next steps in lw pet bottles

Next steps in PET bottle lightweighting

Tuesday 26th June 2007

Phillip Ward

Director for Waste Implementation Programmes: WRAP

WRAP: Waste & Resources Action Programme

Private company, funded by DEFRA and the devolved administrations

Set up in 2001 from Waste Strategy 2000

200 staff, 7 programmes

“Helping businesses and the public to reduce waste, to use more recycled material, and recycle more things more often”

The role of WRAP

“to minimise the production of waste by consumers and maximise the recycling of materials.”

Minimising household wasteCreating markets for recyclateIncreasing recycling infrastructureTraining & increasing collectionsPromotion of consumer recycling

Waste minimisation, recycling, composting

The scale of the challenge

European perspective

Waste Strategy for England 2007• Published by Defra on 24 May 2007• Much stronger focus on waste minimisation• Retail and food manufacturing are both seen as

priority sectors• Reducing food waste an urgent issue for

government• Focus on alternative technology investment

– Anaerobic digestion and composting favoured• Consultation on incentive charging scheme

The changing retail environment

Grocery retailers: ‘Green Wars’

Strategic targets on:

– Reduction in waste and packaging

– Specifying recycled content / biodegradable packaging

– Recyclability / access to recycling facilities

– Sustainable materials

– Carbon foot-printing

http://www.j-sainsbury.co.uk/index.asp?pageid=1

Courtauld Commitment: Phase 1 RetailersThe signatories commit to supporting WRAP in the achievement of its objectives, as follows:

To design out packaging waste growth by 2008

To deliver absolute reductions in packaging waste by 2010

To identify ways to tackle the problem of food waste

Signatories represent over 90% of the UK grocery market

Courtauld Commitment: Phase 2 Brands

Expansion of Courtauld Commitment to include top UK selling brands and suppliers;

Influence the brand sector

Influence own brand

Influence consumers

Partnership working with retailers / WRAP

Focus on suppliers to household grocery sector

Brand signatories now in double figures

http://www.premierfoods.co.uk/

Consumers: seeking engagementRecycling

Incentive charges

Kerbside collection

On-pack messages

Media

Lightweighting PET

Why a conference on lightweighting PET?

Lightweighting has been happening for a long time BUT a new step-change is needed

Commercial, consumer and environmental opportunities

Understanding the challengesBringing together technical & commercial

expertiseFuture plans

WRAP’s PET lightweighting project overview

Three projects involved:Esterform Packaging:500ml and 2 litre bottlesCoca-Cola EnterprisesAmcor PET Packaging

Where we want to get to

Shared understandingClarity on potential benefitsAwareness of barriers to and challenges in

adoptionIdentify areas for collaboration

Thank you

Next steps in PET bottle light weighting

PET bottle manufacturing and light weighting- an overview

Professor Edward KosiorManaging DirectorNextek Limited

Overview• The Light Weighting Issue• The UK PET bottle market• Light weighting design principles• Limitations to Light weighting• Review of current best practice • Potential for future light weighting

The Light Weighting issue

Light weighting of PET bottles

•Light weighting has been occurring since PET bottles were produced in the beverage market•The target has always been to reduce cost without reduction in bottle performance and consumer appeal

Savings delivered by light weighting PET

Each one gram saved on a preform used for a market of 100 million bottles saves•100 tonnes of PET•£80,000 of costs for PET resin at £ 800/tonne•80,000 kWhr of energy for preform moulding•2670 kWhr of energy for preform heating for blow moulding•36 tonnes of CO2 being generated•27.2 tonnes of Carbon being used

The UK PET bottle market

UK Soft Drinks Market

Growth from 2000 to 2005 has been at approx 4% p.a.

Year

Litres (million) index % annual change

2000 9,248 100 NA 2001 9,740 105 +5.3 2002 10,239 111 +5.1 2003 11,128 120 +8.7 2004 10,991 119 -1.2 2005 11,123 120 +1.2

Market Sectors

•Carbonated Soft Drinks 55% of the market•Juice 20% and Water 19%•PET bottles are the major form of packaging (66%)

Estimated % Share of the UK Drinks Industry Market

2005

55%

20%

19%3%

3%

0%

CarbonatesJuice/juice drinksBottled waterSports drinksEnergy & stimulant drinksSmoothies

Share of the CSD market by brand owners

The top three Brand owners for carbonated drinks are•Coca Cola•Britvic•AG Barr (Irn-Bru)They account for nearly 60% of the CSD volume

PET packaging is used for 66% of the total market

% Share of the UK Carbonated drinks market by

brand, 2004 M ltrs

15%

10%

4%

3%

7%

5%4% 3% 4% 5%

14%

26%

Coca-colaDiet CokeFantaSchweppesPepsiDiet Pepsi/Pepsi MaxTangoR WhitesVirgin ColaIrn-BruOther brandsOwn-label

Coc

a-co

la

Ent

erpr

ises

Brit

vic

soft

drin

ks

Share of the Water market by brand owners

•Own Label water dominates the market at 47%•Nestle, Danoneand Highland spring are the other major players•81% of the packaging is in PET bottles

% share by brand of the bottled mineral water market 2005 M ltrs

VolvicEvianHighland SpringBuxtonVittelAqua PuraOwn labelsOthers

Dan

one

Nes

tle

Share of the Juice market by brand owners•Own label account for 41% of the market

The top four brands are•Gerber•Britvic•Glaxo Smith Kline•Coca Cola EnterprisesPET bottles are used for 25% of the market

% share of the UK fruit juice/juice drinks market

by brand 2004, M ltrs

Ocean SprayRobinsonsRibenaCapri-sunSunny DOther brandsOwn-label

Summary of the PET Packaging market

Segment Total volume %PET share Estimated number of PET bottles

Carbonated S.D. 6,057 m litres 66% 3,100 million Bottled water 2,158 m litres 81% 1,500 million* Fruit juice/drinks 2,202 m litres 25% 1,055 million Others 820 million

TOTAL: 6,475 million

Light Weighting Design Principles

PET Bottle design

Key issues for bottle design:•Manufacturing process single stage or two stage

– (economics, material efficiency)

•Size and shape of bottle– (stretch ratio, barrier and rigidity)

•CSD, juice or water market– (Resin IV, base design)

•Neck and Closure design– (Major weight and waste factor)

•Shelf life and oxygen barrier– Wall thickness and construction

•Production stability– Available BM machines

Light Weight Bottle Design Principles•The latest advice on bottle and preform re-design is obtained from leaders in the technology- preform manufacture, moulds, resins blow moulding machines.•The new, lighter design is created on a 3-D CAD System•Surface stress and deformation test is carried using Finite Element Method (FEM) analysis to check the bottle performance•The new CAD design is optimised to meet customer specifications.•Manufacture of prototype tooling to make sample bottles on production equipment.•Testing of prototypes for an additional analysis of all important parameters.•The filling volume and material distribution is checked.•The designs may require further refinement and the moulds adjusted.• Bottles are again moulded and tested.•Bottles are tested at the customer on the filling lines at full production speed and tested with real products.

Issues that often arise in Light Weighting•Wall thickness can get too low and product rigidity is lost- poor feel, low top load resistance•Nesting of preforms (body of preform is less than opening of the neck) leads to preform unscrambling problems in the blow stage •Very light bottles are difficult to handle and fill at high speed •Barrier properties and creep of CSD bottles can cause shelf life and label stability issues.•Stability of base and Stress Cracking of base may become a problem

Review of current Best Practice

Best in Class survey –Wrap/ Exel 2005

Data for CSD based on 2003 data

Product Size Position in class Weight of plastic packaging (grams)

Estimated weight of PET (gms) (assuming 3gm

closure weight) 330ml PET Best 18.8 15.8 Worse 19.09 16.09 500ml PET Best 24.5 21.5 Worse 42.2 39.2 l ltr PET Best 31.7 28.7 Worse 52.91 49.91 1.5lt PET Best 47.81 44.81 Worse 50 47 2 ltr PET Best 44 41 Worse 58 55

Most common CSD bottle weights

Volume: Weight(s): 330ml 17.4gms 500ml 28.1gms 1 litre 31.9gms, 39.5gms 1.5 litre 44.8gms 2 litre 44.2gms, 46gm, 50gms,

51.7gms

Best in Class survey –Wrap/ Exel 2005

Data for Water based on 2004 data

Product size Position in class

Weight of PET packaging (grams)

Estimated weight of PET (gms)assuming 2.5gm closure

Best 17 14.5 330ml PET Worse 28.24 25.74

Best 20 17.5 500ml PET Worse 45.8 43.3

Best 28.79 26.29 750ml PET Worse 40.8 38.3

Best 29.58 27.08 1 ltrs PET Worse 40 37.5

Best 38 35.5 l.5 ltrs PET Worse 58 55.5

Best 46 43.5 2ltr PET Worse 66.5 64

Best 103 98.0* 5ltr PET Worse 147.85 142.85*

Most common Water bottle weights

Volume: Weight(s): 330ml 25.74gms 500ml 17.5gms, 23.5gms 750ml 26.29gms 1 litre 36.4gms 1.5 litres 39.3gms, 43.8gms, 54.5gms 2 litres 44.7gms, 46.5gms, 47.1gms

Best in Class survey –Wrap/ Exel

Data for Juice based on 2006 data

Product size Position in class

Weight of plastic packaging (grams)

Weight of PET (gms) assuming 3.5gm closure

Best 19.5 16 250ml PET Worse 24 20.5

Best 23.9 20.4 500ml PET Worse 41.2 37.7

Best 32.8 29.3 1 ltrs PET Worse 52.3 48.8

Best 45.6 52.1 l.5 ltrs PET Worse 60.6 57.1

Most common Juice bottle weights

Volume: Weight(s): 250ml 16.4gms 500ml 21.8gms, 27.4gms 1 litre 40.1gms, 46.4gms 1.5 litre 58gms

Potential for future light weighting

What is being achieved.• Esterform reduced 500ml CSD preform from 25g to 20g• Esterform reduced 2000ml CSD preform from 42g to 40g• CCE reduced 500ml CSD preform from 26g to 24gWRAP sponsored projects in 2005 and 2006

What could be achieved in UK

A reduction of 10 % of bottle weight for the whole range of UK PET bottles would :•Reduce UK PET usage by 20,000 tonnes ( based on 200,000 tonnes for the bottle market)•This equivalent to 570 million 30g bottles being removed from the waste stream •Reduce resin costs by £16 million ( based on PET•Reduce power demands for process by 16.5 million kWhrs•Reduce CO2 production by 7200 tonnes•Reduce carbon use by 5,500 tonnes

Advancements in Preform Lightweighting

Sylvain TalaricoJune 26th 2007

• Overview of today’s PET market• Why lightweight?• How to lightweight?• Thread Lightweighting Trends• Husky support

Preform Lightweighting

Husky Injection Molding Systems

• World's largest brand name supplier of injection molding equipment and services to the plastics industry

• Manufacturing facilities in Canada, the United States, China and Luxembourg

• Over 40 offices in over 100 countries

Beverage Packaging

Preform Products

A Solution For Every Application

•More than 3.200 Husky PET M/C in Production at 750 Customers

Global PET Support

§

Europe – 72% converters / 77 Billion Preforms

Preform Production in Western Europe

Converters In-House Fillers TotalFrance 3,388 4,404 7,792Italy 6,876 2,040 8,916Spain 4,488 1,968 6,456Germany 4,368 1,696 6,064Benelux 3,760 680 4,440UK 5,264 304 5,568Western Europe 28,144 11,092 39,236

N° Installed Cavities

1980 – 17 Systems Today – 1 System (96 cavities)

Technology Improvements

0 20000 40000 60000 80000 100000 120000

1977

1981

1985

1989

1993

1997

2001

2005

Output (pph)

2.0L CSD

20oz CSD

0.5L Water

144 cavity – G600

96 cavity – G600 phase 1 w/ Servo Robot

96 cavity – SX600 w/ Servo Robot, 3 96 cavity – XL600 w/ Servo Robot, 3

96 cavity – XL600 w/ Servo Robot, 3 Position72 cavity – XL500 w/ Servo Robot, 3 Position

72 cavity – XL500 w/ Air Robot



16 cavity – H388 w/ TE Robot

12 cavity – H388 free drop

144 cavity – HyPET500144 cavity – HyPET500 Speed up

216 cavity – HyPET650

96 cavity – G600 phase 2 72 cavity – Index

96 cavity – Index 400


500ml PET Water Bottle Output Evolution

Weight (g)

Cavitation Cycle (s)

Output(parts/hr)

Output / Capital

1998 21.0 96 11.0 31400 19.6

1999 21.0 96 11.0 31400 19.6

2000 20.0 96 10.0 34500 21.6

2001 17.5 144 10.0 51800 25.9

2002 16.0 144 9.5 54500 27.3

2003 14.5 144 9.0 57600 28.8

2004 14.5 144 8.5 60900 30.5

2005 13.5 144 8.0 64800 32.4

2006 13.0 144 7.0 69100 34.4


PET Price Trend (US$)

Source: PCI 2006

Resin Prices Continue to Increase

50

60

70

80

90

100

Q12003

Q2 Q3 Q4 Q12004

Q2 Q3 Q4 Q12005

Q2 Q3 Q4 Q12006

Q2 Q3 Q4

Cen

ts /

Poun

d

Average PET Prices Trend (Average PET Prices)

• Significant ongoing weight reduction for most beverage containers– 15% – 50% over past 10 years– Combination of shorter and thinner preforms and lighter threads

2L CSD

1.5L Water

600ml CSD

500ml Water

0

10

20

30

40

50

60

1996 1998 2000 2002 2004 2006 2008

Wei

ght (

g)

Trends in Preform Lightweighting

CSD Applications

Milk / Juice Applications Oil Applications

Mineral Water Applications

The above tables are summaries and do NOT include all possible specifications.

Market Trends

Lightweighting Advantages

• Reduce resin consumption

• Increase productivity & performance

• Maximize cycle benefit (thinner means faster)

• Satisfy end consumer demand for sustainable

development

Sustainable Development

“…because it is made with less plastic”

PET Market Trends • Lighter necks • New bottle base and body concepts

5 liters / 38 mm Neck 28 mm CSD 30/25 low, PCF26

500 ml Lightweighted MW Packaging

Bottle: 13.80 g

Closure: 1.73 g

Volume: 500 ml

Height: 196 mm

Max Dia: 65.9 mm

Thread: PCF-26P-1

Bottle: 12.30 g

Closure: 1.58 g

Volume: 500 ml

Height: 205.8 mm

Max Dia: 66.3 mm

Thread: PCF-26P-1

Small Size Containers

• Preform change only– Thread conversion– Body conversion (from 0.1g to several grams)

• Bottle change including a preform change• Resin change including bottle & preform changes

Options in Preform Lightweighting

Neck Body

Core side

Cavity side

Thread side

Thread Lightweighting Projects

Blowingpartner

Closurepartner

Husky

Customer

Case Study ($US)Bottles or preforms per year 240 MillionPET resin cost 1.4 $/kgHDPE cost 1.15 $/kg

Resin (g) $USThread 1.3 436,800$ Body 1.2 403,200$ Preform total 2.5 840,000$ Closure 0.6 165,600$

Sub-total Savings 1,005,600$

Investment cost $USInjection molding machine and tooling 250,000$ Blowing molding investment 250,000$ Capping investment 250,000$

Sub-total 1,550,000$

Additional profit per year 1,005,600$ Return on investment (years) 1.5

Resin Savings Opportunity

Assumptions

Additional Profit Every Year 1,005,600$

Thread Lightweighting

• Focus on:– Carbonated Soft Drinks – Mineral Water

~ 5.7‐6 g

BPF‐C

~ 5.9 g

Alcoa

PCO 1810 / 1816

~ 5.1 g

CSD Thread Evolution – 28 mm

Global Usage

Common in Europe

Common in Americas

PCO is the most widely accepted CSD thread finish

CSD Thread Evolution - What’s Next?

CSD Thread Lightweighting

* Non-exhaustive list

500ml Lightweighted Beer Packaging

Volume: 500 ml

Height: ~235 mm

Max Dia: ~65 mm

Thread: Bericap

~ 3.9 g

30/25

~ 3.9 g

PCF26

Common in Americas

Alaska 267

~ 3.7 g

Global UsageCommon in

Europe

MW Thread Evolution

30/25 High3.9g weight

Target weight below 2.5g

- 36%

MW Thread Evolution - What’s Next?

Mineral Water Thread Lightweighting

* Non-exhaustive list

• 9.9 g with Snap on Closure•10.6 g with 3 start threaded closure

13g today

500 ml Lightweighted MW Packaging

Prototyping with Husky• Preform / mold optimization

– performance at production system level• Latest system / mold technology used• Project confidentiality preserved• Design validation• Competitive leadtimes

Get your product to market faster and safer

Preform Development Center• Show Room integrating

2 new HyPET 90 systems

• Optimized output with 4 cavity modular mold• Various mold tool options available

Moving Forward

• High amount of development activity• Lightweighting demand for all applications• Success of new threads depends on closure

standardization and availability• Need to evaluate overall cost along the supply

chain

Global Impact to the PET Market

• ~35% of the PET global beverage market affected

• Beverage retailers looking for ~5% weight savings

• Brand owners looking for sustainable packaging and cost savings

• Converters taking proactive measures to meet market expectations

Husky Initiatives• Add global manufacturing capacity• Add global refurbishing cells• Support new thread development• Work closely with down stream equipment

providers• Introduce new programs for mold conversions to:

– Preform prototyping – Include body lightweighting – Minimize customer downtime– Incorporate technical upgrades to improve cycle and/or

preform quality

Advancements in Preform Lightweighting

SIG Corpoplast Frank Haesendonckx Date

PET bottles at lighter weightAn integrated approach

Birmingham, June 26th, for WRAP


Heidenreich & Harbeckestablishes SBM division

1968 1997 2000 2002 20031974

SIG acquires Corpoplast: revenue €80m / 270 employees (excl. Moldtec)

2004 2005 2006

PLASMAX 12D;industrialization and pilot launch

ASBOFILL 610with integrated capper launched at Drinktec 2005

World’s first PET Stretch Blow MouldingMachine produced in cooperation with DuPont(8,000 bph 16 cavity)

SIG Corpoplast partners with Schott to develop the PLASMAX barrier coating system for plastics applications

ASBOFILL (GEA)develops first purpose built Linear Aseptic Bottle Filler

SIG acquires Asbofill filling assets from

TechneSIG acquires Schott equity in Technology

JV for Plasmax development

SIG Beverages history shows a pioneering role in PET, barrier development and dry aseptic filling

Corpoplast develops first plasma coating machine for bottles

RANK acquires SIGAnd announces to keep the structure

including Beveragesas is

2007


BottleManufacture

BarrierCoating

ProductFilling

Bottles & Shapes™

SIG Beverages - offering comprehensive PET solutions along the value chain for low speed aseptic filling

Design and processing

Stretch BlowMoulding

BarrierCoating

Aseptic BottleFilling

CustomerRequest

Briefing Packaging and Process Design


ProductFilling

High Speed BottleFilling via partner

SIG Corpoplast … focusing on “value added bottling” for high volume and non aseptic filling lines

Value added bottling: „high quality bottle at lowest cost of ownership”Bottles & Shapes

Stretch BlowMoulding

CustomerRequest

BottleManufacture

Bottles & Shapes™

Briefing Packaging and Process Design


Content

• The playground• Material influence• Design influence• Processing influence and incorporation into machine technology• Examples


Material properties

Bottle design elements

Preform designEnvironment/ specification

Weight reduction

Orientation to fit load

Processing for functional

material distribution

Design features to support

Requied minimal performance

Processing to handle

Filling/ handling load

The playground of lightweighing PET containers… combining all elements of the value chain


Content



Material… Influences on bottle performance and process design• The basics: Strain hardening

• Influences on material use– Reaching above the point of natural strain hardening

– Re.heat capacity influences freedom in preform design


Strain Hardening… through material characteristics and design

Influence of IV on SHP

0

10

20

30

40

50

60

1 1.5 2 2.5 3 3.5 4

ratio

Forc

e [N

]

CP 552 (IV: 0.719)

CP 559 (IV: 0.808)

1101(IV: 0.770)

stretching at 110°C

Thicker Preform

Higher Orientation

Thinner Preform

Lower orientation

Stress Whitening

Typical Design Range


Stretch ratio inside/outside of the preform wall… Consequences on preform re-heat

• Preform inside is more stretchedthan outside

• The thicker the preform wall, themore important to obtain heatpenetration

• Importance of good re-heat resins isincreasing


Content



Preform and bottle design… starting point for good process design

• Factors– Stretch Ratio– Wall thickness

• Reflects on– Process stability– Re-heat capacity– Container performance

• Bottle design– Between technical and marketing optimization– Imperative to respect relation to preform


Preform design


Preform – functional sections

Part below support ringDiameter and

wallthickness defined byneck finish

TaperLength defined by length

of bottle shoulder

NeckDefined by bottle

BodyDiameter, length and

wallthickness defined by bottleshape/dimensions, application

and weight

BaseDiameter and wallthickness defined

by prefomr body and application


Preform design… incorporating stiffness by orientation

1

2

3

4

5

6

7

54321 λL

λQ

Minimize cost („design to cost“)• Minimize amount of material employed• Optimize material distribution• Optimize stretching ratio• Optimize grip resistance


Bottle design… performance at low weight lays in the details


Content



The process of bottle blowing… and the required machine characteristics• Aim

– Obtain a uniform material distribution

– Above NSR, to obtain strenghtby orientation, not wall thickness

• What is required– Stable re-heat

» Small pitch between preforms» Material pull» Repeatable profile

– Stable material distribution» Repeatable stretching» Repeatable bubble development


Wall thickness distribution... Depends on preform re-heat characterisitcs


Preform re-heat profile evolution when traveling in IR oven

• Obtaining a perfect heat distributionwith inside temperature > outsidetemperature

• At minimum required stretchtemperature to have highest stifnessat equal material thickness

Stress / Elongation vs.Temperature

0100200300400500600700

0 100 200 300 400

Elongation ( % )

Stre

ss (

PSI )

90 C95 C100 C


Reheat optimization… machine technology to obtain stable heat penetration• Smallest pitch possible: 38 mm

– Limit is support ring

• 25% less re-heat energy

• Allows for „smooth“ heatingwhere required

• Re-heat profiling– Neck shielding is more simple

» Natural heat convection» No air suction required» Sharp transition under support ring

possible» Top lamp possible

» No water condensation from coolingshield on preform


Optimize material use… only there where required, at minimal variance

MIN limit for bottle property such as TOP LOAD

Pneumatic Stretching

PFM weight

Δ1

= = Δ1 – Δ2

Δ2

PFM weight

Mechanical Stretching


8,20

8,60

9,00

9,40

9,80

10,20

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Mould

Average max min

8,20

8,60

9,00

9,40

9,80

10,20

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Mould

Average max min

Segment weight variation with high precision process

Segment weight variation with low precision process

• Precise oven control, double guided mechanical stretching system, precise valves, short cycle time:

Highest process preciseness and repeatability, thus light weighting

1 g saving:216 T€ /Year

•180 mil bottles/ year (BLOMAX 20 * 5000 h * 95%) , 1l bottle•With energy cost of 12 €c/ kwh, 0,19 kw/qm•Pet resin cost of 1,2 €/ kg

The machine: design to cost …high precision and repeatability


Content



Lightweighting in Water/ CSD

• Brandenburger Urstromquelle, 1.5 l and 0.5 l CSD, 8 gr CO2/l

• 0.5 l weight reductionfrom 23 g down to 19.5 g

• 1.5 l weight reductionfrom 38 g down to 35.5 g

• Pressure reduction from35 bar down to 21 bar at

speed of 1800 bphm


Lightweighting in dairy

• 0,119 l Yoghurt bottle

Weight reduction from7.5 down to 7 g

•speed of 1700 bphm


Example for a sophisticate bottle development

• Japanese field 2.0 l rectangular Aseptic bottle

Weight reduction from 47 g down to 41,9 g

• Wide range of specification items

• Corpoplast task:• bottle shape

• Preform design

• process design


The Bottles & Shapes concept links material, processes, machines and requirements… to deliver a customized bottle at the best performance / price

Bottle

ConceptBottleDesign

PreformDesign

Mold

Design

Design

validation

Process/

Industrial

solution

Bottle ConceptProduct to be filled

–Aseptic integrity–Heat resistance

Required shelf life and barrier– CO2 / O2 transmission

Differentiation

Process / OperationsMaterial costs (resin / cap / sleeve)PaT parts/ change overBlowing costsBarrier costsFilling costs

Bottle DesignDifferentiated shapeCorporate identityProduct suitabilityCoat-abilityFilling Pressure resistanceStability of contoursHandling stabilityPreform Design

Design to give best material distributionMinimum heat for maximum shape

Mold ManufacturingDesign optimized for preformBottle finish

Design Validation3D mock-upPilot moldsPilot bottles / Performance testsConsumer focus groups

Thank you very much

PET PET ResinsResinsEnablingEnablingLightweightingLightweighting

Roland Leimbacher

Market Manager – Polymers EMEAEastman Chemical Company

Seminary "Next Steps in PET Bottle Lightweighting" Solihull, West Midlands – June 26, 2007

Content of Presentation

• Introduction to Eastman• Market Trends & Requirements on PET• Light-Weighting of PET bottles• Vorcalor & Aqualor PET - Eastman's New PET Resins• Reheat Process & Performance of PET• Outlook for PET Resins & Technology

Eastman – At A Glance

• A global manufacturer of chemicals, plastics and fibers

• World's largest manufacturer of PET polymers for packaging

• 2006 sales revenue of $7.5B

• 11'000 employees

• Headquarters in Kingsport, Tennessee

Eastman - History

• Began in 1920 when George Eastman acquired wood distillation plant in Kingsport, TN

• Expanded manufacturing production to include new products such as: – Acetate yarn and acetate tow– Acetic anhydride– Cellulosic plastics– Polyethylene terephthalate (PET) polymers

• Became first to operate a commercial coal gasification facility in U.S. in 1983

• Won Malcolm Baldrige National Quality Award in 1993

• Spun from Kodak in 1994; became independent, publicly traded company on the NYSE

Eastman - Markets

2006 Sales Revenue by Markets 2006 Sales Revenue by Region

20%13%

9%

57%

Eastman - Products

• Coatings, Adhesives, Specialty Polymers and Inks

• Fibers• Performance Chemicals and

Intermediates• Performance Polymers

– PET: Poly-(ethylene terephthalate) • Specialty Plastics

– copolyesters (PETG)– cellulosic plastics

Performance Polymers

• One principal product line:– Polyester (PET)

• Eastman is the leader in PET for packaging; used in packaging of:– Carbonated soft drinks– Water– Juice– Personal care item

• 2006 sales revenue of $2.6B

Specialty Plastics

• Highly specialized copolyesters and cellulosic plastics valued for their unique characteristics– Strength– Durability– Heat and chemical resistance

• Used in a variety of value-added end uses:– Shrink labels – Food and beverage packaging– Store fixtures and displays– Personal care and cosmetic packaging– Medical devices and packaging

• 2006 sales revenue of $818M

Eastman's Polyester History

1975 First PET packaging resin from converted fiber plant (SC)1978 Eastman begins manufacturing PET resin for containers1988 First PET plant in Europe (Workington / GB)1994 Eastman Chemical Company is spun off from Eastman Kodak1996 PET plant start-up in Cosoleacaque - Mexico1997 PET plant start-up in San Roque - Spain1998 PET plant start-up in Rotterdam, Netherlands

PET plant start-up in Zárate -Argentina2006 First world-scale PET plant based on IntegRex Technology

Parastar Resins - commercial since 1Q – 2007450'000 MT PET as of 2008

2007 PET plant in San Roque - Spain sold to La Seda de B.

PET Manufacturing in Europe

Workington - UK1988 built

150 KMT PET

Rotterdam - NL1998 built

190 KMT PET315 KMT PTA

2007 PET Capacity in Europe: 340'000 MT2007 PET Capacity in Europe: 340'000 MT

PET Portfolio in Europe

• Eastman PET CB11E (0.82 IV)• Eastman PET 9921W (0.80 IV)• Eastman Aqua PET 18696 (0.71 IV)• Eastman PET 9921P (0.80 IV)

• Eastman PET CB11E (0.82 IV)• Eastman PET 9921W (0.80 IV)• Eastman Aqua PET 18696 (0.71 IV)• Eastman PET 9921P (0.80 IV)

• Eastman PET PJ003 (0.80 IV – glass like) • Eastman PET 5214A Amber (0.74 IV – pharma)• Eastman PET PJ003 (0.80 IV – glass like) • Eastman PET 5214A Amber (0.74 IV – pharma)

Prod

uced

in E

urop

eIm

port

ed

Trends in European Packaging Market (1)

• Pressure on overall Cost Effectiveness• Differentiated packaging with standard resins• PET packaging the choice over glass, aluminium, carton• Trend towards smaller packaging size• Sustainability PET the best overall choice

PET has established recycling infrastructurePET is a light and durable packaging without compromise

• CSD Market is mature• Water continues to grow but less in Western Europe• Growth in juices, sports & functional drinks, dairy, beer• In film & sheet PS is being substituted by PET, PP, PLA

Prices of Plastics in Europe

PET is a very competitive commodity plastic for packagingPET has had relatively stable, predictable prices since 2004

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

LDPEPPPSPVCPET

Source: PIEwww.pieweb.com

Trends in European Packaging Market (2)

Market Drivers - Specific for PET Packaging• Bottle fillers increasingly blowing their own bottles• More efficient operations, less manpower needed• Less experience/knowledge• Low inventories• Weight reduction in finished articles• Changes in preform design• Use of PCR polymer even in food contact applications

(bottle to bottle recycling)• Emphasis on cost savings• Energy savings• More creative use of standard resins

Requirements on PET

6Control over AA

6Balance between reheat and color

8Energy and cost reduction

9Improved blow moulding consistency

2Same IV for carbonated and still water

4Ability to light-weight

4Cycle time reduction (injection moulding)

8Increased barrier (CO2)

rating from Eastman market study in 2005

Light-Weighting PET Bottles

Technologies Enabling Light-Weighting• Design of Bottle / Preform• Blow Molding Machine• Process /Technology Improvement• PET Resin

PET Resin Parameters Enabling Light-WeightingFor blowing at maximum stretch ratio, followingPET properties need to be optimized:• Viscosity• Reheat Performance• Consistent Reheat • Consistent Viscosity (IV)• Resin Formulation, e.g. Modifications• Barrier properties

Light-Weighting PET Bottles

Eastman's Solution

enabling light-weighting by improved processing, reheat, and barrier performance

Eastman PET CB11E (0.82 IV)Eastman PET 9921W (0.80 IV)

Eastman Aqua PET 18696 (0.71 IV)

Eastman PET CB11E (0.82 IV)Eastman PET 9921W (0.80 IV)

Eastman Aqua PET 18696 (0.71 IV)

Vorcalor PET CB11E (0.82)Vorcalor PET 9921W (0.80)Aqualor PET 18696 (0.72)


Review of New PET Resins

The Premier Reheat PET Resin

• 0.82 IV PET resin• up to 60% energy savings• Highest reheat without compromise

on clarity• The best choice for:

- carbonated soft drink (CSD)- beer applications- ideal for blends with lower IV (PCR)

Vorcalor PET CB11E

Clarity of Vorcalor CB11E

Old

Current CB11E

Vorcalor CB11E

• Better reheat & colour consistency than current CB11E

allows blowing of more complicated shapesallows efficient blowing of light-weighted preform/bottle designs

• Haze free appearance, glass-like colour Wider range of use, less resins in stock needed

• Drop-in replacement of current CB11E • Needs up to 60% less energy for reheating preforms• Very compatible with recycling of PET

Vorcalor CB11E - Benefits

Versatile, General Purpose PET• 0.80 IV PET resins• up to 30% energy savings• maximum light weighting• perfect PET for complicated bottle shapes • The best choice for:

- carbonated soft drink (CSD)- carbonated and still water- juices- dairy- personal care & household- pharmaceutical- high quality film & sheet

Vorcalor PET 9921W

• Even with its reheat performance, Vorcalor 9921W looks like a non-reheated PET wide use of applications

• Needs up to 30% less energy in reheating preforms• Better reheat consistency than PET without reheat

allows blowing of more complicated shapesallows efficient blowing of latest, light-weighted preform/bottle designs

• Wider processing window in injection moulding• Improved CO2 barrier 5 to 10% longer shelf life• Improved AA suitable to replace PET of 0.76 IV

Vorcalor 9921W - Benefits

Aqualor PET 18696

Best PET Resin for Still Water• 0.72 IV PET resins• up to 30% energy savings• fastest for moulding preforms• maximum light-weighting• superb clarity & sparkle of bottles• The best choice for:

- still water- non-carbonated containers- small, difficult to mould - containers

• Moderate level of reheat without compromise on bottle appearance

• Needs up to 30% less energy in reheating preforms• Fast injection speed, potential for reduced preform

cycle time• Low energy consumption in injection moulding of

preforms• Low injection pressure long lifetime of moulds• High definition of bottle imprints (embossing &

engraving)

Aqualor 18696 - Benefits

Reheat performance …is a key element enabling light-weighting of PET bottles

… but what does "reheat" mean ?

Reheat Performance of PET

graphics provided by

What is Fast Reheat? (Blow Stage)

• Quartz-infrared lamps are used to heat preforms to about 100 -110 °C for blowing bottles.

• Maximum power output from lamp at these temperatures occurs at about 1100 -1200 nm

• PET absorbs poorly in this range• Infrared absorbing compounds

are added to the PET to - increase productivity or- reduce energy consumption


Reheat Process

stabilisation

penetration oven

distribution oven

penetration oven

distribution oven

stabilisation

stabilisation


Reheat Comparisonof 6 PET Resins

Comparing:• Eastman PET 9921W• Vorcalor PET 9921W• Vorcalor PET CB11E• Resin A - no reheat• Resin B - moderate reheat• Resin C - "high reheat"

Measurements:• Preform outside temperature• Preform inside temperature• Energy consumption of the

blowing machine

Results from trials with

Preform Temperature

Preform Surface Temperature at 80% power setting

104

112

128

104

110114

80

90

100

110

120

130

140

Pre

form

Sur

face

Tem

pera

ture

O

utsi

de [

°C]

9921W Vorcalor™9921W

Vorcalor™CB11E

PET A - No reheat

PET B -Moderate

reheat

PET C -"High

reheat"

Preform Surface Temperature to Avoid Pearl-Whitening

88

90

92

94

96

98

100

102

104

106

0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 1.80

Reheat Level (indexed)

Pref

orm

Tem

pera

ture

(°C

) Preform SurfaceTemperature Outs ide

Preform SurfaceTemperature Inside

Energy Savings

Benchmarking with Competitive Resins

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00En

ergy

Sav

ings

(%)

PET A no reheat

(reference)

Eastman™ PET 9921W

PET B moderate

reheat

Vorcalor™ PET 9921W

PET C "high

reheat"

Vorcalor™PET CB11E

Benchmarking with Competitive Resins

The lower outside preform temperatures results in following benefits:

– Less risk of (local) overheating– Less crystalline outside layer / gate– Positive effect on all properties that have to do with

avoiding crystallinity

The faster heat absorption of the inside layer leads to:– Less risk on overstretching / white feet– Less critical process, wider processing window

But … Reheat is More Than Energy Saving

"Fast Reheat" PET results in additional benefits:

• More consistent blowing operation– Reheat functions as processing aid– Less scrap

• Faster heat absorption– Higher output on heat limited machines

• Allows blowing of light-weighted and more complicated bottle shapes

• Very suitable for heat-set process

But … Reheat is More Than Energy Saving

Outlook for PET Resins & Technology

Polyester Value Chain

ethaneethane

propanepropane

EOEOethyleneethylene EGEG

DMTDMT

PTAPTA

melt phase

PET

melt phase

PET

solidstatePET

solidstatePET

preformspreforms bottlesbottles

p-xylenep-xylene OR

film &sheet

film &sheet

fibrefibre

bottlersbottlers retailersretailers

Integrated Process "PX to PET"

Integrated Process "PX to PET"

Eastman’s position shown in green

23'000 KMT70% of polyester stream1-3% growth

11'000 KMT27% of polyester stream7-10% growth

1'400 KMT3.5% of polyester streamor 12% of PET bottle stream10-15% growth

• New Plant in South Carolina - 350 KMT per annum; 2008 – debottleneck to 450 KMT per annum

• marketed as ParaStar™ for the American Market• "Next Generation PET" with new product attributes and

benefits• IntegRex Plant #2 – Study Phase

– New, World-Class North America Site– Full IntegRex Technology (PX PET)– Logistics Optimization

• Potential Future Developments: large scale, fully-integrated, new technology sites

IntegRex PET Technology

Next Generation PET

IntegRex PET plant in South Carolina producing ParaStar™

Twice the capacity

Half the footprint

Next Generation PET

PET Barrier Technology

• To improve the CO2, O2, and Light barrier of PET• Numerous technologies & solutions available:

– coatings (internal & external)– mono-layer blends– multilayer– special polyesters– labels (for light barrier)

• No "single best" solution … depends on total system cost, application, volume, logistics, design, recycling ...

• Total cost of many solutions are becoming more acceptable for end-users

Sustainability of PET

• attractive PET recycling system – unique amongst plastics !– an effective bottle collection systems is in place– economically attractive outlets are available for PET

• All outlets/reuse of RPET have a similar, positive influence on the environmental profile of PET containers

• In collection system, like the German DSD, the environmental effects of one-way PET are similar to those of refillable glass

• Negligible effect on fossil resources of "one-way PET" versus refillable glass: similar to an average German citizen driving 40 km extra per year in a standard car

• PET containers use less than 0.1% of global oil production• PET packaging is proven to be the best material for beverage

containers best overall performance regarding properties, life-cycle, cost a true sustainable solution.

Transport45%

Energy & Heating42%

5% Other

Chemistry 8%> Plastics 4%

87%burnt

Use of Oil for Plastic

• Plastics (all) use 4% of global oil consumption• PET for fibers and packaging uses 0.3% of oil consumption• PET for packaging uses less than 0.1%• Plastics protect food and other goods most efficiently

Source: Plastics Europe

Recycling – where to go ?

Oil / Gas

EG + PTA

PET

Preform Bottle In Use

Collection

Incineration (burn)

or landfill

Recycling

Chem. Recycling

Sheet Strapping Fibre Bottle

RPET

1

PET

Conclusion



Only the right PET resins allows maximum light-weighting! Therefore, Eastman launches this year three new resins in Europe:

Vorcalor & Aqualor PET resins are the best resins for making PET containersPET Containers are proven to be the most sustainable solution for beverage packaging

Contact to Eastman

For more information on the new resins, please consult your Eastman sales representative or the following websites:

www.VorcalorPET.comwww.AqualorPET.com

Eastman Chemical International AGHertizentrum 66300 Zug, SwitzerlandPhone: +41 41 727 58 70Fax +41 41 727 58 50E-mail: [email protected] www.eastman.com

Eastman, Vorcalor, Aqualor, IntegRex, ParaStar and the Eastman logo are trademarks of Eastman Chemical Company

DISCLAIMER: Eastman Chemical Company and its marketing affiliates shall not be responsible for the use of this information, or of any product, method, or apparatus mentioned, and you must make your own determination of its suitability and completeness for your own use, for the protection of the environment, and for the health and safety of your employees and purchasers of your products. No warranty is made of the merchantability of fitness of any product, and nothing herein waives any of the Seller's conditions of sale.

Roland Leimbacher – June 22, 2007

Reducing PET bottle weight with new low profile necks

and lighter closures

Speaker: Alexander Krautkrämer, Bericap Holding GmbHPosition: Director Marketing & Sales

What is the Bericap Group

sales 435 million € in 2006

44 billion plastic closures per year

18 closure manufacturing sites in 17 countries in the world,

2 mould factories (Hungary and Poland

4 R&D centres (France, Germany, Spain, Turkey)

Strategic allies in Australia and South Africa

sales offices, and agents in 70 countries

Bericap Package

Some of the significant contributions of BERICAP to the packaging industry of the last 30 years

THUMB’UP®

sports capTERXOCUT®self piercing

carton fitment

Push & Pull sports capTear off

membranePull-up

telescopicspout

BO2S®

passive & active barrier

GALILEO®

1975 1995

20002005

Light weightHEXACAP®Bi-injected

closures for hinge cap and VALVELOCK®

2003

TAPSEAL®

tap closure

1998

DoubleSealTM

28 / 38mm and O2S®

2007

SuperShorty®

lightweighting

Presentation structure

Reducing PETbottle weight for

carbonated soft drinks and water

still water

milk and juices

edible oil and vinegar

CSDcarb water

Short Neck Standard PCO 1881

Neck PCO 1881 as currently under evaluation by ISBT- Technical committee „bottle and closure“

within ISBT selects in November 2006 PET short neck standard PCO 1881- currently under evaluation -

- ISBT = International Society of Beverage Technologists (www.bevtech.org)

- approval of PCO 1881 as voluntary standard foreseen for Oct 2007

- members of ISBT are brand owners (Coca-Cola, Pepsi-Cola etc.), preform manufacturers (Amcor, Plastipack etc.), closure manufacturers (GCS, Alcoa, Bericap, OI etc.) and machine manu-facturers (Sacmi, Husky, Sidel etc.)

- CETIE (European standardization body) will adoptPCO 1881 for Europe

1-start thread neckPitch: 2,7mm

Thread length: 650°Neck weight: 3,74gram

weight saving to PCO 1810 (PCO 28):

1,31 gram

PCO 1881 is the target neck for the industryall closure technologies work on PCO 1881

Short Neck Standard PCO 1881- technical details -

Neck PCO 1881 as currently under evaluation by ISBT

PCO 1881 is the target neck for the industry.All closure technologies work on PCO 1881

17,0 mm

21,0 mm

Neck PCO 1810 called PCO 28

Drop height sufficient for all TE band offers

Centering ring for TEband

40° angle for easy application

Thread length 650°extension to 680° feasiblepitch 2,7mm

Usable thread length:650°

CSDcarb water

Short Neck Standard PCO 1881

PCO 1881 neck drawing as pdf-file or 3D-edrawing

available in the Internet with following link:

button on www.bevtech.org at Technical comittee Packaging Technology

www.profileservices.ca/files/tidbits/tidbits_missc.html(profile services is member of ISBT)

or try

Google: „PCO1881“ or „PCO 1881“

CSDcarb water

The lighter option - a proposal from Bericap -

Short neck standardPCO 1881

under evaluation by ISBTShort neck proposal

Bericap – ENG-00-014132

Neck weight: 3,45grNeck weight: 3,74gr

- weight saving through: + reduced angle at PP ring+ deletion of centering ring

below PP ring+ light weighted support ring

Lighter but off-standard

Limitations of neck 14132:Neck 14132 is a off-standard neckonly SuperShorty® works properly on neck 14132

PCO 1881 is the target neck for the industry - all closure technologies work on PCO 1881

CSDcarb water

SuperShorty®from Bericap

History of SuperShorty® from Bericap- Bericap has started SuperShorty®development in 2004

- development project triggered by emergingmarket of beer in PET in Germany

market introduction:- production start end of Feb 2007 in Germany. Initial capacity 300mln

- capacity to be extended in the course of 2007 to 2.000 mln for beer and CSD

SuperShorty® provides safe bottle Performance for up to 2ltr bottles and 8gr CO2/ltr

CSDcarb water

In the market since March 2007

SuperShorty®- closure design -

Double Seal- outer seal- inner seal

Tamper evidence band- slitted- with flexible wings for easy application

SuperShorty® crown lookweight 2,60 gram

SuperShorty® CSD lookweight 2,40 gram

Option for inshell-moulded oxygen scavenger liner

SuperShorty® still weight 1,70 gram

Product program

Product features

CSDcarb water

SuperShorty® + PCO 1881 economics

Figures acc. best knowledge

Saving = 1,7 to 2,2gr/bottle2,20 to 2,80 EUR/1000

CSDcarb water

reference volume 1.000 mln units

closure PCO systemCSD CSD crown 1-pc closure

closure weight gramm 2,40 2,40 2,60 3,00

resin weight for 1.000 mln units to 2.400 2.400 2.600 3.000weight saving from closure to -600 -600 -400neck neck 14132 PCO 1810

only SuperShorty® (PCO 28)neck weight gramm 3,45 5,05

PET resin weight for 1.000 mln necks to 3.450 5.050weight saving from neck to -1.600

total resin weight saving off-standard

compared to PCO 1810 (PCO 28) to -2.200 -1.910 -1.710valued at 1.300 EUR/to EUR -2.860.000 -2.483.000 -2.223.000

3.740-1.310

SuperShorty® systems

PCO 1881 (under evaluation)

3,74

SuperShorty® and PCO 1881- step blow off -

F-2-01-01 BC_Step Blow off Beverage

Closure: filling date: number of heads: revolutions p. min.

ENG - PRO # : test start: kind of head: adjustment:work procedure: Prod. Info: test end: line speed: topload:order no.: tested by: core no.: closing torque:Customer: kind of neck: kind of closing: CO2 formula:bottler: NR REF screw cap automatic Torque Tester 1 CC - Ffilling: PCO MCA1 Line Trail 2 CC - Nbottle size: PCO HC MCA2 Capper 3 GDB shortbottle manufacturer: BPF 7,5R mechanical Torque Tester X 4 PCz

other X ENG #.: OPT and by hand 5 manual

1

2 X pass3 O fail / leak4 3 Blow off5

6

7

8

9

10

11

12

1

2 X pass3 O fail / leak4 3 Blow off5

6

7

8

9

10

11

12 x x x 0 direktx x x xX x x0 @ 20sX x x x x x x x0 @ 10sX x x x x x x x

x x x 0 direktX x x x x x x xx x 0 direktX x x x x x x x

0 @ 35sX x x x x x x x0 direktX x x x x x x x

x x 0 direktX x x x x x x xx 0 direktX x x x x x x xx x 0 direktX x x x x x x xx x 0 direktX x x x x x x x

x 0 @ 20sx x x xX x x

8 ba

r

[116

psi]

1

min

.

9 ba

r

[130

.5ps

i]

1 m

in.

sawed off preform

x O @ 40s

explanation

1 ba

r

[14.

5psi

]

1 m

in.

2 ba

r

[29p

si]

1 m

in.

3 ba

r

[43.

5psi

]

1 m

in.

4 ba

r

[58p

si]

1 m

in.

5 ba

r

[72.

5psi

]

1 m

in.

6 ba

r

[87p

si]

1 m

in.

7 ba

r

[101

.5ps

i]

1 m

in.

x x O @ 40s

x

x

x xxx x

X x x x x x x xx x x

x xX x x x x x x

x x x xX x x

Tem

p. 2

3°C

leakproofness (Process)

10 b

ar

[1

45ps

i]

1 m

in.

11 b

ar

[1

60ps

i]

1 m

in.

12 b

ar

[1

74 p

si]

1

min

.

x

x x x xx x x x

x XX x x x x x x

x x x xx O direkt

X x x x x x xx x x x

x xX x x x x x x

x x x xx x

X x x x x x xx x x

no.device

Tem

p. 3

8°C

leakproofness (Process)

10 b

ar

[1

45ps

i]

1 m

in.

11 b

ar

[1

60ps

i]

1 m

in.

12 b

ar

[1

74 p

si]

1

min

.

x xX x x x x x x

x x x x

no.

device

sawed off preform

X

X

F 02-05-1122-02

E. Bergmann 16 inchlbs

Eltex 1331

AA 02-05-102806G181

BC Germany

PreformsAmcor

Comparison CSD25.10.200627.10.2006

material

DS28/16 FB 7077 O2S00-012100 b

explanation

1 ba

r

[14.

5psi

]

1 m

in.

2 ba

r

[29p

si]

1 m

in.

3 ba

r

[43.

5psi

]

1 m

in.

4 ba

r

[58p

si]

1 m

in.

5 ba

r

[72.

5psi

]

1 m

in.

6 ba

r

[87p

si]

1 m

in.

7 ba

r

[101

.5ps

i] 1

min

.

8 ba

r

[116

psi]

1

min

.

9 ba

r

[130

.5ps

i] 1

min

.

x x x x x x x x x xx x x x x x x x x x x O direkt

X x x x x x x x x x x x O direktX x x x x x x

Procedure: - closure applied on preform- 1 bar applied over 1 minute- pressure increased over 1 minute

to 2 bars- 2 bar pressure hold over 1 minute- cycle repeated with pressure

increases of 1 bar until closure leaks

Result:

SuperShorty® holds pressure at ambient temperature (23°C) till 11 bar

SuperShorty® holds pressure at elevated temperature (38°C) till 7 bar

CSDcarb water

SuperShorty® and PCO 1881- opening performance test -

CSDcarb water

SuperShorty® and PCO 1881- blow-off performance on 2l bottle -

Measurements taken by the Opening Performance Tester (OPT). The OPTmeasures gas venting.

PressureTests have shown that a half-full2 litre bottle (meaning 1l gas volume)filled with CSD can build up a maximum inside pressure of 2,7 bar. -> therefore opening performance

measured on 4 bar total pressure or3 bar overpressure

Opening speed100rpm means almost 2 turns per second

OPT test for SuperShorty®shows safe ventingon 2l bottle

Opening Perform ance aftertorque dependent clos ing 19 lb.in. /

2 litre - 1 litre gas - abs.4,0 bar Pressure

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

0 100 200 300 400 500 600 700

Opening Angle [°]

abs.

Pres

sure

[bar

] absolute pressure#1 Sk28/16 7077 FB (Eltex 1331)

#2 Sk28/16 7077 FB (Eltex 1331)

open seal ~ 201°

Technical informations:Simulated bottle: litreRest volumne/liquid: litreGasvolumne: litreOpening torque speed: rpm.Abs. pressure: baroverpressure: bar

2,01,01,0

3,0

1004,0

CSDcarb water

Technical performance of SuperShorty® on PCO 1881

• Total weight saving of 1,9 gram realisable with PCO 1881• Weights saving can be increased up to 2,20 gram with off-standard neck

• No blow-off risk also for large size bottles • Secure seal up to 11bar at ambient temperature and up to 7bar at38°C realisable

• PCO 1881 has satifactory performance under hot climate conditions SuperShorty® with DoubleSeal shows superior performance

• CO2 retention comparable with current PCO 1810 / PCO28 solutions

CSDcarb water

Line adjustment

The following bottling line elements need adjustment: - preform infeed- neck rings of blow molds and transfer pins in blowing machine- bottle conveying- bottle grippers in rinser/filler/capper- capper sorter and feeding equipment- capping heads to be equipped with new springs to counterbalancereduced pitch

- new CAM for cappers which cannot adjust to lower bottle height- adaptation of down-the-line equipment to reduced bottle height

total cost of adaptation 50.000 to 150.000 EUR/linetotal saving appr. 300.000 EUR/line/year (150mln fillings p.a. per line)payback in less than 6 months!

CSDcarb water

SuperShorty®- good look on all bottle sizes -

CSDcarb water

Lightweight options for still water

HEXACAP® 30/25 ultralightat 1.50 g on 2.90 g

neck finish

total weight: 4,40 g

HEXACAP® 30/25

at 1.90 g on 3.91 g

neck finish


HEXACAP® 26,7 ultralightat 1.20 g on 2.50 g

neck finish


Savings -2,11g or -36,3% compared to

standard 30/25 necks and closures

still water

Galileo I for juices and milk

juicesmilk

Traditional neck: 38mm 3-start(in use since 12 years)

Proposal from Bericap: Galileo I- press-on light-weight neck- 1-piece hinge cap made from HDPE, completely closed from outside before first opening

- no market application yet

weight saving: 2,9gr/bottle

Galileo I 38mmscrew cap

2-pieceSportscap

weight-2,9 gr

- 25 %

- 46 %

- 37 %

3.3 g

4.5 g

7.8 g

40 % light weighting for juices and milk

2.5 g

2.4 g

4.9 g

Ref. 3419

Total saving

Current 38 mm neck finish and closure

GALILEO® I 38 neck finish and closure

juicesmilk

Neck 26/21 for edible oil and vinegar

edible oilvinegar

Traditional neck: PET 29/21(in use since 20 years)

Proposal from Bericap: neck PET 26/21

- same inner diameter as PET29/21less changes on blow moulding equipment

- first introduction with Castelo, Brazilothers follow

- 1-piece and 2-piece closure available from Bericap

weight saving: 3,7gr/bottle

3.2 g

1.4 g

4.6 g

- 43 % / 51 %

- 49 %

- 45 % / - 51 %

45 % light weighting for edible oil and vinegar

5.6 g / 6.6 g

2.7 g

8.3 g / 9.3 g

current neck PET 29/21

and 2-piececlosure

Total saving

neck finish PET 26/21 and 2-piece closure

GALILEO® II 26/21

edible oilvinegar

There is a lot of plastic to be saved.

Thank you!

Stopping Leakers is only the beginning

Presentation on Bottle & Cap Lightweighting using induction cap sealing.

Presented by: Mr Simon. S. Measures

The Point is…..

The reduction of food packaging materials and the recycling of them, is currently one of the top priorities for the Planet/governments/large supermarkets/food companies/bottle manufacturers/cap manufacturers/packaging line machinery manufacturers/contract packers and the end user – us

How does Induction Sealing Work ?

For many years now, in fact over 30, we at Enercon Industries Ltd, have been successfully sealing foils onto containers to aid packaging weight reduction.


The cap sealer mounts over the conveyor and from the induction coil emits a controlled electromagnetic field through which the containers complete with the foil normally placed in the cap are passed.


The electromagnetic current induced into the foil layer of the inner seal creates a circulating current within the foil, causing it to heat up due to its internal resistance


• The heated foil then ‘makes active’ the polymer coating on the heat seal face, bonding the foil to the neck of the container and creating a hermetic seal.

I will now give an example of how we have helped in a real world application

Within the Milk Industry in the UK some 15 years ago Enercon Industries worked very closely with a large Super-Market to solve an issue

What to do….

What to do….The bottle manufacturer and cap manufacturer were at the time listening to the Milk Industry, who wanted a lower priced container and cap for their customer – the Super Market.

As a by-product of this exercise they received a light weight bottle and cap which was also recyclable and crushable….Unfortunately it leaked due to the many stresses the container under went in transit from the filling line to the home

What to do….After many new cap designs with a varying lack of success, the dairies came up with a credit system for leaking bottles.

This however created a lot of waste not only in production but also in the whole supply chain network

The issue of transit, storage & leakers was eventually solved by sealing the plastic milk bottle hermetically with foil, coated with polymer –Issue Resolved!

The Super Market ended up with the product they required. Which SAVED MONEY, helped the planet by using less plastic, and it was RECYCLABLE.

The bottle and cap suppliers pulled back their investment with the higher volumes of product they sold and we all WON.

What to do….

But; Stopping Leaker’s is only the beginning!

Induction cap sealing creates an hermetic foil seal. It’s Air Tight.

It also reduces:-

Bacterial Contamination and Product OxidationImproves Storage and Transit ConditionsReduces rejects and Scrap in Packaging and Filling LinesInduction Sealing also seals in freshness and can extend shelf life (ESL)

But stopping leaker’s is only the beginning!

But a MAJOR benefit often missed by the industry especially Large Outlets and the Prime Food Suppliers is the proven fact that Induction Cap Sealing allows the cap and bottle to be;

Reduced in Thickness

Reduced in Weight

The foil seal will not stop or hinder the RECYCLABLE nature of the bottle

The strength and flexibility of the seal means that the cap or closure will NOT require a tear band

The foil seal also means that a Bore Seal is not required

Which will reduce cap weight



The bottle can be reduced in it’s thickness at the neck and shoulder because ;

It no longer has to withstand high application torques for cap or closure transit requirements

Air carriage rings on and around the neck can be reduced in thickness and weight as they are no longer need to give additional support to the neck

Add to this an increase in size of the market the packing company can attack meansEvery one benefits.

And the cost for all this?

Machinery Less than £20,000 per Production line

Packaging modification costs & addition of foil – normally paid back by material savings in a short period


Last Thoughts to Take Away with you….With a Foil Seal you can

Remove the Tamper Evident Band on the cap – Saving Weight

Remove the Inner Bore Seal in the cap – Saving Weight

Remove the knurling on the neck for the TE Band – Saving Weight

Reduce the neck thickness and weight as it does not need to be so

strong – Saving Weight

Move from Screw Caps to light flexible clip on covers – Saving Weight

For Single Dose applications the cap can be removed altogether

Last Thoughts to Take Away with you….Target Industries;

DairyPE, PP, PET

Food and beverage (Non-Carbonated)PE, PP, PET, Glass, CO-EX & Barrier Materials

PharmaceuticalPE, PP, Glass

AgrochemicalPE, PP, PET, CO-EX, Fluorinated & Barrier Materials

And on & on & on…..

Any Questions?

Optimising Packaging and Engaging Consumers

Peter SkeltonWRAP: Retail Team

Recyclable

BiodegradableRecycled (PCR) content

Compostable

Challenging time for plastic packaging …..

Weight reduction

Material switch

Low carbon

Biodegradable

Innovation

15g 49g

PET packaging

PET is growing in popularity:– Performance– Weight– Recycability– Recycled content

Polymer switch & material switchThermoformed sheet: move from PVC, PS to PETBottle: move from PVC, glass to PETStill has opportunities for lightweighting but increasingly challenging ……

Sector and product level pack weight dataEnables benchmarking for optimum pack weights.Data covers all pack inc cap/label.

‘Best in Class’ benchmarking …..

Moving to ‘best in class’ProductPackaging weight in 2003

(Tonnes ) Packaging weight reduction if all moved to the

BIC (Tonnes)

1 Wine bottles 274,817 107,000

2 Beer bottles 51,608 19,641

3 Ketchup table sauce 21,632 13,666

4 Frozen ready meals 18,100 11,601

5 Whisky and vodka 49,129 10,546

6 Carbonates (cans) 28,158 9,972

7 Beer cans 27,602 9,171

8 Carbonates (PET) 74,218 8,833

9 Frozen pizza 12,003 8,005

10 Cooking sauce jars 62,984 7,170

11 Fruit juice cartons 30,175 5,595

12 Pet food (cans) 47,773 5,435

13 Cows milk (cartons) 7,597 4,419

14 Water bottles (PET) 25,371 3,468

15 Cows milk (plastic) 62,570 3,076

Estimated total 756,472 222,375

WRAP Innovation fund: PET Bottle Lightweighting projects

…… but why the need for trials

and their relevant supply chains & customers

http://www.cokecce.co.uk/cce/home.jsp

Challenges

Lowest practical ‘best in class’ weightsBranded: shape retentionDesign optionsProcessing options‘Step change’ opportunities

Esterform project2L CSD bottle, 500ml water bottleReduction:

2L: 42g to 40g : 4.8%500ml: 25g to 20g: 20%

Both new ‘best in class’ for category.2L: Own brand CSD500ml: carbonated Radnor Hills waterFocus on lightweighting through design of body/base.

500ml CSD bottle

Retained std neckBody and base design changes25-20g incremental steps using different preformsDifferent preforms designs4 & 5 foot bases trialledOvercome nesting challenge

500ml CSD bottleFindings:5 foot base provides better material distribution, strength and stability. Less distortion by carbonation.4 foot base is standard and accepted design.Shorter preform with wider diameter performed best.20g bottles with 4/5 feet were trialled successfully for production, filling, capping and labelling.

EsterformEnergy saving due to resin reductionEsterform total = 200MWhr

Coca-Cola Enterprises Ltd

CCE's 500ml light weighting progress

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Coca Cola Enterprises

Challenge:To move evaluate feasibility of moving all UK production from 26g to 24g 500ml bottle for all 500ml CSD bottles -c7.5% reductionRetain iconic bottle designsStringent internal testing procedures4 UK production sitesVarying blow mould equipment

Trials

Developed a new innovative preform design to allow material distribution and retain wall strength.Shorter preform pilot tooling trialsStepped trials on all 4 CCE sitesCulminating in 4m bottles being produced for market trials from 2 sites

Outcomes

24g Bottle successfully produced and approved for use.

CCE committed to move to 24g in Sidcup (Sept 2007) and Wakefield (part production start 2008).Bottle blowing equipment at some sites less capable of blowing 24g bottle efficientlyInvestment needed to allow roll out to all production - pending.

Reports, case studies etc ….

Reports or case studies available for projects that have completed.www.wrap.org.uk/retail

Future picture for PET packaging……..

PET recyclingConsumers increasingly engaged with recyclingPlastic collection will growUK reprocessing capacity is increasing

Post consumer plastic collection

• Mixed bottles collected c45% is PET, 45% PE, 10% other/caps• c132,000t of post-use mixed plastic collected (annualised Q4 2006)• 50% of homes have plastic collection

Oil prices?As a general rule, less packaging = less cost …..and less carbon

Material cost …..

Consumer behaviour

• Will want convenience, Value, Choice• But is going to be more demanding:

– ‘Green’ shopper– Carbon– Recycability– ‘Excess’ packaging

• Greater need for education

904g486g

Filled weights

Glass to PET

Carbon

Carbon foot printing/labelling is likely to be more understood and importantGreater need to look at carbon not just recycability, weight etc – more complex.What we do know:

– less material = less carbon– lightweight packaging = less carbon– recycled content = less carbon

WRAP LCA on 500ml non-carbonated drinks bottles:– PET, PE, PLA, Cartons, Glass– Recycling, composting, landfill, incineration

considered.– Due to be published in August

Summary

It’s a changing world!

PET lightweighting needs to continue:– Incrementally– Step change

Carbon debate will require a more radical approach.

PET has a great opportunity in retail packaging.

Thank you

[email protected]

. . . . . . . . . .. . . . . . . . . . LINRO LIMITED . . . . . . . . . .LINRO LIMITED . . . . . . . . . .WRAP ConferenceWRAP Conference

Next Steps in Bottle Lightweighting 26Next Steps in Bottle Lightweighting 26thth June 2007June 2007

Where is the Market Going?Where is the Market Going?Robin YoungRobin Young

. . . . . . . . . .. . . . . . . . . . LINRO LIMITED . . . . . . . . . .LINRO LIMITED . . . . . . . . . .

19811981--20072007Gradual weight reductionsGradual weight reductions

19811981 19971997 20072007 SavingSaving AverageAverage2.0 litre Carbonates2.0 litre Carbonates 60g60g 4444--42g42g 26%26% 1%/yr1%/yr500ml Carbonates500ml Carbonates 34g34g 2626--24g24g 23%23% 2.3%/yr2.3%/yr500ml still500ml still 28g28g 18g18g 36%36% 3.6%/yr3.6%/yr


Historical Barriers to LightweightingHistorical Barriers to Lightweighting

TECHNOLOGYTECHNOLOGY

CONSUMER RESISTANCECONSUMER RESISTANCE

Fit for PurposeFit for Purpose



Technological ImprovementsTechnological Improvements

Improved Oven, stretching and air control with closed loop monitImproved Oven, stretching and air control with closed loop monitoringoringImproved PET material grades and improved temperature uptake.Improved PET material grades and improved temperature uptake.Improved preform and bottle design technologyImproved preform and bottle design technologyIntroduction of FORM/FILL/SEAL technology for PET bottles.Introduction of FORM/FILL/SEAL technology for PET bottles.



FORM/FILL/SEALFORM/FILL/SEAL

Form/fill seal is a lightweighting toolForm/fill seal is a lightweighting tool

The bottle is handled by the neck as it is blown, filled and capThe bottle is handled by the neck as it is blown, filled and capped.ped.

Removes the need to handle flimsy empty bottles allowing thinnerRemoves the need to handle flimsy empty bottles allowing thinner wall wall sectionssections

Permits ULTRA LIGHTWEIGHTINGPermits ULTRA LIGHTWEIGHTING

Conclusion: The technological barrier to ULTRA lightweighting haConclusion: The technological barrier to ULTRA lightweighting has been s been removedremoved



TECHNOLOGYTECHNOLOGY

CONSUMER RESISTANCECONSUMER RESISTANCE

Fit for PurposeFit for Purpose


Historical Barriers to LightweightingHistorical Barriers to LightweightingConsumer ResistanceConsumer Resistance

POLITICAL and CULTURAL CHANGE OF POLITICAL and CULTURAL CHANGE OF CLIMATECLIMATE


Historical Barriers to LightweightingHistorical Barriers to LightweightingConsumer ResistanceConsumer ResistancePOLITICAL and CULTURAL CHANGE OF CLIMATEPOLITICAL and CULTURAL CHANGE OF CLIMATE

The constant barrage of media publicity/propaganda which will onThe constant barrage of media publicity/propaganda which will only increase ly increase as it is at the top of the political agenda, has already affectas it is at the top of the political agenda, has already affected our ed our consciousness and lifestyle.consciousness and lifestyle.We are already aware of our carbon footprint and we have alreadyWe are already aware of our carbon footprint and we have already adapted adapted our habits by sacrificing convenience for our habits by sacrificing convenience for ““the greater good of the planetthe greater good of the planet”” ––some examples:some examples:

ReRe--useable shopping bags useable shopping bags –– a return to the shopping baskets of old?a return to the shopping baskets of old?Fortnightly bin collectionsFortnightly bin collectionsSeparating household wasteSeparating household wasteSwitching off computers and their transformersSwitching off computers and their transformersEco friendly light bulbsEco friendly light bulbsRoad milesRoad milesCongestion chargesCongestion charges


Historical Barriers to LightweightingHistorical Barriers to LightweightingConsumer ResistanceConsumer ResistancePOLITICAL and CULTURAL CHANGE OF CLIMATEPOLITICAL and CULTURAL CHANGE OF CLIMATE

ConclusionConclusionThe consumer is aware that plastic packaging uses non renewable The consumer is aware that plastic packaging uses non renewable resources resources

and contributes to landfilland contributes to landfillThe consumer will accept some inconvenience as his or her contriThe consumer will accept some inconvenience as his or her contribution to a bution to a

reduction of their carbon footprintreduction of their carbon footprint

Has this removed the Consumer Resistance barrier to Ultra LightwHas this removed the Consumer Resistance barrier to Ultra Lightweight eight bottles?bottles?There is already a challenge to the PET bottle from the flexibleThere is already a challenge to the PET bottle from the flexible PouchPouch


On The Market Today in PETOn The Market Today in PET

UltraUltra StandardStandard SavingSaving330ml Still Water330ml Still Water 4.5g4.5g 18g18g 75%75%

1.0 litre Edible Oil1.0 litre Edible Oil 15g15g 24g24g 37%37%

1.5 litre Still Water1.5 litre Still Water 20g20g 30g30g 33%33%

100ml Probiotic100ml Probiotic 5g5g 7g7g 28.5%28.5%

100ml drinking Yogurt100ml drinking Yogurt 2.4g2.4g ---- ----



ConclusionConclusion

TECHNOLOGY TECHNOLOGY –– Barrier RemovedBarrier RemovedCONSUMER RESISTANCE CONSUMER RESISTANCE –– Barrier Barrier RemovedRemovedFit for PurposeFit for Purpose

When considering any level of When considering any level of lightweighting, the consumer should be lightweighting, the consumer should be made aware of the carbon footprint benefits made aware of the carbon footprint benefits


Thank YouThank You

Next steps in PET bottle light weighting

Triple Bottom Line Savings-Waste, Carbon and Costs

Professor Edward KosiorManaging DirectorNextek Limited

Overview• The Light Weighting of existing

bottles• Target weights for PET bottles• Savings in materials, carbon and costs

250 ml Bottles

Estimated weights of 250mL bottles in the UK marketplace

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Millions of Bottles Produced

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330 ml BottlesEstimated weights of 330ml bottles in the UK marketplace

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Millions of Bottles Produced

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Recommended Target Weight: 16gm Key Targets

500ml CSD Bottles

Estimated weights of 500ml csd bottles in the UK marketplace

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1000 ml CSD Bottles

Estimate

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d weights of 1L csd bottles in the UK marketplace

5 10 15 20 25 30 35

Millions of Bottles


1000 ml Water Bottles

Estimated weights of 1L still water bottles in the UK marketplace

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2000 ml Bottles

Est

39404142434445464748

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imated weights of 2L bottles in the UK marketplace

100 200 300 400 500 600

Millions of BottlesRecommended Target Weight: 39gm

Key Targets

The Savings

Savings delivered by light weighting PET

Each one gram saved on a preform used for a market of 100 million bottles saves•100 tonnes of PET•£80,000 of costs for PET resin at £ 800/tonne•80,000 kWhr of energy for preform moulding•2670 kWhr of energy for preform heating for blow moulding•36 tonnes of CO2 being generated•27.2 tonnes of Carbon being used

Assumptions for savings calculations

•The best in class weights or feasible targets were used to model savings•Tonnage savings greater than 90 tonnes /year were considered financial viable •This is equivalent to savings in resin of more than £200,000/yr•The ratio of data submitted by fillers was used to model the UK industry

Data submitted to the seminar

Fillers Volume millions pa

Tonnes used

Ave bottle weight

Annual weight saving tonnes

PET

% Weight saving

Ave % Light weighting

Cost savings

Fillers total 3648 109148 28 12425 11% 14% £9,940,351Moulders total 953 24103 26 3166 13% 24% £2,532,400

Potential weight saving projectsBottle Type (carbonated,

water, or juice)

Fluid Capacity

(ml)

Quantity produced per annum (millions)

Current Bottle

weight (g)

Light weight target

saving grams per preform

Annual weight saving tonnes

PET

tonnes used

% weight saving

Cost savings

Juice 200 22,087 17.5 14.5 3 66 387 17% £53,009Juice 200 26,099 17.5 14.5 3 78 457 17% £62,638juice 250 5.5 20 14.5 5.5 30.25 110 28% £24,200Juice 1000 4,280 39 25 14 60 167 36% £47,936Juice 200 28,197 17.5 14.5 3 85 493 17% £67,673Juice 200 41,984 17.5 14.5 3 126 735 17% £100,762Juice 200 47,182 17.5 14.5 3 142 826 17% £113,237Juice 200 67,559 17.5 14.5 3 203 1182 17% £162,142Juice 200 107,272 17.5 14.5 3 322 1877 17% £257,453Juice 300 25,571 20.5 16 4.5 115 524 22% £92,056Juice 300 30,043 20.5 16 4.5 135 616 22% £108,155Juice 330 60 21 16 5.0 300 1260 24% £240,000Juice 440 12,147 31 20 11 134 377 35% £106,894Carbonated 500 13,679 26 20 6 82 356 23% £65,659Carbonated 500 23,526 28 20 8 188 659 29% £150,566Still 500 60 25.5 20 5.5 330 1530 22% £264,000Carbonated 500 88,016 26 20 6 528 2288 23% £422,477CSD 500 800 26 24 2.0 1600 20800 8% £1,280,000Juice 1000 5,609 40 25 15 84 224 38% £67,308Juice 1000 5,600 43 25 18 101 241 42% £80,640juice 1000 7.9 40 25 15.0 118.5 316 38% £94,800Juice 1000 13,187 38 25 13 171 501 34% £137,145Juice 1000 13,191 40 25 15 198 528 38% £158,292Juice 1000 16,242 40 25 15 244 650 38% £194,904CSD 1000 80 36.5 30 6.5 520 2920 18% £416,000Carbonated 1000 118,044 36 30 6 708 4250 17% £566,611still water 2000 70 43 40 3.0 210 3010 7% £168,000Juice 2000 156,084 43 40 3 468 6712 7% £374,602CSD 2000 500 42 40 2.0 1000 21000 5% £800,000

Total 8346 74994 11% £6,677,156

Summary of savings that could be achieved by companies at this conference

•Based on 74,994 tonnes of current PET useage•Average weight saving is 11%•Tonnage saved is 8346 tonnes of PET•Cost savings of £6,677,156•Ratio of “viable projects” was 69%

Projections for the UK PET market•PET resin savings of 15,300 tonnes per annum•Equivalent to 510 million bottles diverted from waste•Energy savings 12.6 million kWhrs•CO2 emission savings of 5500 tonnes•Carbon savings of 4160 tonnes•Cost savings of £12.2 million

Tonnes saved Bottles equivalent

Energy Saving

CO2 Saving

Carbon Saving

Resin Cost saving

Power cost saving

Tonnes pa Millions at 30 gm/bottle

kWhr tonnes tonnes 0.05£/kWhr

15294 510 12,643,420 5506 4160 £12,235,074 £632,171

next steps in lw pet bottles

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