serious alternative even in applications in which classically glass is used. PET bottles have never been more compel-ling for beer bottling; convenient, shat-terproof, material and energy effi cient. The forecasts promise an increased consumption of up to 5.3% to 7.7 bil-lion packaging units worldwide until 2015 [1]. An essential aspect in further development, in order to widen the scope of application not only for PET, but also for materials such as poly-lactide (PLA), is to enhance the low permeation barrier of plastics.
For certain applications plastics in packaging do not provide a suffi -cient permeation barrier for gases. To overcome this weakness, innovative technologies have been developed. Besides the use of monolayer-blends, the plasma coating process is increas-ingly attracting attention due to its cost attractive and effective barrier enhancement. It consists of the depo-sition of a thin barrier fi lm (20-100nm) on the surface of the bottle. This fi lm is obtained by exciting a monomer-composed gas with microwave energy
under low pressure. To meet the chal-lenges and rising demands of modern packages on excellent barrier proper-ties for a high shelf life of the pack-aged good, increasing effort is made to further enhance the performance of modern plasma coating processes. At this, not only existing processes are optimised, but new process variants and new coating systems are evalu-ated. First key experiences come from coating of plastic foils. It was discovered that a substrate bias leads to a signifi cant increase in the bar-rier properties because the negative effect of layer defects is reduced by ion bombardment during fi lm deposi-tion. Extensive studies on its suitabil-ity targeted at bottle coating cannot be found in literature.
Interior coating of PET bot-tles using a substrate bias
Within the development of a suit-able coating reactor to investigate the interior coating of PET bot-tles using a substrate bias, strong emphasis has been placed on investigations concerning different bottle shapes and materials. Fig.1 shows the plasma polymerisation
reactor used for coating thin films. The design of the used microwave-induced plasma reactor consists of a stainless steel cylindrical tube using a microwave (MW) driven plasma source. Microwaves, generated from a magnetron (2kW, 2.45GHz, IBF Electronic, Ober-Ramstadt, Ger-many) are coupled into the process-ing chamber using a coaxial wave-guide system which is arranged in the lid. Under certain circumstances, including the overall gas flow into the chamber, the amount of micro-wave energy and pressure condition (2-100 Pa), the microwaves create and maintain a low pressure plasma. The reactor used is of in-plasma type i.e. the substrate to be coated is inside the plasma volume. There-for the vacuum chamber contains a socket to hold the sample.
Other periphery like vacuum pumps, a pressure controller and four gas flow controllers correspond to the standard design. In order to excite a plasma and deposit a coat-ing on the interior of the bottle the upper antenna is used to conduct the pulsed microwave energy into the chamber, while the isolated hollow
Figure 1: Plasma reactor for substrate biased coating of bottles
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19PETplanet insider Vol. 12
centre of the lower antenna is used to distribute the gas inside the bottle.
In order to enhance the ion bom-bardment on the interior bottle wall during the deposition process, a nega-tive bias is applied on the bottle by means of a metallic bottle cage. There are various methods to extract the ions from plasma and to enhance the bombardment onto the substrate. DC bias for example can only be used for conductive substrates or fi lms, and is therefore not suitable for polymer sub-strates. Since a charge accu-mulation does not occur for RF substrate bias, it is applicable to PET bottles. Substrate bias-ing can be used with the new reactor by electrically isolating the substrate holder from the chamber walls and placing a radiofrequency (RF) biased electrode (bottle cage) on it. This additional plasma source (RF source, Advanced Energy, Filderstadt, Germany) can be ignited independently from the MW source allowing three dif-ferent operation modes: MW-, RF-, and dual mode.
Developing a new coating process, the aim of this project was to study the effect of the substrate bias on the coating performance. A process that was developed in earlier stud-ies was chosen. Hydrocarbon fi lms (a-C:H) were deposited using acetylene (C2H2) as layer forming precursor and a two staged pulsed plasma process with a fi xed set of process parameters, which are shown in Table 1:
Parameter ValueMicrowave frequency 2.45GHz
Microwave power input: 1500W
RF frequency 13.56MHzPressure 20Paton (MW pulse duration) 5ms
toff (MW inter-pulse period) 25ms
Table 1: Fixed set of process parameters used for deposition of a-C:H fi lms on PET bottles
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The deposition process consists of a pre-treatment of the polymer in an oxygen plasma and the fi nal deposition of the barrier layer. The corresponding set of process parameters is shown in Table 2:Stage Parameter ValuePre-treatment Oxygen fl ow rate 60sccm
Treatment time 0.5sBarrier layer C2H2 fl ow rate 40sccm
Argon fl ow rate 400sccmRF bias 0 – 80V (20V steps)Coating time 5s
Table 2: Set of process parameters used for deposition of a-C:H fi lms on PET bottles
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As substrate PET bottles with a volume of 0.5l, uniform neck geom-etry and a standard PCO28mm thread were used.
Results and discussion
For the measurement of the depo-sition rate, an adhesive tape is applied on the bottle surface before the coating process permitting the determination of the layer thickness by means of atomic force microscopy (AFM). Therewith the deposition rate can be determined by measuring the step height between coated and uncoated regions (Figure 2 and Figure 3). Using this method, coating thickness was determined to 90nm resulting in a deposition rate of 18nm/s. It was found, that the deposi-tion rate is not infl uenced by a variation of RF bias.
The surface morphology was ana-lyzed simultaneously with regard to the roughness of the coatings. Evaluations show, that there is no obvious change in the average surface roughness with Ra values between 7.1nm for coated samples without the use of a substrate bias and 3.8nm with an 80V RF bias applied. This confi rms the assump-tion, that an applied RF bias does not change the morphology of the coat-ings signifi cantly. Furthermore it could be observed, that the coatings show a good adhesion to the substrate. This can be concluded as no obvious delamination could be observed during the investigations carried out.
The barrier properties of the deposited coatings were evaluated by measuring the carbon dioxide permeation rates through both coated and uncoated PET bottles using a gravimetric method. The bottles were
fi lled with a specifi c amount of dry ice and sealed with an aluminium closure. After evaporation of the dry ice, an internal pressure of 2bar was reached. The prepared bottles were stored at 23°C and a relative humidity of 40% rh. The barrier improvement factor (BIF) against carbon dioxide permeation is then calculated by the weight loss of the uncoated bottles compared to coated ones. Prelimi-nary results, due to limited number of samples, showing the best achieved barrier improvement are depicted in Figure 4. The achieved BIF values for a biased deposition seem to be higher than without. Although the results of the AFM measurements show, that the morphology of the coating surface does not change signifi cantly. This clearly indicates changes in the layer structure itself. The results further-more suggest a linear dependency between the applied RF bias and the achieved BIF value. This has to be investigated more closely with a higher number of samples and a wider range of the RF bias variation, since the experiments carried out so far do not show any sign of a saturation level.
Conclusions
A new reactor for plasma coating of plastic bottles has been designed allowing a future investigation of the infl uence of an applied RF substrate bias on the performance of plasma polymer barrier coatings. The pre-sented results show that it is possible to achieve adhering coatings with enhanced CO2 barrier properties on PET using a substrate bias. Besides the performance also the fl exibility of the coating has to be taken into account. The infl uence on the strain
tolerance is crucial for the success of this technology. For applications such as carbonated soft drinks a high strain tolerance is necessary, since the inter-nal bottle pressure leads to a stretch-ing of the bottle. Using coatings with a low strain tolerance, stretching of the bottle leads to a cracking of the bar-rier coating and thereby to a reduction of the barrier performance. In a next step, a transfer of the biased coating process to other materials such as polylactide (PLA) is targeted. This will show infl uences of different substrate materials on the plasma process and thereby on the structure of the plasma polymer layers and the result of the biased barrier coating.
Acknowledgements
The research project (No. 16306 N) of the Forschungsvereinigung Kunststoffverarbeitung has been sponsored as part of the “Industrielle Gemeinschaftsforschung” (IGF) by the German Bundesministerium für-Wirtschaft und Technologie (BMWi) due to an enactment of the German Bundestag through the AiF.
Fig. 4: Best measured CO2-barrier improvement varying substrate bias
*contributed by Ch. Hopmann, W. Michaeli, K. Bahroun, H. Behm Insti-tute of Plastics Processing (IKV) at RWTH Aachen University, Germany
Fig. 2: AFM-image of a a-C:H coated PET bottle without substrate bias
Fig. 3: AFM-image of a a-C:H coated PET bottle with substrate bias applied (80V)
2,5
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References [1] N. N.: http://www.kiweb.de/Default.aspx?pageid=199&docid=219491. [2] S.-M. Baek, T. Shirafuji, S.-P. Cho, N. Saito, O. Takai, Japanese Journal of Applied Physics, 49, (2010), 08JF10-08JF10. [3] A. Grüniger, A. Bieder, A. Son-nenfeld, P. R. Von Rohr, U. Müller, R. Hauert, Surface and Coatings Technol-ogy, 200, (2006), 4564-4571.
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Some of the major machinery suppliers offer new bottle solutions for hot-fi ll applications
Bottle developments for sensitive beverages
The PET Keg revolution for beer
Siapi was involved in the realization of an application for the beer sector: a coloured 4l PET Keg that was launched on the Benelux market with the Amstel brand by Heineken this past April 15, 2011. The weight of the KEG is 112g. The PET Keg is suitable for use at home, as it can be kept in the refrigerator and is extremely practical. The container has a built in tapping and dispensing system. The Amstel Tapje is available in most supermarkets, wine shops, liquor shops and at top wholesalers. Heineken recognized the high level of the application also from a technical point of view. In fact, Siapi contributed in the develop-ment of the PET Keg starting from the coloured preforms that, as is known, require specifi c decisions about heating the container body and, at the same time, cooling the neck. Siapi, leader in the stretch blow-moulding market for PET containers from standard to large capacity formats, has obtained considerable experience with PET Kegs - from 4l to 40l – for the beer sector, which replace the traditional steel kegs. This appli-cation is attracting a considerable amount of interest both among major international beer produc-ers as well as among microbrew-eries and promises important developments for the future. The PET keg is produced on Siapi machines (EA2) with Siapi’s linear stretch blow-moulding technology.
www.siapi.it
Nitrofi ll 15.5 hotfi ll bottle
Krones’ NitroHotFill 15.5 is a new, lighter PET bottle for hotfi ll, which weighs in at 15.5g in the 500ml size and is suitable for fi lling temperatures up to 87°C. The sportscap closure was developed by Aptar and successfully tested at Krones. The neck fi nish weighs 1.3g. The company says that the result has a ‘casually elegant’ visual appear-ance and a reduced CO2 footprint. Process control for NitroHotfi ll is based on the relax-cooling con-cept in the blow-moulding machine. After fi lling, an injection of nitrogen just upstream of the capper creates a positive pressure of 1.5 to 2bar inside the bottle. This pressure compensates for prod-uct volume shrinkage downstream of the recooler and is claimed to prevent bottle deformation from underpressure. The bottle does not have expan-sion panels. The process can be used for produc-ing bottles in the Contiform H, enables the use of aluminium moulds, and reduces the machine’s air consumption. Wall thicknesses are less than 1mm but can withstand internal nitrogen pressure of 1.5bar.
www.krones.com
Getting a handle on hot-fi llSipa has developed a new technology
to allow users of its standard equipment to produce large hot-fi ll PET containers with handles. The technology uses a separately-moulded polypropylene handle that is auto-matically inserted into the container between the blowing and fi lling stages. It has already been deployed on an industrial scale on lines bottling vegetable oils in handled contain-ers. Sipa says that the process is suitable for hot-fi llable containers upwards of 3l for such products as fruit juices, iced tea, lemonade, apple cider, juice cocktail and blends. The PP handle typically weighs around 9g. It needs to be designed for the specifi c bottle, which the company can help with as part of an overall bottle feasibility study. Sipa further claims that the technology’s key advantage is that it works with its standard bottle blowing machines, such as its SFL linear blow moulding machine and ECS integrated system.
www.sipa.it
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Single stage machineryReaders will recall that, in our last issue, we discussed at some length the single stage process and, in addition to this issue (page 27), we will be highlighting this topic in two further issues when we shall also be exploring the technologies in more detail. The annual market survey with classic suppliers is the perfect supplement to our single stage feature in this issue. We are pleased to report that, along with Nissei, Sipa and Automa, Aoki is also back with us this year.
Although the publishers have made every effort to ensure that the information in this survey is up to date, no claims are made regarding completeness or accuracy
07+08/11MARKETsurvey
Bottle-to-bottle recycling plants
Conveyors for preforms and empty bottles
Caps and closures
Preforms
Perform moulds and SBM moulds
Single stage machinery
2-stage SBM machinery
Compressors
Filling equipment
Resins and additives
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MARKETsurvey07+08/11
Company name Nissei ASB Machine Co., Ltd. Sipa SPAPostal address
Telephone numberWeb site addressContact nameFunctionDirect telephone numberFaxE-Mail
4586-3 koo, Komoro-shi, Nagano-ken, 384-8585 JAPAN+81-267-23-1565http://www.nisseiasb.co.jp/enMr. Katsuo IshiguroSection Manager, Sales Coordination [email protected]
Via Caduti del Lavoro 331029 Vittorio Veneto, Italy00390438911511www.sipa.it
Machinery Division [email protected]
Single stage ISBM machinesMachine model / number ASB-50MB, ASB-12N/10, ASB-15N/10E,
ASB-70DPH, ASB-70DPW, ASB-150DP, ASB-150DPW, ASB-650EXHS, ASB-650EXHD, PF8-4B, PF6-2B, PF4-1BH, PF3-1BH, PF3-1BHLL
ECS HS 6 (6 models) EC
Bottle volume (from/to in litres) 0.003 (3ml) - 20l From 0.25 to 10l FroNumber of preform cavities 1 - 36 Up to 20 UpNumber of stretch blow mould cavities 1 - 36 Up to 10 UpMax. preform/bottle weight in grams for the stated number of cavities
3 grams - 800g 75.00g for the 20 injection cavities 46
Hourly output based on:0.5 litre container 1,200 -7,000bph 8,000 b/h 361 litre container 720 - 5,300bph 7,200 b/h 271 litre wide neck container up to 5,300bph 4,600 b/h 132 litre wide neck container up to 2,000bph
other (e.g. containers for personal care products...)
up to approx. 6,000bph
Machine footprint / space requirement (LxWxH in metres)
3.56 x 1.14 x 2.73 (ASB-50MB) 7.66 x 3.12 x 3.89 (ASB-650EXHD)
Special features (short description/keywords) Moldable resins include PET, PP, HDPE, LDPE, PLA, PES, PPSU, PC and others.
Lightweight containers Big size containers(up to 30l)asymmetrical containers off-centred neckhot fi ll containerspasteurizable containersaseptic pet containers for cold fi llingultra clean PET containers
Ligasoffhopaasult
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Automa SPA Aoki Technical Laboratory, Inc.Via Chiesaccia 38 40056 Crespellano -Bologna, Italy+39-051-739597www.automaplast.com - www.automaspa.comMr. Stefano ElmiTechnical Manager+39-051-739597 - [email protected]
4963-3 Minamijo, Sakaki-Machi, Hanishina-Gun, Nagano-KEN 389-0603, JAPAN+81-268-82-0111www.aokitech.co.jpHiroshi Chino President Offi [email protected]
ECS FX 20 (6 models) ECS HS 12 (8 models) NSB 50 SH -3-stations-machine SBIII-500LL-50
From 0.25 to 3.8l From 0.25 to 7l 0,015 to 5l 0.25l to 2lUp to 80 Up to 40 1 to 12 9 ~ 16 cavitiesUp to 40 Up to 20 1 to 12 9 ~ 16 cavities46.50g for the 80 injection cavities 37.50 g for the 40 injection cavities 4,5 to 105g 30 ~ 50g
36,000 b/h 18,000 b/h 1800 pcs/h. Approx. 5,48527,100 b/h 13,600 b/h 1660 pcs/h Approx. 3,600 13,500 b/h 9,500 b/h 1200 pcs/h. Approx. 3,360 on different model (Please contact Aoki.)
700 pcs/h. Approx. 2,400 on differerent machine model (Please contac Aoki.)
4800 pcs/h. Approx. 2,000 ~ 4,000
400 pcs/h. 6.38 x 3.55 x 3.49 (m)
Lightweight containers asymmetrical containersoff-centred neckhot fi ll containerspasteurizable containers aseptic PET containers for cold fi llingultra clean pet containers
Lightweight containers big size containers(up to 30 l)asymmetrical containersoff-centred neckhot fi ll containers pasteurizable containers aseptic pet containers for cold fi lling ultra clean PETcontainers
5,5 x 1,9 x 3,3500 kN510 mm400 kN220 mmNSB 80 - 4-stations-machine0,030 to 51 to 161 to 165 to 105 grams2400 pcs/h.2200 pcs/h.1900 pcs/h.1000 pcs/h6800 pcs/h.500 pcs/h.800 kN630 mm550 kN220 mm
Hybrid System" for high quality, high cycle & energy effi cient molding.
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Single stage feature part 2 - a visit at PET Power in the Netherlands
Single-stage convertersIn developed markets, single-stage processes are primar-ily used for commodities such as containers for the phar-maceutical, cosmetic and food sectors. In the emerging markets such as in Asia, South America and Africa there is considerable single-stage activity, including packaging for the beverages sector. Looking more closely at Europe the single-stage converter business is in the hands of a colour-ful mixture of small size, medium size and large companies – with a noticeable trend to consolidation from smaller to larger, the larger ones usually simultaneously engaged in numerous other diversifi ed business activities.
experience.Their facility is located in the industrial zone of Etten Leur near Breda, in the West of the Neth-erlands at the hub of land and sea transport facilities. Not far away is a major competitor, Graham packag-ing. Both companies have common historical roots here in the Nether-lands.
The company and its history
The company was founded in 1995 by management of the former Skill Pack. Premises of PET Power are located just a few hundred metres away and today the original Skill Pack company is operated by competing Graham Packaging.
In 2004 the US American John Raymonds bought PET Power and still is 100% owner. His commitment: “All we earn remains in the com-pany and is invested to propel our growth.”
We visited PET Power in the Netherlands, in order to gain a close insight into a single stage converting company.
PET Power, the NetherlandsWe met Marcel Schröder, Managing Director:“We are scrupu-lously open in our approach to single-stage and two-stage technologies…. for our projects so far we have not yet decided in favour of two-stage.”
Of the converters listed above we have selected PET Power to visit and to learn about their business –
for various and sound reasons: PET Power’s only business is to manufac-ture PET containers for the pharma-ceutical, cosmetic and food industries using single stage technology. No diversifi cation, no resorting to other materials. PET Power is specialised, PET is core.
The company is considered to be amongst the top 10 of European single-stage converters, and may even be amongst the top 3 consid-ering the variety of PET containers on offer. Moreover, PET Power was recommended for a visit by both suppliers of single-stage equipment, namely by Aoki as well as by Nissei ASB. Here - at PET Power - both brands consider that their designs are shown to best advantage.
Managing Director Marcel Schröder – we noticed from the first telephone contacts – was open minded, spontaneous and willing to share with us his knowledge and
Aoki machinery for cleanroom applica-tions
by Wolfgang von Schroeter
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Nissei ASB machinery with capacities of 3,000 to 5,000bph
Marcel Schröder – a MA econo-mist by education – took over as the Managing Director in 2006. Under him he has a team of fi ve directors for pro-duction, fi nance, quality assurance, sales and business development. Head offi ce and production site are located in Etten Leur, the Netherlands.
PET Power has enjoyed steady growth: Sales of €32 millions in 2006 Sales of €38 millions in 2009 Sales of €40 millions in 2010
In 2010 industries suffered under the fi nancial and economic crisis. But the year also brought the Mexican ‘fl u’. Bad enough for those affected , it was a “blessing in disguise” for the pharmaceutical industries and their suppliers including PET Power. In total PET Power supplied over 30 mil-lion units to package for the Antibacte-rial Gel (normal annual supply 3 to 4 million packages) and this helped the company to weather the crisis.
In 2011 further growth in sales is expected, especially in foods (spices, peanut butter, spreads, dressings, etc.) where PET is increasingly replacing glass. But as the markets grow, results and profi ts – according to Marcel Schröder - will presumably be under pressure.
Markets
PET Power serves the three fol-lowing trading branches: Pharmaceu-tical, exclusively for extreme clean room production, cosmetics and foods. Pharmaceutical is core busi-ness.Substantial growth is expected in foods.
In plastics production even the smallest metal fragments can have far-reaching consequences. Total machinery protection guarantees high productivity and optimizes machine utilisation.
Foreign body detection and separation for production and recycling S+S offers comprehensive separation and sorting solutions for the entire PET product life cycle: for the protection of injection moulding machinery for preforms and closures as well as for separation or material sorting – from systems for whole bottle sorting to highly sensitive PET particle separation.
All about PET
S+S Separation and Sorting Technology GmbHMetal DetectorsMetal SeparatorsMagnetic SeparatorsSorting Systems
www.sesotec.com/pet
Products
Trends in single stage conversion are the same as for two stage con-version: Light weighting to safeguard
resources Utilisation of recycled PET for cos-
metics and foods (for pharma pack-aging no recycled resin permitted).
Energy saving All the above should reduce carbon
print for a sustainable package production.
Facts and fi gures
Approx. 220 employees A multifunctional machine platform
with 52 systems, including Aoki 250, Nissei ASB-70DPW and ASB-150DP, with capacities between 3,000 and 5,000bph. Aoki’s and Nissei’s are both considered to be very versatile and well suited for continuous operation. Both seen as the BMW and Mercedes of this industry, market demand deter-mines which platforms best to use
Between 5,500 and 8,000t/a PET conversion
More than 240 preform moulds. Between 300 and 500 million
containers/a More than 1,200 types of products.
For fast delivery, cost and price consideration: there is always a family of formats from which to select, shapes in different sizes.
More than 100,000 pallets handled annually
Storage space available for more than 20.000 pallets. Average turn around stock every 2 months depending on season
Number of customers: 2,000 Points of sales in 19 European
countries – sales by in-house staff, agents and distributors with licence agreements
Show piece of the clinically clean PET Power production is the clean room area, where currently 10 machines produce for the phar-maceutical industries. After single stage moulding bottles are tightly wrapped with several layers of plastic foils – without manual inter-vention – thus taking care of the delicate fi lling afterwards.
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PET Power’s policies
Asked about PET Power’s policies, Marcel Schröder quotes:
“We are scrupulously open in our approach to single-stage and two-stage technologies. First we monitor the market and listen to the client’s request – then we consider the neces-sary investment to satisfy the demand – then we decide about the machine platform – whether single or two-stage technology is the preferred option.
Certainly, the decision is depend-ent on the volume of bottles to be moulded. In our view the issue should not be handled dogmatically or ideo-logically. The markets of single-stage and two-stage processing commu-nicate with each other, supplement each other.
At times products are developed using single-stage and when they reach higher volumes, they could well be processed in two-stage equipment with small cavitations.
We also know that some products – for edible oil for instance – are well converted in both technologies.”
So far we have confi ned ourselves to an annual volume of 10 million units per product type and stayed with single-stage processing. For our pro-jects so far we have not yet decided in favour of two-stage. But for the future: We would never exclude two-stage processing in principle.”
Fundamentals of company strategy
On basis of the existing single-stage platform - as available for business today and for the fore-seeable future – PET Power has formulated some fundamentals of company strategy:
Operating in Europe only – from Portugal to Russia, from Scandina-via to Italy
Aiming for business up to max. 10 million units per annum
Solid packages/bottles/containers only
Complete packages including labels, sleeves, prints and caps / closure systems, where desired
Subsidiaries to be established – where transport especially of large bottles is a negative cost factor.
Asked about the foreseeable future Marcel Schröder – low key and modest, but also engaged and ambitious:
“Business is very competitive today. PET Power is a decent and respected enterprise within Europe. Our principles in doing business are open communication and fairness to our business partners – clients as well as suppliers. Our slogan “packaging your brand” communicates that we are part of a supply chain. In fi ve years time either we will lead the market or we will be part of a large EU group – as a consequence of consolidation of our single-stage markets.
Here in-house in Etten Leur we are still able to expand. But single-step conversion is geographically a regional business. One needs sub-sidiaries in distant markets. Europe is PET Power’s home selling market. We are currently experimenting in China with some moulds for new product development and small containers. The world is opening up, also within PET Power”.
Bottle range made of preforms of the same size
PET Power .
In forthcoming issues of PETplanet:PART 3: Single stage machinery makers
Nissei
PART 4: Single stage machinery makers:
Aoki Sipa
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PET-Asept D Compact – the aseptic solution from Krones for the low output range*
Krones has developed and fi eld-tested a compact-sized PET aseptic fi ller, for mid-tier companies. Demand on the market is already high, since this provides bottlers with an option for handling even relatively small batches in aseptic mode while retaining viable cost-effi ciency. Aseptic PET fi lling on a com-pactly dimensioned aseptic line facilitates the change-over from carton packages to PET, which is more popular with consumers, or quite generally getting started with PET-fi lling of sensitive beverages without any preservatives.
The option for lightweighting bot-tles by using a nitrogen droppler ren-ders this technology more than equal in terms of cost-effi ciency to the linear machines in the cartoning fi eld. The PET-Asept D Compact technology is based on a line acceptance-tested by the American Food and Drug Admin-istration (FDA). No sterile-water UHT unit is now required to operate it. Containers and isolator are sterilised using gaseous hydrogen peroxide. The machine itself is cleaned using caustic and acid. This means that peracetic acid and foam cleaning products are no longer required on the system. Its small footprint on a mini-mised fl oor area is comparable to that of linear machines.
The output range extends from 6,000 to 12,000 containers/h. The machine can be installed in a stand-alone confi guration or also as a monobloc with a stretch blow-moulder. In the core zone, the machine concept is restricted to an area of 6 x 2m. Here, the containers are passed by a gripper conveyor system fi rst through a pre-warming zone before proceeding to gaseous H2O2 sterilisation and the blow-out section of the steriliser, and fi nally being fi lled and closed. The height-adjustable conveyor is already insulated from the sterile zone, thus enabling minimised change-over times without any handling parts to be achieved.
PET-Asept D Compact is an
authentic aseptic solution for mid-tier
companies.
The containers, closures and the isolator are dry-sterilised using H2O2, thus ensuring container reduction rates for interior decontamination of as much as log 5, and for exterior decontamination of log 4. The H2O2 residue is assured at ≤ 0.5 ppm. Container shrinkage is likewise very low, at ≤ 0.5%. The PET-Asept D Compact can handle containers with heights of 120 to 350mm and diam-eters from 50mm, plus neck fi nishes of 28 to 38mm, as well as fl atcaps and sportscaps as closures. The gentle H2O2 process enables lightweight con-tainers, e.g. 13-to-14g preforms for a 330ml container, to be handled. There is also an option for dosing liquid nitrogen in order to reduce oxygen
Compact and dry
*Based on an article by Roland Laumer, Krones AG, Neutraubling
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Thanks to the dry sterilisation process, no water is consumed during production for bottle and closure decontamination, nor during sterilisation of the product path and the fi ller’s cleanroom. The isolator, hygienically designed in conformity with EHEDG/3A, is fi rst cleaned with caustic, then dried, and fi nally fl ooded with H2O2 gas and decontaminated. Simultaneously, the product paths are cleaned with caustic and then steri-lised in place (SIP)
Minimal product losses
Container sterilisation has been designed as a continuous process, so no switching valves are needed. This reduces the number of components and simplifi es process monitoring. The fi ller’s aseptic fi lling principle provides for the product to come from above out of a rotating central tank with a static inlet, an axial face seal shuts off the gas phase, and the product does not pass through a manifold, all of which combines to minimise product losses. The fi lling valves are steam-able, so no sterile water is required; the media used for CIP cleaning are returned via the isolator.
At the closer, many critical com-ponents like the lifting cam and the
reduction and stabilise the containers. The fi lling system permits the bottling of products containing chunks meas-uring up to 3 x 3 x 3mm (optionally up to 5 x 5 x 5ml).
Product change-overs with-out intermediate fl ushing
In order to avoid breaks in fi lling, the company has developed the fol-lowing procedure: a product change-over can thus take place without any intermediate fl ushing. For this pur-pose, fi lling is continued until the tank runs empty, with a residual quantity remaining in the fi lling valve, which is topped up with the new product, whereupon the mixing phase is fi lled and rejected. This requires about two fi ller rotations, given a fi ller with a pitch circle diameter of 1,080mm and a pitch of 103mm, corresponding to 66 bottles. The new product can then be fi lled, without the isolator being affected by product residues. The elimination of intermediate disinfec-tion ensures optimum availability. This enables long production cycles to be achieved of up to 48h with low-acid products and up to 72h with high-acid products. Availability is also boosted by shortened CIP/SIP times, with less than 3h from the last bottle to the fi rst bottle.
servodrives have been located outside the cleanroom. For closure sterilisation with H2O2, a static chute without any moving parts is used as a steriliser. This makes closure sterilisation afford-able, simple and reliable, and avoids malfunctions on the closure path.
The platform with stairs accom-modates the valve rack, the cen-tral ventilation technology and the H2O2-sterilisable Hepa fi lters. Care has also been taken to ensure good access here to the treatment units. For the ventilation technology, an air route with monitored guidance was set up with supply air from the central zone, featuring infl ow from above and extraction from below. A fi rst refer-ence system for the new PET-Asept D Compact was delivered to a German bottler early in 2011.
Format [ml]
Residues 0.5 ppm
Residues 1 ppm
330 12,000 bph 12,500 bph500 12,000 bph 13,000 bph1,000 10,000 bph 12,000 bph1,500 8,000 bph 9,000 bph2,000 6,000 bph 6,750 bph
PET-Asept D Compact – Maximum out-puts for a pitch of 103mm when bottling still products
www.krones.com
The PET-Asept D Compact’s output range extends from 6,000 to 12,000bph: it can be installed as stand-alone machine or also as a monobloc with a stretch blow-moulder.
sensitiveBEVERAGES
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KHS says that its new-generation Innosept Asbofi ll ABF 611 and Innosept Asbofi ll ABF 711 twin aseptic linear fi llers offer high speed and fl exibility for a range of drinks and liquid phar-maceutical products. The machines can handle both PET and HDPE bottles without conver-sion. The primary target market for the ABF 711 is also carton packaging businesses. It is hoped that the ABF lines will persuade busi-nesses that have up to now used carton pack-aging to change to plastic bottles.
The new Innosept Asbofi ll linear fi llers can process up to 12,000bph. Innosept Asbofi ll ABF 611, the stand-ard model, fi lls 0.1 to 0.75l bottles; the ABF 711 model can fi ll 0.25 to 2.1-l units. In the twin version the 711 can handle 24,000bph. The machines are designed to handle non-carbonated beverages, including milk, yogurt drinks, fruit juices, and fruit juice drinks. KHS says they are suitable for fi lling liquid pharmaceutical products, such as health drinks or products for enteral feeding. The machines’ inte-grated neck handling enables them to process novel designs, such as rectangular and square bottles, and they can fi ll either PET or HDPE bot-tles without conversion. Operators can thus consider diversifi cation of their product range while still using the same equipment.
Bottles and closures are sprayed with a hydrogen peroxide (H2O2) aero-sol in a dry sterilisation process. H2O2 reacts on the surfaces and is then dried by hot air. Whatever the size or shape of the bottles being processed, all surfaces are sprayed evenly. KHS says that the machines need only a very small sterile zone; the area required for the Innosept Asbofi ll ABF 711 – the larger of the two – is 1.5m³ (about 53 cu ft) and the Innosept Asbo-fi ll ABF 611 needs just 0.9m³ (32 cu ft). The bottles are conveyed through all the processing stages in just one holder, eliminating critical mechanical transfers.
KHS launches dual-concept aseptic fi llers
The next generation
F.l..: Bernhard Hinken, Eckes Granini Deutschland GmbH and Thomas Niehr, Director / Competence Centre Aseptic Filling Technology, KHS
F.l.: Paul Winterhoff - Director Con- struc-tion / Competence Centre Aseptic Filling Technology, KHS, Mike Herrmann - Sales KHS Germany, Berthold Burgmeier - Molkerei Gropper GmbH & Co. KG
Filling is by two-stage free-fl ow fi lling valves, which means that bottles never come in contact with the valves themselves. Precise volumetric fi lling is delivered by magnetic inductive fl owmetering. Options include integra-tion of pulp jets into the fi lling valves; and nitrogen fl ushing before the fi lling process and head space nitrogen fl ushing afterwards, which reduces the amount of oxygen remaining in the bottle. Placing of a drop of liquid nitro-gen in the headspace of fi lled plastic bottles is also available as an option – the fi rst time this feature has been offered for linear fi llers. This facility both displaces headspace oxygen and also helps to improve lightweight bot-tles’ stability, which can help achieve savings in materials. All options can be integrated either at installation or subsequently.
Bottles fi lled by the new machines can be sealed with either aluminium seals or plastic screw-on caps. The two distinct processes of placing the caps on the bottles and then screwing them tight are carried out in entirely separate sterile chambers, which removes risks associated with the rotary capping motion.
In anticipation of the forthcom-ing drinktec 2013, the company has announced an extensive update of the higher capacity aseptic rotary fi llers.
www.khs.com
Innosept Asbo-fi ll ABF 711 twin aseptic linear fi ller
sensitiveBEVERAGES
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PETproductsVolumetric fi lling valves
Sipa has developed a new series of volumetric fi lling valves: Isotronic SC for carbonated products and Uni-tronic SC for still products. These valves are designed to replace versions already present in the range. The aim was to achieve higher quality and levels of effi ciency, while maintaining the key features of the previous generation. Both valves can modulate the fi lling speed to better suit the characteristics of the individual liquid product, avoiding tur-bulence, foaming and absorption of air into the product.
The valves are characterised by high dosing precision, thanks to the use of magnetic fl ow meters. The valves can be equipped with additional elements allowing hot fi ll applications with re-circulation or with Ultra Clean. Special features allow the treatment of different bottle and neck sizes with reduced change-over times. All valves are made in stainless steel 316L and are solid and compact.
There is a clear separation between the pneumatic parts and the parts in contact with the fi lling product, in order to avoid any problem with contamination. Each prod-uct/bottle size can be selected directly from the operator touch screen control panel.
Electronic and pneumatic components are located in a box directly over the fi lling valve. The box is air-conditioned by a “vortex” system. Isotronic SC, the isobaric volumet-ric and electronic fi lling valve version, is suitable for fi lling liquids with or without gas into PET bottles. It is particularly suitable for fi lling liquids characterized by good conductiv-ity, such as soft drinks, water and clear fruit juices. The bot-tles are held by the neck ring, no height adjustment of the machine is required and bottle sealing is guaranteed by a short stroke bottle lifter.
Unitronic SC is the gravitational volumetric and elec-tronic fi lling valve version, suitable for fi lling non carbon-ated conductive products like still water, juice, tea, energy drinks and milk in PET bottles. There is no contact between the valve and the bottle. Thanks to this feature, this version in particularly suitable for ultra clean solutions. Valves are very simple, product chambers do not come into contact with a single pneumatic part. The sealing is guaranteed by a pneumatic rise of the bottle lifter.
www.sipa.com
Integrated solution for dairy products and liquid food
Italian company SMI, which has over 4,000 end-of-line packaging solutions and rotary stretch-blowmoulders for PET/PP containers installed worldwide, has launched a new, integrated solution branded as the EcoBloc Plus series. The machines feature integrated stretch-blowing, fi lling/capping and labelling of PET containers ranging from 200ml to 3l. the EcoBloc series, which does not have an integrated labeller, can handle containers with up to 10l capacity.
EcoBloc and EcoBloc Plus systems are both suit-able for bottling lines of milk, edible oil, still and carbon-ated drinks. They have been designed to be compact and feature technologies for synchronisation between the dry environment of the stretch-blowing module and the wet environment of the fi lling/capping module. The direct con-nection between the machine modules by means of trans-fer wheels reduces the number of machines installed and eliminates the need for a rinser, for accumulation convey-ors and for conveyors between the blower, the fi ller/capper and the labeller.
EcoBloc Plus systems are equipped with air recovery, which is claimed to provide up to 40% saving on air con-sumption. The area beneath the bottles is completely clear, which eases operator access for maintenance and cleaning operations. Electronic fi lling on EcoBloc Plus prevents any contact between the bottle and the fi lling valve, thus reduc-ing moving mechanical parts. SMI says that the machines offer low cost of ownership and production capacities of up to 30,000bph.
www.smigroup.it
Bericap completes its range of one-piece closures for hotfi ll
Bericap has been offering one-piece closures for hotfi ll applications since it launched its 38mm and 28mm clo-sures on the Chinese market in 2003. These closures are now also in use in India, Russia, Central Asia and the Middle East. The company recently announced that Egyp-tian company Juhanya is now using Bericap closures for its hot-fi lled products, including Tingo juices. The company has now extended its hotfi ll closure offer with the launch of a 33mm closure, which features reduced wall thickness. Bericap is seeking to introduce thinner walls to 28mm and 38mm closures, also. Future hotfl ll applications with 28mm closures will, in future, use the same closures as CSD. All Bericap closures for hotfi ll are equipped with the compa-ny’s DoubleSeal system.
www.bericap.com
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Chinaplas 2011 – Bigger than everThis year was the 25th Chinaplas jubilee and more than 2,200 exhibitors from around the world presented their products under the theme “Green Plastics – Our Goal – Our Future” to made efforts to promote environmental friendly technologies, recyclable plastics and bioplastics. It was the largest show scale ever with 21 exhibition halls and a total exhibition area reaching 180.000m². Conferences and more than 40 technical seminars accompanied the show. 94,084 visitors (thereof 20.3% from overseas) visited the 4-day exhibition.
It is estimated that in 2010 the Chinese plastics industry consisted of 95,000 companies which produced more than 58 million tons of plastic products, an impressive average annual growth of 20%. Herewith also the plastics machinery sector experienced strong growth and produced 300,000 sets of machines with a total value of RMB 42 billion (€ 4.5 billion), thereof RMB 6 billion (€ 650 million) for export. China-made plastic machinery keeps its share of around 80% in the domestic market.
The PET activities of the exhibitors were mainly focused on PET recycling and PET preform production. Leading PET machinery suppliers such as Husky or Sidel were not present. While some local Chinese companies wanted to show how much they have advanced in the fields of preform injec-
tion moulding machines and moulds others have simply focused to offer the lowest possible price. One of the local Chinese companies for instance stated that a complete 5 gallon PET bottle production line (from preform manufac-turing to bottle manufacturing) would only cost about USD 52,000 –58,000.
The finishing of the displayed moulds and machines was from rather modest to pretty good. Some local Chi-nese companies claim that they can produce up to 96 cavities and use highest-quality steel such as S420 mate-rial (Sweden ASSAB) for their moulds. However, highly polished moulds with “Please No Pictures” signs attached are no indication for good performance in the production environment.
Extended range of clamping-forces with hybrid drive
At the Chinaplas 2011 the hybrid version of Netstal’s Elion range was represented by a model with 2800 kN clamping force. This Elion 2800-2000 machine uses a 96-cavity mould of the Swiss mouldmaker Corvaglia and an HDPE of Ineos to mould light closing caps. It is said that with the new models Elion 2200-2000 and Elion 2800-2000 it is possible to achieve energy savings of up to 30% compared with conventional drives. Production at the show took place at a cycle of less than 2.5s. Directly after mould-ing all parts passed through a visual inspection station for quality control purposes. This inspection system was from the German Intravis company and the raw material feeding devices from the company Piovan.
www.netstal.com
Light closing caps produced on a Elion 2800-2000 machine
Preform equipment from local suppliersSeveral local companies also presented their injection
moulding machines for PET preforms. Haitian Plastics Machinery (www.haitian.com), the worldwide largest manufacturer of injection moulding machines, has no dedicated PET machine in its product range. But the com-pany stated, that there are several customers in China and overseas that are using Haitian “standard” machines for PET preforms.
Chen Hsong Group (www.chenhsong.com.hk), the number two injection moulding machinery manufacturer in China, has a special PET machine. The so-called Chen-PET is a complete preform system (injection moulding machine, hot-runner system, mould and robot) which is able to work with moulds up to 72 cavities and a maxi-mum output of up to 16,000 preforms per hour, accord-ing to the company. However, this machine was not on display this time.
One of the most pro-active PET preform approaches was done by the Chinese company Yizumi Precision Machinery (www.yizumi-group.com.hk) who displayed a servo-driven high-speed PET preform injection moulding machine. According to the company the largest machine is able to hold 96 cavities moulds. Unique is the dual-screw design and synchronous plasticizing unit which is used to achieve higher plasticizing capacity. Yizumi can offer turnkey, i.e. injection moulding machine, moulds and robots and has a special focus on markets outside China: the company just purchased the intellectual property of bankrupt American plastics machinery maker HPM and is moving ahead with plans for a service operation for HPM machines and for a technical centre in the USA.
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4-colour offset printing machine for closures
The company Wutung Holding Co., Ltd. (Hongkong) has exhibited its high-speed 4-colour automatic offset print-ing machine WT-3025 for closures.The automatic feeding system is made of aluminium and stainless steel, the condi-tions of the feeding tracks are monitored with sensors. Any dust on the caps surfaces is removed by means ofstatic bars before printing. The heart of the machine is two sets of colour offset printing heads equipped with magnetic print rollers. Each print head can be individually adjusted to dif-ferent directions. In order to have a better shining effect on the cap surface, a varnishing unit with anilox rollers is employed. The caps are automatically unloaded, with counting and placing them into the carton system. The whole printing system can be operated via a user-friendly touch screen display. The WT-3025 is suitable for the caps sizes 28-38mm, with a maximum printing area of 34mm and a capacity 90,000 pcs/h. Smaller units with less capac-ity are also available.
www.wutung.com.hk
KraussMaffei and Netstal subsidiaries to merge in China
In parallel with the merger in Brazil, the KraussMaffei Group is also bundling its activities in China. In the future a single subsidiary will market the products of all three brands, namely KraussMaffei, KraussMaffei Berstorff and Netstal. The new KraussMaffei Group subsidiary in China merges two existing Chinese subsidiaries into Shanghai KraussMaffei Machinery Co. Ltd., located in Shanghai. It started operating on July 1, 2011. Managing Director of the new, larger subsidiary in China is Harald Schweitzer. Each brand will continue to operate independently in the market.
www.kraussmaffei.com
Organoleptic HDPE grade for caps and closures
Organoleptic properties are important requirement for materials used in water packaging as they ensure the high quality of the water. Sabic HDPE CC862 injection mould-ing grade is targeting the Caps & Closures (C&C) segment for qualitative still water packaging with high demands on organo-leptic properties. This grade counts with the approval of triangular test NF V09-013 and has several key advantages that include being odourless, tasteless, easy to process with good mechanical proper-ties, ESCR and high impact strength. During manufactur-ing, the process ensures no contamination with any foreign materials which makes Sabic HDPE CC862 suited for caps used in the packaging of still water.
www.sabic.com
PETbottles
36 PETplanet insider Vol. 12 No. 07+08/11 www.petpla.net
Original cocktail Under its own ”Rioba“ label Metro Cash &
Carry is marketing a range of alcoholic cock-tails in specially designed 0.2l PET bottles. The round-bellied bottle is decorated with a silver-coloured shrink sleeve label and sealed with a black aluminium screw cap with a tear-off tamper-evident guarantee. The product supplier is MCC Trading Deutschland GmbH of Düsseldorf.
www.metro24.de
A taste of wine The French company Chamarré based in Paris is
marketing red wine from Bordeaux in a 0.75l PET bottle. At fi rst sight the dark bottle featuring an indented base and resembling glass is not readily identifi able as a PET bottle. It is fi tted with a screw cap, the surface area of which is extended downwards so as to form a type of collar and labelled in the same way as a conventional wine bottle. A sticker affi xed to the top serves as a tamper-proof guaran-tee; this splits when the cap is screwed open, thus provid-ing a reliable indication that this is the fi rst time the bottle has been opened.
www.chammare.com
Naturally cloudy The Jacoby Kellerei in Auggen, Germany is mar-
keting its naturally cloudy apple juice under the brand name of “Schwarzwaldhof“ in a 1l PET bottle. The somewhat squat moulded bottle sports informative labels both at the neck and at the base and is fi tted with a large 32mm diameter opening for dispensing the contents. The colour-matched plastic screw clo-sure is equipped with a tear-off tamper proof seal.
www.schwarzwaldhof.de
Juicy quality 250ml orange juice, brand name “Sunny Delight“,
is available in France in a 250ml PET bottle. The small, handy bottle features an easy to peel-off all-round fi lm label and a screw cap which is large by comparison with the container format, having a diameter of 32mm and an integral tamper-proof seal. Stabilising crosswise elements in the base and central section are of con-siderable help in ensuring that the bottle is safe when placed in the upright position and in providing assur-ance of stability.
www.sunnydelight.fr
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Juice drink for childrenCzech drinks company Mattoni has
recently launched a new juice drink for chil-dren, named Aquila Bimboo Frutta, which is available in three fl avours and was developed in cooperation with Czech paediatricians. Labelling on the 33cl PET bottle features popular movie characters such as Shrek and Captain Jack Sparrow. The high-fruit drink has no added sugars and is fi lled on a Krones aseptic fi lling line. The package is completed with a standard Original 30/25 sport cap from Aptar. Mattoni has a long-standing relationship with Aptar and has been using the 28mm Original sport cap on its leading brands for several years.
www.mattoni.cz www.aptar.com
Fine food German retail giant Metro is selling milk in
a one litre PET bottle under its own premium label, Fine Food. The tall, easy grip bottles have a shrink sleeve label with a nature-orientated design and a 32mm screw cap with tamper-proof seal. The shelf life of the low-fat UHT milk and UHT full-cream milk is six months if kept in cold storage.
www.metrofi nefoods.com
Slimming without tears750ml sugar-free fruit drink for slimmers is being
marketed by the French company Juvaligne of Paris in a distinctively shaped, red PET bottle. The waisted bottle features front and rear labels adapted to suit the shape and a screw cap with tear-off tamper-proof seal. Its bright red, strident colour and its waisted shape ensure that it stands out at the POS.
www.juvaligne.com
Lightweight hotfi ll bottle in SE AsiaPT Ultra Prima Plast, a manufacturer of VC shrink fi lm and
injection-moulded products in Jakarta, Indonesia, has entered the growing PET packaging business in SE Asia with a new lightweight 500ml bottle, which is being used for FitActive, a house brand for distribution in supermarkets and local retail stores in Jakarta. The new product is intended to satisfy demand for affordable, quality packaging for new dairy-based nutritional drinks with real fruit juice, delivering quality packaging and reducing waste. The company worked with Sidel to develop a customised solution. The project’s aim was for a 20% weight reduction and savings on manufacturing costs. Sidel conducted design and feasibility testing at its Packaging & Tooling Center (PTC) in Shanghai and developed a 22.5g 500ml square-section hotfi ll PET bottle with a fi lling temperature of 89°C. Good high-temperature and mechanical performance is delivered by special panels.
www.sidel.com
PETbottles
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Personal Care
Total care out of a bottle The German marketing partner for
Listerine anti-bacterial mouth rinse, Messrs. McNeil Consumer Health-care based at Neuss in Germany, has recently launched its latest creation – 6 in 1 Protection “Total Care” in the typical 0.5l PET bottle. According to the manufacturer, Total Care reduces dental plaque, strengthens the teeth, keeps gums healthy, stops calculus from reforming, ensures fresh breath and effectively combats harmful bacte-ria. The product, which has a slight dark red colour, is packaged in a transparent bottle and a high gloss, metallised front label enhances the impression of a qual-ity rinse as well as superior packaging. The screw cap, which is childproof, also acts as a dispensing unit and is secured by means of a printed shrink label.
www.listerine.de
Mickey mouse fragrance for the bath
Spanish company Air-Val Interna-tional based in Gava has enlisted the help of the licensed character “Mickey Mouse” to assist with marketing its 750ml fragrance “Colonia Splash Colo-nia“ in an attractively designed PET bottle. The front of the bottle sports a coloured, “non-label look” label, whilst colour printing on the inside of the rear label gives it an original appearance, attractive to children, that catches the eye at the POS. The fi nishing touch to the packaging is a snap-on lid, locked when in the open position, that can be operated using one hand only.
www.air-val.com
Body oil 150 ml gentle body oil with sea
buckthorn and wild rose oil is being marketed by Berlin Cosmetics under the brand name “Indra Natural Cos-metics“ in an appropriately designed PET bottle. The bottle is decorated with front and rear labels adapted to its shape; the colour of the body oil is tinged with blue and the fi nal crowning touch to the packaging is a screw-on, green hinged lid.
www.berlin-cosmetics.de
Soap bubble bath 200 ml soap bubble bath, the fi rst chil-
dren’s bath product that can also be used to blow soap bubbles, is being marketed by Messrs. Hipp from Pfaffenhofen/Germany in a transparent PET bottle. On the front the bottle sports a transparent, “non-label look” label giving a clear view of the screw-in bubble blowing wand which is combined with the dispensing beaker. This ph-neutral skin care bath has no mineral oils, is soap-free and particularly gentle on the eyes.
www.hipp.de
Equine ointment Dr. Jacoby Vital GmbH based in
Lahnau, Germany are marketing, under the brand name of “Apothekers Original“ a 250ml sports gel equine ointment in a PET bottle for relaxing the whole of the muscu-lature. The packaging features an informa-tive non-label-look label and a screw-on push-pull mechanism for ease of applica-tion prior to massage.
www.pferdesalbe.com
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IN EVERY BOTTLETHERE IS ALL OUR
KNOW HOW.
RESEARCH& DEVELOPMENT A constant projection towards the future oriented to search not only for new materials but also new PET technologies of transformation and innovative materials.
CONSULTANCYA concrete answer to all your questions. We put at your disposal all our know-how for every single requirement.
PROTOTYPATIONPrototypes of containers and innovative preforms in record times: you will be able to touch with your hands the bottles within a short time after approval of the design.
DESIGNCreativity in search of elegance and refinement. Innovative designs, ergonomic structures, eye-catching and functional containers. We give a true shape to your product!
Shower gel The cosmetics manufacturer Beiers-
dorf of Hamburg is marketing the “Nivea” brand shower gel ”Sensitive Balance“, 250 ml, in a transparent PET bottle. The packaging features a ’non-label look’ label on the front and, at the back, a white plastic label that emphasises the prod-uct’s transparency at the POS. A snap-on, two-colour lid which is locked in place in its open position to enable the contents to be dispensed more easily, puts the fi nish-ing touches to this attractive cosmetics packaging.
www.nivea.com
Baby’s fi rst body oilThe Germany company,
Bübchen-Werk Ewald Hermes based in Soest is marketing its sensitive body oil, which is free of any perfume or preservatives, under the brand name of “Büb-chen“ in a transparent 150ml PET bottle. The packaging includes informative front and rear labels and the company cites a positive classifi cation in an eco-test by way of an additional incentive to purchase. The colour-matched, snap-on hinged lid remains stable in the open position and is combined with a self-closing silicon valve.
www.buebchen.de
Nievina gel fresh The Spanish company, Lab Vigmar, based
in Real de Montroy, is marketing 250ml gel fresh in a transparent PET bottle under the brand name ”Nievina“. The product has a light blue hue and the packaging features printed “non-label look” labels to front and rear. A clear, screw-on hinged cap which can be relied upon to stay in place in the open posi-tion, puts the fi nishing touches to the product’s appearance. The company markets many kinds of cosmetics articles under the brand
name “Nievina“, which is very similar to a well known German brand name article (Nivea).
www.cosmeticosvigmar.com
Green tea bath salts1.3kg of green bath salts with green tea
additives by way of active ingredient are being marketed in a transparent, round PET jar by the French company Laboratoires Sarbec based at Neuville en Ferrain. The paper label encircling the jar contains information in a number of languages. The shape and appear-ance of the plastic screw cap are based on a twist-off metal screw cap.
www.corinedefarme.com
PETpatents
www.verpackungspatente.de
40 PETplanet insider Vol. 12 No. 07+08/11 www.petpla.net
Plastic bottle European Grant of Patent No. EP 2049405 B1Applicant: Sidel Participations, Octeville-sur-mer (FR) Application Date: 13.7.2007
A European patent has been granted for this process for manufacturing a plastic bottle with this particular shape base.
Spray optimisationInternational Patent No. WO 2010 / 131066 A2Applicant: Stormes Cuuvene Ltd., St. Peter Port (GB) Application Date: 15.5.2009
A pump sprayer is fi tted with at least two riser tubes which guarantee prod-uct delivery regardless of position and permit optimum removal of residual quantities when the container is empty-ing. Depending on the requirement the “correct“ tube will be enabled.
Pouch bottle European Grant of Patent No. EP 2050677 B1Applicant: Krones AG, Neutraubling (D) Application Date: 1.10.2008
The European Grant of Patent describes a bottle preferably featuring a wall thick-ness of less than 0.05mm and having a specifi c volume relative to the grip area. The procedure used for its manufacture is also illustrated.
Tamper-evident closure Disclosure No. DE 102009019362 A1Applicant: Krones AG, Neutraubling (D) Application Date: 29.4.2009 In the interests of making the tamper-evident closure on a bottle cap even better and/or more readily identifi able a proposal has been put forward to fi t a seal between the cap and the bottle which will be destroyed on opening the cap.
Bottle for hot fi lling International Patent No. WO 2010 / 129402 A1Applicant: Ball Corp., Broomfi eld (US) Application Date: 30.4.2010
Thin-walled PET bottle for hot fi ll applications. The shape of the bottle prevents any “oval” deformation of the container during cooling.
Moulded bottle International Patent No. WO 2010 / 126829 A1Applicant: Johnson & Johnson Consumer Comp. Inc. Skillman (US) Application Date: 26.4.2010
So as to suggest a usage to the consumer or to remind him of something, this plastic bottle is fi tted with a neck similar to a “baby bracelet“, including the associated haptics.
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Buyer’sguide1.0 MATERIALS
1.1 Materials for bottle and cap production
1.1.9 Additives and colorants
Americhem Europe LtdCustom colour and additive
masterbatches
Pierre Vandekerckhove
Tel.: +44 782 541 9086
www.americhem.com
Clariant Masterbatches
(Italia) S.p.A.
Via Lainate, 26
20010 Pogliano Milanese (MI)
Italy
Tel +39.02.9918.7558
Fax +39.02.9918.7552
http://mb.clariant.it
Advanced Colorants and Additives COLORMATRIX EUROPE LTD.
Knowsley Business Park,
Knowsley, Merseyside.
L34 9GT. UK
Tel: 0044-151 632-8800
www.colormatrix.com
GABRIEL-CHEMIE Gesellschaft m.b.H. (Zentrale)Industriestrasse 1
A-2352 Gumpoldskirchen
Tel.: +43 (0)2252 / 63 630-0
Fax: +43 (0)2252 / 62 725-0
e-mail: [email protected]
www.gabriel-chemie.com
TM
M.P.I. Srl Moulds Plus International
15050 Villalvernia (AL) – Italy
Tel. 0039 0131 836136
www.ultrapurge.com
Liquid colours and additives
REPI S.p.A.
Via B. Franklin 2
21050 LONATE CEPPINO VA
ITALY
tel. +39 0331 819511
fax +39 0331 819581
www.repi.it
1.2 Packaging components and accessories
1.2.1 Preforms
Gastro PET d.o.o.
Kotna ulica 5
SI-3000 Celje
Tel: +386 (0)3 425 80 30
Fax: +386 (0)3 425 80 31
www.gastropet.si
PET PREFORMS AND CLOSURES
INTERGULF LTD. (EMPOL)
KHALID SEAPORT
P.O.BOX 6131,
SHARJAH, U.A.E.
Tel. 009716 502 9244 / 9246
Fax. 009716 528 5720
www.empol.com
PDG PLASTIQUESF-45330 Malesherbes - France
Tel. 00 33 2 38 34 61 95
www.pdg-plastiques.com
PET PreformPlastic cap and closureRue de la plaine
47230 Lavardac - France
Tel.: +33 (0)5 53 97 41 00
Fax: +33 (0)5 53 65 85 97
www.sbecm.com
Preform manufacturer3 Rue de l’île Macé44 412 REZE FranceTel: + 33 (0)2 40 05 09 37Fax: + 33 (0)2 51 70 00 [email protected]
1.2.4 Caps and Closures
Creative Dispensing Solutions
Seaquist Closures Löffl er GmbH
D94078 FREYUNG
Tel: + 49 8551 975 234
Fax: + 49 8551 975 180
www.aptar.com
BERICAP GmbH & Co. KG
Kirchstr. 5
D - 55257 Budenheim
Germany
Tel. +49 (6139) 2902 0
Fax +49 (6139) 2902 181
www.bericap.com
www.corvaglia.ch
Has Plastik San. Tic. A.S.
Esenyurt Fabrikalar yolu No: 50
34325 Avcilar
Istanbul, Turkey
Tel +90 212 695 50 00
Fax +90 212 694 97 24
www.hasplastik.com
Georg Menshen GmbH & Co. KG
Industriestraße 26
D-57413 Finnentrop
Tel.: +49-2721-518 0
Fax: +49-2721-518 198
www.menshen.com
2.0 MACHINES AND EQUIPMENT
Bulk conveying and storage specialists for Preform, Closures and Bottles. Bottle and Closure Silos
Totes
Bulk Conveyors
Pneumatic Conveyors
Complete Turn Key Automation
www.teceng.net
Tel.: +52 449 971 06 53
2.1 Preform production(machines and equipment)
Idsteiner Strasse 74
D-65527 Niedernhausen,
Germany
Tel. +49 6127 8954 + 8850
Fax +49 6127 78189
www.cct-gmbh.com
PREFORM and CAP Production
Hong Kong
Tel: 852-2665 3888
Fax: 852-2664 8202
www.chenhsong.com.hk
2.1.1 Injection moulding machines
Ferromatik Milacron India Pvt. Ltd.
93/2 & 94/1, Phase - I, GIDC Vatva,
Ahmedabad - 382 445, Gujarat,
India
Tel: +91-79-25890081
www.milacronindia.com
42 PETplanet insider Vol. 12 No. 07+08/11 www.petpla.net
Buyer’sguide Entries from 5,70 Euro/mm, Call +49-6221-65108-0
NETSTAL-MASCHINEN AG
Tschachenstraße
8752 Naefels, Switzerland
Tel. 0041-55-618-6111
Fax 0041-55-618-6605
www.netstal.com
2.2 Bottle production(machines and equipment)
Nissei ASB Machine Co., Ltd.4586-3 Koo, Komoro-shi, Nagano-ken 384-8585, JapanTel. 0081-267-23-1565Fax [email protected]
Bottle-Top Development Co., No. 143-1, Renhe Rd., Nantou
City, Taiwan 540
Tel: +886-49-2258335
www.bottop.com
KHS Corpoplast GmbH
Meiendorfer Str. 203
22145 Hamburg
Deutschland
T +49 40 67907-0
F +49 40 67907-100
E-Mail: [email protected]
www.khscorpoplast.com
Norgren AG
Ventilfabrik
Postfach
8362 Balterswil, Switzerland
Tel +41 71 973 83 00
Fax +41 71 973 83 01
www.norgren.com/sbm
Eugen Seitz AG Spitalstrasse 204
8623 Wetzikon, Switzerland
phone: +41 44 931 80 80
fax: +41 44 931 80 90
www.seitz.ch
SIPA S.p.Avia Caduti del Lavoro,3
31029 Vittorio Veneto, Italy
Tel. +390438911511
Fax +390438912273
www.sipa.it
SMI S.p.A.Via Piazzalunga, 30
I-24015 S. Giovanni Bianco (BG)
Tel. +39 0345-40111
Fax +39 0345-40209
www.smigroup.it
Compressed air savingsystem for PET blowers.
www.technoplan.info
Your partner for improvement and
innovation for the P.E.T. industry
Krones®, Sidel®, KHS®, SIPA®, others
Wide diversifi ed inventory available
www.umallette.com
2.2.1 Single stage stretch blow moulding equipment
2.2.2 Two stage stretch blow moulding equipment
Amsler Equipment Inc.Swiss Engineered - Canadian Built 1245 Reid St, Toronto,
Canada L4B1G4
Phone 905 707 6704
www.amslerequipment.net
No. 688-1, Zhong-shan road,
Sec. 3, Wuri, Taichung,
414, Taiwan
Tel: 886-4-23388289
Fax: 886-4-23380219
www.chumpower.com
MAG-PLASTIC MACHINERY S.A.
Rue Alfred-Pot 1
P.O. Box 140
CH - 1896 - Vouvry (VS)
Switzerland
Tel. 0041-24-4820-820
Fax 0041-24-4820-819
www.magplastic.com
Stretch Blow Molding Machines,
Preform Molds & Cap molds
Tel.: +86-576-84066853
Fax: +86-576-84020107
www.MegaMachinery.com
www.petkamold.com
PETTechnologies Europe
PET Technologies Europe GmbH
Austria
Tel.: +43-720-555300
www.pet-eu.com
SIAPI S.r.l.
Via Ferrovia Nord, 45
31020 San Vendemiano (TV), Italy
Tel: +39 0438 4096
Fax: +39 0438 401016
[email protected] www.siapi.it
UROLA S.C.
20230 Legaz pi, Spain
Tel. + 34 943 737003
Fax + 34 943 730926
www.urola.com
2.2.3 Coating systems
KHS Plasmax GmbH
Meiendorfer Str. 203
22145 Hamburg
Deutschland
T +49 40 67907-364
F +49 40 67907-353
E-Mail: [email protected]
www.khsplasmax.com
2.2.4 Compressors
ARIZAGA BASTARRICA Y CIA, S.A.www.abc-compressors.com
AEROFLON ENGINEERS PRIVATE LIMITEDTel: +917926589712
+919824049737
info@aerofl on.com
www.aerofl on.com
PETplanet insider Vol. 12 No. 07+08/11 www.petpla.net
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www.atlascopco.com/petcompressors
Oil free compressors for PET bottle blowing
Gardner Denver Ltd.
Claybrook Drive, Redditch,
Worcestershire, B98 0DS, England
Tel: + 44 (0) 1527 838600
Fax: +44 (0) 1527 838630
www.gardnerdenverproducts.com
LMF GmbH & Co. KG
Suedbahnstraße 28,
A-2544 Leobersdorf, Austria
Tel: +43 2256 9001-0
Fax: +43 2256 9002
E-mail: [email protected]
www.LMF.at
SIAD Macchine Impianti S.p.A.Via Canovine, 2/4
24126 Bergamo, Italy
Tel. +39 035 327611
Fax +39 035 316131
www.siadmi.com
2.2.5 Heating boxes for blow molding machines
2.2.8 Unscramblers
Unscramblers, Silos and Air
Conveyors for empty plastic bottles
www.posimat.com
2.3 Cap production(machines and equipment)
BMB SpAVia Enrico Roselli 12
25125 Brescia (BS) - Italy
Tel.: 0039 030 2689 811
Fax: 0039 030 2689 880
www.bmb-spa.com
www.cct-gmbh.com
www.imdvista.ch
www.intravis.de
NETSTAL-MASCHINEN AG
Tschachenstraße
8752 Naefels, Switzerland
Tel. 0041-55-618-6111
Fax 0041-55-618-6605
www.netstal.com
www.packsysglobal.com
SACMI IMOLA
Via Selice Prov. le 17/a
40026 Imola BO, Italy
Tel. 0039-0542-607-111
Fax 0039-0542-642-354
www.sacmi.com
2.3.2 compression moulding machines
2.3.4 Printing equipment
TAMPOPRINT® AGLingwiesenstrasse 170825 Münchingen, Germany Tel.: +49 7150 928-0Fax: +49 7150 [email protected] www.tampoprint.de
2.4 Crate production(machines and equipment)
Werner Koch
Maschinentechnik GmbH
Industriestraße 3
75228 Ispringen / Pforzheim
Tel.: +49 72 31/80 09 0
Fax: +49 72 31/80 09 60
E-Mail: [email protected]
www.koch-technik.com
2.5 Ancillary equipment for the production of preforms, caps and crates
Material Drying and
Mould Dehumidifi cation
Eisbär Trockentechnik GmbH.
A-6840 Götzis
Tel.Nr. 0043 5523 55558 0
[email protected] www.eisbaer.at
Green Box S.r.l.Cooling systems - cap coolers - mould dehumidifi ersTel. +39 049 9703319Fax. +39 049 [email protected]
MANN+HUMMEL ProTec [email protected]
www.mh-protec.com
Moretto S.p.A. Tel. +39 049 9396 711
www.moretto.com
motan-colortronic gmbhOtto-Hahn-Straße 14
61381 Friedrichsdorf
Tel.: +49 6175 792 167,
Fax +49 6175 792 284
www.motan-colortronic.com
Tel. +39 041 57 99 111
www.piovan.com
2.5.3 Dryers
200 West Kensinger Drive
Cranberry Township, PA 16066, USA
Tel.: +1-724-584-5500
www.conairgroup.com
3.0 SUPPLIERS FOR STRETCH BLOW MOULDS AND PREFORM MOULDS
Molds, Change Parts, SBM and
Injection Molding Machinery for
the PET/Bioplastics Industries
284 Pinebush Road
Cambridge Ontario
Canada N1T 1Z6
Tel: 001-519-624-9720
Fax: 001-519-624-9721
www.hallink.com
44 PETplanet insider Vol. 12 No. 07+08/11 www.petpla.net
Buyer’sguide Entries from 5,70 Euro/mm, Call +49-6221-65108-0
3.1 Preform moulds
www.wtbvc.com
Preform Moulds, Components,
Refurbishments and Conversions.
Highest Quality, Fastest Delivery,
Lowest Cost.
United States - 937-898-8460
Poland - 48-17-860-1020
UK - 44-1623-658-416
Argentina - 54-11-4753-1111
PET Preform and Blow Molds for Different Application
Guang Dong Xing Lian Precise Machinery Co., Ltd.Baoshi Rd, Xiabei, Pingzhou,
Nanhai, Foshan, Guangdong, China
Tel: (86-757) 8677 7168
Fax:(86-757) 8623 3168
E-mail: [email protected]
Website: www.gdxl.com
HuayanHuayan PET Preform Injection Molding Systems Guangzhou, China
Manufacturer of High Precision
High Performance PET Preform
Injection Molds and Machines;
Tel. +86 20 8226 6148 ext. 8215
Email: [email protected]
Website: www.gzhuayan.com
Single & Two Stage PET Molds
33-4, Wonmi-Dong, Wonmi-GuBucheon City, Kyunggi-DoKorea 420-110Tel.: [email protected]. ksmold.com
Production of blow moulds and PET mould partstel.: +359 32 606 821
fax: +359 32 606 888
offi [email protected]
www.itd.bg
KHS Corpoplast GmbH
Meiendorfer Str. 203
22145 Hamburg
Deutschland
T +49 40 67907-0
F +49 40 67907-100
E-Mail: [email protected]
www.khscorpoplast.com
Specialist for PET Preform Injection Mold, Injection Stretch Blow Mold & PET Blow Moldwww.moltechkorea.com
Tel : + 82-11-224-1571 /
+ 82-32-684-0153
Fax: + 82-32-684-0139
for North American market
for International market
No.1517, Sec.8, Huanjhong Rd, Wurih
Township, Taichung 414, Taiwan
Tel: +886-4-2335-9689
www.passcard.com.tw
via Caduti del Lavoro,3
31029 Vittorio Veneto, Italy
Tel. +390438911511
Fax +390438912273
www.pmci-solutions.com
R&D -Integrated Solutions In PlasticsLeverage - Integrated Industrial DesignHamilton Road
Sutton-in-Ashfi eld
Nottinghamshire, NG17 5LD
England
Tel: +44 1623 556287
Fax: +44 1623 552240
www.rdleverage.com
1009 SE Browning Avenue
Lee’s Summit, Missouri
MO. 64081, USA
Tel: +1 816 525 0353
Fax: +1 816 524 5068
www.rdleverage.com
PREFORM MOULDS / STRETCH BLOW MOULDS Tel: 0039 071 7500214
Fax: 0039 071 7501958
[email protected] · www.simexitaly.it
TOOLING PREFORM
SYSTEMS BV
Moulds & Robotics
PET-related Services
& Technologies
C. Houtmanstraat 42
Emmen, The Netherlands
Tel +31 (0) 591 679768
Fax +31 (0) 591 630616
[email protected] · www.tps.nl
www.wtbvc.com
Blow Molds for All Technologies,
All Machine Types, All Sizes.
Highest Quality, Fastest Delivery,
Lowest Cost.
Canada - 905-574-0010
Poland - 48-81-820-5730
UK - 44-1623-658-416
China - 86-137-646-05384
Argentina - 54-11-4753-1111
Mold-Masters Europa GmbH
Postfach/P.O. Box 19 01 45
76503 Baden-Baden, Germany
Neumattring 1
Tel: +49 7221 50990
Fax: +49 7221 53093
www.moldmasters.com
MHT MOLD & HOTRUNNER
TECHNOLOGY AG
www.mht-ag.de
Otto Hofstetter AG
Zürcherstrasse 73
8730 Uznach, Switzerland
Tel. +41 55 285 22 11
Fax +41 55 285 22 44
www.otto-hofstetter.com
www.petkamold.com
Single Step ISBM Moulds, Reheat Blow MouldsPreform Moulds - Hot & Cold HalfPet Moulds Pvt Ltd, India
+91 9884390999, 9884390666
www.petmoulds.com
50 Galaxy Blvd. #13
Toronto, Ontario
M9W 4Y5, CANADA
P- (+1) 416 213 9400
F- (+1) 416 213 9379
www.rnaprecision.com
PETplanet insider Vol. 12 No. 07+08/11 www.petpla.net
BU
YER
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www.sidel.com
PET Packaging design and development, blow molding equipment and molds
North America+1 678 221 3000
Central America+52 33 3952 0324
Latin America+55 11 4668 7000
Western Europe, Northern Europe, Africa+33 232 858 798
Eastern Europe, CIS, Middle East+43 1 370 1661 105
Asia+86 21 5048 4088
Mumbai, India
PET Container Blowing Technology
System compliance: ISO.9001:2008
www.techno-pet.com
3.3 Cap moulds
www.cantoni.biz
www.corvaglia.ch
Erwes Reifenberg GmbH & Co KG
High Precision Mould Maker
www.erwes-reifenberg.de
z-werkzeugbau-gmbh
Hoechster Strasse 8
6850 Dornbirn, Austria
Tel. 0043-5572-7272-720
Fax 0043-5572-7272-8620
offi [email protected]
www.z-moulds.com
3.6 Mould Cleaning
3.7.3 Hot runner systems and controllers
4.0 FILLING / BOTTLING
Blow molding, Filling,Packaging equipment
Tech-Long, Guangzhou, China
Tel: +86-20-62956881
Fax: +86-20-82266913
www.tech-long.com
SIPA S.p.Avia Caduti del Lavoro,3
31029 Vittorio Veneto, Italy
Tel. +390438911511
Fax +390438912273
www.sipa.it
4.3.4 Aseptic fi lling lines
Aseptic & Ultra-clean fi lling lines 12 route de Mamers - BP 46
72402 LA FERTE BERNARD
Cedex
Tel.: (33) 2 43 60 28 28
www.serac-group.com
4.4.1 Labelling machinery
GERNEP GmbH
Benzstraße 6
D-93092 Barbing
Tel: +49 9401/9213-0
Fax: +49 9401/9213-29
Email: [email protected]
www.gernep.de
P.E. LABELLERS S.p.A.
Via Europa 25
46047 Porto Mantovano (MN), Italy
Tel.: +39 0376 389311
www.pelabellers.it
3.2 Stretch blow moulds
Awanti Polymoulds Pvt. Ltd.
25/5A/1/2, Nanded, Sinhagad Rd.,
Pune - 411 041, INDIA
Telefax: - 91 20 24392805
www.awantipolymoulds.com
PET engineering, bottle design, Prototyping, industrial blow mould and services -Rue du buisson Moreau 16100 Cognac FRANCETel : 0033 (0)5 45 36 63 [email protected]
DEMO Design and Moulds
31020 San Vendemiano (TV) - Italy
Tel.: +39 0438 409048
Fax: +39 0438 409046
www.designandmoulds.com
www.petkamold.com
RÖDERS GMBH
Scheibenstr. 6
29614 Soltau, Germany
Tel. 0049-5191-603-53
Fax 0049-5191-603-36
www.roeders.de
Solent Mould Tools Ltd
Tel: +44 (0) 23 9223 9950
SMT Americas Inc.
Tel: +1 905 315 9882
www.solentmouldtools.co.uk
4.5 Downstream equipment
ZECCHETTI S.R.L.
Via Galileo Galilei, 1-1A
42027 Montecchio Emilia RE,
Italy
Tel. 0039-0522-867-411
Fax 0039-0522-866-034
www.zecchetti.it
5.0 RECYCLING
Bühler AGThermal ProcessesCH-9240 UzwilT +41 71 955 3466F +41 71 955 [email protected]
PET-Recycling PlantsConsulting & EngineeringComplete Solutions
Effective cleaners, antifoams,
separation agents and additives
for PET recycling.
Diversey Deutschland GmbH & Co. oHGMallaustraße 50-56
D-68219 Mannheim
Tel +49 621 8757-0
www.diversey.com
Herbold Meckesheim GmbHPET Granulators, Agglomerators, Shredders, Complete PET washing and recycling linesIndustriestrasse 33
74909 Meckesheim
Tel.: 06226 - 932 – 0
Fax: 06226 - 932 – 495
www.herbold.com
46 PETplanet insider Vol. 12 No. 07+08/11 www.petpla.net
Buyer’sguide Entries from 5,70 Euro/mm, Call +49-6221-65108-0
PET Chemical treatments:
Cleaners, fl otation compounds
and additives
Via Vigevano 61
28069 - San Martino di Trecate
Novara - Italy
Tel. 0039-0321789770
Fax 0039-0321789765
5.8 Complete recycling plants
Complete PET recycling plants, FDA approved, integrated IV increase without Pellet-SSP, process features lowest overall energy consumption, more than 100 plants supplied to industry. EREMA GMBH
Unterfeldstr. 3
4052 Ansfelden/Linz, Austria
Tel. 0043-732-3190-0
Fax 0043-732-3190-23
www.erema.at
“PET washing and recycling plants, turnkey and modules for B2B, fi ber, sheet”SOREMA division of PREVIERO N.srl
Via per Cavolto 17,
22040 Anzano del Parco (Co) -Italy
Tel:+39 031 63491250
[email protected] · www.sorema.it
PET recycling technology:
Recycling extruders with
inline SSP (IV increase,
food-contact, FDA)
Starlinger & Co. Ges.m.b.H.
Sonnenuhrgasse 4
AT-1060 Vienna
Tel.: +43/1/599 55 0
Fax: +43/1/599 55 180
e-mail: [email protected]
www.recycling.starlinger.com
lonely in space – or plugged in to the world-wide PET community? A few ways to benefi t from PETplanet‘s many offers.
Price of the entry:
number of lines
x 3,2 mm line height
x 5,70 EUR
= entry per issue
Stay permanently listed in the
magazine‘s Buyer‘s Guide with
your company logo and contact
information (includes printed and
online version). For only EUR
5,70 per mm you can be present
among top suppliers of PET pro-
cessing materials – in every issue
of the year.
contact Ask for your
individual offer – call +49-6221-65108-0
Complete washing lines for PET recycling, for fi bre, sheet, B-t-B applicationsTECNOFER ECOIMPIANTI SRL
Via Calto, 409/28
45030 Ceneselli (RO) - Italy
Tel: +39 0425 849090
www.tecnofer.biz
6.0 OTHER
6.1 Laboratory equipment
6.1.2 O2 barrier measurement
Non-invasive oxygen/
pH measurement
PreSens Precision Sensing GmbH Germany
Tel +49 941 94 27 21 00
www.PreSens.de/PET
6.1.4 Bottle and Preform inspection equipment
www.agrintl.com
Intravis GmbHRotter Bruch 26a
52068 Aachen, Germany
Tel.: +49 (241)9126-0
Fax: +49 (241)9126-100
E-Mail: [email protected]
www.intravis.de
EMPTY BOTTLE
INSPECTION SYSTEM
P&S technology Co. Ltd
#326-1, Taejeon-dong
Gwangju-si, Gyeonggi-do
464-805, Korea
Tel.: 0082-31-763-5621
Fax: 0082-31-763-5623
www.pnstech.co.kr
6.3 Contract manufacturers
6.3.2 Suppliers of custom designed bottles
Engineering P.E.T. since 1980
30037 Scorzè (Venice / ITALY)
www.novapet.it
P.E.T. Engineering Srl
Via Celtica 26
31020 San Vendemiano (TV), Italy
TEL + 39 0438 403069
FAX +39 0438 408420
www.petengineering.com
7.0 USED MACHINERY
MachinePoint Used Machinery
Parque Tecnológico de Boecillo
Edifi cio C.E.E.I. - 2.01
E-47151 Valladolid (SPAIN)
Tel.: +34 983 549 900
Fax: +34 983 549 901
www.machinepoint.com
1 Line = 3,2 mm
Example: 1,824.– EUR/year
PETplanet Insider
Landhausstr. 4
69115 Heidelberg, Germany
Tel. 0049-6221-65108-0
Fax 0049-6221-65108-28
www.petpla.net
32 m
m
Your one stop shop for mold makers and molders
www.rnaprecision.com
50 Galaxy Blvd Unit 13, Toronto, Ontario, M9W 4Y5 CANADA : (P) +1 416 213 9400 : (F) +1 416 213 [email protected]
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