Sustainable from the outset
Husky is committed to sustainable packaging solutions for future generations
In Luxembourg, I had the great pleasure of visiting Husky’s impressive campus. I was warmly welcomed by Pedro Oliveira, Business Manager for Sustainability and Recycling Solutions at Husky Injection Molding Systems, as well as Maria Carbonaro, Marketing & Communications Manager, along with numerous employees during my tour of the production site.
Interview with Husky // May 19, 2025
We met: Pedro Oliveira, Business Manager for Sustainability and Recycling Solutions at Husky Injection Molding Systems (photo top on the right), and Maria Carbonaro, Marketing & Communications Manager (photo top on the left)
Sustainability is a top priority at Husky. The company’s technical centers and manufacturing facilities worldwide are designed with energy-saving features to reduce their environmental impact. Many of these facilities are constructed using highly insulated concrete, with solar energy systems and radiant floors and ceilings to reduce heating and cooling loads. Skylights and strategically placed windows allow more natural light indoors, cutting down on electrical energy use. Additionally, Husky employs naturalized landscaping that minimises or even eliminates the need for pesticides. The company is also committed to recycling every possible waste stream – including water and fluids, paper, compost, glass, plastic, metals, wood, and general refuse. As a result, up to 86% of waste is diverted from landfills.
Since 2021, Husky has been reporting on its sustainability goals and achievements through its ESG (Environmental, Social, and Governance) reports. An ESG Committee oversees the company’s strategy, risk management, and regulatory compliance. In 2024, Husky supported 10 customers with its rPET Resin Quality Grading Services and contributed to PETCORE EUROPE’s educational social media campaign, ‘Recycle the One,’ which promotes the Circular Economy.
Husky is also committed to the Science-Based Targets initiative (SBTi), aiming to expand greenhouse gas (GHG) emissions disclosures to include all Husky operations, with a focus on Scope 3 reporting. The company is dedicated to fostering an ethical society and has become an employer partner of the Canadian Centre for Diversity and Inclusion (CCDI), providing access to all employees with educational resources on diversity, inclusion, and strong governance practices. In 2024, several technical highlights were closely linked to Husky’s Luxembourg campus, underscoring the company’s continued innovation and commitment to sustainability.
Sustainable PET preform production
In 2024, Husky showcased several sustainable technology highlights, including receiving the Packaging Europe Sustainability Award for its innovative PET closure. The launch of the new HyPET6e was also a significant success. Pedro Oliveira guided me through the production hall in Luxembourg, explaining the new machine in detail.
He began with the machine’s tooling capabilities: “The HyPET6e platform is specifically engineered for sustainable PET preform manufacturing. With high-density 45-pitch tooling, the machine is available in configurations ranging from 32 to 200 cavities. It supports rPET processing with up to 100% rPET content, all with a cycle time of just 4.5 seconds. This allows customers to produce ultra-lightweight preforms.”
For lightweight water preforms, the machine can produce up to 144k preforms per hour (pph) with a 200-cavity configuration, representing a 25% increase in output compared to the previous model. This performance improvement is driven by three key components: a larger mould stroke cylinder, a new clamp decompression accumulator, and an electric clamp lock.
Pedro also highlighted the new HyMIX Screw, which improves throughput and melt quality: “Throughput is increased by 7%, which may allow for the downsizing of extruder configurations, leading to both lower costs and energy savings.”
The most significant highlight of the HyPET6e is, of course, its 13.5% energy savings. A key factor in this improvement is the use of variable servo pumps, which enable independent pressure control for both the clamp and injection units. These pumps are no longer voltage-dependent, enhancing efficiency. Another important step was insulating the barrels to optimise energy consumption and prevent temperature fluctuations. The incorporation of smaller transfer cylinders also helped significantly reduce oil consumption.
The required pressure is lowered thanks to a new accumulator for precharging, along with a new circulation pump motor assembly. Additionally, the newly optimised Coolpik DH2.2 system is integrated into the machine. This system provides feedback on the cold water temperature and enables seasonal reductions in compressor energy consumption. It also features an automatic bypass valve, further enhancing energy efficiency. The entire HyPET6e system has been optimised for processing rPET. It is designed to handle the varying behaviour of rPET material throughout the production process. A self-cleaning mould minimises maintenance requirements while ensuring consistent preform quality. The machine also accounts for the drying of rPET material, with a longer dwell time to achieve optimal results.
Additional features such as blenders, a metal separator, cyclone filters, an oil condenser, and closed-loop preform quality monitoring with colour correction are also integrated. These upgrades lead to improved system performance, reduced variability, and higher preform quality. Pedro proudly announced that since the launch, over 200 HyPET6e system orders have been received, a testament to the success and impact in the market of the new platform.
Mono-material PET closure
In Luxembourg, a second sustainable innovation was born: the new PET cap system, enabling mono-material PET packaging. The HyCAP SecuRE+ closure system offers a sustainable alternative to traditional HDPE closures. Moulded from bottle-grade PET resin, these closures further contribute to the circular economy in beverage packaging. Depending on the application, the closure can account for up to 15% of the total package weight. An all-PET beverage package results in a meaningful improvement in rPET bale yield.
The challenges of producing a closure made entirely from PET were primarily related to the design of the tamper-evident band. To address this, Husky developed a patented process called SecuRE+. This design eliminates the need for integrated cams on the tamper-evident band, replacing them with a clearance fit that allows the band to pass over the pilfer-proof band like a sleeve. This approach prevents stress on the bridges and eliminates the need for a post-moulding slitting process, making it a dust-free manufacturing method.
Despite having a higher mass density than HDPE, PET’s more rigid nature opens up opportunities for further lightweighting, especially at the dispensing system level. The molecular structure of PET also provides superior barrier performance compared to HDPE, extending shelf life for oxygen-sensitive and carbonated beverages. Additionally, the system allows for complex closure geometries and intuitive, patented tethered designs.
Pedro explained that all PET closure designs are 100% compatible with existing CETIE standard neck finishes, meaning no modifications to the necks are required. Commercial launch will occur in 2026.