INSPECTION 38 PETplanet Insider Vol. 19 No. 03/18 petpla.net Preform temperature – the invisible parameter As the world advances towards half a trillion plastic bottles/annum by 2021, productivity is hampered by large inefficiencies frequently caused by temperature variables such as operator subjectivity, environmental changes and variation in material properties. This gives rise to over-engineered bottles, product defects and machine down-time. However, a greater understanding of temperature in the SBM process will lead to more optimised bottle production, greater productivity and reduce energy consumption. It will ensure the consumption of fewer raw materials; generate less waste and decrease product defects, thus reducing trouble-shooting, product deformation, and machine down-time. It will lead to lighter more efficient preforms which can still reach the targeted performance standards such as ‘shelf-life’ and ‘top-load’, with greater ease of manufacture. Blow Moulding Technologies (BMT) developing state of the art temperature measurement technology for the stretch blow moulding industry. Launched in 2011 as a spin-out from Queen’s University of Belfast ‘Advanced Materials and Manufacturing Group’, BMT’s unique products and services are designed to solve problems in production trouble-shooting and to enhance bottle efficiency. BMT’s clients span far and wide, with their products and services in frequent use by major multi-national players across USA, Europe and China. Due to the unique optical characteristics of polymers in general, preforms develop a different temperature profile inside and outside. Depending on the type of lamp, power, cooling conditions, as well as the grade of the polymer, the difference between the internal and external temperature profile can be 10 degrees or more. Such a difference can be useful as the internal preform wall has to travel and deform further than the external one. However, in certain conditions, minimising temperature difference is paramount, such as, in multilayer preforms where a large difference in temperature profile can lead to localised layer delamination. BMT’s recently launched Thermoscan 3D is a simple to use offline device which enables the accurate and simultaneous measurement of the internal and external preform temperature profile on a longitudinal and/or circumferential (Fig. 1) scan path. As temperature is a non-visual parameter it can be difficult to understand these variations and the impact it has within the process. Without a clear temperature map, managing temperature settings can often prove difficult, and can lead to temperatures exceeding the required tolerances desired to achieve the optimum plastic bottle. In addition, BMT developed proprietary software to evaluate through thickness temperature distribution (Fig. 2) to allow further in depth preform temperature understanding. Thermoscan 3D provides engineers with the knowledge and data required to improve their understanding of temperature control during the production process. It can be used in both the SBM production environment, during the bottle R&D phase and facilitates the scale up from the R&D lab to production. As opposed to pressure, pre-blow timing and other machine parameters that affect preform processing globally, temperature is the only factor that Fig. 1 Fig. 2,@ID:40}, BOTTLING / FILLING PETplanet Insider Vol. 19 No. 03/18 petpla.net 25 Filling management and full container inspection The Heuft Spectrum II VX combines highly precise inspecting and monitoring functions with the advantages of the new Heuft Spectrum II platform. This makes an extensive fill management easier - new detection technologies identify lost fill tubes and even cloudy products. The Heuft Spectrum II VX checks the fill level, the closure and the label presence of up to 100,000 containers per hour as a full container inspector. It takes over the continuous monitoring of the filler and closer as a fill management tool. The modular system of the new generation combines proven detection units with a very high degree of automation and the audiovisual Heuft NaVi user guidance. Underfilled and overfilled bottles can be identified with this just as easily and reliably as those which are incorrectly sealed or unlabelled. A new add-on module for a safe fill tube detection and innovative optics for the reliable identification of product cloudiness are integrated. The Heuft Spectrum II VX constantly monitors all the filler valves and closer heads. It provides exact data about their respective performance in order to easily pinpoint the causes of quality defects. Malfunctions which result in costly serial faults and high rejection rates are identified before they can thwart the efficiency and productivity of complete filling lines. Further standalone modules for a detailed label and closure inspection can be connected without a problem. All-around inspection of returnable PET bottles before cleaning A new solution based on the platform is for bottlers of returnable PET: the new washing machine infeed check finds returnable PET bottles which could cause malfunctions and standstills during the cleaning process and in downstream inspectors (e.g. the “sniffer”) and sorts them out in good time. Non-brand, misshapen, defective, closed, extremely soiled bottles or those contaminated with foreign objects are detected as reliably with it as those polluted with critical liquids. A special IR based inspection module detects the fill level of residual liquids. Severe deformation is already detected before the infeed by means of ultrasonics. There are six cameras available for the sidewall inspection. Thus the contour examination is just as reliable as the verification of imprints, label remains and rose embossing. In addition the colour of the residual liquid contained inside and the presence of large foreign objects as well as severe contamination can be clearly identified. This not only ensures a top quality empty bottle pool but also maximum line efficiency and productivity. www.heuft.com BOTTLING / FILLING 25 Filling Special,@ID:27}, BOTTLING / FILLING PETplanet Insider Vol. 19 No. 03/18 petpla.net 34 A modular rotary machine concept for the hygienic filling of sensitive beverages Hygiene customised A new modular system with rotary machines for hygienic filling gives producers of sensitive beverages the exact degree of safety they need. Customised to suit their respective hygiene requirements, reliable and economical systems can be configured which prove convincing in practice. Filling Special The new rotary filler blocks are precisely tailored to suit hygiene requirements with standardised modules which can be easily configured. Compared to the classic means of preserving food and beverages, aseptic filling is a gentle alternative which does not have a detrimental effect on either the product taste or vitamin content. It is thus with good reason that this method has vastly increased in importance over the last ten years. As one of the founders of this technology KHS is therefore one of the specialist in the filling of sensitive beverages such as milk, mixed milk drinks and juice. Modular and tailored to requirements The company has now presented a new development which has a positive impact on the company’s portfolio: a concept which satisfies all hygiene specifications and required production capacities. The system’s most important classification criteria are the hygiene categorisation classes specified by the German Engineering Association, VDMA. A distinction is made between the following three categories for the filling of sensitive products: Class III (ultraclean filling): includes low-germ filling products such as fresh juice and slightly carbonated spritzers; depending on the product specifications, natural and drinkable yogurt with a shelf life of less than 14 days. Class IV (extended shelf life): pertains to dairy products in the cold chain, such as ESL milk with a shelf life of 28 days, natural and drinkable yogurt, cold-filled smoothies and iced tea and fruit juices which have to be filled without the risk of recontamination. Class V (aseptic filling): includes germ-free products to be filled, such as UHT milk and cream which uncooled have a shelf life of several months, and non-carbonated water, juice beverages and nearwater beverages. For each of these hygiene classes the new KHS concept has its own machine engineering adaptations in the form of standardised modules. In the future the filler can be configured depending on which hygiene class a bottler’s products fall under and precisely tailored to suit the exact specifications of each and every customer. Adjusted to the producer’s capacity requirements, the KHS concept can cater for outputs ranging from 24,000 to 54,000bph. The system offers plenty of scope as regards the bottle size, too; the combination of container volume and output capacity can be configured for 500ml, 1.0l and 1.5l. Based on its many years of experience KHS has opted for a method of preform, bottle and cap sterilisation which is considerably easier to operate than the aseptic blow moulder setup. “Keeping a rapidly rotating blow moulder permanently sterile is a very complex challenge - one without any notable benefit,”states Thomas Niehr, head of Aseptic Filling Technology at KHS. “A lot of time and effort is involved in format changeovers to prevent the sterile blow moulder from being recontaminated. This makes great demands of the operator and the machine environment and poses a high risk of serious errors.” In the rotary machine range a future alternative to the proven bottle sterilisation system on the Innosept Asbofill ASR is proffered by the new Innosept Asbofill ASR 2Step. This differs from the classic version that it integrates new, space-saving H 2 O 2 systems on the transfer stars between the stretch blow moulder and filler. This reduced form of bottle sterilisation is made possible by the preforms being sterilised at the infeed to the stretch blow moulder. On the Innosept Asbofill ASR 2Step there is thus no need for a sterilisation carousel and the drying module can be made much smaller. Both features result in a system which is much neater and more compact.,@ID:36}, BOTTLING / FILLING PETplanet Insider Vol. 19 No. 03/18 petpla.net 35 Preform sterilisation The 2Step sterilisation has the advantage that it is much simpler to perform and that product-dependent parts and moulds can be replaced much faster than on a sterile blow moulder. On the stretch blow moulder changeovers are made under normal environmental conditions; this does not affect the degree of microbiological risk. In this context Niehr refers to another important benefit of 2Step sterilisation.“Preform sterilisation enables the bottle material to be disinfected upstream of the stretch blow moulder. Experience has shown that only few very micro-organisms come again into contact with the bottle in the stretch blow moulder. Bearing this in mind we can considerably streamline the disinfection of the ‘finished’ bottles, which in turn greatly reduces the footprint of our machine.” Another advantage of this process is that in aseptic filling according to hygiene class V the amount of hydrogen peroxide required for sterilisation can be decreased and the bottle drying temperature lowered. For reliable, recontamination-free filling it is of central importance that the aseptic or hygienic zone and the external influences on this zone are kept down to a minimum. This means that all modular fillers can be blocked with standard stretch blow moulders from KHS. A specially developed block module for the hygienic transfer of the fully blown bottles to the filler reduces the space requirement, lowers the amount of investment, cuts down on the installation effort and calls for much less intervention in the customer’s infrastructure. “Safety always comes first,” explains Niehr. “As simpler the cleaning and monitoring of the system, as lower is the risk of recontamination. This is why all electronic components, drives, wires and piping are positioned outside the aseptic zone; even with the capper only the cone is in the area to be sterilised. The fewer parts there are in this section, the less I have to keep clean as a bottler.” A sophisticated room-within-a-room concept with cladding doors mechanically protects the seals in the aseptic section, providing not only maximum hygienic safety but also ease of operation. The principle of clearly separating the process and filler areas is another plus where hygiene is concerned. The valve manifold and sterile air filter are placed at the top of the systems to keep the space The modular design of the rotary filler block is flexible with regard to its hygiene class and capacity. It cuts costs and reduces delivery times. required for the sterilisation unit, filler and capper as small as possible. The aseptic zone on KHS’ rotary machines takes up just 12 to 14 cubic meters of space, depending on the container size. Economical system Alongside all of the hygienic safety features, for which KHS’ entire sensitive product portfolio has stood for many years, the modular system gives sensitive beverage bottlers three main advantages, emphasises Niehr. “Firstly, thanks to the concept of modularisation our customers can configure their machines exactly according to their requirements. Oversized systems not running at full capacity often lead to longer downtimes which always increase the risk of contamination. Secondly, modularisation leads to standardisation, which in turn means that in principle all basic and module parts can be pre-produced and stocked by KHS. The customer thus benefits from shorter delivery times. And thirdly, the modular system also generates certain cost benefits,” concludes Niehr. “These savings give us additional scope for integrating further safety systems, with which we consistently endeavour to permanently increase the standard of safety on our aseptic filling machines.” www.khs.com Preventive maintenance of aseptic machines The standards of quality in hygienic filling are high – as is the cost of production downtime. KHS provides a proven preventive maintenance system for both the linear and rotary version of its Innosept Asbofill aseptic filler – with fixed modules at fixed prices. KHS offers special maintenance modules which Thomas Niehr, head of Aseptic Filling Technology for KHS in Bad Kreuznach, Germany, describes as being comparable to a service for a car. The intervals are always gauged by certain time cycles and machine operating hours, with KHS providing the material packages and engineers. During maintenance not only are smaller wear parts replaced; the overall condition of the machine is inspected and settings are corrected where applicable. The customer is given detailed information on all results in a concluding machine status report. “We coordinate the entire maintenance management process together with the customer. This again increases machine and production safety and reliability. A dairy, for instance, can’t afford long downtimes. Customers know exactly how much maintenance costs them. It’s also possible to compute costs according to the number of bottles filled, with a fixed allocation of maintenance costs to product giving bottlers planning security,” Niehr emphasises. Physically separating the process technology (above) from the filling system (below) results in a smaller aseptic zone and improved hygiene.,@ID:37}, PETpatents www.verpackungspatente.de PETplanet Insider Vol. 19 No. 03/18 petpla.net 48 Lightweight bottle for drinks Internal Patent No. WO 2016 / 019318 A1 Applicant: The Coca Cola Comp., Atlanta (US) Application date: 31.7.2015 This describes the special shaping of the base of a bottle for carbonated drinks. Special shaping, including a manufacturing process, is required to save weight in the base area. Base shaping International Patent No. WO 2016 / 029023 A1 Applicant: Amcor Ltd., Victoria (AU) Application date: 20.8.2015 Described here is the shaping of a plastic bottle with a movable – foldable – base, either to balance pressure differences or to increase the internal pressure by folding the container “inwards” to make the bottle more stable. Lighter container International Patent No. WO 2016 / 028393 A1 Applicant: Amcor Ltd., Victoria (AU) Application date: 29.6.2015 International application for the structure and shaping of a lighter weight container. Container without support ring International Patent No. WO 2014 / 053212 A1 Applicant: Alpla Werke Alwin Lehner GmbH & Co. KG., Hard (AT) Application date: 11.9.2013 Application for structure and manufacturing procedure for a plastic bottle without support ring. Plastic container European Patent issue No. EP 2799354 B1 Applicant: Yoshino Kogyosho Co. Ltd., Tokyo (JP) Application date: 10.12.2012 Plastic bottle with a special integrated grip created by partial processing/compression of the bottle during manufacturing. Plastic bottle European Patent issue No. EP 2857321 B1 Applicant: Yoshino Kogyosho Co. Ltd., Tokyo (JP) Application date: 24.5.2013 A plastic bottle with reinforcement ridges in the side wall and a base specially formed for pressure equalisation is issued with a European patent. Several variations and sizes of base shape are described.,@ID:50}, BOTTLING / FILLING PETplanet Insider Vol. 19 No. 03/18 petpla.net 36 Soft drinks and beer for Laos by Kay Barton Lao Brewery Company (LBC), based in Vientiane, the capital of Laos, is the country’s market leader in each of the three categories in which it operates: beer, drinking water and carbonated soft drinks (CSD). LBC’s iconic beer brand, Beerlao, has the reputation of being a trustworthy beer brand, with a high profile and immediately identifiable image. Lao Brewery Company is a joint venture between Carlsberg Group and the Lao State. With three production facilities, it is one of the biggest companies in Laos. Currently, the company bottles some 20% of its output in PET; Beerlao packaging is currently some 75% in glass and 5% in cans. Supply Chain Director Duncan Crow took time to talk with us about how the business came into being, its technology, and the future. Lao Brewery Co., Ltd., June 29, 2017 We met: Mr Duncan Crow, Supply Chain Director The LBC head office and main brewery are separated by the wide main street in Vientiane’s business district. The office complex, on our right as we approach from downtown Vientiane, also hosts its showroom and merchandise shop of the Lao Brewery. Founded in the early 1970s as co-operative by businessmen from France and Laos, the brewery was nationalised by the government in 1975. The gradual opening up of the market for foreign investors allowed Carlsberg Group to acquire shares in the business in 2002, before it was able to form a full joint venture in 2005. In addition to Beerlao, the house beer brand, the “Tigerhead” line of water beverages has now been in existence for some 20 years and is bottled in four different pack sizes. LBC is also the market leader for drinking water, with an estimated 60% market share. The consumer preference for premium drinking water is moving towards smaller bottles, under 500ml; an aspect of the local culture is for water often to be given as a free gift, especially at festivals. Its third Filling Special Tour Sponsors: Duncan Crow sees growth especially in water and CSD. Beer Lao’s administration premises business segment is bottling Pepsi CSD products. LBC operates three production locations, two of which are located in Vientiane; the third is in the south of the country. Total annual production amounts to approximately 300 million litres of beer, 150 million litres of water and 80 million litres of soft drinks.,@ID:38}, PETnews 6 NEWS PETplanet Insider Vol. 19 No. 03/18 petpla.net Bottling manufacturing to take centre stage at NPE2018 The only show feature of its kind in the United States, the Bottle Zone at NPE2018 will showcase more than 80 companies within more than 5,300m2 on the show floor. The exhibits within the zone will promote the latest advancements, products and trends in bottling and container manufacturing for this booming sector of the plastics industry. With higher consumption of bottled products and low cost of materials, the NPE Bottle Zone provides a place for manufacturers and suppliers to explore ways to incorporate new technology, supplies and equipment into their manufacturing processes. The NPE Bottle Zone, presented with supporting partners PETplanet, drinktec and the International Society of Beverage Technologists (ISBT), intends to give attendees access to everything needed for competitive success. With the Bottle Zone, NPE2018 provides a deeper look at issues important to this vertical segment to ensure they are able to more effectively meet consumer demands, such as sustainability and safety, while giving manufacturers the ability to invest in new technology and solutions to address these challenges and opportunities “Plastics are integral to the bottling world’s ongoing success and continued innovation,” said William R. Carteaux, president and CEO of the Plastics Industry Association. “This vital industry segment hasn’t had a singular event and exposition where solutions providers and industry professionals can gather to exchange new ideas, technologies and answers to the unique challenges facing the beverage, bottling and PET market. The Bottle Zone at NPE2018 will change that. This is where every company in the bottling supply chain can connect with market-leading equipment and solution providers and access the combined expertise they need to move their businesses forward.” The show floor will give leaders in bottling, pharmaceutical and container manufacturing the ability to explore the next generation of bottles and containers from 80-plus manufacturers and suppliers: resins, colourants, additives, preforms, moulds, dryers, labelling, filling, capping, closure design, compressors, inspection equipment and recyclers. The Bottle Zone Technical Forum conference, hosted by PETplanet and ISBT will put front-and-centre the innovations, trends and data focused on recent advances and the next-generation technology driving the future of bottling. Topics covered in the Technical Forum will include: preform and closure manufacturing; bottle blow moulding technologies; bottle filling and inspection; downstream packaging and recycling; and raw materials, additives and barriers. And, in the NPE Bottle Zone Biergarten, plastics professionals and bottling manufacturers will have a place to do business with new and existing partners, socialise with colleagues and mix with industry leaders and experts. In addition to the programming featured in the Bottle Zone, NPE2018 will play host to the 2018 Re|focus Sustainability & Recycling Summit, designed for plastics and packaging leaders. Of particular interest for bottling manufacturers is the panel discussion Biobased Bioplastic Polymers and the Future of Bottling with focus on innovations in plastics derived from renewable sources and the positive impact it will have on manufacturing operations. NPE2018: The Plastics Show - produced by the Plastics Industry Association (PLASTICS) and set to stage May 7-11, 2018, at the Orange County Convention Center in Orlando, Florida, USA - is featuring more than 2,000 suppliers from across the globe, nine targeted conferences, and more than 65,000 manufacturing leaders. www.npe.org/bottlezone Frutarom opens colour formulation centre in Slovenia Frutarom recently opened a natural colour formulations centre at its Etol plant in Celje, Slovenia, to provide its European customers full, customised service. The centre will help clients with natural colours application, creating natural flavour combinations, and utilisation of its beverage compound technologies. Frutarom invested €5 million in advanced equipment and technology for the new facility. The new formulation hub will serve 15,000 Frutarom’s customers in Europe— about 50% of the company’s global customers. The 90-year-old company Etol was acquired by Frutarom in 2012. Frutarom has become one of the top five suppliers of natural colours worldwide following its acquisition of several natural colours companies, and major investments in building fully integrated, safe, and controlled supply chains. The company has experienced double-digit growth annually in the natural colourants segment. Frutarom initiated dozens of agriculture collaborations with local farmers in multiple locations and countries to ensure the supply of continuous and sustainable natural sourcing of pigments and food colourings. In addition, the company has increased the technical competencies for its extract capabilities. www.frutaromnatural.com,@ID:8}, BEVERAGE INGREDIENTS PETplanet Insider Vol. 19 No. 03/18 petpla.net 18 With protein enrichment increasingly moving into more mainstream products, taste has become a crucial concern Masking the taste of protein Protein is a mega trend. Formerly used by athletes as a staple for building muscle, most consumers are now well aware of the need for high protein levels in their diet. However, manufacturers who want to capitalise on its current popularity and include protein in their formulations are faced with sensorial disadvantages associated with most of the available protein sources. Animal as well as vegetable variants often add an unpleasant mouthfeel and off-notes that can best be described as dry and bitter, or even cardboard-like. To mask these undesirable attributes, Sensient Flavors, one of the world’s leading flavour manufacturers, has developed a solution that is based on a combination of different flavouring technologies. This approach is suitable for all protein sources and can be applied to all kinds of flavoured products. The number of consumers seeking out foods with high protein content has skyrocketed in the past years. By 2018, the global market for protein ingredients is forecast to increase in value to $31 billion (based on estimates by Frost & Sullivan and Grand View Research). Consumers buy into protein-rich products for health reasons in particular. They want to increase their muscle mass, maintain their weight or achieve a toned and well-defined body – and protein is the perfect ingredient for reaching these goals. It is also very beneficial for the body as it grows older. In view of the world’s ageing population, it therefore has the potential to help vast numbers of people lead more active lifestyles. Another protein plus-point lies in consumer perception: fats and carbohydrates are split into “good” and “bad” variants by health professionals. However, proteins are generally perceived as being “good” and thus as a key element of a balanced and healthy diet for all age groups. Applications The current high demand for protein has stimulated the creativeness of product developers across the globe, with innovation in high protein launches having been driven by the snack and dairy segments in BEVERAGE +ingredients,@ID:20}, 43 PRODUCTS PETplanet Insider Vol. 19 No. 03/18 petpla.net , / 0 Toronto New York Atlanta Orlando Denver Las Vegas Seattle Los Angeles San Francisco Vancouver Dallas New Orleans Phoenix Washington, D.C. Boston Detroit Kansas City Oklahoma City Albuquerque Milwaukee Chicago Minneapolis Charlotte Ottawa Montreal Quebec www.npe.petpla.net March – August 2018 The North American Road Show - Bottle Zone on tour PETplanet has successfully deployed its “Editourmobil” Road Shows across the world for seven years now. This is in addition to traditional forms of reporting; we have found that travelling by road enables deeper insights into markets; interviews with bottlers, suppliers and manufacturers can be conducted with greater flexibility, both in cities and in more rural areas. The appearance of the Editourmobil has created quite a stir in several countries - in addition to the impact of the interviews and meetings themselves. The Editourmobil is to return to North America once again, in cooperation with the NPE trade show (May 7 – 11, 2018 in Orlando, Florida). From March through August 2018 - three years after our last tour in 2015, which proved to be very successful - the PETplanet team will, once again, visit a variety of locations across the USA and Canada. The “Editour“ journeys will take in professional discussions and interviews with market leaders from the West to the East Coast. We will be stopping off at the NPE show itself, where the PETplanet and Editourmobil team will present initial reports of our visits and interviews. We will be part of the new Bottle Zone, which will be a first for us as well! Make sure you’re on board with us when we set off again. Get ready for in-depth analyses of the special features and trends in the bottles and beverages sectors of North America! All aboard! Premium Sponsor to date Sponsors to date The worldwide round trip with,@ID:45}, 8 NEWS PETplanet Insider Vol. 19 No. 03/18 petpla.net Petcore Europe launches Plastic Aerosol Recycling Special Industry Group Petcore Europe has created the new Plastic Aerosol Recycling Special Industry Group (SiG) in order to anticipate the need to recycle higher amounts of plastic aerosols. This industry task force is therefore looking for ways to increase the recycling volumes of PET products from the household packaging waste stream. In 2020, the Aerosol Dispenser Directive (ADD) will potentially allow plastic aerosols beyond 220ml in Europe. “Currently, the capacity is restricted due to the fact that theADD was written in a time when only brittle plastics were available. This led to the approach to treat plastics the same way as coated glass containers”, explains Chairman Johannes Burghaus the background of the new SiG. “With PET we have today an ideal plastic aerosol material at hand. That is why FEA, the European Aerosol Federation, started an approach to change the ADD and allow plastic aerosols beyond 220 ml capacity in 2018.” As this will enable mass market instead of only niche production, the market volume of plastic aerosols is expected to increase. That will eventually lead to a higher amount of plastic aerosol packages in the collection, sorting and recycling systems in Europe. For this reason, FEA and Petcore Europe took the initiative to establish the Plastic Aerosol Recycling Special Industry Group (SiG) under the umbrella of Petcore Europe. The objective of the new SiG is in line with Petcore Europe’s voluntary commitment to grow the volume of recycled PET, also with more difficult recycling streams. www.aerosol.org Anuga FoodTec 2018: The event and congress programme Anuga FoodTec, international supplier fair for the food and beverage industry, will be opening its doors from 20 to 23 March 2018: Around 1,700 suppliers from more than 50 countries will be presenting their new products for the production and packing of all types of food on 140,000m2 of exhibition space in Cologne, Germany. The range of exhibits will once again be accompanied by a multi-faceted event and congress programme, i.e. target group-specific lectures, conferences, forums, guided tours, special events and networking events. The top theme of Anuga FoodTec 2018 is Resource Efficiency. Optimise production processes, reduce the energy and water consumption, minimise the loss of foodstuffs as far as possible: The half-day opening conference of Anuga FoodTec, which is completely dedicated to the theme resource efficiency, demonstrates this and much more. Expert forums From food and beverage technology, to packing, through to current and future trends: The expert forums of Anuga FoodTec offer numerous possibilities of informing oneself and for the exchange with national and international experts. This year’s leading theme ‘Resource Efficiency’ is both the focus of the forum and the opening conference. Two further focuses of the export forums are ‘Themes, Trends, Technologies - that are moving the food industry’ as well as ‘Food Ingredients’. Guided tours The guided tours offer a compact and informative overview of specific themes of the food and beverage industry. In the course of the tours, selected exhibitors will present and explain their products, machines and functions live on-site. Registered visitors can take part in different tours daily. The themes of the guided tours include among others robotics, Industry 4.0, flexibility in the filling and packing technology, meat and dairy technologies as well as packing materials. Speakers Corner and more Anuga FoodTec 2018 exhibitors will present their companies, their product range and/or innovations to a broad trade audience in the Speakers Corner (Passage 4/5). A different theme is on the agenda every 30 minutes. Furthermore, the trade visitors can look forward to special events like the ‘Robotik-Pack-Line’ or a special exhibition on the theme of ‘Packaging Design’ plus numerous live presentations of the exhibitors. www.anugafoodtec.com WikiPETia.info New contents at wikipetia.info corvaglia group announces U.S. expansion in Georgia Switzerland based corvaglia group announced plans to build a new manufacturing facility in Newnan, Georgia. The company provides plastic cap and closure technology solutions to the beverage industry around the world. The new U.S. production facility will compleiment corvaglia’s existing advanced manufacturing operations in Eschlikon, Switzerland and Ixtlahuaca, Mexico. corvaglia’s business begins and ends with closure design and as a vertically integrated supplier of caps and closures for PET containers, corvaglia delivers expertise all along the value chain. Founded in 1991, corvaglia continues to focus on one-piece closure technologies deployed from the design concept all the way through to the consumer. This end-to-end market approach is embodied in their slogan ‘Think, Shape, Make, Apply’ caps. The new U.S. facility will be operational by year-end and utilisze corvaglia’s inhouse proprietary moulds to manufacture lightweight one-piece caps and closures for the North American beverage market. Additionally, corvaglia will bring high-speed digital printing to the new U.S. facility that will provide valuable branding opportunities with virtually no limitations to artwork or graphics. www.corvaglia.ch,@ID:10}, PETplanet Insider Vol. 19 No. 03/18 petpla.net 45 BOTTLES Family smoothie Under its own brand “rio d’oro” and the name Family Smoothie, Aldi Süd is selling a smoothie in an unusual 750ml size as a family pack. The mixed fruit juices have a fruit content of 100% and are made from juice and/or pulp. The clear bottle has easy-grip contouring that features reinforcement ridges in this area and is decorated with a colourful sleeve label featuring illustrations of the main ingredients of the particular flavour variety. www.aldi-sued.de Easy-grip bottle for a refreshing drink Sunny Delight Florida is an orange juice based drink that is free from preservatives and artificial colours and is sold in Spain by Schweppes S.A. Each contoured bottle holds 310ml and has reinforcement ridges in the grip area. There are further horizontal ridges under the plastic label for further stabilisation. At the opening there is a screwed-on seal with a guarantee band and a push-pull top. A transparent, easy-grip protective cap secured with a guarantee band must be removed before first use, to access the push-pull top. www.sunnydelight.es Smoothie with tea Under its own brand “rio d’oro”, Aldi Süd sells a variety of different juices and smoothies and is always looking out for new product ideas. One idea was to combine smoothies with different types of tea. Pictured here are Orange-Apple-Kiwi + Mint Tea and Red Berry-Pear + Jasmine Tea. The drinks contain a tea proportion of 25% and are available in slender, transparent 250ml bottles with a generous opening. An opaque screw cap with a guarantee band and a selfadhesive paper label with a roughened surface completes the packaging at POS. www.aldi-sued.de Detox water in PET The American company Superleaf is selling 473ml drinks with components from the aloe vera plant and the brand name “detoxwater” on its domestic market. The company focuses on the health-promoting effects of aloe vera plants on the complexion, digestion, the immune system and antioxidants. The vegan, gluten-free and kosher waterbased drink is purified using reverse osmosis. The specific flavour is indicated by the colour of the sleeve label. The bottle is contoured and has circulating reinforcement ridges, a transparent screw seal and a stable base shape. www.detoxwater.com MANAGE PREFORM VARIANCES CONTACT US TODAY TO LEARN MORE! AGRINTL.COM | +1.724.482.2163 | SALES@AGRINTL.COM 1MEASURE 2CONTROL 3OPTIMIZE Blowmolder management easy as . . . PROCESS PILOT® Automatically manage preform variations to produce better, more consistent PET containers.,@ID:47}, BOTTLING / FILLING PETplanet Insider Vol. 19 No. 03/18 petpla.net 24 Super-light solutions Partner for sustainable packaging With the new Sacmi Heroline, manufacturers can make lighter, higher-performing containers while lowering raw material costs, optimising consumption and enhancing logistical efficiency. The super-light solutions are in the pipeline, starting with the most dynamic market, bottled water. Filling Special Every minute, the world manufactures and sells over a million drinking water bottles, most of which will be used for still mineral water. Euromonitor forecasts that, by 2021, output will increase to over 580 billion bottles a year, a further 20% increase in what has, in recent years, been one of the fastest-growing segments of the global packaging industry. Sacmi has responded to this challenge with Heroline; this complete, integrated solution for making lighter, higher-performing bottles provides net savings on raw materials while optimising energy consumption and boosting the logistical efficiency of the entire process. Thanks to a lot of experience with food-grade plastics and accompanying R&D facilities, Sacmi has developed extremely light, high performing containers. These range from the 200ml Hero bottle with Exalite 26-22 cap (total weight 5.8g, of which 1.9g are accounted for by the neck) to the 500 and 600ml formats (total weight 8.4 and 9.9g respectively) and the lightweight solutions that minimise PET requirements. While extremely light, the 200ml Sacmi bottle can withstand, once filled and capped, a peak load of over 230 Newtons, paving the way for further solutions (already being tested at Sacmi’s labs) on the standard 25-22 neck to lighten the bottle by at least another gram without affecting performance. The exclusive technology that goes into Heroline - the dimensional and manufacturing layout of which can be modulated to meet customerspecific needs - includes CCM and IPS. These cap and preform manufacturing solutions can be integrated upstream from bottling thanks to CPB Link, the automatic Sacmi-built magazine that synchronises the two processes to smooth logistics. Thanks to individual elements designed to operate as stand-alone solutions as part of a coordinated system, Sacmi provides added value through overall functional optimisation. It does so by integrating blowing (SBF), filling and labelling downstream from the cap and preform magazine; those phases can be merged on the new all-in-one Heroblock, the new uniquely versatile, compact Sacmi ‘quadblock’ that is ideal for medium output rates. Each Heroline phase is aided by advanced Sacmi in-line quality control solutions. Moreover, downstream sections can incorporate innovative Colora Cap digital cap decoration units and D-Match, Sacmi’s latest digital labelling solution. The latter has been designed to ensure versatility of use and maximum personalisation but without the plant complexity that stems from digital printing on prelabelled containers. Optimised energy and fluid consumption, a high reduction in internal logistics costs (pallets, octabins and relative maintenance) and less storage space are some of the advantages provided by Sacmi Heroline. The latter offers excellent hygiene standards (an offshoot of fewer handling tasks and a direct consequence of the special storage magazine configuration where caps and preforms are kept in a controlled, positive-pressure atmosphere). Manufacturers can move from a set of high-performing stand-alone machines towards a complete system that integrates the process and generates three types of enhancement: energy, logistical and reduced PET consumption. www.sacmi.it,@ID:26}, BEVERAGE INGREDIENTS PETplanet Insider Vol. 19 No. 03/18 petpla.net 16 Dry and liquid ingredients combine in a reusable bottle to create beverage blends in a variety of flavours Peel, pop and shake A PepsiCo venture, Drinkfinity announced the launch of a new personalised beverage designed to fit the individual lifestyles of today’s busy go-getters. With Drinkfinity, people can combine the dry and liquid ingredients contained in portable Pods with water in a specially designed, reusable bottle, the “Vessel”, and create beverage blends in a variety of flavours. Piloted in Brazil in 2014, PepsiCo is now launching the product in the United States and in selected markets in Europe. As sales in carbonated soft drinks decrease, beverage giant Pepsi has come up with a creative dual-chamber Pod system for consumers to flavour their water as they like. The consumer orders a reusable co-polyester bottle online in which he pours drinking water. After inserting a PET pod with a flavour of choice, the hitherto sealed pod will release its dry and liquid ingredients to create a 20-ounce (591ml) beverage. All 12 blends are free of artificial sweeteners and flavours and contain only natural sugar, intended to appeal today’s health-conscious consumers. “Drinkfinity is a delicious new beverage option that allows today’s busy consumer the unique opportunity to personalise a drink based on their individual preferences and unique lifestyle needs,” said Hernan Marina, Vice President, Global Business Innovation, Drinkfinity. “Better yet, Drinkfinity was made to do more than just hydrate – it was created with a simple vision to make a beverage that connects the dots between wellness and versatility, while trying to balance the needs of both people and the planet.” Each portable Drinkfinity pod falls within one of four ‘modes’, including caffeine-containing “Charge” pods, vitamin infused “Flow” mode, electrolyte-packed “Renew” capsules or the “Chill” mode featuring relaxing botanicals. Within each ‘mode’ there are multiple flavour profiles, such as Açaí, Pomegranate Ginger, Elderflower and Coconut Water Watermelon, which are made up of dry and liquid ingredients like chia seeds, acai fruit, ginger root extract and concentrated fruit juices. The dry and liquid ingredients within each pod are sealed separately in dual chambers until the beverage is mixed with cold water in the Drinkfinity vessel to create a beverage that can be enjoyed on-the-go and throughout the day. Pod recycling Drinkfinity has partnered with Loop Industries, Canada, and TerraCycle, UK, for a free recycling programme for empty pods. Up to 30 used pods have to be collected at home before being boxed and returned via a freepost envelope to the hubs where they can be recycled. However, the brand states that their goal is to invest in technologies to allow the manufacture of pods that are even easier to recycle and made from 100% post-consumer recycled PET. www.drinkfinity.com BEVERAGE +ingredients After inserting a pod with a flavour of choice, the hitherto sealed pod will release its dry and liquid ingredients in the water-filled bottle to create a 591ml beverage. The Drinkfinity set consists of a co-polyester bottle, the “vessel”, and a dualchamber PET pod.,@ID:18}, 42 PETplanet Insider Vol. 19 No. 03/18 petpla.net PETproducts “Snap” in new PET bottle for Snapple Snapple single-serve premium teas and juice drinks are now available in a PET bottle designed in a collaborative effort between Dr Pepper Snapple Group (NYSE: DPS) and R&D/Leverage. A key driver behind the conversion to plastic was to provide consumers with a convenient, lighter weight container to enjoy on-the-go. But the glass Snapple bottle is iconic, so an absolute requirement for this project was to maintain both the look and the feel of the original glass bottle. According to Patrick George, senior director of packaging engineering for DPS, a successful conversion had to have all the things a glass bottle had. “We decided that success would mean that when the bottles were put side-by-side - we couldn’t tell the difference between glass and plastic,” said George. That also meant including the famous metal cap that produced the iconic “snap” when the bottle was opened. “As far as we know, it’s the first metal cap on a plastic beverage bottle - a hot-fill bottle,” said George. This created several challenges for the engineering team. First, when hot-filling the PET bottle it shrinks, then pulls a vacuum. George explained that they needed to pull the vacuum on the top without distorting the bottle in any way. Secondly, the PET bottle had to work with existing manufacturing equipment. And last, the Snapple team had to ensure the plastic bottle would make the same “snap” with the metal closure as the iconic glass bottle. R&D/Leverage was able to accomplish the “look” that Snapple wanted and maintain the attributes of the iconic shape, as well as the “snap” feature of the metal cap on a PET bottle. The manufacturing process was developed in R&D/Leverage’s lab under its product development program. “A lot of things about this project were very technically challenging,” said DPS’s George. “R&D/Leverage are truly good at packaging design and structure. We’ve dealt with R&D/Leverage for a number of years and I’ve personally dealt with the company for over a decade. It was natural to integrate them into this project to achieve the success outcome we anticipated.” www.rdleverage.com A strategic partnership Multi-Color Corporation announces a strategic partnership with Talkin’ Things, a smart packaging system. This system enables brands to communicate with consumers, protect against counterfeiting, track products throughout the supply chain, and much more. #RethinkPackaging – With this agreement, MCC and Talkin’ Things have established a strategic partnership to raise awareness among brand owners about the rapidly growing trend of connecting products to the Internet of Things (IoT) through packaging. A long-term agreement has been signed to provide joint smart packaging solutions, i.e. NFC/RFID, Augmented Reality, IoT sensors and anti-theft protection based on EAS technology. As a result of this cooperation, MCC and Talkin’ Things are strategically focused on connectivity and joining the new world of smart packaging. The new world based on smart packaging, offers digitally extended labels protected against counterfeiting and refilling, real-time promotions management, direct communication with end-customers, personalised mobile promotions and rewarding real customers directly through the product which increases loyalty to the brand. Talkin’ Things and MCC become a one-stop-shop for making products connected, secured, interactive and traceable through the entire distribution chain. MCC and Talkin’ Things offer a dedicated implementation technology to all kinds of labelling solutions such as pressure sensitive, shrink sleeves and roll fed labels. Connected products are beneficial for a number of markets including Wine & Spirits, Healthcare, Food & Beverage, Home & Personal Care, Automotive and Consumer Durables. www.mcclabel.com .com 100815dmyL,@ID:44}, BOTTLE MAKING 13 PETplanet Insider Vol. 19 No. 03/18 petpla.net packaging did not convey the values of this very wellknown brand in Georgia: premiumness, high quality ingredients and heritage. That’s why the brand asked us to design a glass-like bottle in order to revamp the overall image of this product, which represents a “host” for any Georgian table during celebrations and in daily life. The new packaging, developed in 1l and 2l formats, makes Zandukeli stand out on the shelf thanks to a strong packaging system with a big impact. This has been achieved thanks to the perfect combination of shape and label, developed by Stranger & Stranger. A new star on the shelves At the Drinktec 2017 PET Engineering received the World Beverage Innovation Award in the category “Best Bottle in PET” for FonteVita. This new PET premium bottle was developed with Husky Injection Molding Systems and LaBrenta. The FonteVita bottle weights 39g with a shade created using the multilayer technology of Husky, LuxCap developed in collaboration with Labrenta a new PCO 1881 cap, and The new star: FonteVita bottle with LuxCap from the Luxo line for the Horeca sector of PET Engineering. Your KHS line optimization service gets more performance out of your existing production lines. 6JG NQPIGT C OCEJKPG KU KP QRGTCVKQP VJG OQTG KVU NGXGN QH GHƂEKGPE[ FTQRU 6JGTG CTG OCP[ TGCUQPU HQT VJKU YJKEJ CTG PQV CN YC[U KOOGFKCVGN[ TGEQIPK\\CDNG 1WT NKPG QRVKOK\\CVKQP UGTXKEG VJQTQWIJN[ UETGGPU [QWT NKPGU RKPRQKPVKPI CNN YGCM RQKPVU CPF QRVKOK\\KPI [QWT OCEJKPG GHƂEKGPE[ D[ WR VQ +PVGTGUVGF! YYY MJU EQO UGTXKEG AND WE KNOW WHERE. A S P E C I A L S E RV I C E F ROM a shape that appears as a flower slowly blossoming. Together there are three different versions at this new premium line of PET Engineering: FonteVita, Queen and Erawan with a 0.75l capacity. www.petengineering.com,@ID:15}, 20 PETplanet Insider Vol. 19 No. 03/18 petpla.net BEVERAGE INGREDIENTS products Multi-sensory & nutritional excellence The look into the future of the beverage world of Döhler at Drinktec included a broad portfolio of natural ingredients, ingredient systems and product applications which are intended to meet the individual lifestyle of consumers, offer added health value and an outstanding taste. A series of customised product concepts, featuring bright colours, optimal texture or outstanding taste, are intended to provide unique Multi-Sensory Experiences. For example, tropical fruits such as goldenberry and guava are characterised by a fresh and fruity taste in a new generation of fruit-based drinks, chia seeds as well as fruit and vegetable purees with chunks create an extraordinary mouthfeel and turmeric provides a particularly natural bright colouring. The company stated that consumer preferences include beverages with optimised nutritional value that go hand in hand with a modern, healthy lifestyle. Plant-based ingredients, “free from” solutions and reduced-sugar foods are more popular than ever. From Protein Water and Herbal Detox Teas to Better Nutritional Colas, Döhler presented beverage concepts with healthy added value and fewer calories. The MultiSense flavours range can be used to achieve significant sugar reduction without having to use sweeteners, or to improve the taste and mouthfeel of reduced-sugar products. Especially for soft drinks, the MultiSense flavours achieve a particularly balanced overall multi-sensory impression and are therefore perfect for reduced-sugar carbonated soft drinks or still drinks, says Döhler. The portfolio also includes botanical plant extracts, which promise a health-promoting additional benefit, create new taste experiences and remain one hundred per cent natural. African extracts from baobab, moringa leaves or honeybush are also represented. www.doehler.com Flavoured milk – trend in India Growing health consciousness and lack of time for sitdown meals in India, especially among urban millennials, has contributed to a growing preference for healthier beverages like flavoured milk over carbonated drinks and sugary juices. Flavoured milk accounted for 39% of India’s dairy drink launches during the first half of 2017. The emerging trend caught the attention of major beverage players like PepsiCo and Coke who launched nutrient-rich, flavoured milk like PepsiCo’s Quaker Oats brand of flavoured milk and Coke’s Vio among other dairy products. Parag Milk Foods introduced its mango milk drink ‘Slurp’ to expand its footprint in the beverage segment. With the launch of value-added products to its line, revenue from the Indian dairy industry stands at Rs.10-15 crores. Flavoured milk is produced using the UHT (ultra-high temperature) technology, which ensures a shelf life of six to nine months, without refrigeration. Demand for flavoured milk is driving the growth of the packaging industry, which is adopting advanced techniques to enhance the shelf life, flavour and portability of perishable dairy products. PET has emerged as the preferred packaging material for packing flavoured milk. Amul, which pioneered aseptic technology in India, is packing its flavoured milk and other value-added products in PET bottles. Parag Milk Foods too is upbeat about PET bottle packaging. PET packaging major, Manjushree Technopack receives 4% of its revenue from dairy packaging. According to Manjushree, the rising consumer interest in value-added dairy products like flavoured milk and yoghurt is owing to the convenience, packaging safety and hygiene that these products offer. www.manjushreeindia.com BEVERAGE +ingredients,@ID:22}, BOTTLING / FILLING PETplanet Insider Vol. 19 No. 03/18 petpla.net 22 Optimising flavour manufacturing The technology group GEA has specified its process solution for flavour manufacturing and developed a new machine design as well as control and cleaning elements for the production facilities from the handling of raw materials right through to final packaging. With this, GEA helps flavour manufacturers to ensure the taste, consistency and repeatability of their products. Filling Special The goal is to create a flavour that mimics, as closely as possible, the real thing. But it is not just the combination of raw materials that contributes to the taste result; the manufacturing process is equally crucial. Any variation in method can cause variations in a product that, for all companies, are unacceptable. GEA uses its experience in the production of mixing, pumping, homogenisation, drying and handling equipment to bring them together, to develop them and provide a consistent quality of the flavours. Technology know-how ensures consistency When producing flavours there is much opportunity for something to go wrong. An ingredient added too quickly into a mixing vessel, inconsistent temperature, insufficient mixing or incomplete homogenisation can all have an effect further downstream that affects the outcome. Similarly, variations in oil droplet size, shearing or drying parameters can all have an effect that in some subtle way alters the product. All these parameters are critical to producing a consistent product. The process becomes more complex when 300 to 400 different flavours are produced on the same machinery. The control and automation should rule out deviations. The new GEA integrated line controls all the individual unit operations precisely and, by doing so, controls the output. But repeatability is not just a question of adjusting a computerised control system. Achieving a consistent product requires very precise engineering to allow the component parts of the line to work together in harmony. For example, feed systems must be calibrated specifically to match the capabilities of the mixer and the size of the mixer must be scaled precisely with the size of the dryer to ensure compatibility. Cleaning removes residues and odours In order to comply with the hygiene regulations, every producThe ultimate goal is to create a flavour that mimics, as closely as possible, the real thing. The Batch Formula Mixer,@ID:24}, imprint EDITORIAL PUBLISHER Alexander Büchler, Managing Director HEAD OFFICE heidelberg business media GmbH Bunsenstr. 14 69115 Heidelberg, Germany phone: +49 6221-65108-0 fax: +49 6221-65108-28 info@hbmedia.net EDITORIAL Kay Barton Heike Fischer Gabriele Kosmehl Michael Maruschke Ruari McCallion Waldemar Schmitke Anthony Withers WikiPETia.info petplanet@hbmedia.net MEDIA CONSULTANTS Martina Hirschmann hirschmann@hbmedia.net Johann Lange-Brock lange-brock@hbmedia.net phone: +49 6221-65108-0 fax: +49 6221-65108-28 LAYOUT AND PREPRESS EXPRIM Werbeagentur | exprim.de Matthias Gaumann READER SERVICES Till Kretner reader@hbmedia.net PRINT Chroma Druck & Verlag GmbH Werkstr. 25 67354 Römerberg Germany WWW www.hbmedia.net | petpla.net PETplanet Insider ISSN 1438-9459 is published 10 times a year. This publication is sent to qualified subscribers (1-year subscription 149 EUR, 2-year subscription 289 EUR, Young professionals’ subscription 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 identified as trademarks is not an indication that such names are not registered trademarks. 3 PETplanet Insider Vol. 19 No. 03/18 petpla.net I use PET bottles just like any other consumer; I drink from them then throw them away. I never give a moment’s thought as to how essential the bottle can be for some people when drinking water is not available at the required quality or in the required quantity. Water shortages are always far away from us; they are issues for the drier areas of the world, not our “civilised” regions. Or so we like to think. Do we still remember the city of Flint in Michigan, USA? Legionella and other contaminants were found in the city’s rundown pipework. Drinking water provision has been interrupted there for two years now and has been replaced by water in PET. The situation is different in Cape Town, where the quality is sufficient but not the quantity. Because of three years of drought, drinking water reservoirs in the region are almost empty and “Day Zero” looms on August 27. After that, the city will have to initiate water provision, unless sufficient rain falls prior to this. Then, residents will have to collect their daily ration of 25 litres of water from 200 public distribution centres monitored by the army and police. Besides HDPE water canisters, PET bottles and PET canisters will play their part in providing supplies to the population. Perhaps when I drink from my next PET bottle, I will think how much more it can be than just consumer-friendly drink packaging. Yours Alexander Büchler Dear friends of PETplaner Insider, Water, Water, Water...,@ID:5}, MARKET SURVEY 28 PETplanet Insider Vol. 19 No. 03/18 petpla.net 03/2018 MARKETsurvey Resins & additives Preform machinery Preform production Preform inspection SBM 2-stage Compressors Filling equipment & filling inspection Caps & closures and inspection Palletising & shrink film machinery Recycling Preform Equipment Suppliers for preform moulds and preform equipment This time the market survey is about the newest developments in preform equipment and preform moulds. Have a look on the results of the machines and moulds engineers! We are pleased to show you an overview of the participating companies: R&D/Leverage, Unique Injection Molding Systems Co., Ltd., Sacmi Imola, Otto Hofstetter AG, Otto Systems, Steelmades, NetstalMaschinen AG, Sipa S.p.A. and Husky Injection Molding Systems Ltd. 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 accurancy. Preform Moulds Company name Unique Injection Molding Systems Co., Ltd. Otto Systems AG Netstal-Maschinen AG Postal address Telephone number Web site address Contact name Function Direct telephone number E-Mail No. 19 Shenzhou Road, HuangPu District, GZ, China +86 20 8226 5488 www.unique-pet.com +86 150 18791 820 lzy@unique-pet.com Zürcherstrasse 73, 8730 Uznach, Switzerland +41 55 285 22 11 www.otto-systems.com Mr Stefan Zatti CEO +41 55 285 22 09 stefan.zatti@otto-systems.com Tschachenstrasse CH-8752 Näfels, Switzerland +41 55 618 6111 www.netstal.com Mr Stefan Kleinfeld Application & Product Manager +41 55 618 6241 stefan.kleinfeld@netstal.com Preform injection moulding systems Machine model number / name U-PET500E_5000/8000 Various PET-Line 2400, PET-Line 4000, PET-Line 5000; PET-Line 2C; PETForm 175 Number of cavities (min/max units) Min. 2 cavities to max.144 cavities Up to 144 cavities 32 - 144 Maximum individual preform weight 38g~100g max shot weight 6,600g Maximum resin through-put (kg/h of PET) 1,100kg/h Up to 1,350kg/h Up to 1,350kg/h Standard features (short description / keywords) Clamping unit, injection unit, Siemens PLC closed loop control, hydraulic system, robot unit, remote supervision, turn-key engineering, hydraulic system Consulting & Engineering of Preform Systems Intrusion Options / Special features (short description / keywords) Dynamic injection; injections: compression injections Controlled Production shutdown during a Power outage (CPP), Netstal remote Support (NRS), Energy Measurement (CALITEC) Company name Unique Injection Molding Systems Co., Ltd. Sacmi Imola Postal address Telephone number Web site address Contact name Function Direct telephone number E-Mail No. 19 Shenzhou Road, HuangPu District, GZ, China +86 20 8226 5488 www.unique-pet.com +86 150 18791 820 lzy@unique-pet.com Via Provinciale Selice 17/A Imola Italy +39 0542 607 111 www.sacmi.it Mr Moraldo Masi Director of Business Unit PET +39 0542 607 888 moraldo.masi@sacmi.it Preform moulds Horizontal opening Number of cavities 144 16-32-48-72-96-128 Preform sizes 29/25 neck finish 14.6g L 190mm Moulds already built for (makes) Ganten Vertical opening Number of cavities 96 Preform sizes 29/25 neck finish 9.7g Moulds already built for (makes) PT.Surya Sukess Abadi Prima Do you produce single stage tooling sets? (preform moulds AND blow moulds) We produce preform moulds No Other,@ID:30}, BOTTLING / FILLING PETplanet Insider Vol. 19 No. 03/18 petpla.net 32 BOTTLING / FILLING 32 New hot fill options Reduced change over time Fogg Filler, a market leader in the design and manufacture of rotary filling systems for the liquids industry, is seeing a renewed interest in hot filling products. One of the features that Fogg offers for hot filling applications regards temperature management for hot fill applications. With using the Fogg recovery trough, this has been made simple, states the company. The built-in sensor allows the operator to manage product temperature in the bowl and filling valve tip temperatures, when line stops occur. The trough can be sent easily into position to purge the cooled product in the valves until production can be resumed, sending only a small amount of product back to rework. When customers have specifications that will not allow the product to encounter the atmosphere by using the trough system, Fogg has developed another option. This new system recirculates the product within the bowl including the product in the valve tips. This virtually eliminates the product loss associated with other hot fill methods. Switching from cold filling to hot fill is claimed to be as easy as warming up the product and go. Fogg’s proven technology is intended to help lower operating costs and to provide the highest level of reliability for production lines. Time saving, tool-less back pockets As the beverage industry continues to reduce the amount of plastic in their PET bottles making them more light weight than ever before, it poses some bottle handling challenges. Fogg has created back pockets to ensure precise bottle handling. In the past, one has to change these back pockets with a wrench or adjust them per each of the different bottle sizes. Now, Fogg has created toolless back pockets to save time and money when changing bottles on the filler. The change over time with these tool-less back pockets is five times faster than the time it takes to change out standard back pockets. To release the back pockets from the base, the operator simply has to push the centre button and the entire back pocket comes off. For the next set of back pockets to be securely mounted, the button simply has to be pushed again to move the piece into place. With the release of the button, the back pocket is securely locked into place. The tool-less nature of these back pockets allows for easy change over by operators without the help of maintenance. These new back pockets come in multiple styles and can be retrofitted with an adapter. www.foggfiller.com Filling Special • 28mm, 33mm and 38mm screw closures • Robust and trouble free capping • Established DoubleSeal™ technology - for secure sealing performance - for better protection against micro-organisms • Slit FLEXBAND® band technology for enhanced tamper evidence • O 2 barrier and scavenging options for screw flat caps supporting longer shelf life and fresher taste • Sports closures for aseptic filling and hot filling without aluminum foil • Special closures for syrups and carton packaging Unique range of screw and sports closures designed for cold fill and aseptic application BERICAP Technology for juices, RTD teas, health drinks www.bericap.com,@ID:34}, BOTTLING / FILLING PETplanet Insider Vol. 19 No. 03/18 petpla.net 33 From juice manufacturer to PET blow moulding Keeling F. Juices Ltd. position themselves as the producer of quality juice products that not only taste fresh but also retain the maximum amount of minerals and vitamins. This is normally achieved by cold pressing as pasteurisation reduces the amount of goodness within the juice. Filling Special CEO John Keeling (on the left) and Operations Director Adrian Kavanagh (on the right) The main downside of cold-pressing is the short product shelf-life; Keeling Juices has therefore been using the innovative HPP method in their production to extend it. High Pressure Processing (HPP) is a cold pasteurisation technique whereby freshly squeezed juice is bottled in a pressureresistant PET container and treated by high level of hydrostatic pressure (transmitted by water). This is a safe way to get rid of unwanted microbial content, and save the nutrients. Keeling Juices is owned by Fred Keeling, and he, together with his team, is continuously working to advance the quality and value of healthy beverages available today. Fred has over 50 years of experience sourcing fruit and making juice products in order to create fully natural products that are a blend of harvests from different countries in order to maintain a consistent pleasing taste and colour throughout the year. “We not only produce our own brand juices, here at Keeling Juices we’re proud to supply household names in Ireland & the UK with products under their own label. From our national airline to countrywide supermarket chains and cafés, our juices have been stimulating taste buds with the fresh tastes of nature for over twenty years.” “Almost every product we make is contained in some bottle or other. Our contract manufacturing means that we had to store stacks of pallets of bottles according to the needs of our client’s products. From HDPE jugs to all different types of PET bottles with different neck finishes the management of the packaging stock was a massive unrewarding chore which not only took up valuable warehouse space with empty bottle space, but also tied up a lot of capital in stock with the risk of the stock becoming out of date through product discontinuation.” “Our meeting with FlexBlow (Terekas) happened quite by accident – through an old email address belonging to a brand we had inadvertently acquired. However, after the meeting it became immediately apparent how PET bottle blowing could fit in our business. We had a fairly predictable usage of bottles for our own products and a growing requirement from clients to allow for different bottles for specific projects. Our usage justified the purchase of a bottle blowing system, however this is still a new area for us and the next hurdle was to find the best, most reliable partner for PET blowing equipment. There is plenty of choice out there and it could have taken us years to understand all the options and decide on the best equipment on offer. As we were looking for the possibility to produce a wide range of bottles from 100ml to 5,000ml with different neck standards, and easy bottle format change – FlexBlow answered our needs perfectly. We were losing money through outsourced bottles and our clients’ needs were expanding all the time. We validated FlexBlow as a partner by visiting some of their client sites in Europe and from this we took away the good impression that FlexBlow continued to work with and support their clients for many years. “ “Now that we have the blowmoulding machine installed, it has become clear that there is a huge sustainability benefit to this system. We had been importing bottles from the UK and the Netherlands with trucks and ships carrying empty space bottles. Now the shipments are reduced by many factors as we are only importing the more compact preforms. The reduction in transport brings a financial and environmental benefit that helps us meet our targets for sustainability and reassure our customers that we are always re-evaluating what we do to be more planet-friendly. Not only have we reformed our own bottle usage, we now have an opportunity to serve the local market and thus reduce the imports and the transportation of empty bottles from abroad.” www.keelingjuices.com www.flexblow.com,@ID:35}, MARKET SURVEY 29 PETplanet Insider Vol. 19 No. 03/18 petpla.net Sacmi Imola Sipa Husky Injection Molding Systems Via Provinciale Selice 17/A Italy +39 0542 607 111 www.sacmi.it Mr Moraldo Masi Director of Business Unit PET +39 0542 607 888 moraldo.masi@sacmi.it Via Caduti del Lavoro, 3 31029 Vittorio Veneto, Italy +39 0438911 511 www.sipa.it Mr Stefano Baldassar Sales Director, Preform Systems & Tooling +39 0438911 511 stefano.baldassar@zoppas.com 500 Queen Street South Bolton, ON, L7E 5S5 Canada +1 905 951 5000 www.husky.co Mr Pierre Pruvost Business Development Manager - PET Systems ppruvost@husky.ca IPS220 IPS400 XForm 350 XForm 500 GEN3 H-PETAE HyPET HyPET HPP5 16 - 72 48 - 128 8/128 8/180 2 - 48 cavities 6/144 (in standard matrix) 48/144 (in standard matrix) 140g 140g 750 750 Dependent on number of cavities and preform design 83g (dependent on number of cavities and preform design) 102g (dependent on number of cavities and preform design) 625kg/h 1,250kg/h 1,350kg/h 1,350kg/h 448kg/h 1,470kg/h 1,700kg/h injection cylinder (shooting pot) electrical drive for plasticising screw injection cylinder (shooting pot) electrical drive for plasticising screw XFORM 350-500 GEN3: Reduced lock-to-lock; full legacy tooling compatibility; reduced energy consumpiton Cost effective, all-electric, complete preform moulding system (including machine, mould, robot, full auxiliaries), low system energy consumption Performance enhancement, energy efficiency, system robustness, faster controls Performance package, increased uptime and tooling life, reduced maintenance package with alignment features and self-cleaning technology T-belt for preforms extraction, belt free robot linear motor with KERS, 3 post-cooling stations, HMI with control, double cylinder ejection, digital valves for each actuator, water unloading system prior to mould changing Direct unloading from gripper plate, belt free robot linear motor with KERS, 4 post cooling stations, HMI with control, boosters on moving platen for first phase ejection, digital valves for each actuator, water unloading system prior to mould changing XForm 350-500 GEN3: XP technology, LongLife, XMold for ultra-thin preform injection capability, wide-mouth preforms capability Integrated auxiliary controls (HMI), mould change with split gate & magnetic platen option, stripper ring mould technology for wm applications, 30mm to 180mm neck finishes as standard Adaptive post-mould cooling, performance packages Multi-Layer technology, flexibility package, high cavitation option, compatibility packages, 30mm performance package, injection completion during power outage R&D/Leverage Otto Hofstetter AG PETform Steelmades Sipa Molds Husky Injection Molding Systems Leverage House, Hamilton Rd, Sutton in Ashfield, Nottinghamshire, NG175LD, Great Britain +44 1623 556 287 www.rdleverage.com Mr Alan Tolley Managing Director +44 1623 552 240 atolley@rdleverage.com Zürcherstrasse 73, 8730 Uznach Switzerland +41 55 285 22 11 www.otto-hofstetter.swiss Mr Stefan Zatti Division Manager Sales & Mktg +41 55 285 22 09 zat@otto-hofstetter.ch 54 Daman Industrial Estate Kadaiya, Daman 396210, India www.PETform.net Mr Shurid Mody CEO +91 9769758634 Shurid.Mody@PETform.net B/14, Ghatkopar Industrial Estate, Off LBS Road, Ghatkopar (West), Mumbai - 400086, India +91 22 25007774 www.steelmades.com Mr Vipul Mehta Design & Marketing +91 9323907 774 steelmades@gmail.com Via Caduti del Lavoro 3 - 31029 Vittorio Veneto Italy +39 0438911 511 www.sipa.it Mr Stefano Baldassar SalesDir.,PreformSystems&Tooling +39 0438911 511 Stefano.baldassar@zoppas.com 500 Queen Street South - Bolton, ON L7E 5S5 Canada +1 905 951 5000 www.husky.co Mr Raphael Juvan Business Development Leader, PET Tooling rjuvan@husky.ca 1 through 96 2 up to 192 96 Up to 96 cavity (cold half) Up to 192 6 to 144 24mm through 63mm neck, 12g through 350g weight Up to 500g Any size 28mm neck Up to 30l Threads up to 100mm in diameter and up to 205mm in length Husky, BM Biraghi, Milacron, Engel, Krupp, Krauss-Maffei Netstal, Arburg, BMB, Husky Husky, Netstal, Sipa, Sacmi, SIG, Milacron, Demag MHT, Husky, Mould Master Sipa, Husky, Netstal, KraussMaffei Moulds to support all preform designs and output requirements 2 up to 112 96 Up to 48 cavity (Cold half) Up to 96 Up to 500g Any size 28mm neck Up to 10l Arburg, Krauss-Maffei Krauss Maffei & Nissei ASB PM Series MHT, ASB, Aoki Standard and custom Sipa, Krauss-Maffei Yes No Yes. We manufacture preform & blow moulds No Yes, for Sipa machines Tooling suppliers for single stage, injection stretch blow moulding ISBM. Product solution laboratory with Nissei and Aoki machines for product, colour, material trials plus production tool qualification. Multilayer moulds up to 72cav, moulds for PP, for thinwall packaging and cartridges and tubes Hot runner sys PET preform mould up to 48 cavity for all IMM HyPET preform injection molding system delivers reduced variability and increased part quality with lowest energy consumption,@ID:31}, PETplanet Insider Vol. 19 No. 03/18 petpla.net 46 PETbottles Home + Personal Care Two-phase mouthwash In the USA, Colgate-Palmolive sells a two-phase antibacterial mouthwash called “Colgate Total Advanced Health”, which according to a statement removes or renders harmless up to 24 times more bacteria than previous mouthwashes. Before use, the bottle must be shaken to mix and activate the two phases. The dosing cap is used to measure a certain quantity to put in the mouth, and this is spat out after the allotted time. The specially shaped clear bottle contains 200ml of the green and blue phases. The child-safe screw seal with dosing function is further protected from tampering at POS with a shrink foil. www.colgate.com Hand soap in apothecary bottle Under the name “Alchemist Rhubarb & Raspberry Hand Soap”, the cosmetics manufacturer Jean & Len sells a fruity, rhubarb and raspberry scented liquid soap in a 250ml plastic bottle reminiscent of an apothecary bottle. The company credo states that the vegan, skin-friendly product does not contain silicone or parabens but only premium ingredients. The bottle is brown in colour, sealed with a lockable pump dispenser and is decorated with dark self-adhesive labels. www.jeanlen.de,@ID:48}, BOTTLING / FILLING 27 PETplanet Insider Vol. 19 monobloc. Flextronic C is suitable for filling CSDs, still and sparkling mineral waters, cold- and hot-fill juices. The configuration of the valve makes it suitable for processing products containing pulps and fibres. On top of all this, maintenance is claimed to be very straightforward. An ideal configuration for Flextronic fillers is Xfill. Here, the carbonating or mixing unit tank can be used as a buffer tank for the filler, which has no on-board product tank. A pump sends the product to a ring-shaped manifold in order to ensure that the product is fed into the filling valve correctly. This provides numerous advantages, including: reduction in product loss (less than 100l during flavour change); the integration of the mixing and filling units produces a final product that is of higher quality and more stable, resulting in an improved filling process; reduction of product change-over downtime (ideally under 15min with water rinsing); lower electrical power consumption, thanks to the light weight design; lower consumption of carbon dioxide (typically 10% less); lower product losses from snift circuit; improved performance at filler start-up. Flextronic is also available in a version with a central tank equipped with a stirrer, for treating pulpcontaining products. www.sipa.it,@ID:29}, PETplanet Insider Vol. 19 No. 03/18 petpla.net 15 BOTTLE MAKING PETplanet: That sounds expensive. Lozano Domènech: We are operating in a quality as well as a pricing market. As a result, we naturally try to keep costs to a minimum as much as possible. Thus far, we have produced PET and glass bottles. For example, we work with standard preforms in terms of PET. The clean bottle making inclusive mould of a Vitbot bottle is not that much more expensive than for a regular cylindrical bottle. Putting labels on ovoid shaped bottles is another thing we are working on. PETplanet: In what quantities and forms are Vitbot bottles being produced? Lozano Domènech: We are producing PET and glass bottles and are also considering HDPE. We are inclined towards current bottle sizes when considering our choice of material. For example, PET bottled organic juices are already well established worldwide. capacity, materials, neck or mouth design – at its regular bottle supplier, paying us only a small royalty. PETplanet: We wish you every success for the future and thank you very much for the interesting interview. www.vitbot.com Engineering Excellence PRELACTIA® Milk bottled the Swiss way www.netstal.com/prelactia PRELACTIA® is the cost-efficient light barrier preform for liquid dairy products in PET containers. PRELACTIA® is made using an overmolding process on a PET-LINE 2C, the high-performance injection molding system for two-layered preforms. The side unit can simply be deactivated. This lets you maintain flexibility and manufacture single-layer preforms with up to 72 cavities as necessary. Anuga FoodTec, hall 8.1, booth F081 At present, we are producing 0.5 litre bottles and jars in Italy in various designs for personal use, as well as prototypes for industrial purposes. We are also seeking partners in a variety of sectors who can help drive industrialisation forward with us. However, every drinks’ manufacturer can already produce their own customised Vitbot containers, personalised according to its needs regarding,@ID:17}, BOTTLING / FILLING PETplanet Insider Vol. 19 No. 03/18 petpla.net 26 A filling line to match new market trends Hello versatility, goodbye preservatives! New market trends and the long shadow of possible new European legislation limiting use of artificial preservatives in food and drinks, are leading Sipa to develop new systems in bottle filling lines to enhance flexibility as well as sanitation. Thus it is now possible to process carbonated soft drinks (CSD) without any form of artificial preservatives. With nextgeneration lines for liquid preparation and filling, it is also possible to fill CSDs at ambient temperature (20 °C); given that this is higher than standard filling temperatures, energy savings can be appreciable. Meanwhile, to provide bottling companies with improved flexibility, it is now possible for a single Sipa bottling line to be configured for a wide range of products, whether they be CSDs or hot-fill products, with or without pulp. Goodbye preservatives The idea of being able to do away with chemical preservatives for drinks is one that has always generated a lot of interest in the food and beverage industry, as well as among consumers. On the one hand, there is the cost issue, and on the other there is the desire for more “natural” food products. Sipa has been studying various aspects of its filling line equipment that will facilitate the elimination of such preservatives. On its Sincro systems, for example, various options are now available to maintain the cleanliness of PET preforms between the injection moulding machine and the stretch-blow moulding unit: the collection hopper, lift and slide can all be enclosed and subject to over-pressure to keep out dust; preforms can be treated to eliminate any possible contamination; preforms can be blown with ionised air and subject to ventilation to remove possible dust; special ventilation filters can be installed in the reheat oven area. Various enhancements can also be made to ensure that the filling system is clean and easily sanitised, with advanced cleaning systems for both the production circuit (CleanIn-Place, CIP) and the total filling environment (Clean-Out-of-Place, COP). Automatic false bottle loading, together with the use of microbiological isolation around the immediate filling area, produce a reduction in the space that needs to be kept under control, making it possible to use sanitising systems that are cost effective, says Sipa. Isolation can also include the transfer module between the blower and the filler. With a pressurisation system with HEPA (High-Efficiency Particulate Arrestance) filters, a separation between the air in the “dry” zone (where the blow moulding unit is located) and the “wet” zone (the filler) can be guaranteed. Furthermore, contamination of closures can be minimised with the use of a peroxide washing tunnel. Product treatment As for preparation of the filling product itself, Sipa has developed a flexible integrated product preparation system made up of the following components: Xblend multicomponent de-aerating and mixing unit; Xtherm pasteuriser, available in two different versions, flat and tubular, for products with or without pulp or particles; Degasser with aroma recovery; Carbo-SD carbonation unit. Flexible filling valves Sipa’s multi-product filling valve concept finds perfect form in the Flextronic C multi-product volumetric filling Filling Special,@ID:28}, BOTTLE MAKING PETplanet Insider Vol. 19 No. 03/18 petpla.net 14 Ovoid shaped bottles that preserve the properties of liquids The vitaliser bottle by Gabriele Kosmehl Inspired by nature, the biomimetic Vitbot bottles and jars have been designed with an oval shape and Phi proportion in order to allow water to move in a vortex inside. These characteristics are claimed to preserve the beverages inside in an aesthetic and the most natural way. PETplanet: Mr Lozano Domènech: Your bottles are really striking to the eye because of their unusual ovoid shape. How did you come up with the idea? Lozano Domènech: Observing nature, we discovered that the egg is the perfect container. Inspired by almost a million species who use eggs to contain life, we designed our bottles. But not only that. In Vitbot, the proportion flows through the Golden Ratio – a proportionality that is often found in nature. Out of this combination has come the vitaliser design that allows for and facilitates the water’s vortex movement within the bottle. PETplanet: Is vortex drinking water something we should be aiming for? Lozano Domènech: Very much so! The movement of liquid in a natural vortex is an expression of the water’s vitality. The overall effect of the drink’s individual compounds is that minerals and electrolytes can be assimilated more efficiently by the human body – and not only by water. We also have customers from the organic beverages’ sector who are looking for bottles that can preserve the essential ingredients that make up their juices or fermented beverages in the best and most durable way possible. Thus far, all drinks regardless of their ingredients have always come in the same kind of bottle, namely a cylindrical container. This is of little or no use when one is involved with a vibrant product whose vitality needs to be preserved. Once the bottling process has been completed, the manufacturer is no longer in a position to influence their product – the bottle is the interface with the end user. This is why choosing the perfect container is so important not just from an aesthetic but also a qualitative perspective. PETplanet: The fact that a bottle not only never distracts from but in an ideal situation even improves a product is something we have hitherto only associated with alcoholic drinks that finish their maturation process inside the bottle. Lozano Domènech: Wine and beer are excellent examples of the rigorous process that drinks have to go through. Fermentation within the bottle improves the product’s taste and our bottle enhances this process. PETplanet: Are any tests being carried out on alcoholic drinks? Lozano Domènech: Yes. We have trialled our bottles of water and wine with a number of sommeliers. The drinks came in classic cylindrical bottles packed in cartons as well as in our Vitbot bottles. The next day we had a blind tasting session. The difference became quite clear with the sommeliers expressing amazement at the effect the containers had on the drinks. Everyone thought the drinks from our bottles tasted the best, and that only after a few hours! PETplanet: From a taste and vitality point of view, is your unusual ovoid-shaped bottle as “differentiation at point of sale” really a persuasive marketing argument? And what about issues around processability and logistics? Lozano Domènech: You are right; there are lots and lots of products on the market. Every exceptional product that is put on the market requires an equally good container. It is also better for consumers if they are able to find their product on the shelves quickly instead of having to look around endlessly for it. However, up until now, everything has had a cylindrical shape. For example, if you want to pack our bottles in a case, you cannot use a standard one. You must first produce one that is shorter and stronger than other solutions that are available on the market. Antonio Lozano Domènech and Dolores Martorell Reyes (in the middle) ran a water treatment company in Barcelona, Spain. Their observations of nature were the impetus behind their move to California in 2012 in order to design Vitbot bottles there.,@ID:16}, BOTTLING / FILLING PETplanet Insider Vol. 19 No. 03/18 petpla.net 30 Serac launches Aseptic Combox for low to medium production rates Aseptic to go During 2017, Serac announced the launch of its combined PET linear blower (SBL) and rotary weight filling machine, marketed under the trade name of Combox. Around 15 units had been installed by the end of the year at customer premises in Europe, North America, South America and Asia. Now, an aseptic version is available. The Combox aseptic version provides new opportunities in the dairy and beverages industry by offering a low and medium work-rate solution for applications using pH neutral and acidic products, says Serac. Aseptic bottle packaging includes volumes of up to 12,000 PET bph for the 1-litre format and up to 18,000 PET bph for 250ml formats. Serac states that the range of of integrated, medium work-rate aseptic filling machines is currently very limited and that the Aseptic Combox offers a single-unit, blowing-filling solution for this market. On the go and flexible Packaging of beverages in small bottles, outside the cold chain and with re-closable and easy-to-hold bottles, is ideally suited to the needs of ‘nomad’/’onthe-go’ consumption – for example, at school, in sport halls or in the office. Serac maintains that the Aseptic Combox gives bottlers and producers the opportunity to capitalise on this trend and take advantage of new and developing market opportunities, and that the range of products offered by bottlers could be rapidly expanded by the use of a production tool that offers both high performance and flexibility. Improved safety, operations and operation Positive and direct transfer of containers by the neck between the blower and the filling machine limits the risk of container contamination, and the elimination of container transfer via silos, uprighters, etc., reduces investment costs. Combox has no open air conveyor. This helps to make it a more compact and more reliable, with less risk of blockages. As both HMI control panels are located on the same support, a single operator can run the entire unit. Peroxide (H 2 O 2 ) container decontamination reduces the risk of re-contamination just before filling. Serac claims that Combox is a flexible system with fast, easy and risk-free format changeover. As the blower is located outside the sterile zone, there is no risk of re-contamination when the forming mould is changed. Tool changes at the filling machine exit also take place outside the sterile zone. The provision of easier access points outside the isolator makes maintenance simpler. The Aseptic Combox incorporates Serac’s SAS 5 filling machine, which meets the strictest requirements for sensitive products. The current model features H 2 O 2 sterilisation of bottles & caps as standard. Serac says that a version with βluStream, its latest sterilisation module, will have its commercial launch during 2018. www.serac-group.com Filling Special,@ID:32}, BOTTLE MAKING 12 PETplanet Insider Vol. 19 No. 03/18 petpla.net Customisation possibilities for a range of brands Multiple bottle designs PET Engineering’s ITM (Insert Technology Moulding) solution makes clever use of inserts: For example this solution allowed Efes Rus to launch three new PET bottles at a low cost and with more modest investment expected in the future. The new shape of the Efes Rus brands, Gold Mine Beer, Stary Melnik and Zolotaya Bochka, is unique and distinctive at the same time as offering flexibility, thanks to the fact that the appearance and format of the bottles can altered using interchangeable inserts with the original mould: this means that it is constantly possible to insert new decorations, to alter their size compared to the surface of the bottle, to move and resize the label area and, to alter the capacity of the bottle by approximately 5%, depending on end users’ changing consumption patterns. Designing different variants with a single shape results lower implementation costs. With one insert that can be variety implemented in the original mould it is possible to remodel the image of the products. During the process the shape and overall dimensions of the bottle remain the same, meaning that expensive interventions to change formats on the production line won’t be necessary. Such interventions would previously have involved costs for the design, implementation and installation of the different machine parts necessary to process a brand-new container. PET Engineering’s packaging flies high Boneau, the water that springs in the county of Bama, in the Guangxi region of south-east China, is famous for being rich in negative ions and known as the vitamins of the air. Those living in the county of Bama are famous for having the longest life spans in all of China. In fact, the county itself is defined as the “place of longevity and wise men”. The strata of special rock found in Bama purify, mineralise and magnetise the water there, giving it its rare, natural and alkalescent properties. Bama Boneau water comes from the depths of the rock strata of the Guangxi Bama karst. It has five distinctive features, making Bama Boneau well-balanced and healthy water. China Eastern Airlines, the third largest airline in the People’s Republic of China, with over 580 aeroplanes, 177 international routes and 1,062 routes in total, has chosen precisely this water to show its passengers how much they care about their health and well-being. Furthermore, they selected the company Bama Boneau to bottle the water in such a way as to make it easy to drink, even at high altitudes. PET Engineering proposed a bottle with a well-structured grip, strengthened by an alternating pattern of small oval shapes, allowing the bottle to withstand the levels of inflight pressure and temperature experienced in the stowage areas, without becoming deformed. At the same time, the bottle’s solid grip makes it easier to handle for both the end consumer and the flight crew during refreshment services. “PET Engineering tailor-made the new Bama Boneau’s water bottle combining ergonomics, comfortable handling, and convenience. This design is highly appreciated by the airline staff and its passengers. At the same time, it offers a high-standard look that will last across time”, said Bama Boneau Marketing Manager Ms Lin. Zandukeli: delicious lemonades in a glass-like packaging Zandukeli is a range of Georgian traditional, delicious lemonades available in a variety of flavours: lemon, pear, tarragon, orange, cream-soda, saperavi. The previous The new shape of the Efes Rus brands, Zolotaya Bochka, Stary Melnik and Gold Mine Beer designed by PET Engineering China Eastern Airlines has chosen Boneau water packed in withstand bottles which can stand the levels of inflight pressure and temperature in the stowage areas without deforming.,@ID:14}, PETplanet Insider Vol. 19 No. 03/18 petpla.net 47 BOTTLES New bottle for Soft & Oils The bottle shape and size for “Soft & Oils”, a fabric conditioner from Vernel with a long-lasting fragrance and oils that care for clothing, has been relaunched. The previous shape was rather bulbous but the new shape has been adapted in line with other Vernel products, or these bottles are used with the appropriate labelling. The new, easy-grip, contoured bottle contains 600ml, features two adhesive labels – transparent on the front - and has a gold-coloured shiny screw cap with dosing function. The transparent bottle offers a view of the oil-rich, shimmering yellow product. www.vernel.de Indulgent shower gel from Lacura naturals The German discounter Aldi Süd is offering 300ml of its indulgent shower gel with organic orange water and mirabilis extract under its own brand “Lacura naturals”. The vegan product is transparent and viscous. It is packaged in a transparent bottle with a snap-on transparent hinged cap with dosage opening. The movable section of the cap is finished in a second colour to match the colouring of the two self-adhesive labels. www.aldi-sued.de Witches help with cleaning “Las 3 Brujas”, a Spanish brand of household cleaner, is selling 750ml of allpurpose cleaner for various surfaces on its domestic market. The manufacturer claims that surfaces will smell pleasant after cleaning and the product is sold in a clear bottle with grip dimples. The bottle is available both with a push-pull top and with a trigger attachment. The front features a no-label-effect label while the back has a label which is also printed on the inside. www.las3brujas.com Full inspected!,@ID:49}, CAPS & CLOSURES 40 PETplanet Insider Vol. 19 No. 03/18 petpla.net Closure production and mould manufacturing by Kay Barton The assembly and production division of Prospack Industry is situated near the city of Ayutthaya, the former capital city of the Kingdom of Siam, built around its famous “Historical Park”. In addition to mould manufacturing, the company specialises in the production of caps and closures. In addition to local and regional customers, it supplies its products to a number of well-known multinational drinks producers in Thailand. We met with Managing Director Chaiying Sriprasert and talked about his business. Prospack Industry Co., Ltd., June 23, 2017 We met: Mr Chaiying Sriprasert, Managing Director “Prospack was founded in 1991 as a producer of caps and closures,” Mr Sriprasert said. “We started our business activities with four injection moulding machines and began by making closures for cooking oil bottles. Over the following years our business expanded, and we extended our activities into other fields. We started manufacturing plastic components for electrical appliances and for the automotive industry, before we finally integrated our mould manufacturing business right here.” He indicated the assembly department, which is where the company manufactures injection moulds for these fields. Prospack’s Ayutthaya site basically consists of two large halls. Offices and meetings rooms adjoin the mouldmanufacturing department, with closure production and storage space Tour Sponsors: located in the neighbouring hall. In the clean room, which we were only able to view through large panes of glass, were two Husky HyCap 225 models, along with testing equipment from IMD Vista. It is here that the company manufactures more than 1 billion closures per year in 30/25 and 29/25mm formats; the majority are currently used for CSD and water production. “We regard the production of caps to be a highly sensitive activity, in terms of quality, precision and speed. We therefore decided to use high-quality equipment from Western Europe and North America at an early stage,” Mr Sriprasert explained. Prospack’s moulds are primarily from Corvaglia, Husky, Wiro and Plastisud. Its key customers are bottlers such as Nestlé, Coca-Cola and PepsiCo. The company currently generates an annual turnover of approximately US$20 million, of which around 30% is accounted for the closure business. It employs approximately 350 people. www.prospack.com Prospack’s goods waiting to be delivered Colourful portfolio,@ID:42}, BOTTLING / FILLING 37 PETplanet Insider Vol. 19 No. 03/18 SIPA S.p.A. - Via Caduti del Lavoro, 3 - 31029 Vittorio Veneto (TV) - Italy Tel. +39 0438 911511 - Fax +39 0438 912273 - email: sipa@zoppas.com We make it happen. www.sipa.it Imagine taking your operating costs at the lowest level. Designed to adapt. Built to last. Preform Systems MAINTENANCE COST i stment Less than1%of the capital nve PET packaging facilities: Vientiane: 1x Sidel Blower and 1x KHS Blomax for water 1x Sidel Blower for CSD Champasack (South) 2x KHS Combibloc for water and CSD Duncan Crow’s office looks across to the beer production facility on the opposite side of the road. His position as a Supply Chain Director was introduced three years ago, when he joined the company. The native Briton has lived with his family in Vientiane ever since. “I am a Chemical Engineer and a Brewmaster,” he says. “My role here is to build a high performing supply chain organisation and we have made great improvements throughout the chain, from planning through production and logistics. Since last year, I have also been responsible for the procurement.” PET, glass and cans The plant at the head office bottles beer in in glass, and water in PET. The second plant, which is only 4km away, bottles both Pepsi CSDs and water products. “In addition to PET and glass, cans are also used there,” says Duncan Crow. The third production plant, located near the town of Pakse in the south of Laos, produces beer, water and CSDs, in PET and glass. “Pepsi is the market leader in soft drinks in Laos. It has been in the country for a long time and obviously set the right course at an early stage and was able to remain in the market after the re-unification in 1975. That is one of the reasons Pepsi maintains a strong market position here.” The markets are certainly developing quickly: Heineken has been present in Laos for several years and Coke recently opened a production facility in Laos. “Looking at the consumer behaviour, I see growth in all segments, especially in water and CSD,” he says. The company’s preforms are sourced from local and Thai suppliers such as LT Plastics Laos and PETform (Indorama) Thailand. It imports all of its caps. “We also have a project for the future that we are bringing to fruition step-by-step,” says Duncan Crow, pointing to the water bottles on the meeting table. “We are planning a new PET line for water.” www.beerlao.la,@ID:39}, BOTTLE MAKING 11 PETplanet Insider Vol. 19 No. 03/18 petpla.net Freshly produced PET bottles PPT Mould, part of the core activities of Pro PET, is a fully-equipped mould design operation that provides services from customer’s concept, to CAD drawing, to the completed injection and blow mould, is to be found in another part of the facility. “This is our main characteristic”, says Mr Santhudkijkarn. “We do not only process on the plastics side; we regard ourselves as one-stop service providers who help customers save packaging cost and are prepared to accompany the customer through the entire production process, if required. The customer has the idea; we can do all the rest – design ideas and everything up to the finished bottle – right here on site.” The CNC equipment it has on site enables ProPET to produce to tolerances of 10 microns. During our visit, the Mould Department was working virtually flat out. The quite popular two-shift process is employed 24/7. “We use high quality German steel, exclusively, for our moulds,” Mr Pookhaw says. We then made our way quickly, by golf cart, from the ProPET plant to the more or less adjoining TCK works, which produces three types of products: PET bottles for other applications, such as detergents, personal care, beauty care, health and pharmaceutical products; HDPE pallets; and PET extrusion sheet. “We see our future as lying primarily in PET packaging for food products and similar applications,” said Mr Santhudkijkarn. He indicated wide-mouth cans, that will soon be on the market, as ideal illustrations of the way the company is developing. www.pptthailand.com,@ID:13}, BOTTLING / FILLING 23 PETplanet Insider Vol. 19 tion plant must be cleaned effectively. But, as every flavour manufacturer knows, that is not the whole story. Flavours and aromas can linger in equipment even after they have been cleaned to the most scrupulous hygiene standards. Any residue of the previous flavour can easily taint the next product, destroying the all-important consistency. To prevent this, GEA has done much more than provide an efficient rotating-ball cleaning system. Getting the design right With the overall concept, GEA has eliminated sharp edges or dead zones in the machines, pipework and valve systems, which even the smallest quantity of product could become trapped. Special materials have been carefully chosen to provide smooth internal surfaces to which product cannot adhere. The size of cleaning fluid tanks has been calculated to ensure that they hold precisely the right volume of medium to clean the whole system efficiently in less than four hours. Even gasket materials have been chosen to ensure that they do not harbour traces of product. These elements combine to ensure the efficiency of the Cleaning In Place (CIP) system making it efficient and enabling fast product changeover, reduced downtime, minimal waste and low use of water and detergents. Sequenced production There is also another key factor in maintaining repeatability. When producing multiple products on the same line it is critical that products are processed in the correct sequence to help prevent any tainting from one to the next. Purer flavours such as melon or strawwww.npeguestpass.org/588580 Visit us at Booth S15089 Free Ticket at: berry, instantly recognised by consumers and often consumed on their own, take precedence. Stronger flavours such as orange, garlic, chilli, curry, etc., that are usually mixed with dishes, come later. The control system on the GEA line is capable of not only managing the recipe for each product, but sequencing the production for maximum efficiency ensuring that after each operation the line is cleaned sufficiently. Deep cleaning can be performed at the end of the sequence before the program begins again. This also helps to minimise the use of chemicals and water and reduces plant downtime. www.gea.com,@ID:25}, INSPECTION 39 PETplanet Insider Vol. 19 No. 03/18 petpla.net can be applied locally on a preform for any given design and therefore control the material distribution. A good handling of the temperature distribution allows the operators to achieve the thickness distribution suitable for the specific bottle performance. A recent case study of a major SBM production plant demonstrates the extreme variations in temperature during the SBM process caused by external variables. For example, over a 10-day period it was observed that an unnecessary 25% increase in preform temperature (Fig. 3) occurred at the exact same time as a change in operator staff. This had an obvious impact on not only the bottle quality and production downtime, but also the running costs of the ovens and overall energy consumption by the business. Thermoscan 3D identified this extreme temperature variation on the production floor and ensured that oven temperatures were readjusted to suit optimum levels and that operator staff were made aware. This is even more important when the same product is manufactured at various sites in different geographical locations, where quality is also paramount. BTM ‘preview’ simulation software is a user friendly validated stretch blow moulding simulation available in the web browser which will be launched in 2018. In addition, BMT provide their services in bi-axial testing, in-house simulation, material characterisation and free-blow experiments. Born out of 20 years of scientific research in SBM, BMT are committed to making impactful, innovative and practical solutions for the SBM industry. www.bmt-ni.com motan-colortronic gmbh - info@motan-colortronic.de www.motan-colortronic.com LUXOR A 80-2400 ETA plus® considerably reduces energy consumption and protects materials. Drying has never been this efficient: ETA plus® Fig. 3,@ID:41}, BOTTLE MAKING 10 PETplanet Insider Vol. 19 No. 03/18 petpla.net Leading one-stop PET converter from Singburi, Thailand by Kay Barton Pro PET is part of Thailand’s TCK group of companies, which also includes TCK Interplas, Superpack Plastic and TCK Plastic. Its core business is plastics processing and integration of different fields of packaging to a single, comprehensive and easy-to-use package, according to customers’ requirements. PET conversion accounts for 80% of Pro PET’s business; the balance is concerned with PP, HDPE and LDPE. The company’s portfolio includes preforms, bottles and closures for beverages and food. Tour Sponsors: Pro PET (Thailand) Co., Ltd. June 22, 2017 We met: Mr Chaichana Santhudkijkarn, Managing Director Mr Kittisak Pookhaw, Production Manager Preform & Closures In Central Thailand, in the Province of Singburi, we spoke with Pro PET’s Managing Director, Mr Chaichana Santhudkijkarn, and Production Manager Mr Kittisak Pookhaw. It might be hard to overlook an 80,000m2 commercial building even in a bustling South-East Asian city but Pro PET’s main production facility is some way away from the main communications route and some visitors can only locate them with outside help. We found that, in the end, if you follow the directions precisely you will get there! It is quite a picturesque approach; a fountain sits behind the gateway and, beyond it, is the main entrance. Pro PET, which was founded in 2001, now employs almost 1,000 people. As we arrived it became immediately apparent that hygiene is taken extremely seriously: shoes had to be removed before entering and swapped for slippers. When we arrived in the meeting room, Mr Santhudkijarn provided us with a first overview of the different fields of activity of the group, which was last visited by PETplanet in the person of Editor Wolfgang von Schroeter in 2009 (see PETplanet 09/2009). “Our head office is located in Nonthaburi, but the TCK Interplas and TCK Plastic plants are only 200m from here”, Mr Santhudkijkarn said. Nonthaburi is about 130km from Singburi. “Superpack Plastic is in Khonkaen Province, the north-east of Thailand. As well as customer supplies we also take care of in-house production lines for some customers.“ Pro PET currently has capacity for approximately 100 million preforms and 50 million bottles per month. PET bottles: 250ml, 350ml, 400ml, 500ml, 600ml, 750ml, 1l, 1.5l, 5l, 5.2l, 6l; Preform types: 29/25, 30/25, PCO 1881; Preform weights: 11g,13.5g, 14g, 15g, 17g, 18g, 20g, 22g, 26g, 28.5g, 31.5g, 37.5g; Caps & closures (incl. customised closures); 29mm, 30mm, flip top cap, sauce cap, ice cream cap, mouth wash cap. The company’s strict attention to hygiene has been recognised with the award of GMP, HACCP and ISO 9001 & 22000 certification. Nothing happens here without haircover, facemask, shoe covers, hand disinfection and an air shower, even before entering the production area. Its two-stage injection moulding equipment consists of four KM PETform machines, each with 96 cavities, and a large number of 24-cavity preform injection machines. It has approaching 30 Nissei single-stage ASB machines, in addition. The company produces seal caps and flip top closures with five 200t KM CX machines, one with 110t of closing force. A foil extruder specifically equipped to ProPET’s requirements shapes PE plastic bags in-house, for cleanliness. They are then carefully packed with completed bottles, which are thus protected until they are filled by the customer. Four camera-equipped inline preform inspection machines from P&S, along with an Intravis Prewatcher sampling inspection machine, provide the backbone of quality assurance. Workshop visit with (f.r.t.l.) Chaichana Santhudkijkarn and Kay Barton,@ID:12}, PETplanet Insider Vol. 19 No. 03/18 petpla.net 44 PETbottles Beverage + Liquid Food Enlarged advertising surface On well-stocked shelves of smoothies and fresh juices, it is important to have a sales tool that will capture the attention of customers and distinguish a product from others. For this purpose, German company Rewe is adding a cardboard sleeve to the upper section of its various, coldpressed juices in their “Rewe to go...” brand. The cardboard sleeve protrudes to the seal, is placed over the neck of the clear 330ml bottle and is attached under the support ring. The bottles are sealed with a black screw cap with guarantee band. www.rewe.de Protein drink Under its own brand “Sportness”, the German discount pharmacy chain dm is selling 500ml of a sugar, fat and lactose free protein drink with a tropical flavour in a contoured, transparent bottle. The product is light in colour and satisfies the increased protein requirements of athletes. The product can also be used as part of a low-sugar and low-fat diet. The slim bottle is decorated with a partially transparent sleeve label and is sealed with a tamperevident screw cap. www.dm.de Juice with tomato extract “Sirco” is the brand name for a range of bioactive fruit juices that contain tomato extract to promote good circulation. Each transparent bottle holds 250ml and has reinforcement ridges and a robust appearance. The bottle is decorated with a sleeve label and the large drink opening is sealed with a screw cap. www.sirco.at Hall 2H · Booth 2P07 German Technology,@ID:46}, 21 PRODUCTS PETplanet Insider Vol. 19 No. 03/18 petpla.net Mixed milk drinks The turmeric latte, often referred to as “golden milk”, was last year’s popular drink. According to the Mintel Global New Products Database (GNPD), imports of hot drink products containing turmeric rose by 359% in the European retail sector between 2013 and 2017. Julia Büch, a food and drink analyst at the Mintel Market Intelligence Agency, spoke of this latest drinks’ trend at the Dairy Congress on “international dairy trends” in Munich, Germany. “The idea for the turmeric latte was inspired by a traditional Indian remedy made from hot milk, turmeric and other spices such as pepper, cinnamon and ginger. The drink is said to have positive health benefits but the golden milk’s rich photogenic colour which goes down particularly well on social media may better reflect the drink’s popularity. Milk is not usually renowned for being a fashionable drink, nor is it often seen on Instagram. However, colourful and delicious drinks such as turmeric latte could soon change all that”. According to the analyst, new recipes will focus more on colours and textures. Inspiration could come in the form of matcha or spirulina. These ingredients, which are already common in Asia, are something new to the Western world. “Fizzy milk”, a carbonated mixed milk drink which is already extremely popular in Asia, is being talked about as the next popular drinks product. Texture is emerging as the next major trend in food and beverage recipes as was predicted by Global Mintel Food and Beverage Trends “New Sensory Impressions”. New ingredients that give drinks an unusual texture are on the rise. One such example is macchiato tea from China, a drink which combines tea with whipped cream cheese. Although popular in Asia for centuries, matcha is currently experiencing a boom in the West and, for example, can be found in colourful matcha lattes. New European imports in the hot beverages’ sector of products that contain matcha increased tenfold between 2014 and 2017. Spirulina is one of Mintel’s trend ingredients of 2018, one that gives the popular “Mermaid Latte” drink its pastel blue colour which is increasingly to be found on Instagram. Imports of fizzy milk drinks, i.e. mixed milk beverages that contain carbonic acid, have also gone up in recent years despite initial numbers being very low. The Asia-Pacific region was the area that accounted for 86% of fizzy milk drink imports in 2017 and is the birthplace of this popular drink. The mixture of carbonic acid and milk creates a creamy texture which is unusual in fizzy drinks. According to Mintel research, this innovation is well positioned to be the next big thing on the market. www.mintel.com,@ID:23}, BEVERAGE INGREDIENTS 19 PETplanet Insider Vol. 19 particular. However, while 2014 Mintel research showed that snack bars and yoghurts accounted for the majority of high protein launches, the protein trend has spread so quickly that it is now possible to find protein in almost every conceivable type of product on the market. In the beverage sector also, the number of protein-added drinks have been on the rise in recent years, and not just in the sports drink segment. But as the diversity of products continues to increase, superior sensorial qualities are becoming ever more vital in the battle to stand above the competition. Barbara Lezzer, Director of Marketing Europe Sweet and Beverage at Sensient, comments: “The variety and intensity of off-notes that have to be covered is the key challenge when it comes to protein masking. Most current protein masking solutions just involve strong flavour usage, but this is an unsophisticated approach that often leads to low levels of consumer acceptance. We at Sensient follow a different route. Our natural protein masking solutions are a combination of different Sensient flavouring technologies, which have excellent synergies. We make use of the individual enhancement properties of each technology to calm the negative taste of protein while promoting the desired flavouring profile.” Sensient’s protein masking solutions can be used in various liquid applications such as RTD sports, wellness and beauty drinks. To achieve the best possible sensorial results for each application, Sensient recommends working closely with the company’s technical team. Barbara Lezzer adds: “From concept ideation to product launch, we partner with our customers every step of the way. This approach delivers complete product solutions built upon innovation, depth of market vision and creativity. Our value-added services help our clients excel in highly competitive markets and create protein-enriched products that really appeal to today’s consumers.” Foresight Over the course of the next few years, the market will see a rise in the diversity of the protein sources used in food and beverage applications, from plant-based proteins like pea to marine-based sources like algae. Experimental proteins such as insect protein or synthesised meat protein will take longer to gain acceptance. However, every protein source is likely to pose numerous sensorial challenges to manufacturers. As a consequence, the role of flavour experts is expected to become more important in the future development of tasty and healthy, protein-rich foods and beverages. www.sensient.com We do more. Contipure AseptBloc #GermanBlingBling #ContipureAseptBloc Anuga FoodTec 2018 Cologne, 20 – 23 March Hall 8.1, Stand A020/B039,@ID:21}, PETcontents 03/18 4 PETplanet Insider Vol. 19 No. 03/18 petpla.net INSIDE TRACK 3 Editorial 4 Contents 6 News 42 Products 44 PET bottles for Beverage + Liquid Food 46 PET bottles for Home + Personal Care 48 Patents BOTTLE MAKING 10 The future lies in PET Leading one-stop PET converter from Singburi, Thailand 12 Multiple bottle designs Customisation possibilities for a range of brands 14 The vitaliser bottle Ovoid shaped bottles that preserve the properties of liquids BEVERAGE INGREDIENTS 16 Peel, pop and shake Dry and liquid ingredients combine in a reusable bottle to create beverage blends in a variety of flavours 18 Masking the taste of protein With protein enrichment increasingly moving into more mainstream products, taste has become a crucial concern 20 Beverage ingredients products FILLING 22 Optimising flavour manufacturing 24 Super-light solutions Partner for sustainable packaging 25 Filling management and full container inspection 26 Hello versatility, goodbye preservatives! A filling line to match new market trends 30 Aseptic to go Serac launches aseptic Combox for low to medium production rates 32 Reduced change over time New hot fill options 33 From juice manufacturer to PET blow moulding 34 Hygiene customised A modular rotary machine concept for the hygienic filling of sensitive beverages 36 Soft drinks and beer for Laos MARKET SURVEY 28 Suppliers of preform machinery INSPECTION 38 Preform temperature - the invisible parameter CAPS AND CLOSURES 40 Closure production and mould manufacturing BUYER’S GUIDE 49 Get listed! Filling Special BEVERAGE +ingredients Page 44 Page 22 Page 10,@ID:6}]}}
