{"pages":{"page":[{"@ID":26
"MARKET SURVEY 24 PETplanet Insider Vol. 25 No. 10/24 www.petpla.net Filling inspection systems Company name KHS GmbH Pressco Technology Inc Heuft Systemtechnik GmbH Postal address Telephone number Web site address Contact name Function Direct telephone number E-Mail Juchostraße 20, 44143 Dortmund, Germany +49 231 569 0 www.khs.com Mr Helmut Schmitt Project Man. & Production Man. Inspection Technology +49 231 569 10124 helmut.schmitt@khs.com 29200 Aurora Road, Cleveland, OH, USA +1 440 498 2600 www.pressco.com Mr Tom Murphy VP, Sales & Customer Service +1 440 498 2600 sales@pressco.com Am Wind 1, 56659 Burgbrohl, Germany +49 2636 56 0 www.heuft.com Mr Sjoerd van Laar Product Manager +49 2636 2431 sjoerd.van.laar@heuft.com Fill level control Infrared No Yes X-ray Yes Yes Yes Gamma Yes No (too unsafe) Camera Yes Yes, high frequency Yes Contamination control Foreign substance inspection (sniffi ng) for empty ref PET bottles No Yes Closure inspection Yes Presents of cap Yes Yes Yes Crooked cap Yes Yes Yes Lifted cap Yes Yes Yes Wrong cap Yes Yes Yes Tamper evident band control Yes Yes Yes Camera: 360° / sensor Yes, both Yes Yes Label inspection Torn label Yes Yes Vertical / horizontal misalignment Yes Yes Yes Best-before date control Code presence inspection No Yes Camera: 360° / sensor Camera and sensor Yes Yes Pressure leak detector Squeezer No Yes Applicable bottle type Diameter 40-110mm Up to 150mm in standard up to 200mm Height 150-360mm Up to 400mm in standard up to 400mm Rejecting bottle Into bin and onto collecting table Push reject and diverter reject options available Yes Inspection speed PET: up to 86,000bph Over 3,000ppm 72,000cph with 360° inspection included; otherwise up to 144,000cph Monitoring Filler-/sealer management Filler valve, capper head correlation Yes Filling equipment Company name Krones AG SMI S.p.A. KHS GmbH Postal address Telephone number Web site address Contact name Function Direct telephone number E-Mail Böhmerwaldstr. 5 93073 Neutraubling, Germany +49 9401 70 0 www.krones.com Mr Tim Schorb Product Manager +49 9401 70 0 Via C. Ceresa, 10, 24015 San Giovanni bianco BG, Italy +39 0345 40111 www.smigroup.it Mr Pietro Volpi Marketing Dept. Manager +39 0345 40316 pietro.volpi@smigroup.net Juchostraße 20, 44143 Dortmund, Germany +49 231 569 0 www.khs.com Mr Manfred Härtel Product Manager Filling +49 231 569 0 manfred.haertel@khs.com 1. Machine designation / model number Modulfi ll Filler and capping machine in Ecobloc confi guration Innofi ll PET DRV-VF 2. Number of fi lling heads (range: from/to) 16-216 9-114 for standard bottle (up to 3 l); 9-20 for high capacity bottle (up to 10 l) 48/216 3. Min to max bottle contents (in liters) 0.1-5 0.25-10 l 0.1/3.0 4. Filling speed: output (bph) (min to max): Up to 100,000 1,000-50,000 Up to 82,000 specifi y: 1l bottle / still water (bph) Up to 86,000 Up to 44,000 Up to 82,000 1l bottle / CSD (bph) Up to 72,000 Up to 28,600 Up to 72,000 1l bottle / Milk (bph) Up to 60,000 Up to 33,500 1l bottle / Juice (bph) Up to 60,000 Up to 34,400 (*) depending on the preform/bottle features Up to 60,000 5. Filling process Pressureless (still drinks) Yes Yes Yes Pressure fi lling (carbonated drinks) Yes Yes Yes Hot fi lling Yes No Yes Cold aseptic fi lling Yes No Yes Juices with high pulp content Yes No 6. Type of fi lling valve and metering system Volumetric fi lling system: inductive and mass-fl owmeter, net weight fi lling systemwith weighing cell and height fi lling systemwith electronic fi ll height measuring Electronic volumetric fi lling valves Flowmeters (metering system) Volumetric fi lling system; pneumatic cylinder; MID (inductive fl ow meter); mass-fl ow (Coriolis) 7. Special features (short description/keywords) Monotec (starwheel columns with servo drives), cap disinfection (UV light / PAA / H2O2, optional), clean room cover, foam cleaning system, nitrogen injection system, automatic CIP-cups, capcade, Bloc solutions Compact modular frame, with a wide choice of customisation options; operating and maintenance costs cut; easy and quick format changeover, high hygiene, easy maintenance and cleaning; optimal performances with reduced costs of the Ecobloc series as it does not require a rinser and conveyor belts between the stretch-blow moulder and the fi ller. The machine base plate is inclined towards the drainage points. This allows the drainage of liquids that are on the machine base and a higher level of hygiene. CSD warm-fi lling up to 24°C; simple fi lling valve; compact unit; slow & fast-fi lling; gentle fi lling with low foaming; no beverage loss during production; PTFE-sealing technology prevents aroma transfer."},{"@ID":17
"EDITOUR PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 15 Plastipak Deutschland: Pioneering Innovation & Sustainability in Packaging Plastipak Deutschland produces up to 350 million bottles and containers for the beverage, food, and personal care sectors annually, primarily in Europe. Since pioneering recyclable PET (rPET) in 1989, the plant has delivered over 5 billion reusable containers. Today, we are discussing innovation and product development with two key management members from our Mendig plant. Sebastian Rupprecht, who has been with Plastipak for over 15 years, became Operations Manager in April 2024 after serving as Technical Manager. Joining him is Martin Rehan, our QHSE Manager since October 2023, who brings over a decade of experience in quality and production management. Considering todays’, market dynamics what are the current trends and challenges in product development? SEBASTIAN RUPPRECHT: In today’s market, sustainability is driving significant innovation in the packaging industry. Consumers and brand owners alike are demanding packaging solutions, which contribute to a circular economy while ensuring quality and safety of the products. Besides the use of recycled PET (rPET), there is an increased focus on reuse and refill containers, which brings us a significant step closer to a circular economy. With over 30 years of experience in the manufacturing of reuse and refill containers, Plastipak Deutschland is well positioned to offer a range of innovative solutions. The fact that we are part of the Plastipak Packaging group allows us to present fully integrated packaging solutions, from our PET Resin PPK Natura up to our O2Blox additive range, we offer a One-Stop Shop to our customers. MARTIN REHAN: One of the main challenges in the innovation process, particularly in the development of sustainable packaging, is balancing sustainability with performance and cost-effectiveness. While there is a strong demand for eco-friendly solutions like recycled PET (rPET) or biodegradable materials, these innovations often come with higher production costs or limitations in material performance, which must be carefully managed. SEBASTIAN RUPPRECHT: As a key player in the PET industry, you need to be agile and reactive. Together with our European Technical Center consisting of the finest packaging development engineers and our in-house design studio based in Belgium, we are able to walk the path from ideation, innovation and development and have the production site involved right at the start of the process. This allows us to accelerate into the industrialization phase and significantly reduces time to market. This year Plastipak Deutschland has chosen to focus on the themes of Innovation, Sustainability, Quality and EHS; what are the key takeaways for Brau Beviale 2024? At Brau Beviale, visitors will gain valuable insights into Plastipak’s comprehensive development process, from preform to bottle. Our team will showcase our rigorous Quality Control and EHS practices.Attendees will witness firsthand how Plastipak leads the industry in innovation, quality, and sustainability — demonstrating our dedication to advancing responsible packaging. We look forward to discussing how we can create value for our customers with sustainable packaging solutions. Thank you and have a great Brau Beviale 2024! www.plastipak.com - Advertisement -"},{"@ID":47
"PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 27 EVENT PREVIEW Röders laboratory achieves ISO-9001 certifi cation Four steps, one supplier: Design, manufacturing, sampling, testing Independent mould supplier Röders will be presenting its full range of services at two key industry events this autumn, Gulfood Manufacturing and Brau Beviale. The company’s state-of-the-art equipment is claimed to enable comprehensive qualification of new PET bottles, blowing processes, and preforms. Equipped with a modern laboratory blow moulding machine with one blow moulding station, Röders can flexibly adapt to various production requirements. The laboratory is capable of extensive testing for new bottle designs, including the installation of different mould types for rotary and linear blow moulding machines, testing of quick-change or standard blow moulds, and adjustment for different thread types and preforms. The lab can also work with PET and rPET materials, optimise blowing pressures, test material distribution, stretch ratios, and process parameters, and conduct weight optimisation to reduce material costs. Röders can deliver sample bottles in requested quantities, including larger runs. The company’s long-serving employees offer customers support in adjusting and optimising blow moulding processes and can assist in converting blow moulding machines on-site. Tests, optimisations, and evaluations can also be conducted collaboratively with customers at Röders’ facilities. The company can conduct a wide range of examinations, including drop impact, thermal stability, stress crack testing, top load, burst resistance, carbonation retention, weight, fill point and brimful capacity, bottle dimensions, perpendicularity, base clearance, wall thickness, section weights, and appearance & odour assessments. The laboratory has long been certified by PepsiCo and was recently authorised by Coca-Cola, in addition to offering testing according to customers’ specific requirements. For over 50 years, Röders has produced several hundred thousand blow moulds for non-returnable and refillable bottles. The company is completely familiar with the various machine types and generations from leading manufacturers such as KHS Corpoplast, Krones, Sidel, and Sipa, with expertise down to the finest detail. Röders offers specially developed coatings to enhance the durability of standard blow moulds upon request. The company recently pursued ISO certification, a standard that ensures stringent quality management. Following several weeks of system adjustments and a comprehensive ISO audit, Röders’ bottle testing laboratory has been awarded the DIN EN ISO 9001 certification. www.roeders.de F.r.t.l.: Laboratory Manager Julia Oldenburg and Laboratory Technician Denis Bär proudly presenting the ISO certificate HEUFT SYSTEMTECHNIK GMBH AmWind 1 · 56659 Burgbrohl · info@heuft.com · heuft.com INTELLIGENT IN-LINE INSPECTION From compact entry-level EBI to X-ray and AI-boosted highspeed full-bottle inspection. From fill level check to foreign object detection. From smart sensors and optics to to pulsed X-rays with HEUFT reflexx A.I. image analysis: The state of the art for in-line inspection in the filling and packaging process can be found at the HEUFT stand during BrauBeviale 2024! From medium-sized companies to industrial giants: all will find intelligent systems for fault detection at the HEUFT level. Come and have a look: BrauBeviale 2024, Stand 8-104, HEUFT SYSTEMTECHNIK GMBH Röders Hall 7A | Booth 301 Röders Hall 1 | Booth S1-G52"},{"@ID":34
"32 EVENT PREVIEW PETplanet Insider Vol. 25 No. 10/24 www.petpla.net A broad closure portfolio Bericap will be showcasing closure solutions for present and future requirements. Whether plastic or aluminium, the company’s closures for alcoholic beverages, mineral water, soft drinks, or energy drinks are claimed to be convenient and safe to use, environmentally friendly, and individually tailored to the needs of the beverage industry. Visitors can discover how manufacturers can easily switch over to the tethered caps that are already mandatory for many beverages to overcome new challenges. They can also learn about the different types of sport caps and the sustainable options that are already possible today. Clip Aside tethered caps The Clip Aside tethering system on the closure’s drop band was developed early on by Bericap to simplify the process of switching filling lines over to the new tethered closures. Today, more than 15 billion bottles on over 70 filling lines have been fitted with the Clip Aside caps. The sustainable and user-friendly closures with an up to 180-degree opening angle are available for neck finishes ranging from 26 to 38mm in beverage categories such as carbonated soft drinks (CSDs), water, juice and tea drinks, and dairy products. Customers aiming for a quick and flexible switch over to resealable tethered caps that represent an alternative to aluminium seal foils (“alu seal-free”) in the milk and dairy segment will also find solutions. Sport caps for a mobile future The company’s sport caps are also available in a tethered version. Sustainability and comfort are key attributes of the products in this port fol io, and the Ber icap spor t caps are produced in an eco- f r iendly way. For example, the one-piece sport cap “Biarritz” and the two-piece premium closure “Monet” are manufactured in a mono-material design for opt imum recyclability. Users also appreciate the sport caps’ convenience. They can be opened using just one hand and the dus t cap folds back up to 180 degrees for ease of drinking, even when exercising or on the go. The sport caps have an additional tamper-evidence feature for optimum product protection. Eco-friendly production Bericap says that it is a pioneer in the development of sustainable closure systems and committed to the reduction of material use. The specially developed lightweight range for cooking oils is produced in a mono-material design across different closure categories, avoiding the need for additional sorting in the recycling process. The company has introduced energy-efficient manufacturing processes at its 30 plants in more than 25 countries, established global sustainability standards, and is involved in various sustainability initiatives. Aluminium closures The team at Bericap Aluminium, formerly Mala Verschluss-Systeme GmbH, offers a diverse portfolio of roll-on closures for wines and spirits, milk-based drinks and edible oils. The range extends from simple roll-on pilfer proof (ROPP) aluminium closures to highly complex safety closures. All aluminium closures are available with different types of seals, and both they and the Bericap plastic closures can be custom designed. www.bericap.com Bericap Hall 4 | Booth 219 BEYOND THE HORIZON PROCESS SOLUTIONS FOR POLYMER RECYCLING AND SOLID STATE POLYMER UPGRADING Polymetrix, a Sanlian Buhler Company, provides process technology including EPCM services for the polymer recycling and manufacturing industry. Leading supplier of rPET systems and integrated rPET plants for single line capacities up to 70’000 tons per year. www.polymetrix.com www.slhpcn.com"},{"@ID":49
"The worldwide round trip with PET world in the Middle East In a spectacular project taking us well into 2024, we will be travelling in a wide variety of ways to various countries and regions of the Middle East with different mobile editors. There we will interview machine manufacturers, the supply industry, bottle and beverage producers, as well as PET recyclers and everyone involved in the process chain. What market-specific trends are there now or will arise in the future? What developments and technologies are in vogue on the consumer and plant construction site in some of the hottest regions of the world? What special requirements are there? What role do topics such as food safety, shelf life and sustainability play in PET packaging and how are companies preparing themselves for the coming years? This, and much more we will be discussing face-to-face with all the key players and then our results will be presented to you in a series of must-read reports in PETplanet Insider. Please join on this enchanting voyage to the world of PET in the Middle East. We look forward to welcoming you on board! Our previous Road Shows at a glance 2010-2011-2012-2013-2014-2015- 2016-2017-2018-2019-2020-2022 Interested in being visited? barton@petpla.net Autumn 2023 - 2024 6 countries numerous interviews with PET companies Sponsors to date Editour The Middle East Roadshow"},{"@ID":14
"EDITOUR PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 12 Waterbrands Group focusses on vertical integration for packaging by Kay Barton The United Seqa Group, a bottling group founded in 1994 and headquartered in Riyadh, is supplied with the necessary PET preforms and closures from the plant built in 2010 by Riyadh-based Alsad Modern & Advanced Co Ltd. Seqa includes the water brands Adhari, Aqtra, Aqua 8, Aqua Life, Faline, Ramah, Rhine, Sehtak, Vein, Vow, Yanbua Alkawthar and Zulal. During the Middle East Road Show, we were able to make a detour to the plant, which is around an hour and a half north of Riyadh, and talk to the Operations Manager there, Mr Mohammad Abdel Moneim, who is in charge of 15 preform lines and ten capping lines. Interview with Alsad Modern & Advanced Co. Ltd. February 20, 2024 We met: Mr Mohammad Abdel Moneim, Operation Manager Alsad’s premises cover an area of 60,000m2, of which around 20,000m2 is used for production and 17,000m2 for the fully automated warehouse. The company employs 200 people in a two-shift system. The all-white office wing on the first floor allows plenty of natural light to enter the interior through large roof glazing and onto the office planting in the corridor area. The offices, which have an open-plan feel thanks to glass walls and doors, also benefit from the very bright layout and artificial lighting is only required in bad weather or at dusk. An adjacent and almost completed part of the building will soon house additional meeting capacities and the future, very elegant office of the CEO. Operation Manager Mohammad Abdel Moneim in his office F.r.t.l.: Mohammad Abdel Moneim in the workshop with an employee In front of the company entrance with Mohammad Abdel Moneim EDITOUR"},{"@ID":42
"PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 38 PETbottles Beverage + Liquid Food Manuka honey in a dispenser In the past, Manuka honey was seen as a special , hip honey for zeitgeist fans, but now the honey and its properties are becoming better known and therefore more interesting for the masses. This also includes user-friendly packaging and packaging sizes. The Capilano company, for example, sells various types of honey in squeeze bottles. The bottles each contain 250g of honey - in the picture the variant with an MGO content of 30+ - an indication of the amount of healthy methylglyoxal. The sleeve label with the product information is pulled over the lid and serves as a first-opening safety device. To open the lid and dispense the honey, a pre-perforated part of the label must be removed. www.capilanohoney.com Stylish bottle for new brand The new brand ‘Neqi’ from the German company New Flag GmbH, positioned as a premium hair care brand and available exclusively from the German drugstore discounter dm, has its own composition and fragrance as wel l as packaging that immediately catches the eye. The Repair Reveal Shampoo, for example, is f i l led in a special ly designed plastic bottle. The slightly conical bottle is shaped with vertical grooves of different lengths at the base, printed directly on the front and fitted with a screw-on disc top cap, also with grooves and a conical shape, with contrasting colouring of the movable part. www.neqi-hair.com PETbottles Home + Personal Care"},{"@ID":35
"33 EVENT PREVIEW PETplanet Insider Vol. 25 No. 10/24 krones.com For a closed loop: Recycling solutions made by Krones It’s important to look beyond tomorrow, which is why Krones regards plastic waste as a valuable resource and is working on recycling innovations that contribute to steadily advancing the circular economy round the globe. prs ASIA 2024, Singapore, 13-14 November Stand K24 Claranor Hall 8 | Booth 309 Pulsed light and UV decontamination Claranor will present its advanced solutions in pulsed light and UV packaging decontamination, specifically designed for thebeverage market. Visitors can discover six machines, each tailored to meet different needs. The company offers a range of three cap decontamination machines that are claimed to be compact, efficient and, above all, easy to integrate into a filling line. Inncap Essential The Inncap Essential has been developed as an economical solution, ideal for low- to medium-speed lines, with a capacity of up to 18,000 bph. It offers producers of slower-filling lines an efficient, cost-effective decontamination process through Claranor ’s pulsed light technology, outperforming UV systems and lowering the total cost of ownership (TCO). Inncap Evolution and Hispeed Claranor’s ultra-clean cap decontaminat ion equipment Inncap Evolution and Highspeed is designed for high-speed lines, supporting capacities of up to 100,000 bph. It can handle all types and sizes of closures efficiently at these speeds. Fullcap The Ful lcap system is designed for both sports and flat caps, decontaminating the inner and outer surfaces at speeds of up to 120,000 bph, depending on the required level of decontamination. It ensures an extended shelf life of over 60 days (ESL 60 days). This compact and economical alternative to hydrogen peroxide (H2O2) tunnels is suitable for both sensitive refrigerated products and acidic aseptic applications. www.claranor.com"},{"@ID":12
"TOP TALK PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 10 How Krones is integrating the Netstal plants 2-stage PET bottles from one line by Alexander Büchler The acquisition of Netstal by Krones has been the subject of much discussion in the industry. Time to ask around in Neutraubling to find out how the new arrival is getting on. We spoke to Jochen Hirdina, Head of the Plastics Technology department. In passing, the conversation drifted towards AI. PETplanet: Mr Hirdina, Krones has consolidated Netstal in the “Filling and Packaging Technology” segment since March 28, 2024. How did this come about? Mr Hirdina: In our approach of offering systems for the entire PET bottle cycle, we lacked an injection moulding machine. With MHT, we had added an outstanding preform mould manufacturer to our portfolio years ago, so the acquisition of Netstal was a logical consequence. PETplanet: Netstal had developed the side extraction as a new range. Would you have taken over Netstal if there had only been the range with top removal? Mr Hirdina: Strategically, I think so. However, side extraction is more favourable for our system concepts. PETplanet: With Netstal, you have acquired a plant manufacturer that sells mainly to converters and less to bottlers. Does Krones now also want to address the converters as a target group? Mr Hirdina: Yes and no. When we acquire companies, we leave them largely independent. Examples of this are Kosme, Gernep or MHT. Nevertheless, we see ourselves as a system provider rather than an individual machine supplier. For our target group, the bottlers, we therefore offer an integrated injection moulding stretch blow moulding system. PETplanet: How does it all fit together? Mr Hirdina: We call our new system Prefero. It combines our line concept with the plastic cycle. The line starts with PET material preparation. The preforms are produced in the Prefero machine (built by Netstal) with an MHT mould, which are transferred by the Prenexo Link directly to the stretch blow moulding machine where they are processed into bottles. The performance of the stretch blow-moulding and injection moulding machines is coordinated. Depending on the capacity, the clamping force is 300 to 500 t and moulds with up to 192 cavities can be used. PETplanet: In other words, in contrast to a 1- or 1.5-stage process, the preforms cool down completely and are then specifically reheated in the stretch bubble? Mr Hirdina: Yes, this makes sense for high outputs. The advantage of direct transfer to the stretch blow moulding machine (SBM) is that the preforms are fed in the order in which they were injection moulded. This allows the SBM to constantly adjust to fluctuating material qualities, which is particularly important with rPET. If preforms are processed in the wrong order, one batch could result in clear bottles, but the next batch could result in milky or yellowish bottles. No SBM, however good, can compensate for TopTalk"},{"@ID":28
"7 NEWS PETplanet Insider Vol. 25 No. 10/24 The Erema Group mourns the loss of company co-founder Helmut Bacher Helmut Bacher is regarded as a pioneer of plastics recycling. Together with his two colleagues Georg Wendelin and Helmuth Schulz, Helmut Bacher founded Erema Engineering Recycling Maschinen und Anlagen Ges.m.b.H. in Linz, Austria, in 1983. Their life’s work was acknowledged in 2008 when the three founders received the Golden Award of Honour from the Province of Upper Austria. Helmut Bacher displayed visionary foresight and an open mind in playing a key role in shaping the plastics recycling industry. Following his training as a fitter and completing his schooling as a mechanical engineer, he worked in various technical positions before moving to a mechanical engineering company for plastics processing in the early 1970s. Helmut Bacher shared with his two colleagues a belief in the potential of plastics recycling. During countless trials, he searched for the right solution - until he found it. Despite initial adversity, the three founders remained convinced of the idea of a cost effective recycling machine for plastic waste and started up their own company in 1983. At the K trade fair in Düsseldorf in 1983, Erema presented a simple, robust, reliable and economical recycling system. The young company produced its first orders in modest premises in Leonding with two small workshops and a double garage. Today, the plants and components suppl ied by the group achieve recycl ing capacities of over 25 million t/a of plastic worldwide. Up until his retirement from company management in 2004, Helmut Bacher was a driving force behind the company and remained closely associated with the Erema Group until his death. His technical ability, coupled with solution-orientated thinking and genuine appreciation of his employees, have left a lasting impression and continue to shape the company to this day. www.erema-group.com The Erema Group mourns the loss of co-founder Helmut Bacher, who passed away at the age of 81. CREATING FUTURE STANDARDS Japan’s leading Aseptic PET Filling System Provider. Our website Our solution high quality reliable technology safe & secure"},{"@ID":48
"OUTER PLANET 46 PETplanet Insider Vol. 25 No. 0/24 www.petpla.net OUTER PLANET Plastic waste traps for rivers Several million tonnes of plastic enter oceans yearly, with around 1,600 rivers responsible for most of it. To prevent it from spreading uncontrollably in the water and turning into microplastics, the start-up Plastic Fischer collects plastic waste from rivers in India and Indonesia - with the support of the Cologne-based plastics specialist igus, among others. “TrashBooms” - floating barriers that prevent plastic from flowing downstream (Source: Plastic Fischer; igus) Plastic Fischer has developed its own “TrashBooms” for this purpose. These floating barriers prevent plastic from flowing downstream - a technically simple and cost-effective solution made from locally available materials that enables quick repair and high scalability. Every day, the waste traps are emptied and the plastic is taken to the sorting plant, where it is dried, separated and further processed. “We sell all recyclable materials to local recyclers,” explains Karsten Hirsch, CEO and Co-founder of Plastic Fischer. “As most high-value plastics such as PET bottles are already collected by the informal waste sector, only 5% of our non-organic material can actually be recycled. All non-recyclable materials such as plastic bags Plastic Fischer has collected and processed over 1,600t of plastic waste since the initiative started in 2021. Plastics specialist igus has been one of the supporters of the initiative since 2022. Thanks to the financial support from the Cologne-based company, 33,611t of plastic were collected from rivers between November 2022 and August 2024, especially in Kanpur in northern India. The city is the main centre of commercial and industrial activities in the state of Uttar Pradesh and located directly on the Ganges river, one of the dirtiest rivers in the world. Non-profit company Plastic Fischer employs 15 full-time employees here to manage the daily tasks. They have already collected more than 315t of plastic from the drains that flow into the Ganges. are burned and used as an alternative energy source in cement plants, replacing coal.” www.igus.de www.plasticfi scher.com INDIA 4-6 December 2024 Mumbai, India NEW IN 2024 Register for your FREE entry badge today! www.prseventindia.com The launch edition of the Plastics Recycling Show India (PRS India) is the first event in India specifically dedicated to plastics recycling. Organised by In association with: ASIA 13–14 November 2024 Marina Bay Sands, Singapore Supported by:"},{"@ID":27
"MARKET SURVEY 25 PETplanet Insider Vol. 25 No. 10/24 www.petpla.net Sacmi Imola S.C. Krones AG Newamstar Packaging Machinery Co., Ltd. Via Selice Prov.le 17/A Imola (BO) Italy +39 0542 607111 www.sacmi.com Mr Stefano Severi Sales Area Manager +39 0542 607553 stefano.severi@sacmi.it Böhmerwaldstr. 5 93073 Neutraubling, Germany +49 9401 70 0 www.krones.com East Xinjing Road, Zhangjiagang Economic & Technological Development Zone, Jiangsu 215618, P.R. China +86 512 5869 1111 www.newamstar.com market@newamstar.com No Yes Yes No Yes Yes No Yes Yes Yes Yes and high frequency Yes No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes, Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes 130 50-105mm 50-250mm 380 60-340mm & closure diameter 27-46mm 100-470mm Yes Yes, without air consumption Yes Up to 90,000bph Up to 84,000bph 1,000-72,000bph Yes Yes Newamstar Packaging Machinery Co., Ltd. Enoberg s.r.l. Sacmi Beverage S.p.A East Xinjing Road, Zhangjiagang Economic & Technological Development Zone, Jiangsu 215618, P.R. China +86 512 5869 1111 www.newamstar.com market@newamstar.com Via del Lavoro, 14, 24060 Telgate BG, Italy +39 035 845908 www.enoberg.it Mr Fabio Bonaldi Sales Manager +39 0345 40545 / Mobile +39 347 5448971 fabio.bonaldi@enoberg.it Via Enzo Ferrari, 1, 43058 Sorbolo Mezzani PR, Italy +39 0521695411 www.sacmi.com Ms Federica Marozza Marketing & Communication Innofi ll PET NV XGF Rinser, fi ller and capper machine in stand alone confi guration Equafi ll ESF Equafi ll AWF 32/144 12-130 9-114 for standard bottle (up to 3 l), 9-20 for high capacity bottle (up to 10 l) 12-192 12-120 0.1/3.0 0.25-20 0.25-10 0.1-3.1 0.05-11 Up to 90,000 1,200-81,000 1,000-55,000 Up to 82,000 Up to 48,000 Up to 44,000 Up to 72,000 Up to 72,000 Up to 36,000 Up to 28,600 Up to 65,000 Up to 36,000 Up to 33,500 Up to 60,000 Up to 36,000 Up to 34,400 Up to 65,000 Up to 60,000 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes No Yes Yes Water valve, hot fi lling valve, isobaric valve, electronic valve; Flometer, weight, liquid level inspection Electronic volumetric fi lling valves by means of Flowmeters, Level fi lling: counter-pressure fi lllers and gravity fi llers Volumetric electronic fi lling by magnetic fl owmeter (or massic) Contact-free fi lling Intelligent Factory Management Platform Compact modular frame, with a wide choice of customisation options; operating and maintenance costs cut; easy and quick format changeover; high hygiene, easy maintenance and cleaning; precise and fast fi lling and capping processes, thanks to electronically controlled operations and to the use of high-effi ciency valves controlled by fl ow meters; the machine base plate is inclined towards the drainage points. This allows the drainage of liquids that are on the machine base and a higher level of hygiene. Intergrated mixer, automatic dummy bottles, easy changeover by grippers neck handling, clean room, automatic external cleaning No contact bottle fi lling, easy solution with 1 fl owmeter (water), integrated cip, automatic dummy bottles, easy changeover by grippers neck handling, cleanroom, automatic external cleaning"},{"@ID":15
"EDITOUR 13 PETplanet Insider Vol. 25 In one of the aforementioned glass-walled offices, we sat opposite Mohammad Abdel Moneim, who has been involved in the packaging industry for 14 years and whose professional background is actually in finance. “We have an installed capacity of eight billion preforms and closures per year, and we are certainly at 95% capacity utilisation,” he explained during our conversation. “This year we will process an estimated 65,000 t of material, of which around 55% is PET.” Suppliers include Sabic, Alpek, Reliance and Chinese suppliers. On the PET side, processing is carried out on eleven Sipa Xforms with 180 and 200 cavities and four Netstal PET lines with 128 cavities from Otto Hofstetter each. “With Netstal, for example, we like the broad compatibility with third-party suppliers for moulds,” says Mr Moneim. “We also use Netstal for closures, alongside Husky and Sacmi.” Two Elion systems from the Swiss machine manufacturer with 96-cavity Corvaglia moulds and four Husky HyCAP systems, each with in-house 96-cavity moulds, are available for injection moulding applications, as well as a further ten Sacmi rotary machines. Alsad’s portfolio includes preforms in 5.6 g, 6 g, 6.8 g, 7.2 g, 7.9 g, 8.5g (the most popular format), 9.1 g, 9.8 g, 10.4 g, 10.6 g, 11.3 g, 12.5 g, 65 g and 190 g. There are three formats for closures, 30/25, 29/25 and 38mm. 80% of the products remain within the group of water brands, the rest is exported to Gulf countries. “One of our current main topics is comprehensive, computercontrolled automation,” Mr Moneim told us. “Of course we are talking about large investments. But we also want to stand for quality and reliability by using quality equipment from the world’s leading machine and equipPreforms for water from the Sipa Xform ment suppliers and, together with our own dedication, continue our success story.” During the factory tour, we met technicians from IMD Vista who were setting up one of their inspection lines on a brand new Husky HyCAP. Pointing to the new setup, Mr Monem said: “With the new Husky system we will save 0.1 g of material per cap.” www.alsadcap.com"},{"@ID":7
"PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 39 BOTTLES Coconut water with cherry flavour The energy drink market is an innovative market with a constant stream of new products. Under the brand name ‘Prime’ and the addition ‘Hydration’, an energy drink is on offer that consists of 10% coconut water. Two well-known influencers - Logan Paul and KSI - are the inventors of the drink with 200mg of caffeine and various vitamin supplements. There are various flavours on offer, including strawberry, lemon lime, blue raspberry and several others. The picture shows a flavour that tastes of sour cherry. Each 500ml bottle is filled in a PET bottle with all-round reinforcing grooves and a colourful sleeve label. The drinking opening is sufficiently large and closed with an opaque screw cap with a tamper-evident seal. www.drinkprime.com Black water with humic acids The Polish company Fulvica sells 500ml of dark, almost black water in a transparent PET bottle. The colour of the still, tasteless and odourless water is the result of its special extraction and production process. The water contains natural fulvic and humic acids and 77 trace elements which, according to the manufacturer, are said to counteract skin ageing. The pH value is 8.1 and the eye-catching appearance of the black water is completed by a black label all the way round and a black screw cap with a tamper-evident seal. www.fulvica.pl Stylish bottle for water The German company Fine Liquids fills 500 ml of natural, still mineral water from the Pyrenees in an eyecatching, styl ish PET bottle. The bottle, known as a limited edition and mar ke t ed under t he name St. Luapi and a stylised skull, is coloured deep blue and the screw cap with opening makes it easy to carry with a finger or attach to a backpack using a carabiner. www.fi ne-liquids.com CONTEXO GMBH Tel. +49 (0) 7181 / 606-100 info@contexo-gmbh.de www.contexo-automation.de HIGHSPEED ASSEMBLY MACHINES CARTON CLOSURES POUCHES, CANS AND MORE PET CLOSURES + TETHERED CAPS"},{"@ID":6
"PETcontents 4 PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 10/2024 TOP TALK 10 2-stage PET bottles from one line - How Krones is integrating the Netstal plants EDITOUR 12 Waterbrands Group focusses on vertical integration for packaging 14 Closures from the Saudi province of Qassim - Potential for the Gulf region and beyond for bottled water BOTTLE MAKING 16 The sustainability imperative - Balancing consumer demand and environmental responsibility in large-size PET containers with Sipa technology BOTTLING / FILLING 18 Valley Water invests in a modern 36,000 bph PET plant COMPRESSORS 20 Lower blowing pressure in PET compressors MARKET SURVEY 23 Suppliers of filling equipment & inspection systems EVENT PREVIEW 21 Gulfood Manufacturing 2024 preview 27 Four steps, one supplier: Design, manufacturing, sampling, testing - Röders laboratory achieves ISO-9001 certification 28 Brau Beviale 2024 preview 34 Optimising production with AI-powered quality control system - Romina Mineralbrunnen reducing false rejections and addressing challenges with tethered caps on PET bottles OUTER PLANET 46 Plastic waste traps for rivers BUYER’S GUIDE 40 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 37 PET bottles for home + personal care 38 PET bottles for beverage + liquid food Page 21 Page 10 Page 16 EDITOUR"},{"@ID":11
"43 PETplanet Insider Vol. 25 No. 10/24 www.petpla.net BUYERS GUIDE INSPIRING PARTNER www.z-moulds.com 3.6 PET mould cleaning 4.0 FILLING / BOTTLING www.index-6.com SIPA S.p.A via Caduti del Lavoro,3 31029 Vittorio Veneto, Italy Tel. +390438911511 Fax +390438912273 sipa@zoppas.com www.sipa.it 4.3.4 Aseptic filling lines Blowing, filling, packaging Turnkey Solution Supplier Tel.: +86-512-58691111 www.newamstar.com 4.4.1 Labelling machinery Ergonomic Modular Labeling Machines P.E. LABELLERS S.p.A. Via Industria 56 46047 Porto Mantovano (MN), Italy Tel.: +39 0376 389311 pelabellers@pelabellers.it www.pelabellers.com Leo precision products, ISBM, Precision PET moulds, Change parts Silvassa, Ut of DNH, INDIA M: +91 99798 67490 +91 93288 85884 Mail: contact@leopp.in Web: www.leopp.in Otto Hofstetter AG Zürcherstrasse 73 8730 Uznach, Switzerland Tel. +41 55 285 22 11 Fax +41 55 285 22 44 hofstetter@otto-hofstetter.ch www.otto-hofstetter.com No.5, 36th Road, Taichung Industrial Park. Taichung City. 407. Taiwan Tel. +886 4 23553779 Ext: 103 info@passcard2.com.tw www.passcard.com.tw www.petkamold.com info@petkamold.com Injection Molds and Integrated Systems Americas: +1-416-749-1698 x. 577 runterlander@stackteck.com Asia: +82 31 8059 7000 stackteck@stackteckasia.com www.stackteck.com 3.2 Stretch blow moulds Packaging and Preform Engineering, Moulds and Line Conversion Tel: +33 (0)5 45 36 63 50 info@competek.com marketing@competek.com DEMO Design and Moulds 31020 San Vendemiano (TV) - Italy Tel.: +39 0438 409048 Fax: +39 0438 409046 info@designandmoulds.com www.designandmoulds.com www.kiefer-mold.de info@kiefer-mold.de www.petkamold.com info@petkamold.com 29614 Soltau, Germany mold@roeders.de www.roeders.de 3.3 Cap moulds Injection Molds and Integrated Systems Americas: +1-416-749-1698 x. 641 smartin@stackteck.com Asia: +82 31 8059 7000 stackteck@stackteckasia.com www.stackteck.com 4.5 Downstream equipment Tel: +34 954779200 andyor@andyor.com www.andyor.com 4.6 Liquid Nitrogen Dosing 5.0 RECYCLING Food-grade PET Recycling info@bariq-eg.com www.bariq-eg.com Bühler Thermal Processes AG As of April 2015, the company is renamed to Polymetrix see Polymetrix Highly efficient RECYCLING chemicals, tailor-made process solutions & an unique technical support. CHT Germany GmbH Tel +49 7071 154 - 233 recycling@cht.com www.cht.com Lindner Washtech GmbH Tel. +49-7148-160538-0 info@lindner-washtech.com www.lindner-washtech.com loginplast@loginplast.com www.loginplast.com"},{"@ID":21
"BOTTLING / FILLING PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 19 APS 3070 L Ergon automatic palletising system: single-column system with two Cartesian axes for palletising cardboard boxes arriving from the WP 600 Ergon in 1,000 x 1,200mm pallets flexible modular structure, adaptable to the logistical conditions of the line operational flexibility that allows the creation of multiple palletising patterns eco-sustainable solution, thanks to the use of ICOS motors equipped with integrated digital servo-drive (driver), able to simplify the wiring of the machine and ensure greater energy efficiency, lower noise and reduced wear of the components optimised TCO (Total Cost of Ownership) thanks to low management and maintenance costs WP 600 Ergon wrap-around case packer: continuous packaging through a wrap-around system: smooth production process, without jerky movements packaging in impact-resistant 4x5 cases (0.6 l bottles) and 3x4 cases (1.5 l bottles): higher protection of the product during transport possibility to graphically customise the cardboard box sliding Posy control panel, which allows the operator an easy and efficient use of the system highly intuitive, graphical interface, touch-sensitive screen and advanced real-time diagnostics and technical support Ecobloc Ergon HEVF blowing-filling-capping system: compact solution for the blowing & filling of 0.6 l and 1.5 l containers: rinsing machine and air conveyors between blower and filler are not required rotary stretch-blow moulding system equipped with motorised stretch rods, for productions up to 36,000 bph precise management of the stretch rod stroke and accurate control of its position preform heating module with energy-efficient IR lamps two-stage air recovery system, for reducing energy costs easy management of the format changeover filling system with high-precision flow meters installed near each tap walk-in frame to easily access the filler and capper filling chamber isolated from transmissions machine frame inclined towards the drainage points, resulting in a higher level of hygiene With Netstal’s leading preform injection molding technology. Our PET-Line impresses with broadest compatibility, maximum throughput, exceptional ĆďĆēĈĚ ĆħĄĊĆďĄĚ ĐđĕĊĎĂč đēĐĄĆĔĔĊďĈ Đć ē÷ìû Ăďą other challenging recyclates, and with its intuitive Axos control unit. Wemaximize your đēĐąĖĄĕĊĐď ĆħĄĊĆďĄĚ Preforms"},{"@ID":22
"COMPRESSORS PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 20 Lower blowing pressure in PET compressors by Kris Vermeulen, Global Product Manager PET, Air & Nitrogen, Oil-free Air division, Atlas Copco Airpower N.V. In the world of PET packaging, continuous improvement is key. One of the biggest advancements has been reducing the amount of PET material used for making bottles, which not only lowers costs but also benefits the environment. Less material means lighter packaging, which reduces transportation energy, and most importantly, less energy is needed for heating and compressing air in blow moulding machines. across different PET lines. It has a high efficiency and reliability, and can be customised to specific plant layout and needs. Of course, it is a more complex to set up and requires expert planning to get the best results. Atlas Copco solutions for every setup For centralised systems in which PET lines require high-pressure air, Atlas Copco offers the ZP FF compressor. This is a plug-and-play unit, easy to install and energy-efficient. For larger requirements, the ZD FF compressor offers more cooling stages, which makes it more efficient for larger compressed air volumes. The ZD Flex system from Atlas Copco is used for decentralised installation. The compressors can be placed closer to the machines while minimising piping and optimising the pressure supply. The ZD Flex system is also applicable for combined setups, offering flexible modules that can adapt e.g. if the plant grows. It balances both low and high-pressure needs, saves energy and reduces operational costs. www.atlascopcogroup.com PET lines Blowing pressure difference between the lines 0-2 bar 2-5 bar 5-10 bar 10-15 bar 15 bar 1 Centralised 2 Centralised Centralised Decentralised Decentralised Combined 3 Centralised Centralised Decentralised Combined Combined 4 Centralised Centralised Combined Combined Combined 4 Centralised Combined Combined Combined Combined Choosing the fitting setup: Small pressure differences (0-2bar): Centralised setup works best. Moderate Pressure Differences (2-5bar): Centralised or decentralised, depending on the number of lines. Large Pressure Differences (5+ bar): A decentralised or combined setup is ideal, especially for larger plants. Modern blow moulding machines have evolved to use less air pressure, thanks to innovations like air recuperation. But how can companies fully benefit from these lower blowing pressures, especially when some machines still need higher pressure? Compressed air systems The basics - There are three main types of compressed air system setups in the PET industry: 1) Centralised setup 2) Decentralised setup 3) Combined setup Each setup has its advantages and disadvantages. In the centralised setup all air compressors are in one central area, supplying air to the entire facility. This system is easy to manage and control, and the best for handling large amounts of air with stable pressure needs. It is efficient for managing overall energy usage. When the PET lines require similar pressure levels and are close to each other, this system is suitable because there is only one pressure level available for the whole system. In the decentralised setup air compressors are placed near each machine or area where the compressed air is needed. With a minimal piping each machine gets the exact pressure it needs. This system is recommended if there are large pressure differences between the machines or if the machines are far apart. Because it is harder to manage energy use across the plant and compressors may run less efficiently without a central control. Finally, the combined setup merges the benefits of both centralised and decentralised systems. It offers flexibility to meet different pressure, and flow needs Decentralised setup: Atlas Copco’s ZD Flex system allows to place the compressors closer to the machines, minimising piping and optimising pressure delivery."},{"@ID":8
"PETnews 6 NEWS PETplanet Insider Vol. 25 No. 10/24 www.petpla.net All4Pack Emballage Paris 2024 All4Pack Emballage Paris 2024, taking place from November 4-7 at the Parc des Expositions at Paris-Nord Villepinte, will be the showcase for all solutions in the packaging and logistics sector. The show is a platform for business, innovation and exchange for packaging, printing, process, and logistics and expects around 40,000 professionals from 80 countries, mainly from the EMEA zone, as well as over 1,000 exhibitors. Through its events and conferences, the show will explore the challenges of the sector, both in terms of regulations and the prospects of an industry. Alongside French and international speakers, high-level experts and entrepreneurs, the event provides an opportunity for visitors to share their issues with peers, to think together, and to find solutions for the future. Dedicated to highlighting innovations from around the world that are capable of making a lasting difference to the packaging and intralogistics industry, the All4Pack Innovations Area is back again in 2024. As usual, this area will provide visitors with the opportunity to discover a multitude of projects from the All4Pack Innovations Awards, as well as products and winning companies from numerous competitions organised by their partners. The All4Pack Circularity Area offers visitors to the fair the opportunity to meet companies and start-ups that are working to reduce packaging and resource consumption in their manufacturing processes; improve recyclability and facilitate the use of recycled materials; and reuse existing packaging, particularly through bulk dispensers, deposit systems, etc. In addition, visitors will be able to participate in numerous workshops, exhibitions and start-up pitches organised in the Agora at the heart of this new zone. A conference program addresses topics such as plastic packaging trends, weight reduction and recycling or e-commerce. www.all4pack.com www.agrintl.com +1.724.482.2163 • Accurate. Fast. Intuitive. • Powerful, Simple Job Creation and Editing • 3UH 'HȴQHG &RQWDLQHU 0HDVXUHPHQW 5RXWLQHV • AutoJob® ȃ $XWRPDWHG )HDWXUH 5HFRJQLWLRQ and Job Setup in Seconds 3DUWQHU ZLWK $JU WR DFKLHYH VLPSOLȴHG GLPHQVLRQDO PHDVXUHPHQW IRU \\RXU SODVWLF FRQWDLQHUV DQG SUHIRUPV ® Plastipak: Leadership transition announcement Plastipak Packaging, Inc., a wholly-owned subsidiary of Plastipak Holdings, Inc., has announced that its founder President and CEO William C. Young will transition out of his role and welcome the next generation of leadership, Edward V. Morgan. Mr Young has been the Chairman of the Board of Directors, and President and CEO of Plastipak since its inception in 1967. He will continue to serve as Chairman of the Board following his transition. The Young family will retain ownership of Plastipak, and the organisation will remain a privately held family business. Mr Young founded Plastipak alongside his parents, Mary and William P. Young, in Jackson Center, Ohio, USA. Following Mr Young’s transition, Edward V. Morgan, Mr Young’s son-in-law, will assume the role of President and CEO of Plastipak. Mr Morgan holds more than 25 packaging-related patents and has been with Plastipak for over 20 years, serving in a variety of management and executive roles, including Senior Vice President of Operations, Extrusion Development, Global Manufacturing Processes, and Intellectual Property. He has also served as Director of Transportation for Whiteline Express, LTD., and most recently as an Executive Advisor at Plastipak. Prior to joining Plastipak, Mr Morgan worked at Deloitte Consulting and Ford Motor Company. He has an MBA from the University of Michigan and a Bachelor of Science in Business Administration from Ohio State University. www.plastipak.com"},{"@ID":18
"BOTTLE MAKING 16 PETplanet Insider Vol. 25 No. 10/24 www.petpla.net Balancing consumer demand and environmental responsibility in large-size PET containers with Sipa technology The sustainability imperative In an era marked by increasing environmental awareness, the beverage industry faces the challenge of meeting consumer demand while adopting sustainable practices. One area where this tension is particularly evident is in the production of large-size PET containers, typically those exceeding 5 l. While these containers offer convenience and practicality, their environmental impact must be carefully considered. Advances in technology, alongside a growing commitment to circularity are paving the way for more sustainable solutions in this sector. Large-size PET containers, often used for water coolers and bulk dispensing, offer several sustainability advantages over their smaller, single-serve counterparts. Firstly, they require less PET resin per unit volume, minimising raw material consumption and reducing waste. Secondly, their larger format enhances transportation efficiency, lowering fuel consumption and greenhouse gas emissions. Finally, and perhaps most importantly, many of these containers are refillable and reusable, significantly extending their lifecycle and minimising waste. Sipa, well-known in the large-size PET container market, offers a comprehensive suite of solutions that span the entire production process, from design and engineering to blowing, filling, and palletising. The company’s expertise extends beyond machinery manufacturing, boasting a team of experienced designers and engineers who specialise in creating large-size PET containers that are not only functional and aesthetically pleasing but also optimised for sustainability. Utilising advanced FEA simulation systems and in-house prototyping facilities, Sipa says that its containers meet high standards of performance, durability, and environmental responsibility. The range of blow moulding machines specifically designed for large-size PET container production includes the SFL Maxi and SFL Big linear blowers which cater to small- and medium-scale operations, producing containers from 12 to 30 l. These versatile machines handle both returnable and one-way containers, including those for water dispensers, stackable applications, and various other large formats. For high-speed production of containers up to 12 l, Sipa’s Xtra Big rotary blow moulder is claimed to deliver good performance. From filling to palletising Sipa’s Big Fill volumetric gravity filling monoblock is optimised for handling large formats up to 20 l. This system is claimed to ensure precision and hygiene, featuring no valve-tobottle contact and high flow performance with filling speed modulation. Its stainless steel construction and automated dummy bottles further enhance cleanliness and efficiency. Large-size container filling with Big Fill monobloc Blowing of large size container with inserted handle with SFL Maxi Xtra Big, rotary blowmoulder"},{"@ID":25
"MARKET SURVEY 23 PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 10/2024 MARKETsurvey Suppliers of filling equipment and filling inspection systems It’s time to present some selected state-of-the-art filling equipment and filling inspection systems in our annual market survey. Please have a look at the up to date technical details provided by: Sacmi Beverage SpA, SMI S.p.A., Enoberg s.r.l., Krones, KHS GmbH, Sipa S.p.A, STM SP. Z o.o., Pressco Technology Inc., Newamstar Packaging Machinery Co., Ltd. and Heuft Systemtechnik GmbH. Although the publisher has made every eff ort to make sure that the information in this survey is up to date, no claims are made regarding accuracy and completeness. Filling equipment Company name Sipa S.p.A. STM SP. Z O. O. Postal address Telephone number Web site address Contact name Function Direct telephone number E-Mail Via Caduti del Lavoro n. 3 31029 Vittorio Veneto (TV), Italy +39 0438 911 511 www.sipasolutions.com Mr Matteo Tagliaferri Marketing and Communication +39 0438 911 511 matteo.tagliaferri@zoppas.com Ul. Piaskowa 12, 78-520 Zlocieniec, Poland +48 94 367 14 71 www.stm-pack.com Mr Matuesz Kinda Sales & RND Director +48 5030 366 35 mk@stm-pack.com 1. Machine designation / model number Isofi ll P Stillfi ll Evo Flextronic C Synchroblock Combifi ll ISO EPV: a blow moulding-fi llingcapping machine for CSD and still drinks fi lling Synchroblock Combifi ll WM/ FM: a blow moulding-fi llingcapping machine for still product contactless fi lling Synchroblock Combifi ll BIG WM/FM: a blow moulding-fi llingcapping machine for still product contactless fi lling in BIG bottles 2. Number of fi lling heads (range: from/to) 20-140 20-140 30-180 16-60 16-40 16-20 3. Min to max bottle contents (in liters) 0.125-3 0.125-3 0.125-3 0.2-2.5 0.2-2.5 1.0-6.0 4. Filling speed: output (bph) (min to max): specifi y: 1l bottle / still water (bph) 60,000 62,000 60,000 6,000-14,000 6,000-14,000 3,000-5,000 at 5.0 l 1l bottle / CSD (bph) 51,000 (CMW) 55,000 (CMW) 6,000-14,000 1l bottle / milk (bph) 6,000-14,000 1l bottle / juice (bph) 53,000 60,000 59,000 6,000-14,000 5. Filling process Pressureless (still drinks) Yes Yes Yes Yes Yes Yes Pressure fi lling (carbonated drinks) Yes Yes Yes No No Hot fi lling Yes Yes No No No Cold aseptic fi lling Yes Yes No No No Juices with high pulp content Yes No Yes Yes 6. Type of fi lling valve and metering system Isobaric mechanical level fi lling Mechanical gravity fi lling Isobaric volumetric fi lling valve EPV - Electropneumatic isobaric mechanical level fi lling Electronic fl ow meter fi lling or electronic weight fi lling Electronic fl ow meter fi lling or Electronic weight fi lling 7. Special features (short description/keywords) AISI 316L SS valve, product defl ection without defl ector on the fi lling tube, quick changeover for different neck diameters, automatic dummy bottle insertion, mobile vent tube, centralised remote fi ll level adjustment AISI 316L SS valve, product defl ection without defl ector on the fi lling tube, quick changeover for different neck diameters, seperated bottle air return, hot fi ll kit for product recirculation, constant and controlled recirculation rate in bottle, centralised remote fi ll level adjustment no bottle no fi ll system AISI 316L SS valve, product defl ection without defl ector on the fi lling tube, quick changeover for different neck diameters, automatic dummy bottle insertion, magnetic fl ow meter product control, fi lling speed control, XFill confi guration without tank on board, dry pressurisation separated bottle air return AISI 316 SS valve, quick change over, ultra clean version available, three big touch panels for user friendly software with automatic diagnostic system for machine's operation limited to minimum; wide choice of options for further customisation of machine AISI 316 SS contactless fi lling valve, quick change over, ultra clean version available, three big touch panels for user friendly software with automatic diagnostic system for machine's operation limited to minimum; wide choice of options for further customisation of machine AISI 316 SS contactless fi lling valve, quick change over, ultra clean version available, three big touch panels for user friendly software with automatic diagnostic system for machine's operation limited to minimum; wide choice of options for further customisation of machine Resins & additives Cap producers, systems & inspection systems Preform machinery Preform production & inspection systems Preform, cap & SBM mould manufacturer SBM 2-stage Compressors Filling equipment & inspection systems Palletising & shrink film machinery Recycling machinery"},{"@ID":24
"22 EVENT PREVIEW PETplanet Insider Vol. 25 No. 10/24 www.petpla.net Circular economy across the complete plastics lifecycle With increasing consumer demand for more recyclable packaging and regulations tightening, producers in the UAE and around the world need innovative solutions to stay ahead. To address these challenges, at Gulfood Husky will be exhibiting latest technologies, solutions, and services that enable the circular economy across the complete plastics lifecycle, and support producers to: Enable sustainability with technologies that support the production of high-quality packaging that is lighter weight, contains more rPET, or is made from bio-based materials. Enable growth by adopting manufacturing processes that facilitate speed to market and streamline production. Enable innovation with industry-leading solutions that produce attractive, safe, and sustainable packaging that out-performs alternative materials. Husky will be showcasing its integrated solutions that enhance the recyclability of end products, including the production of packaging made from up to 100% rPET. Visitors can also learn about the recently launched HyPET6e preform moulding platform. The company says, that the HyPET6e sets new standards in the use of rPET, energy efficiency and quality control in closed loops. Husky will also present a range of new design and development innovations for food and beverage applications, including lightweight closures, tethered closures and the latest 100% PET closures for mono-material packaging to streamline the recycling process. This will be complemented by the presentation of a suite of intelligent, connected solutions that use closed-loop reporting to leverage data and analytics, optimising operations, reducing waste, and improving overall equipment effectiveness, including the Advantage+Elite monitoring program. www.husky.co Sustainable and efficient PET packaging solutions Sipa will be exhibiting its latest technologies and innovations at Gulfood Manufacturing 2024. Visitors can explore new solutions for sustainable and efficient packaging production. Key highlights at the Sipa booth include: Large-size container production: Sipa offering a complete production system for large PET containers, from blow moulders to fillers and end-of-line solutions. Learn about the SFL linear blow moulder, renowned for producing containers up to 30 l at medium speeds, and the Xtra Big rotary blow moulder, capable of producing bottles up to 12 l at high speeds. Discover how Sipa’s comprehensive approach streamlines the production process for largesize containers. Sustainability: Sipa demonstrates its commitment to a circular economy with diverse rPET production solutions. Highlights include the Xtreme Renew system, transforming flakes directly into rPET preforms, the high-speed Xform Renew system, producing preforms from rPET pellets, and the ability to create rPET bottles using Sipa’s established SFL and Xtra systems. At the Gulfood stand, Sipa will also showcase its expertise in neck lightweighting, presenting a range of light versions of well-recognised neck finishes. An important example is the lightweight version of GME 30/40, weighing 2.1 g. Packaging design expertise: Sipa’s global team of design experts (Sipa has design facilities across three continents, Europe, USA and China) will be on hand to discuss how their comprehensive design services can create packaging that stands out on the shelf, promotes brand, and offers both aesthetic and functional excellence. Mould innovation: With a legacy of mould design innovation, including the introduction of the 200-cavity injection mould, Sipa will share its deep knowledge of hot runners and cold halves that optimise preform machine capacity. www.sipasolutions.com Husky Hall 2 | Booth B2-4 Sipa Hall 4 | Booth A4-42 200-cavity injection mould by Sipa"},{"@ID":20
"BOTTLING / FILLING PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 18 Valley Water invests in a modern 36,000bph PET plant In the desert area of Wadi El Natrun, a depression about 23m below sea level, Elano water is extracted and bottled by the Valley Water company. To increase the production of 0.6 l and 1.5 l PET bottles, the Egyptian company recently turned to SMI for the supply of a complete line of 36,000 bph. Increase efficiency and productivity To preserve the quality of Elano water and offer consumers a pure, uncontaminated and healthy product, Valley Water pays great attention to every detail and collaborates with the experts of the industry. The decision to rely on SMI for the supply of a new complete line of 36,000 bph for the bottling and packaging of Elano water in PET bottles ranging from 0.6 l to 1.5 l is the result of a close collaboration between the two companies, that began in 2013 with the installation of a rotary stretch-blow moulder and a shrink wrapper from the LSK range for the packaging of 0.33, 0.5 and 1.5 l containers in PET. SMI has been involved in the process of automation of the end of the line of the pre-existing plant, to allow Valley Water to meet the growing demand for bottled water in Egypt, a market featuring one of the highest levels of consumption per capita in the world and in which consumers tend to choose healthy drinks. The new technologies supplied by SMI allow the company to achieve greater production capacity and efficiency, improved market competitiveness, high energy savings and reduced environmental impact, said SMI. Restyling of the bottles to improve performance Starting from existing 0.6 l and 1.5 l containers and keeping the “core concept” unchanged, SMI’s designers emphasised the iconic image represented and improved the resistance and stability of the containers. These objectives have been achieved by enlarging the maximum diameter of the bottles and lowering their height, with the result of optimising the center of gravity of the same. The base of the bottle was also subject to a restyling process, with the aim of improving the mechanical properties of the containers during filling. Thanks to these measures and the supply of new moulds for the stretch-blowing, the entire packaging and palletising process of Valley Water has become more efficient and sustainable. The solutions for Valley Water Valley Water pays great attention to environmental issues and for the bottling of Elano water in ecocompatible and recyclable PET bottles, uses green technologies of the latest generation that allow reduced environmental impact and energy savings. The 36,000 bph complete line allows the customer to optimise the space within the production plant. The new system consists of an EBS 16 E Ergon stretch-blow moulder in Ecobloc version with a HEVF filling and capping system; a WP 600 Ergon case packer; an APS 3070 L Ergon palletiser; conveyor belts, labelling machine, encoder and control systems. www.smigroup.it www.elanowater.com"},{"@ID":5
"imprint EDITORIAL PUBLISHER Alexander Büchler, Managing Director HEAD OFFICE heidelberg business media GmbH Hubweg 15 74939 Zuzenhausen, Germany phone: +49 6221-65108-0 info@petpla.net EDITORIAL Kay Barton Heike Fischer Gabriele Kosmehl Michael Maruschke Ruari McCallion Anthony Withers Editorial & WikiPETia. info petplanet@petpla.net MEDIA CONSULTANTS Martina Hirschmann hirschmann@petpla.net Johann Lange-Brock lange-brock@petpla.net phone: +49 6221-65108-0 LAYOUT AND PREPRESS EXPRIM Werbeagentur Matthias Gaumann www.exprim.de READER SERVICES reader@petpla.net PRINT Chroma Druck Eine Unternehmung der Limberg-Druck GmbH Danziger Platz 6 67059 Ludwigshafen, Germany WWW www.hbmedia.net | www.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. 25 No. 10/24 www.petpla.net The holiday season is coming to an end. All that’s left are hopefully good memories, relaxation and, of course, souvenirs. And what do you bring home from a beach holiday? Why not a small lighthouse that would look great in the living room among all the other stuff you’ve brought back? So I paid over the top for one in the souvenir shop and unpacked it at home. It’s great when the lighthouse also lights up, as ours did. It gives off a nice light in the evening. After a few weeks the excitement wore off. It lit up. So what? But then, when I came to dust it, my editorial curiosity got the better of me. What was the glass housing made of? Had the manufacturers of the model lighthouse decided to imitate the “Fresnel lenses” themselves? I took a closer look and somehow the pattern looked familiar. A transparent plastic component with a transparent ring. The roof of the lighthouse could be unscrewed to replace the light bulb, and then it all became clear: the interior of the lighthouse is a PET preform, and the roof sits on a PCO 28 cap. I’ve seen no end of creative ideas involving PET preforms and bottles, but for the moment, this is probably my top favourite. Yours, Alexander Büchler Dear readers,"},{"@ID":31
"29 EVENT PREVIEW PETplanet Insider Vol. 25 No. 10/24 www.petpla.net Holistic line concept Pioneering filling technology combined with extensive inspection technology, the new Plasmax generation and a broad spectrum of service products are the focus of this year’s trade show for the KHS Group. Besides its Innofill Can C can filler model, KHS will showcase the latest-generation InnoPET Plasmax. This coating process for PET containers covers the insides of plastic bottles with an ultra-thin layer of glass. Available as a single machine or blocked with a stretch blow moulder and/or additional filler unit, it is claimed to provide effective production protection that unifies quality, freshness and shelf lives with 100% recyclability by type. Digital planning The group also offers a broad range of service products and consultancy services. These include, for instance, modular service packages that aim to make sure that beverage fillers’ production lines run efficiently and without disruption. Unplanned downtime and unexpected consequential costs are thus claimed to be avoided. Virtual line design at KHS makes use of up-to-the-minute 3D software that gives customers a holistic impression of their potential line as early as during the offer phase. Thanks to the new mobile laser scanning and virtual reality presentation features, advance planning is now even quicker and more detailed, says KHS. The system supplier will also be enabling visitors to explore its selection of digital services using ConnectApp Guide and its MES systems Innoline Basic Line Monitoring (BLM) and Innoline Flex Control (IFC). ConnectApp Guide addresses the challenges of line maintenance. It facilitates digital, paperless maintenance management by flexibly planning servicing tasks across all sections of a company using a web platform that can be accessed by a mobile app. This gives bottlers greater reliability in maintenance that in turn results in less downtime and optimised production performance. Innoline BLM and IFC are modular software packages specially conceived for the beverage industry that are claimed to ensure transparency and efficiency throughout the entire filling process. Both can be integrated into the operating company’s infrastructure. www.khs.com KHS Hall 8 | Booth 516 / 416 / 418 (MKMXEP VEXMSREP TVSƤXEFPI ;LEX IPWI# SACMI.COM 300 4VIJSVQ MRWTIGXMSR ERH TVSGIWW IRLERGIQIRX MRGPYHIH DIGITAL (MKMXEP TVSGIWW GSRXVSP VIEGLIW TVIZMSYWP] YRXLMROEFPI PIZIPW STIRMRK YT XLI MRHYWXV] XS -S8 WGIREVMSW RATIONAL 7%'1- 4VIJSVQ :MWMSR 7]WXIQ MRGPYHIH JSV EHZERGIH GSQTVILIRWMZI TVSGIWW GSRXVSP PROFITABLE '330 TSWX GSSPMRK MRWMHI GSSPMRK W]WXIQ\r WLSVXIRW G]GPI XMQIW ERH PIEHW XS QSVI TVSƤXEFPI TVSHYGXMSR momic"},{"@ID":30
"28 EVENT PREVIEW PETplanet Insider Vol. 25 No. 10/24 www.petpla.net EVENTpreview Brau Beviale 2024 Brau Beviale 2024 will be held from November 26 to 28 in Nuremberg, Germany, offering a comprehensive event for the beverage industry. Over the course of three days, the trade show will serve as a central platform for the international beverage community, promoting professional and personal exchanges, displaying the latest industry innovations, and setting new trends. In addition to the exhibitor portfolio featuring brewery and beverage technology – as well as offerings for the wine sector – the lecture programme will provide valuable insights. Expert forums will be hosted in Halls 1 and 9, focusing on key topics such as raw materials, marketing, technology, and packaging. Special areas will be dedicated to start-ups, young talents, logistics, and wine & spirits. Additionally, a Craft Drinks Area will highlight craft brewers, while home and hobby brewers will find a dedicated space in Hall 6. Beverage manufacturers interested in current packaging issues will be well served on November 27, 2024, also in Hall 9. The programme will address the implementation of the PPWR in individual markets at this point: “The EU has decided - what now? The PPWR for beverages in Europe.” The main aim here will be to provide an assessment of the implications and solutions in various markets. Marketing specialists should therefore plan their visit to BrauBeviale on Wednesday in particular, as this is when they will also be able to take in the key areas of marketing and packaging in the lecture programme. www.braubeviale.com Sustainable labelling solutions As a global market leader in labels and packaging solutions, CCL Label introduces the newest members of the Sustainable Label Family: Low-Temperature WashOff, Low-Temperature EcoStream, and EcoFloat White. These products are claimed to offer advanced solutions for the beverage industry and make a contribution to the circular economy. Low-Temperature WashOff and Low-Temperature EcoStream are specially designed labels that can be removed from the primary packaging without residue, even at low temperatures, says CCL. This simplifies reuse and recycling, while also reducing energy consumption during the cleaning and recycling process. EcoFloat White is a labelling solution for light-sensitive products. It enables the transition from white HDPE containers, which are rarely recycled into food-grade material, to transparent PET containers that can be easily recycled and reused for food applications. Another highlight is the pouches from CCL Specialty Pouches – flexible beverage packaging made from monomaterials, making them recycling-friendly. These pouches can also be equipped with RFID chips, enabling intelligent tracking and product monitoring. www.ccllabel.com CCL Hall 7A | Booth 511 To make the most of what differentiates you, our complete solutions are based on future-proof technology, disruptive concepts and human ingenuity. Our goal: to bring you performance all along the line. POWER UP YOUR LINE! READY TO SHINE? You are unique, so are our solutions. Nuremburg, 26 - 28 Nov, Booth 7A-223 BrauBeviale Meet us at sidel.com"},{"@ID":3
"No.10 2024 www.petpla.net D 51178; ISSN: 1438-9452 21 . 10 . 24 M A G A Z I N E F O R B O T T L E R S A N D B O T T L E - M A K E R S I N T H E A M E R I C A S , A S I A , E U R O P E A N D A L L A R O U N D T H E P L A N E T PETplanet is read in 159 countries Suppliers of filling equipment & inspection systems Page 23 MARKETsurvey EDITOUR Page 28 Page 12 Page 21"},{"@ID":1
"Crystal Thumb Up Our extended SportCaps range Biarritz NEW In sport, you never settle for less. That’s why we strive for the perfect closures, also when it comes to sustainability. Many closures, such as Biarritz and Monet, are made from a single material, making them easy to recycle. In addition, our sport closures are easy to handle, have integrated tamper evidence solutions and are suitable for cold, dry, or wet aseptic filling. So take the leap – and opt for more sustainability. NEW Monet Visit us at BrauBeviale Hall 4, Booth 219 Contact us and arrange your line trials now! www.bericap.com New mono-material caps for optimized recyclability Going the extra mile for you"},{"@ID":33
"31 EVENT PREVIEW PETplanet Insider Vol. 25 No. 10/24 www.petpla.net Secondary packaging SMI will present its range of secondary packaging. The ACP 22 S Ergon case packer, designed to package 33 cl glass bottles in 4x3 cardboard cases with adhesive tape closure, is claimed to create packaging that is both practical and visually appealing. These durable cardboard cases provide an ideal solution for multipacks, offering customisable graphics for product promotion, says SMI. The ACP 22 S Ergon uses a pick & place system to load loose products from the top. Equipped with a double-picking gripper, the machine can achieve an output of up to 25 packs per minute. The case packer is part of the broader ACP Ergon series, which consists of compact, automatic machines designed for a wide range of products, including glass, metal, plastic, cardboard containers, and rigid bags. These products are packed into American RSC (Regular Slotted Container) cardboard cases, a strong, customisable packaging solution optimised for product size and maximum shelf visibility. The ACP Ergon packers feature a monobloc structure, combining all essential machine functions in one system, including product separation, insertion into cases via top loading, cardboard magazine and top sealing. The machines from the ACP range can pack diverse products - ranging from glass bottles and jars to bags of pasta, rice, and coffee - by simply changing the gripper or suction cup. Additionally, they can handle stacked products, further expanding their range of applications. The carton magazine, located next to the machine, allows the loading of pre-folded blanks in an easy and ergonomic way. Advanced automation and control are provided by the MotorNet System, based on Sercos fieldbus technology, which ensures full compatibility with Industry 4.0 and Internet of Things (IoT) platforms. www.smigroup.net SMI Hall 7A | Booth 503"},{"@ID":37
"35 EVENT PREVIEW PETplanet Insider Vol. 25 able system with a small footprint that generates extensive statistics and ensures reliable detection. A powerful Gigabit Ethernet camera and LED lighting from above and below detect the crate shape, colour, handle grip breaks, incorrect crate orientation, and deformed crates. Inside the containers, foreign objects, misaligned, broken, overturned, and especially foreign bottles are detected by both the camera and ultrasound sensors for height control. “With this new control system, the number of rejected crates is drastically reduced, and foreign bottles or objects can now be sorted out manually with ease.” Tethered caps problem For PET bottles, Romina Mineralbrunnen have to inspect returned empties very carefully. Their own Petcycle bottles are crushed and shredded. “This means, however, that no glass bottle can be included, as it would damage the press,” explains Gugel. Additionally, other PET bottles cannot go through the press. “We send those to a counting centre in Stuttgart, where they are counted, and we are reimbursed for the deposit.” This process refers to the German bottle deposit scheme (DRS), which is the largest in the world. However, the main problem in the PET sector has been the new tethered cap, where the screw cap must remain attached to the bottle. “Sometimes the cap is closed, sometimes it sticks out at an angle, and sometimes it hangs down the neck. Then there are the different Petcycle bottles, which can appear octagonal, decagonal, or almost round from above, which the previous cameras could no longer recognise. As a result, we had enormous amounts of rejected crates,” Gugel says. P E R F O R M A N C E D E TA I L S CIRCULAR SOLUTIONS OF COLOURS AND ADDITIVES FOR RECYCLED POLYMERS PRS ASIA - BOOTH K30 With the “Teta-Line LG DL” system, all bottles – whether glass or PET – are reliably detected, even with tethered closures."},{"@ID":2
"30 EVENT PREVIEW PETplanet Insider Vol. 25 No. 10/24 www.petpla.net New blow moulding machine, moulds & more PET Technologies will unveil its latest linear blow moulding machine, the APF-Max 2L, making its public debut at Brau Beviale. This machine represents the newest advancement in the APF-Max series. This series incorporates NIR heating technology that is claimed to enhance efficiency. The APF-Max 2L can produce bottles with unique volumes, allowing for the blowing of containers up to 3 l, as opposed to the standard 2 l offered by earlier models. This machine achieves high productivity, capable of producing up to 3,500 bph. The machine’s energy-efficient heating system minimises electricity consumption through preferential heating techniques, says PET Technologies. Attendees can expect to see the machine in operation, providing a firsthand experience of its capabilities. In addition to the APF-Max 2L, visitors to PET Technologies’ stand will have the opportunity to view a selection of blow moulds manufactured in-house. This display will feature a range of intricate and unconventional designs, showcasing complex shapes, detailed engravings, and unique textures. These blow moulds are produced using advanced 5-axis CNC machining centres and are designed to perform for both rotary and linear machines. Built for durability, the moulds are crafted to deliver accuracy and consistency in production. The stand will also highlight an array of PET bottle designs developed by PET Technologies over its 25-year history, illustrating the company’s commitment to innovation within the industry. The company offers a comprehensive turn-key solution for bottle design, which includes conducting market research and analysing global trends, developing branding elements such as product names, logos, and labels, modifying existing bottle shapes to adapt to market needs, and providing precise 2D drawings and 3D renders of PET bottles. www.pet-eu.com PET Technologies Hall 7 | Booth 646 Bottling equipment Through its Promec, Blowtec, and Melegari Technology brands, the Promec group will present solutions for the bottling, beverage, and food industries, offering a wide array of products catering to diverse sectors. Promec’s portfolio includes rinsers and sterilisers, as well as bottle lines designed for capacities ranging from 5 to 20 l. In addition, the company will be featuring complete bottling lines, providing comprehensive solutions for various production needs. Blowtec specialises in linear blow moulding machines, delivering advanced technology for efficient bottle production. Melegari Technology brings expertise in several filling systems, including isobaric, gravity, and volumetric fillers with flow meters. They also offer hot-fill machines, and their Comby system, which combines blow moulding and filling functions in one unit. Additionally, the brand features mixers and saturators for enhanced beverage production. www.promec-srl.com www.promecblowtec.com www.melegaritechnology Promec Hall 7 | Booth 443 Protecting Product Integrity With Torus gauges, you can rest assured all of your inspection requirements are covered. Would you like to know more? Email us for more information. tms.sales@torus-group.com Wall thickness Thread, body & thickness Burst pressure Top load, weight & volume Internal diameter Total Quality Laboratory Measuring your plastic containers quickly, accurately and reliably"},{"@ID":43
"EDITOUR PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 14 Potential for the Gulf region and beyond for bottled water Closures from the Saudi province of Qassim by Kay Barton The foundation stone for the water bottle cap manufacturer Cap House Plastic Factory was laid in 2012 in the small town of Ar Rass in Qassim, just under 100 km southwest of the Saudi Arabian provincial capital of Buraida. The idea was developed by General Manager Yousef Alassaf after realising the constantly increasing demand for safe, packaged drinking water in the country and not least because there was still a lack of suppliers in precisely this segment in the country. Today, the company produces with its Plasticap brand not only for Saudi Arabia, but also for many neighbouring countries and GCC states and is also interested in the potential in African countries. In conversation with the passionate entrepreneur, we learnt how passion and vision go hand in hand. Meeting with Cap House Plastic Factory February 26, 2024 We met: Mr Yousef Alassaf, General Manager It all began in 1977 with a familyowned baking factory. “My father,” explained 37-year-old Yousef Alassaf, “wanted to produce his baked goods on a larger scale and bought fully automated equipment from Japan. This was before I was born, but by the age of 16, I was helping out in the factory for my pocket money. It was my first contact with a real production environment and I learnt to appreciate the benefits of higher output. Later, during my studies in Alabama, I visited the Thyssen Krupp steel plant in Calvert. At that time, I was totally impressed by the high turnover of the company with just 16 employees, and I realised once again that I felt at home in the field of highly automated production.” When the idea of his own factory in the beverage packaging sector came up, Mr Alassaf was initially interested in preform production. His close contact with Eng. Abdullah Obeikan, CEO of the Obeikan Investment Group, a group that is primarily active in the fields of digitalisation and education, but also in packaging, ultimately advised him that a cap business would make even more sense, as there were no companies specialising in this field at the time. Cap House, which is ISO 22000:2018, ISO 9001:2015 and HACCP:2003 certified by TÜV Austria, now produces 2.9 billion 29/25, 1.22 g closures a year under the “Plasticap” brand, so far exclusively for bottlers of still water. “When production started back then, we used injection moulding machines from Taiwanese manufacturer Jon Wai, each with 220 t and 24 cavities for 30/25 caps. After a few years, however, it became clear that we needed to increase capacity and quality. This is where Husky and Corvaglia came into play.” The setup now includes three Husky HyCAP4.0 systems with Corvaglia moulds, of which the first machine with 300 t force and 72 cavities was delivered in 2018 and went into operation in April 2018. This was followed in 2020 by a second HyCAP4.0, 400 t with 96 cavity mould and in 2023 a third HyCAP4.0, 400 t also with a 96-cavity mould. All injection moulding machines are equipped with IMD Vista closure inspection systems. Sabic supplies the raw material for the caps, together with masterbatches from Avient, which are now supplied to around 20 regular customers, including Azbah, Berain, Najran, Rest Water, View and many more. In addition to GCC countries, more and more countries in Africa are also attracting business interest. 47 employees work at Cap House. “We are also planning to expand into other segments in the future, such as CSD, juices, milk or possibly non-food,” says Mr Alassaf. According to its own estimates, Cap House is probably in fourth or fifth place in terms of market share among the five major converters Oasis, Gulf Packaging, Alsad and Takween. www.plasticap.sa Husky HyCAP equipped with 96-cavity mould from Corvaglia View into the Cap House factory hall PETplanet interview with GM Youssef Alassaf (right) and Kay Barton EDITOUR"},{"@ID":50
"EVENT PREVIEW PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 36 product development caps & closures design high cavitation moulds multi-component moulds closure production systems after sales service +43 5572 7272-0 | sales@z-moulds.com | www.z-moulds.com z NEXT SHOW GULFOOD Manufacturing Dubai, Nov. 5-7th Sheik Saeed Hall 2 / S2-A10 INSPIRING PARTNER On average, they have one to two per cent foreign bottles in the crates, but depending on the source, this can rise to up to ten per cent. Once again, Gugel turned to BBull. Boris Rurenko, who is responsible for developing the AI deep learning at BBull, explains, “The Petcycle bottles were trickier than glass because from above, they look very similar with their eight or ten corners, or even nearly round.” Rurenko adds, “We took thousands of photos of the bottles from every conceivable angle and fed them into the system. The more data we input, including close-ups, the more the system learned to differentiate between the various bottles.” It was a long process, but recently BBull specialists have reached a point where the system can distinguish between the different PET bottles and glass bottles with multiple embossings from above. For the two PET lines, the “TetaLine LG DL” is equipped with a second sensitive camera and a high-resolution 22-inch monitor. The system is claimed to achieve a detection accuracy of 99.8%, aided by special LED and UV lighting from all sides. “What isn’t Petcycle is ejected. The other good crates go to the unpacker - of course without foreign objects or glass bottles,” says Rurenko. New bottle types can also be quickly trained into the system. Technically, the BBull system could inspect two crates per second, and Romina’s operational speed will be around 4,000 crates per hour. www.bbull.com A major issue is the tethered closures. The new “Teta-Line LG DL” system with AI technology detects these bottles as well, significantly reducing the number of rejected crates. It is now also used for Romina’s PET containers."},{"@ID":46
"21 EVENT PREVIEW PETplanet Insider Vol. 25 No. 10/24 www.petpla.net TRADE SHOWpreview 10th edition of the Gulfood Manufacturing Taking place from November 5-7, 2024 at Dubai World Trade Centre, Gulfood Manufacturing is a global platform for the industry to learn, engage and present their products, services, and solutions focused on moving the food manufacturing industry forward toward a more sustainable, resilient, agile and efficient future. Gulfood Manufacturing will be a convening platform for the industry, as it addresses optimising operational efficiency, driving responsible sourcing with traceable supply chains, navigating entry barriers in new markets, adopting sustainable practices, and generating new funding sources across the entire F&B manufacturing value chain. For the first time at Gulfood Manufacturing, the ‘Hall of Fame‘ will be featured in a dedicated area of the Pavilion Hall, showcasing ingredient, processing, and packaging innovations from the past decade that have transformed the industry and significantly influenced the region’s production processes. www.gulfoodmanufacturing.com Closure technology and mould design Z-Moulds will present its latest innovations in closure technology and mould design. The company will highlight key developments, such as the 26mm 3-start water closure, which is claimed to represent the future of lightweight solutions for still water. Trends are shifting toward 25mm and 26mm closures, weighing under 0.8 g. The new 55 mm pitch wi th patented z-s l i de will be presented, which enables Z-Mould to build a mould with 128 cavities. This design reduces fal l t ime by 0.12 s and opening/closing time by 0.08s, resulting in recordbreaking cycle times, like the 1.85 s cycle for 26mm closures. www.z-moulds.com Committed to innovation and customer satisfaction Petka Mold, a well-known manufacturer of preform- and blowing moulds, will be showcasing its expertise at the upcoming Gulfood Manufacturing Fair. With 19 years of experience in the industry, Petka Mold has established itself as a trusted provider of high-quality moulds for the PET industry. At the fair, the company will be presenting a wide range of products and services, as well as discussing the latest developments in the PET industry. Petka will exhibit together with Rieckermann in hall 2, C2-4. www.petkamold.com Z-Moulds Hall 2 | Booth S2-A10 Petka Mold Hall 2 | Booth C2-4 Aseptic Combi Predis and Super Combi technologies Sidel will spotlight its well-knownAseptic Combi Predis technology on-stand, as well as highlighting its Super Combi advanced technology solution for high-speed water and carbonated soft drinks. As well as showcasing its award-winning bottle designs, Sidel will offer insights into how customers can maximise data intelligence and artificial intelligence (AI) to achieve their ESG goals. Sidel will be highlighting on-stand the Aseptic Combi Predis, an integrated blow-fill-cap solution for PET bottles that incorporates Predis dry preform sterilisation. With water and carbonated soft drinks (CSD) remaining two of the world’s most valuable beverage categories, Sidel will demonstrate its next-generation Super Combi technology to on-stand visitors. The Super Combi integrates five process steps - preform feeder, blower, labeller, filler/capper and cap feeder - into an all-in-one smart system. To deliver this self-optimising performance and increased long-term value, it combines intelligent automation with innovative technologies to advance production and maintenance services. Utilising the Super Combi solution, Sidel installed the fastest PET complete bottling water line in the Middle East, Africa and Asia for Mai Dubai, helping the UAE-based company take the next step towards becoming the region’s number one water brand. Through a film demonstration, visitors to the stand can witness how the line fills 86,000bph in three different formats (200ml, 330ml and 500ml), with the optimal use of space, high consistent quality, and efficiency with flexibility. www.sidel.com Sidel Hall 3 | Booth A3-4"},{"@ID":13,
"TOP TALK PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 11 Mr Hirdina: A control system consists of control loops: An input value influences an output value, and if this changes, the input value is adjusted to achieve the desired output value. AI, on the other hand, works differently: It analyses a wide range of data and measured values and automatically determines correlations in order to find optimum solutions. This already works well with Linatronic AI, for example it can distinguish a drop of water on a bottle from an actual particle. PETplanet: Where does the AI get this amount of data from? From all systems installed worldwide? Mr Hirdina: This is a sensitive topic. Nobody gives out their data voluntarily. If a company participates, we guarantee anonymisation of the data. We have implemented many protection mechanisms so that the data cannot be traced. PETplanet: Is this comparable to the development of bottle designs, where designers draw on projects that have already been realised? But not in the minds of the designers, but in the IT? Mr Hirdina: Yes, something like that. A new bottle design is rarely developed from scratch. We hope that this acceptance will also increase in AI projects. Our initial successes confirm this: with Linatronic AI, we can reduce reject rates. But it will probably be a while before everyone puts aside their reservations. PETplanet: Thank you very much, Mr Hirdina. www.krones.com this. With direct transfer, we also reduce the influence of fluctuations in humidity, temperature or preform weight, as these factors only change slowly and the SBM control system can react accordingly. PETplanet: Where does AI fit into the scheme of things? You already have experience with such control systems, for example with the Linatronic AI empty bottle inspection systems. Mr Hirdina: You’re right, with AI we can significantly reduce sorting errors. However, I think we will have to wait a little longer when it comes to controlling systems or lines. PETplanet: What is the difference between a classic control system and AI?"},{"@ID":39
"PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 37 BOTTLES PETbottles Home + Personal Care Cleaner in a bulbous bottle The Pink Stuff - a brand of the English manufacturer Stardrop - sells various cleaning and laundry products in packaging designed to match the name. These include a spray cleaner for dishes. The product is sprayed on, wiped off and rinsed off, and all dirt is supposed to come off easily. It comes in a 500ml bulbous PET bottle with a screw-on pump sprayer. The side wall of the container has a multi-faceted surface, which is visually enhanced by the glossy sleeve label. www.thepinkstuff .com Distinctive refill bottle The Airwick brand, which belongs to RB Hygiene Home GmbH, sells a 24/7 fragrance spray system with a matching refill bottle. The system consists of a device that can be operated without a power connection for dispensing an aerosol-free, water-based fragrance spray that is free from colorants and propellants. After approx. 70 days, the starter kit bottle is empty and must be replaced. The refill bottle is designed to fit the dispenser and is easy to replace. The 228ml bottle is fitted with a red safety feature at the bottom which prevents accidental activation and which must be removed before insertion into the dispenser. www.airwick.co.uk Shower gel with olive At first glance at the packaging with the word “Olive” as the heading, the consumer wonders what he is looking at. A food or a care product? A closer look reveals the words shower gel and pomegranate. The Greek company Korres has stood for skin care products with natural active ingredients since 1996. The shower gel shown here uses olive leaf extract and pomegranate to gently cleanse and care for the skin. 250 ml of the shower gel, which shimmers in the greenish colour of olive oil, is filled in a slim bottle with a screw-on hinged cap with a dosing opening. An all-round self-adhesive label provides all the necessary commercial information. www.korres.com"},{"@ID":19
"BOTTLE MAKING 17 PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 41-\"4) 1300'&% BOE XBTIBCMF MBCFM BOE DMPTVSF JOTQFDUJPO TPMVUJPO 888 */53\"7*4 $0. The company’s Robby Rack system provides palletisation of large-size container racks. Integrating an anthropomorphic robotic arm with other essential components, this system offers a flexible and efficient alternative to traditional palletising methods, says Sipa. A commitment to circularity By developing integrated solutions for large-size PET container production that focus on efficiency, resource optimisation, and reusability, Sipa aims to help beverage producers reduce their environmental impact while addressing market demands. As consumer demand for large-size PET containers continues to grow, their solutions are claimed to provide an answer to the sustainability challenge by combining cutting-edge technology with an understanding of circular economy principles. www.sipasolutions.com 4-gal returnable container production with SFL"},{"@ID":10
"8 NEWS PETplanet Insider Vol. 25 No. 10/24 www.petpla.net China Brew China Beverage 2024 – International Forum launch: embracing sustainability, innovation, and intelligent exploration China Brew China Beverage 2024 (CBB), an international exhibition for brewing and beverage production technology and equipment, will be held from October 28 to 31, 2024, at Shanghai New International Expo Centre. The CBB 2024 International Forum offers a communication platform for professionals within the beverage and liquid food industry, encompassing sectors such as beer, beverages, dairy, and more. This platform facilitates the exchange of technology, innovation trends, experiences, and cultural insights. Sustainable Liquid Food Innovations International Forum The sustainable liquid food innovations International Forum on CBB 2024, organised by Messe München Shanghai Co., Ltd., Yontex, and China Light Industry Machinery Association, will be held on October 28-29 at International Forum Area in hall W2 of the Shanghai New International Expo Centre. With the theme “Innovation Driven, Green Development — Exploring the Sustainable Journey of Beverage and Liquid Foods,” the forum will convene a diverse group of stakeholders, including industry leaders, technical experts, and academic authorities from around the world, along with over 20 leading enterprises in the beverage and liquid food sector. With a global outlook, attendees will engage in discussions and share insights on the latest innovations and forecasted trends in sustainable practices within the industry. Beverage Innovation & Concept Forum The Beverage Innovation & Concept Forum, organised by the Shanghai Beverage Association, FMCG China, and Messe München Shanghai Co., Ltd. will be at International ForumArea on October 29. With the theme “Leading the Future of Beverages: Innovation, Insights, and Premium Progress,” the forum will gather well-known brands, senior experts, and pioneers in the beverage industry to discuss cutting-edge trends, technological innovations, and brand development strategies in Chinese market. “Fresh insights on the Chinese beverage market” will be released at the forum, highlighting shifts in consumer preferences, evolving market segments, and the growing demand for health-oriented and tailored products. It will also showcase the latest practices of major companies in product innovation, brand premiumisation, and digital transformation. The 5th China International Craft Beer Summit The 5th China International Craft Beer Summit, jointly organised by Beijing Zhongqing Heli International Exhibition Co., Ltd. and Messe München Shanghai Co., Ltd, will be held at Forum Area in hall E1 on October 29. With the theme “Smart brewing for the future, sharing the splendour — Exploring the new era of digitalisation and intelligentisation in Craft Beer,” the summit actively responds to the national strategy of promoting the transformation and upgrading of traditional industries and fostering the deep integration of the digital economy with the real economy. It aims to accelerate the development of China’s craft beer industry, deepen the integration and application of digital and intelligent technologies, and build a high-end, professional platform for technical exchange and cooperation. www.chinabrew-beverage.com smi Carbios and Selenis collaborate on producing sustainable PETG Carbios, a pioneer in the development and industrialisation of biological technologies to reinvent the life cycle of plastic and textiles, and Selenis, a leading supplier of high-quality speciality polyester solutions, have signed a Letter of Intent (LOI) to cooperate in the production of PETG (polyethylene terephthalate glycol). By leveraging Carbios’ enzymatic depolymerisation technology and Selenis’ expertise in polymerisation, the companies aim to develop a PETG material made from PET waste for the Cosmetic and Healthcare packaging sectors across Europe and the U.S. This partnership follows a two-year collaboration between the two companies. Carbios’ and Selenis’ partnership is the result of extensive pilot and industrial polymerisation trials that have refined the quality of the end product. The result is high-speciality PETG grades issued from bio-recycling that meet the strict requirements of sectors like cosmetics and healthcare, where Selenis has a strong presence through its Selcare brand. www.carbios.com CONVEYING PALLETIZING PACKAGING BLOWING FILLING LABELLING"},{"@ID":36
"EVENT PREVIEW PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 34 Romina Mineralbrunnen reducing false rejections and addressing challenges with tethered caps on PET bottles Optimising production with AI-powered quality control system Romina Mineralbrunnen, part of the German “Franken Brunnen” group in Reutlingen-Rommelsbach, has been using BBull Technology’s deep learning AI technology for years in its glass line for empty bottle inspection. Based on the good detection performance, the system is now being applied to both PET lines, particularly to address the new tethered cap issue. Around 150 employees at Romina Mineralbrunnen fill 178 million glass and PET bottles annually with water and soft drinks under the “EiszeitQuell” and “SilberBrunnen” brands. Two PET lines (with capacities of 20,000 and 16,000 bph) fill inhouse blown Petcycle bottles. In the German Petcycle system, PET bottles are used only once but the bottles are delivered and sold in reusable crates. The glass line has a capacity of 40,000 bph, filling standardised reusable glass bottles in 0.7 l and 0.75 l, and two custom bottles. Glass bottles still account for 60% of the bottles distributed across Baden-Württemberg. Water from the Ice Age In 1957, Friedrich Scheuermann founded the bottling company with a used filling machine, producing soft drinks delivered to Reutlingen. By 1973, three springs were tapped, and the company and brand “Romina” (Rommelsbacher Mineral-Natur) were established. Geological studies suggested Ice Age-era deep wells in Reutlingen-Rommelsbach, leading to the drilling of a new deep well in 1994. Water analyses revealed a unique water source formed over 10,000 years ago at a depth of 400m, protected by impermeable rock layers. In 1996, Romina surpassed the milestone of 100 million bottled units per year. In 2000, the water was renamed “EiszeitQuell,” and thanks to marketing campaigns, sales continued to grow. Since 2002, the company has been filling Petcycle bottles. Control systems BBull Technology, based in Königsbach-Stein, Germany, has been a global leader in control systems, sorting and distribution technology, and transport and conveyor systems for the beverage and food industries for decades. The company develops and manufactures a range of container and packaging inspection systems as well as customer- and product-specific sorting, distribution, and ejection systems. Due to the constant introduction of new bottle shapes and sizes by providers in the beverage industry, along with the vast variety of labels, containers, and closures, BBull developed a PC-based filler management and control system. This system is based on high-performance cameras, powerful PC technology with AI, a graphical display with a touch screen, and advanced lighting systems. Additionally, it comes with correspondingly fast rejection systems. “We have been using BBull’s camera systems for many years on our glass line to detect foreign objects in crates, misaligned, broken, or overturned bottles, as well as incorrect bottles,” says Romina CEO Stefan Gugel. Due to a new standard glass bottle and many custom bottles from other companies, which are hard to distinguish from Romina bottles via cameras, along with protruding rings on the bottle caps, the number of rejected crates increased significantly. “These foreign bottles could no longer be detected by our old camera systems, so we had to manually sort out many foreign bottles,” Gugel explains. Their long-time partner BBull had just developed a new system, “so we seized the opportunity and installed BBull’s ‘Teta-Line LG DL’ in the line. It has proven to be highly effective,” says Gugel. Fewer rejected crates Teta-Line LG DL - “DL” stands for deep learning - is a system designed to detect crates and bottles and eject defective ones. Self-adaptive algorithms and easy training for new containers make it a flexible and scalAround 150 employees at Romina Mineralbrunnen in Reutlingen fill approximately 178 million glass and PET bottles annually. Defective crates are reliably identified and rejected for manual reprocessing. BBull Hall 7 | Booth 251"}]}}
