{"pages":{"page":[{"@ID":35
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 33 Hot fill moulds - A growing market Beyond technological advancements, PET Technologies continues to expand its portfolio by diversifying the types of moulds it manufactures. One of the fastest-growing segments is hot fill PET bottles, which are projected to grow at a CAGR of 5.4% by 2032. Meanwhile, the overall PET bottle market is expected to expand at a CAGR of 4.44% by 2030. PET Technologies has adapted to meet market needs by producing specialised hot fill moulds. Additionally, the company has developed its own linear blow moulding machines specifically designed for the high-temperature filling processes. www.pet-eu.com PET Technologies has vertical plastic blow moulding machines manufacturing with a complex of units and workshops to manufacture at the same plant all parts and units for blow moulding equipment starting from metal cutting till machines assemble and start-up: Two R&D departments: equipment engineering and to design PET bottles as well as filling line conversions for another preform neck standard, programming section; 9,000m2 of production areas: welding unit, powder painting shop, plasma cutting, heat treatment site, electrical assembly area, quality control at each stage of production; a park of over 130 processing machines with both universal machines and 3-, 4-, 5-axes CNC machinery centers by Deckel Maho (Germany), Stroitos Lipnik (Czech Republic), Dugard (England), Doosan (South Korea); trials blow moulding site equipped with machinery to produce PET, rPET, RefPET, PP bottle samples of various designs and volumes up to 40 l; laboratory for PET bottles testing equipped with Agr (USA) devices to evaluate PET containers physical properties and with detailed report to the customer."},{"@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 [email protected] EDITORIAL Kay Barton Heike Fischer Gabriele Kosmehl Michael Maruschke Ruari McCallion Anthony Withers Editorial & WikiPETia. info [email protected] MEDIA CONSULTANTS Martina Hirschmann [email protected] Johann Lange-Brock [email protected] phone: +49 6221-65108-0 LAYOUT AND PREPRESS EXPRIM Werbeagentur Matthias Gaumann www.exprim.de READER SERVICES [email protected] 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. 26 No. 04/25 www.petpla.net The first part of our Circular Economy Tour 2025 has started and took me to Spain. But what awaited me there? Exciting projects, of course, but at the same time every visit brought back memories of previous projects from the last 25 years - a real déjà vu! But first things first. My first stop was at Mr Guillem from Inden Pharma, which now operates in cooperation with Alpla Pharma. About 20 years ago, we already had the idea of publishing a publication called Plastics in Pharmaceuticals alongside PETplanet. However, our research quickly revealed that the authorisation procedures for medicines and their packaging take several years. Once on the market, changes are virtually impossible, so innovations in this area are very slow to gain a foothold. And today? The situation has hardly changed. This means that a specific PET from a specific manufacturer is authorised for almost every type of packaging. Inden Pharma therefore relies on many small batches which are processed in bags - a real logistical feat. My next visit took me to Mrs Masó from Retal Iberia. She gave us a warm welcome and we were delighted to see each other again after ten years. After all, my colleagues Waldemar and Kay had already paid a visit back then. We quickly got talking about the history of Retal. One particular impression: my first major visit abroad with PETplanet 25 years ago also took me to Retal - at that time still in Dnipro, Ukraine. It was moving to hear that the company continues to operate despite the war and has moved its headquarters closer to Kyiv to meet the challenges of the current times. My trip ended with a meeting with César Rodriguez, the founder and CEO of MachinePoint. He founded his company at the same time as I launched PETplanet. Over the years, he has led MachinePoint through all the ups and downs and developed it into a profitable trading centre for used machines with comprehensive service backup, now employing 50 people. I still remember my early days when I was also involved with used machines for PETplanet - but the business was far less dynamic back then. Instead of structured markets, there were often only dusty halls in which discarded machines waited for new owners. During these intensive discussions, the topic of sustainability also took on a different dimension. It is also valuable to pause and look back - on developments that have had a lasting impact on us and on people who have accompanied us along the way. Yours, Alexander Büchler PS: The new Circular Economy 2025 tour reports will start in one of our coming issues! Dear readers,"},{"@ID":32
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 30 MOULD MAKING 30 Precision cap mould manufacturing The Austrian-based company HTW Molds GmbH produces customised mould solutions for high-performance injection moulding, ranging from packaging and closures to medical applications like CRC closures. The company operates its own test centre, which will soon be enhanced with the addition of a Sumitomo Demag PAC-E IMM. Cap mould manufacturing With a worldwide customer base spanning over 50 countries, the company specialises in designing and manufacturing high-precision, multi-cavity moulds for beverage, pharmaceutical, and personal care industries, producing lightweight and sustainable closures. The company claims that its in-house product development department is able to quickly turn an idea for a customer closure into a mouldable, commercially usable closure. With over 25 years of expertise in hot-runner technology the company has more than 400 systems running successfully worldwide. Well-known suppliers like MoldMasters or Husky can also be integrated into HTW moulds. HTW Mold provides a complete, turnkey package, including in-house manufactured hot-runner systems. It offers both valve gate and open gate solutions, which, according to the company ensures optimised flow, consistent quality, and high-performance production. Testing every mould The company operates its own state-of-the-art test centre, equipped with three injection moulding machines with clamping forces up to 550 t. The testing centre is equipped with two Netstal machines, one Wittmann Battenfeld EcoPower machine and will be completed with a Sumitomo Demag PAC-E injection moulding machine soon. With these machines, the company can thoroughly test any mould, ensuring optimal function, cycle time efficiency, and precision. The moulds are tested under real production conditions, providing the customer with peace of mind before shipment. HTW’s Mold portfolio covers a wide range of applications: Standard beverage closures Sports caps Flip-top caps Aerosol caps Motor oil caps Spouts for flexible packaging Dosing caps CRC (Child-Resistant Closures) in 2, 3, 4, and 5-piece designs Measuring cups and other medical applications www.htw-molds.com MOULD MAKING STEPS TO THE PERFECT BOTTLE. www.roeders.de www.roeders.de Idea & Design Technology Manufacturing Blow Mould 100% Service Y O U R PA R T N E R F O R B L OW MO U L D S ."},{"@ID":44
"PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 42 Healthy dressing from Holland Under the ‘Callowfit eat better’ brand, Dutch company Dline BV sells a wide range of modified dressings and sauces, from chocolate sauce to curry ketchup, in vegan, gluten-free and lactose-free recipes that also contain no aspartame. Each of the transparent bottles - the picture shows a honey mustard style dressing - contains 300ml, is decorated with a full sleeve label and is sealed with a hinged lid with a silicone valve. The lid must be unscrewed and a sealing membrane removed before the bottle can be tapped for the first time. www.callowfi t.store Water+ from Rewe The growing market for drinks with added vitamins and minerals means that the major retailers are also offering suitable products. Rewe, for example, sells several functional drinks with added vitamins B, C and E and magnesium. The drinks without added sugar are available in raspberrygrapefruit or apple-kiwi flavours. The transparent disposable bottles are made from 100% recycled plastic, decorated with a semi-transparent sleeve label and sealed with a screw cap. www.rewe.de"},{"@ID":43
"PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 41 BOTTLES Drink with cactus flavour Dovgan GmbH from Hamburg se l l s a ca r bona t ed so f t d r i nk ‘Tropical Kaktus’ with cactus flavour in Germany. The packaging is a greenish-coloured bottle with embossing all around and a capacity of 1.5 l. The bottle is sealed with a black screw cap. The belly label is decorated to match the flavour. www.shop-dovgan.de Oat drinkable meal from Kölln The traditional manufacturer of oat-based products has developed an oat-based drinkable meal called ‘Realoat’ and has now launched it on the market. The drink is enriched and flavoured with proteins, sunflower oil, vitamins and minerals. A total of four flavours are available: Classic, Vanilla, Chocolate and Banana. The 500 ml is filled in a whitecoloured bottle with sleeve labels designed to match the variety. The screw cap has a sticker on the top with the wellknown brand logo, the product name and the flavour variant. www.koelln.de"},{"@ID":3
"No.04 2025 www.petpla.net D 51178; ISSN: 1438-9452 PETplanet is read in 159 countries Suppliers of cap systems & cap moulds MARKETsurvey 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 14 . 04 . 25 MOULD MAKING EDITOUR Page 10 Page 25 Page 20"},{"@ID":47
"BOTTLE MAKING 16 PETplanet Insider Vol. 26 No. 04/25 www.petpla.net Cypet Technologies claims big savings for extra large containers The bigger the better – and lighter by Ruari McCallion Cypet Technologies, which is located near Nicosia, Cyprus, has made a speciality of designing and manufacturing large capacity PET containers. Later in 2025 it will be launching a 1,000 l container in partnership with a company in South Asia, and a similar sized Intermediate Bulk Container (IBC). We spoke to Michalis Sideris, the company’s Business and Technical Development Director. Cypet Technologies was established in 2013 by Michalis Sideris’ father, Constantinos Sideris, who had a chemical engineering background and many years’ experience in the plastics industry; he had been running a trading company in Cyprus. It now employs 25 people at its Nicosia HQ and an additional 15 people at its facility in India. Innovative design was a strength from the start. As a start-up, the company was not in a position to take on the established and global businesses, whose scale of operations meant that it was impossible to compete in the mainstream market on price or, realistically, on technology. But Mr Sideris Senior had a clear vision of where he wanted the business to be: in larger-sized containers. He was also in possession of a patented process to make such containers through single-stage injection stretch blow-moulding, which – he maintained – would save operators time, material and energy. As these are the three factors that are most likely to push up costs, the Sideris family and Cypet Technologies believed they were on to a winner – and so it has proved. Cypet has established itself in its niche with a combination of innovation and demonstrable cost saving technologies. Simpler, cheaper – and larger “Our machinery uses a single clamping unit to open and close the injection mould and to blow them but it was the layout of the two moulds inside the machine that was a novel innovation,” Michalis said. “When we developed that first machine, we thought that the main benefit would be a simpler and cheaper machine. We subsequently found that our machine was capable of making much larger containers than were available at the time. Back then, the maximum container size that could be blown was 30 l, which is a popular beer keg size. The Cypet machines were capable of going up to 120 l blow-moulded containers, which was demonstrated via a live production demo at the 2019 K’ Show.” This capability took Cypet well into areas that were traditionally dominated by HDPE, although its mission was, initially, to drive the market to PET containers as a more environmentally friendly alternative to traditional materials. Sustainability “PET is the most sustainable plastic packaging available. It is recyclable indefinitely and another way of making it sustainable is to produce your plastic packaging using the lowest amount of energy possible. These two factors were the main motivation for establishing Cypet,” Michalis explained. Cypet also saw that the ISBM market was ripe for disruption, with two Japanese companies dominating the market. As a start-up, it took some time to convince potential customers that its innovations were going to deliver their promises but it has now, while remaining a niche player, established itself as a serious contender, with customers in 20 countries on all five continents. And it was customers themselves who identified the potential for the Cypet technology. “By the time we reached machine number three, we were already blow-moulding 50 l beer kegs for a specific application in Australia. It was the market that guided us into looking at larger containers,” he explained. F.l.t.r.: Michalis Sideris, Head of Business and Technical Development, and Constantinos Sideris, Director & General Manager at Cypet Technologies Preform for a 1,000 l PET water container"},{"@ID":8
"PETnews 6 NEWS PETplanet Insider Vol. 26 No. 04/25 www.petpla.net Alpla has new leadership in Western Europe and Asia Packaging and recycling specialist Alpla is restructuring its leadership in its two Western Europe (WEEU) and AsiaPacific (APAC) regions. Roland Wallner, Managing Director APAC since 2021, will take over as Managing Director Western Europe (WEEU) on April 1, 2025. Ronald Tichelaar, General Manager China, will succeed Wallner as Managing Director APAC. Wallner brings 27 years of international management experience and has been with Alpla for 14 years. During his time in Asia, driving significant top- and bottom-line growth, Wallner built up and expanded the company’s presence in several Asian countries and oversaw multiple major projects. WEEU, Alpla’s largest region, includes 31 base plants and 17 in-house plants across 10 countries, employing 5,700 people. Wallner will be based at the headquarters in Hard, Austria, and report to the CEO. Ronald Tichelaar takes over APAC region Tichelaar, with 14 years at Alpla, has led operations in North Asia and Spain. As General Manager China, he oversaw six plants and technical centres, achieving strong business growth and operational excellence. The APAC region includes 12 locations in four countries, with 2,650 employees. Alpla recently opened its second plant and headquarters for Thailand in Chachoengsao. www.alpla.com Husky strengthens 25-year commitment to India Husky Technologies, a global leader in injection moulding technology and solutions, is reinforcing its commitment to India with expanded facilities, technology innovations, and service enhancements designed to support the country’s emergence as a global sustainability leader. This commitment was recently commemorated with a two-day customer event that took place March 20-21, hosted by Husky’s regional leaders and senior executives. Husky’s presence in India has significantly grown since selling its first system into the country in 1999. The company opened a flagship sales and service office in 2001, followed in 2009 with the construction of their Chennai manufacturing facility. In May 2023, Husky kicked off the next phase of expansion that culminated with the opening of a new Delhi office in November 2024. The company has now established additional capabilities in India. India’s ambitious sustainability mandates, which require 30% recycled plastic content in packaging by 2026 and 60% by 2029, create both challenges and opportunities for regional producers. Husky’s expanded presence supports customers in navigating these requirements through circular economy solutions. Husky’s strategic focus on India recognises the country’s potential as a global model for sustainable manufacturing, demonstrating how countries can maintain economic growth while embracing circular economy principles. Introduction of new global enterprise-level monitoring solution A highlight of Husky’s customer event included an early preview of the company’s new Advantage+Enterprise solution, a global offering that builds on the success of the existing Advantage+Elite platform to deliver enterprise-wide operational insights. Introduced in 2021 and currently supporting more than 1,100 contracts around the world, many of Husky’s customers have been using this solution for single or multiple system monitoring. By studying these systems, Husky was able to determine that those connected to this innovative experience improved operational effectiveness, performance, and part quality. Even more so, customers who employ this system across an entire factory experience even steeper improvements, says Husky. These observations are what led to the development of the new Advantage+Enterprise program. www.husky.co F.l.t.r.: Roland Wallner and Ronald Tichelaar"},{"@ID":2
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 34 MOULD MAKING 34 100% rPET lightweight bottle base for still products StarLite-R Still is a new bottle base that employs Sidel’s patented technology to ensure 100% recycled PET (rPET) integration, lightweighting, and high-speed production for water, juices, milk, and edible oil from 0.25 l up to 2.5 l. Balancing production speed, material type, and bottle weight presents a complex challenge for manufacturers in maintaining high performance. According to Sidel the StarLite-R Still overcomes these with precise bottle base shaping and efficient material distribution. Its design can be seamlessly retrofitted onto existing production lines ensuring versatility and the solution requires low blowing pressure, further enhancing its sustainability credentials. High performance The StarLite-R Still bottle base features Sidel’s patented technology which includes smooth materialstretching and precise distribution; optimised venting for easy shaping; and a base cooling circuit ideal for rPET which is likely to be processed at higher temperatures. According to Sidel, the new design ensures that the base does not deform or break, crucial for maintaining the bottle’s integrity during production, conveying, storage, transportation, and use. The mould base’s rounded-edge design makes it easier to shape during blow moulding, which increases the bottle base resistance to defects such as bursts during the blowing process. This feature is particularly important for lightweight bottles, which are more prone to such issues due to the use of thinner material. With a high base clearance, structural design prevents deformation, ensuring functionality and stability even in high-temperature conditions. The bottle base performs during high-speed production, thanks to efficient cooling. This cooling process prevents deformation and defects, maintaining consistent quality at rapid manufacturing speeds. The bottle production process can use up to 20% less blowing pressure due to improved mould venting of the StarLite-R Still mould base. The carefully designed grooves and venting holes in the mould are claimed to ensure that air escapes smoothly, allowing the bottle base to take its desired shape at lower pres- ? SEE HOW MUCH YOU CAN SAVE 70% LESS ENERGY MAINTENANCE COSTS 90% LESS 70% REDUCTION IN CO2e 50% MORE PRODUCTIVITY The savings will vary based on your circumstances and should be reviewed with our sales team. [email protected] www.maguire.com Discover your potential savings. With just a few clicks, you’ll gain valuable insight into how ULTRA will positively impact your bottom line. 1. Go to ultra.maguire.com 2. Input your data. 3. Receive your customized PDF report of potential savings via email. MOULD MAKING"},{"@ID":42
"PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 40 PETbottles Beverage + Liquid Food Capri-Sun now also available as Zero Syrup Following the launch of Capri-Sun Zero Orange in a pouch some time ago, Capri-Sun Zero Syrup Orange has now been introduced, allowing consumers to enjoy the typical Capri-Sun taste at home or on the go. The 600ml syrup is packaged in a slim, easy-grip bottle with a sleeve label. The sleeve label has a perforation for easy separation of the bottle and label for sorting and recycling. The syrup is mixed in a ratio of one part syrup and nine parts water. The contents of the bottle therefore make 6 l of Capri-Sun ready-to-drink beverage. There is a sealing membrane under the hinged lid cap, which should be removed before first use. www.capri-sun.com Apple / Watermelon in PET Tymbark, a drinks manufacturer from Poland with a history of almost 90 years and a wellknown brand there, also offers its products in some supermarkets in Germany. These include the apple-watermelon variety in a 500 ml PET bott le. The lower part of the waisted bottle is embossed in the shape of a leaf, while the upper part has a sleeve label. A green-coloured screw cap completes the pack. www.rewe.de"},{"@ID":40
"MATERIALS / RECYCLING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 38 Complex intermediate steps can be avoided with Plastcompactors from Herbold Meckesheim Agglomeration, desiccation, crystallisation Agglomeration systems are an efficient solution that is in constant demand for achieving free-flowing regrind with a high bulk density that can be directly processed in extruders or injection moulding machines. Plastcompactors from Herbold Meckesheim have been designed to save even complex intermediate steps when reprocessing recycled PET. The agglomerate does not require any special silos for storage as it can be easily discharged and conveyed, unlike classic flakes. In addition, the agglomerated recycled PET is already partially crystallised. All in all, the material is much easier to handle and therefore more suitable for further processing steps in preform injection moulding machines or film extruders with gravimetric dosing, says Herbold Meckesheim. Furthermore, the specific energy requirement for the extrusion of compacted plastics is lower and the throughput higher. The Plastcompactor HV 70 is the most powerful of the series from Herbold Meckesheim. It compresses the feedstock in continuous operation between a rotating and a stationary disks that are equipped with bolt-on and easily replaceable kneading bars. A continuously adjustable feeding screw constantly conveys granulated material from the buffer silo into the working zone through the centre of the stator disk in a controlled manner. Since the rapidly warmed material leaves the compacting zone within fractions of a second, the thermal impact on the plastic is low. The process is regulated by two degrees of freedom – the speed of the screw and the distance between the discs. HV Plastcompactors can be used to agglomerate a wide variety of materials into products with a high bulk density: thermoplastics such as fibres, fines, tapes, foams, stretch or thin films, powders or shavings, as well as plastics that are difficult to convey, store or mix. In particular with stretch films or foams, adequate drying by mechanical or thermal means would only be possible with an immense use of energy. Moreover, the compactors from Herbold Meckesheim are often installed downstream of washing lines: here, the damp material is heated in the compacting zone to such an extent that the moisture escapes. Subsequent agglomeration, in conjunction with a secondary granulator and a classifier, can achieve residual humidity of less than one percent. Likewise, various additives such as lubricants, plasticisers or colour pigments can be incorporated using special dosing units on the feeding screw. Compounding or the recrystallisation of PET flakes are further fields of application. The HV 70 from Herbold Meckesheim is also claimed to combine high throughput with low maintenance costs and a fully automatic control system in which settings for different infeed materials can be recorded. And thanks to the performance and temperature monitoring, the process is controlled in such a way that only minimal personnel deployment is necessary. In the course of the latest enhancements, the disk geometry of the solution has been modified. In combination with improved automatisation of the compactor and a more compact design, manual interventions during operation are less frequently required, offering customers a higher degree of operational reliability. In addition, the silo and the feeding device have been optimised in such a way that even more complex materials with the lowest bulk densities and the most difficult flow characteristics can be handled safely. www.herbold.com Plastcompactors process the feedstock in continuous operation between a rotating and a stationary disk. (Photos: Herbold Meckesheim) The HV 70 Plastcompactor (Picture: Herbold Meckesheim) Agglomeration plant for fibres, fines, tapes, foams, films, powders or shavings."},{"@ID":16
"EDITOUR PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 14 From preform to film by Alexander Büchler Inconspicuous from the outside, the production halls house not only the largest preform and cap manufacturer in Kuwait, but also a major player in the production of films. But first things first. Interview with Genoa Plastics Industries, September, 24, 2024 We met: Plant Manager Logesh Sathyanarayanan and CEO Abdullah Abdulmohsin Al Faris It all started with a trading company that did a lot of work with Italy. As the founders liked the Italian city of Genoa so much, the name was added to the company title: Genoa Plastics Industries. The trading business still exists, but in 2008 the production of preforms was added - initially with two PPS 350 t Sipa systems equipped with 96-cavity horizontal moulds. The company got off to a good start. The customers recommended Genoa Plastics to others and business snowballed, and so three Husky HyPET HPP 4 and 5 with 72 cavities were added. Three Husky HyCAP 225 closure systems and a Netstal Elion Hybrid 2200 closure system were also added, all primarily with 48-cavity Corvaglia moulds. The plants process a total of 1,800 t of PET per month into preforms and 180 t of HDPE per month into closures. Inline inspection systems from IMD are located behind the canopy systems. Unlike the usual setup, they are elongated rather than angled, as the machines are positioned close together. As a result, the length of the IMD visual inspection systems is longer than that of the actual injection moulding machine - an unusual sight. An Intravis Prewatcher III system is available in the factory for preform inspection. According to plant manager Logesh Sathyanarayanan, customers are very satisfied with the comprehensive material and quality control. In the event of problems, he has three technicians in his team who are very familiar with Sidel, Krones and KHS systems and can usually help the customer directly. Its customers include major brands such as PepsiCo and Coca-Cola. The preforms for lightweight water bottles are the main product, but CSD preforms for multinational manufacturers also leave the factory. When it comes to closures, Genoa Plastics focuses on water closures. Depending on the season, a third of production is exported to Saudi Arabia, Oman, Qatar, the UAE, Bahrain, and Jordan. A two-cavity Chumpower blow moulding machine forms special bottles (for water, juices, hand sanitiser, glass cleaner, hand soap detergents) from preforms. The owner, Mr Abdullah Abdulmohsin Al Faris, was always on the lookout for new expansion opportunities. This is how he came up with the idea of film production. An 18m high film Windmöller & Hölscher – Varex Extrusion blown film system was added to the newly constructed 26m high plant in 2021, along with a Windmöller & Hölscher Miraflex CI Press L 8-colour printing system and a Nordmechanica Lamination machine, Bimec Italy & Kody slitting machine, four bag making machines for producing bags of all kinds. Only a small part of the film production goes to its existing customers in the beverage sector. Genoa Plastics produces shrink film and printed labels for them. While the customer base and competitors for preforms and caps are clearly defined, the owner has unlocked significant potential for new customers with the film business. According to him, competition is tougher in this sector, as the market is also much larger. www.gpikuwait.com EDITOUR F.l.t.r.: Plant Manager Logesh Sathyanarayanan, CEO Abdullah Abdulmohsin Al Faris and Alexander Büchler"},{"@ID":31
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 29 Label-free bottles for improved sustainability The most sustainable label? No label at all The Carvalhelhos blow moulder not only produces traditional PET and rPET bottles that require label application, but it is also equipped with specialised moulds designed by SMI MEC for the stretch-blow moulding of its 0.33l, 0.5l, and 1.5l flat-bottom rPET bottles without paper or plastic labels. This eco-friendly solution eliminates the need for glue and additional paper or plastic materials, simplifying the recycling process and ensuring higher purity in recycled PET. The area dedicated to the label has been removed, eliminating the ribs typically found in traditional bottles. An innovative combination of embossed and debossed engravings on the bottle body therefore provides additional space for the brand logo and essential product information, which would traditionally appear on a label. This approach also allows for the inclusion of information in braille. Beyond its environmental benefits, this solution aligns with Carvalhelhos’ aesthetic and branding needs, helping the new bottle stand out on store shelves and attract consumer attention. The shift to label-free bottles offers several advantages for the environment, consumers, and bottlers. Advantages for the environment and the consumer From an environmental and consumer perspective, label-free PET bottles are fully recyclable without requiring the removal of labels, which simplifies the recycling process and ensures a higher purity of recycled materials. The absence of labels also eliminates the need for adhesives, reducing the use of chemicals that can interfere with recycling. Additionally, reducing packaging materials helps minimise overall waste, contributing to more sustainable resource management. Advantages for the bottler For bottlers and manufacturers, eliminating labels leads to cost savings, as there is no longer a need to purchase labels or adhesives. Storage requirements for raw materials are also reduced, freeing up space in production facilities. The manufacturing process is further streamlined by removing the need for labelling machines, which lowers production complexity and maintenance requirements. Additionally, the absence of labels allows for a more efficient PET recycling process, as the bottles can be processed without the additional step of separating materials. Giving shape to ideas The quality of the moulds installed on rotary stretch-blow moulders and the efficiency of the stretchblow moulding process are two fundamental factors in producing highquality bottles that attract consumers’ attention. To support manufacturers transitioning to label-free designs, SMI’s subsidiary SMI MEC has developed special mould couplings that enable quick changeovers between traditional and label-free bottle formats. This solution allows companies to adapt their production lines without requiring extensive modifications to existing equipment. www.smigroup.it MOULD MAKING Label-free bottles are an increasingly popular trend among food and beverage manufacturers. Portuguese company Carvalhelhos has embraced this approach by introducing label-free PET and rPET bottles in 0.33 l, 0.5 l, and 1.5 l sizes. These bottles are produced using SMI’s EBS 8 KL Ergon stretch-blow moulder, which allows for the creation of containers without traditional labels while maintaining product branding and regulatory information."},{"@ID":19
"BOTTLE MAKING 17 PETplanet Insider Vol. 26 No. 04/25 www.petpla.net Innovation and invention lead to big savings Cypet has built its reputation with features including handles moulded into the container, not added after, and designs that use less material and need less energy to produce than conventional HDPE or other materials. Anyone can make larger containers with thicker walls but that means more material and more energy expended on heating the material, as well as blowing and manipulating it. When PET is stretched, it becomes much stronger than stretched HDPE, which means that manufacturers can obtain the same strength and capacities with rather less material. Michalis gave as an example a 5 l jerrycan. The lightest HDPE 5 l can requires 140 g of material. A PET container (handle included) can be made with just 100 g: 35% saving on material and with consequent energy costs. Savings extend right the way up the range. The largest container the company makes now is 120 l. It explored 220 l drums but saw that the market for them was shrinking; they were being replaced with IBCs, the familiar cuboid containers that are packaged within a wire cage. The bigger the better – and lighter “We undertook a lot of calculations and simulations and we found that, in theory, it would be possible to design a bigger version of our machine that could blow mould containers as large as 1,000 l,” Michalis explained. “We were able to demonstrate in theory that an IBC made of PET could be much lighter and use much less material. It could reduce the cost of production by so much that it would remove the need to return an IBC bottle, wash it out and redeploy it. You could just send the package back, remove the used, dirty bottle and put a brand new, clean one, inside and ship it out to the market again.” The discarded IBC would be recycled. The immediate project is for a 1,000 l container for water, for India, which will offer an economic and sustainable alternative to traditional packaging. Cypet plans to launch a demonstrator of the water tank by the end of April and the IBC project is expected to be ready by Summer 2025. Material, energy and labour savings “We estimate that our technology will achieve around 40% material savings on both water tanks and IBCs, compared to the HDPE versions. This means that material per IBC will come down from 12 to 15 kg in HDPE to less than 10 kg in PET. A saving of 5-6 kg for each water tank or IBC is absolutely huge in raw material costs, alone.” The energy and cycle time savings offered by ISBM compared to rotary moulding are similarly impressive. Rotary moulding cycle time is up to five times longer than ISBM and energy costs are between 30- and 80% higher, depending on the product being moulded, as rotary moulds must be heated and kept hot for a long time and then allowed to cool down. Labour costs are also higher because of the extended opening and closing process. The advantages are clear but going from 120 l bottles to 1,000 l containers was still a big step up. From virtual world to real time solutions “We had to engineer everything from first principles. We used all the tools that we had available, from design to simulations, including structural injection moulding and blow moulding, and we strove to do the best possible job in the simulation world first,” Michalis explained. “To make sure we could achieve what we had done in the simulation, we added a lot of extra provisions on our machines and our models to be able to ensure even better control of the process, above what the simulations showed that was needed, so that we could be as foolproof as possible and maximise the chances of success.” The new, extra-large range of containers required a significant investment, which has been achieved with the involvement of a strategic partner in India. The next step will be to introduce the bulk water containers and IBCs commercially and to convince users across the world – for this is a global market – that the promised savings can indeed be achieved. The figures should speak for themselves. Cypet is not only focusing on the big picture, if 1,000 l containers can be called that. Later in 2025 it will be launching its Pro Series, which will take the productivity of ISBM machines to a new level in the 20 ml to 50 l space. 2025 looks like an exciting year for Cypet, all round. www.cypet.eu"},{"@ID":30
""},{"@ID":46
"39 PRODUCTS PETplanet Insider Vol. 25 No. 0/24 www.petpla.net Wipotec and Coca-Cola closing the loop via laser marking Wipotec, a company based in Germany’s Palatinate region, and Coca-Cola Latin America are strong partners. Together, they have launched a new project to make the circular economy a reality in the region. Coca-Cola was actively looking for a partner to realise its vision of direct bottle marking. “The development took about two years and included not only Wipotec’s hardware, but also the business case and the data management pool,” says Thomas Krämer, Global Account Manager Product Marking at Wipotec. “Our experience in pharmaceutical serialisation was extremely valuable here.” Each bottle is labelled with an individual QR code in accordance with the GS1 Digital Link Standard using special laser technology, making its life cycle transparent. Read by an industrial camera system, Coca-Cola obtains important data about the service life or return rates and can therefore plan more efficiently and use resources more sustainably. Consumers receive information about recycling on their smartphone via the code. It is also used when returning bottles at the deposit machine. Operations are already underway in Chile. “In Brazil, another production line is currently being installed. Next up is Costa Rica as a pilot for Central America. A rollout across Latin America is also in planning,” says Krämer, who is closely involved in driving the project forward. He adds, “Latin America is quite active when it comes to the circular economy. The market is large and offers strong potential for better resource utilisation. Additionally, some of the regions are geographically quite isolated, making them ideal for regional pilot projects.” www.wipotec.com PETproducts"},{"@ID":52
"OUTER PLANET 50 PETplanet Insider Vol. 26 No. 04/25 www.petpla.net OUTER PLANET New environmentally-friendly mortar comes with recycled PET Reducing heating bills and plastic waste alike “Wouldn’t it be wonderful to reduce heating bills of all our new builds and at the same time significantly reduce plastic waste in the world?” Professor Lidija Šiller, Professor of Nanoscale Science at Newcastle University’s School of Engineering asked herself. Together with Marof Kaniaw, she contributed to the development of a mortar made from recycled PET and silica aerogel which is claimed to improve insulation and reduce plastic waste. The researchers developed the cement mortar mix by replacing sand with silica aerogel and recycled PET plastic which they then showed improved thermal insulation and weighs less. Aerogels are known for their high insulation properties and are increasingly used for thermal insulation, particularly in the building sector and in aerospace. Publishing in the journal Construction and Building Materials, the team shows that the new mortar mix reduced heat loss by up to 55% compared to conventional mortar, while maintaining the required strength for masonry construction. It also meets international standards (BS-EN 4131:2011, ASTM C270-10, AS 1012/ AS 3700), presenting an eco-friendly alternative for energy-efficient and sustainable construction. This could improve sustainable construction practices while reducing heat loss in buildings, in areas where you get thermal bridging, for example through gaps between bricks in the walls which are filled with mortar. As one of the study lead authors, Professor Lidija Šiller, explains that the study demonstrates that their formulation of recycled PET plastic waste can be used to produce cement-based mortars, and that it is an effective way to reduce their impact on the environment. The new mortar mix Seven different formulations were tested alongside traditional mortar with the most effective of the new mortar mixes proving to be 7% untreated silica aerogels replacing natural sand combined with 3% recycled PET. The PET plastic particles used in the study came from shredded plastic bottles waste and were coarse, irregular in shape and between 2.5-3.5mm. The scientists washed the plastic pieces with water after shredding and left them to dry at room temperature for 24 hours. The team analysed key properties, such as setting time, flowability (a measure to determine the workability of cement mortar), density, strength, and thermal conductivity. The new formulation helped reduce the thermal conductivity of mortar by up to 55%, compared to standard mortar samples. Study lead author, Kaniaw Marof, PhD researcher at the School of Engineering, added: “Improvement of the thermal performance of masonry buildings by reducing the energy required for heating and cooling in buildings to meet the users’ comfort it is one of the main topics considered in the modern construction sector. In our work, the modification of surface of the silica aerogel particles was a crucial step towards successfully implementing silica aerogel particles within the cement binder and PET plastic.” The scientists are aiming to test the new mix in a large-scale, real-world setting. Professor Šiller explains: “Now it is possible to reach all British standards for this new reduced thermal heat mortar with plastic and aerogels. For the next step, we wish to find collaborators such as a construction company to apply for funding and build the house with our ‘recipe’ for mortar. This will allow us to provide the direct evidence of potential energy savings and assess the economics for masonry buildings applications.” www.ncl.ac.uk Thermal tests were carried out for the samples Reference: Kaniaw Marof and Lidija Šiller, “Enhancing thermal insulation in cement mortar with silica aerogel and recycled PET plastic’’, Construction and Building Materials, 467 (2025) 140320 https//doi.org/10.1016/j.conbuildmat.2025.140320"},{"@ID":34
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 32 Advanced blow mould solutions Client-centric approach The PET bottle industry is constantly evolving, driven by the demand for more efficient, sustainable, and cost-effective solutions. One of the most crucial areas of innovation is blow mould technology. As clients demand change, moulds must adapt, integrating new advancements to enhance production efficiency, reduce costs, and improve sustainability. At the forefront of these developments are rotary and linear moulds, the backbone of PET bottle manufacturing. PET Technologies has 26 years of experience in the development of blow moulding machines and blow moulds. It offers tailor-made solutions for the needs of modern production lines. The company owns a 9,000m² state-of-the-art facility dedicated to blow moulding machines and moulds, equipped with 140+ metalworking machines and a specialised mould R&D department. 5-axis CNC machines enable the production of moulds for precision finishes and engravings, compatible with all major European blow moulding brands. PET Technologies’ mould sizes range from 100ml to 40 l. Whether it’s a 30 l PET keg, a 5-gallon water cooler, or a 10 l oil bottle with a handle, PET Technologies offers customised solutions to meet diverse client needs in large bottle volumes. Enhanced durability with anodisation Anodisation is an electrochemical treatment that enhances durability by improving hardness, wear resistance, and corrosion protection, extending mould lifespan. PET Technologies offers black anodising upon client request, providing an additional layer of oxidation that further enhances resistance to wear and thermal stress. Unlike standard anodisation, black anodising absorbs more heat, making it particularly beneficial for high-temperature applications. Cooling for consistent quality Efficient cooling is essential for maintaining optimal blow moulding performance. PET Technologies says that its machines are equipped with specialised cooling units designed to regulate mould temperature, ensuring consistent bottle quality and faster cycle times. Inserts: flexible solutions Bottle design varies widely, with the only real limits being imagination and physics. When a client wants multiple interchangeable design elements, inserts provide a good solution. These allow for quick design modifications without the need for an entirely new mould, offering cost savings, flexibility, and faster production adjustments. Smart Base - The key to sustainability PET Technologies offers the intelligent Smart Base mould technology which claims to significantly improve the blow moulding process. It is designed to reduce the main blow mould pressure by increasing the number of air exhaust channels between the bottom of the blow mould and the preform. The blowing pressure reduction by 32%, this results in the reduction of energy and CO2 by 25%. Deep Grip technology The Deep Grip technology is an alternative to traditional PET bottle handles. Conventional handles are separate plastic pieces, adding complexity to logistics, costs, storage, and the bottle’s integrity and shape. Deep Grip technology eliminates these challenges by integrating a deeper, ergonomic grip directly into the bottle design - and, consequently, into the mould. The company says that this technology not only simplifies the manufacturing process but also enhances user experience, making bottles easier to handle while maintaining structural integrity. MOULD MAKING"},{"@ID":23
"MOULD MAKING 21 PETplanet Insider Vol. 26 Advanced blow moulding technology Röders has a long history of pioneering developments in PET stretch blow moulding. Together with Corpoplast, Röders introduced this technology for beverage packaging in 1975, moving from PVC to PET long before it became the industry standard. Since then, they have worked closely with market leaders developing advanced mould solutions that have shaped the industry. Today, Röders produces over 6,000 moulds annually in Soltau, Germany. Their ability to adapt quickly to market changes, combined with customer-driven R&D, contributes to their strong position in PET blow mould technology. Röders at SaudiFood Manufacturing, drinktec & Gulfood Manufacturing As Röders celebrates 50 years of innovation, the company remains committed to driving progress in PET packaging. To showcase their latest developments, Röders will be exhibiting at SaudiFood Manufacturing in Riyadh, Gulfood Manufacturing in Dubai and drinktec in Munich. www.roeders.de/en Ensuring on-time delivery: Jani Rickert (left), Sales Director, and Hendrik Holm (right), responsible for production scheduling, stay in daily contact to meet customer deadlines."},{"@ID":25
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 23 tles had identical maximum diameters and lengths, indicating no difference in shrinkage post-demoulding. Topload performance for the printedmould bottle was just 2.3% lower, well within acceptable limits. Mechanical testing of sidewall samples showed axial and hoop modulus differences of only 7% and 1% respectively. Wall thickness difference between the two was minimal - just 2.5% on average. These findings suggest that BMT’s 3D printed mould technology can reliably produce bottles that mirror production-grade quality. More importantly, when combined with Blowscan and simulation tools, this allows customers to move from concept to confident validation in a matter of days - not weeks - without compromising on performance. Packaging smarter, not just faster Originally, BMT offered prototyping services using machined metal moulds, providing high-fidelity results at the cost of time. While this met the needs of traditional development timelines, it became clear that today’s FMCG market demands something more agile. The introduction of 3D printed tooling, in-house SBM simulation, and advanced lab-scale blowing technology has transformed the offering. It’s no longer just about prototyping; it’s about delivering actionable insight, fast. This approach aims to provide manufacturers with confidence in their preform and bottle design and process before committing to fullscale production. Whether working with internal designs or those provided by the client, the BMT process is designed to optimise every stage of development - from virtual validation to physical formation, from prototype to production. By integrating virtual validation with physical testing, companies can streamline development, reduce costs, minimise material waste, and accelerate innovation. www.bmt-ni.com"},{"@ID":12
"EDITOUR PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 10 From plastic motor lubricant bottles to beverages and food PET packaging and caps from Alexandria by Kay Barton Alexandria Company for Industrial Packaging, or ACIP for short, has its plant around an hour south-west of the port city of Alexandria in the industrial area of Borg El Arab El Gedidah City. It is part of the ABCO Group of companies, which also includes the divisions ABCO United for Plastics and Chemicals (ABCO), active in the production of PP and PE containers, and the Alexandria Detergents and Chemicals Company (ADCO), active in the filling of household cleaners, personal and car care products. With ACIP, founded in 2002, PET processing entered the group as a new business segment and produces preforms and bottles for the beverage, food and non-food industries, as well as closures for these sectors, but with a focus on markets outside of standard caps for water and CSD applications. We interviewed Chairman Samy Awad, whose father founded and developed the company. Interview with Alexandria Company for Industrial Packages September 11, 2024 We met: Mr Samy Awad, Chairman Samy Awad has been on board the family business since 1999 and has a bachelor’s degree in economics and minor in business administration from the American University in Cairo (AUC). In the ‘newer part’ of the company, as he told us, we sat together in the meeting room, which also functions as a showroom for the ABCO product range and talked to each other. This is how the company’s success story began in 1970, when father Mahmoud Awad, who has a Bachelor in Engineering degree, founded ABCO as a pure trading company and as a local representative for European machines and accessories. In 1979, he began producing plastic containers himself for the first time as ABCO Plastics. His first project was a PE bottle for motor lubricants - the first ever in Egypt. The idea for this arose from previous work with the lubricant manufacturer Esso (now ExxonMobil), which at the time, like all its competitors, packaged engine lubricants exclusively in tin cans. “My father had the idea of producing the first lubricant bottle made of PE, a real game changer for the industry,” said Samy Awad, explaining the start of the company. The company was able to expand when it moved to the current industrial estate in 1990. Today, ABCO claims to be the largest blow-moulder for PP and PE in Egypt and was the first company in this sector to be certified according to ISO 9002 (QMS) back in the 1990s and received a UN certificate for the transport of dangerous goods for some of its products. Also in the 1990s, the company began to diversify into new areas and gradually moved into the food and beverage sector. “With the founding of ACIP in 2002, we first set our sights on PET processing, an up-and-coming market sector that we were very interested in,” explained Mr Awad. In 2003, ADCO was added as a division for filling household, personal care and car care products. The 9,000m2 plant is ideally located directly in the building next door, which makes the logistical effort between packaging production and filling obsolete. A number of brands, the company’s own brands and also Private Label OEM brands filled to order, totalling over 400 SKUs, come from here, including packaging, closures and contents. The company supplies more than 40,000 customers nationally and internationally, we learned. In 2013, together with Husky, ACIP designed and built a new 12,000m 2 factory for preform moulding, bottle blowing, IML and cap production, including all-electric machinery - the building where we met for the interview. Mr Awad showed some of his products on the table. 28mm, 38mm, 30/25, 29/25, 28/400, as well as dropless neck preforms for beverage, edible oil, detergent and personal care applications are also in the CEO Samy Awad with some of the ACIP products Various PET bottle formats from the Sidel SBO 6 EDITOUR"},{"@ID":14
"EDITOUR PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 12 four Arburg all-electric and hydraulic machines in use for closures. The entire material distribution in production is centralised using Piovan equipment. There are currently 250 employees working in 3 shifts at the plant. Around 20% of production is exported to African countries and the Middle East - ideally, the company CEO would like this figure to rise to 40%, as he reveals. The company’s annual growth averages 10%, with above-average growth of 25% in 2024. 10% of turnover is continuously reinvested. The company is in direct competition with the leading preform, bottle, cap and IML suppliers in Egypt. A relatively new line of business was added to ACIP in 2022, which is probably due in no small part to the experience gained in planning, installation and implementation. “The sector is still marginal, but we have a small but growing engineering portfolio for the supply of custom-made machines and equipment to be used as stand alone or in-line on the customers’ filling and capping lines,” said Mr Awad, showing some pictures of ACIP equipment that the company has developed. “The initial target group here is small and medium-sized bottlers and filling companies. However, we have been successful in supplying patentpending systems to large multinationals. In close consultation with customers, we can advise on everything from planning and process design in the respective plant to the set-up and control of the components and offer turnkey solutions. If customised solutions are required, we can also plan and build machines to customer specifications. Already, we are pleased to have been recognised by Germany’s Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) and the Egyptian government for our Industrial Innovation in this area. “The future lies in sustainability,” said Samy Awad. “This naturally includes environmental aspects, such as material and CO2 reduction, but also more far-reaching, holistic approaches, such as the fundamental corporate responsibility towards employees and society. In addition to our ISO9001:2015, ISO14001:2015 and ISO45001:2018 certifications, we have also obtained FSSC22000 Ver. 5 and Sedex certification. We have also undergone an audit by a reputable inspection agency, which found us to be in full compliance with the audit scope. This audit covered ABCO’s compliance with local laws and regulations, child labour, discrimination, freedom of association and collective bargaining, health and safety and the environment. In a CDP score report that we commissioned in 2023, we received a ‘B’ score, which is the highest score in Egypt and also above the global and African average of the plastics Industry. ACIP also has a Bronze medal from Ecovadis. We will continue to work on this.” He went on to explain: “We never take the customer for granted, we will offer the best service we can, but there’s always room for improvement.” This philosophy is very tangible at the meeting. There should be a constant process of optimisation that affects all areas of the company which can never be completed entirely, according to Mr Awad. One of these areas that ACIP is currently planning for the near future is the further reduction of CO2 emissions by installing solar panels on the company’s roof, which will generate 20% of its own electricity requirements. www.acipegypt.com www.abcogrp.com At the Editourmobil with Samy Awad (left) and Kay Barton Everything from a single source: Mr Awad with a selection of products from his ABCO Group"},{"@ID":38
"MATERIALS / RECYCLING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 36 MATERIALS / RECYCLING 36 Filtration effi ciency in PET recycling thanks to automated inline cleaning Simplified handling, economic efficiency Large-area filtration faces the stigma of high costs, maintenance efforts, and time-consuming changeover and cleaning activities. However, good filtration is unavoidable with increasing rPET proportions. BB Engineering has addressed these issues with its experience in extrusion and filtration. The new Cobra filter is claimed to combine continuous and automated large-area filtration with integrated intermediate filter cleaning – meeting the demanding requirements of recycling processes. Recyclers are facing a dilemma when it comes to filtration: increasing recycling quotas require handling lower-quality inputs with more challenging contaminants, while also targeting higher-quality applications that demand fine filtration. Some systems handle large contaminants but do not filter as finely as a candle filter, while candle filters provide excellent filtration but can struggle with high contamination levels. BB Engineering claims that its new Cobra filter can do both. It was specially developed for demanding filtration tasks with high levels of contamination, particularly in PET recycling. Cobra unites large-area fine filtration with simultaneous, fast and effortless cleaning, and is therefore able to handle higher contamination rates, which common candle filters would fail on, says BB Engineering. It can also be used for other applications, e.g. in synthetic fibre spinning. Rendering of BB Engineering’s new Cobra filter"},{"@ID":48
"PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 13 EDITOUR The first rPET bottle from Qatar: Visit to Polytech by Alexander Büchler Polytech is a classic converter for water preforms and caps. 50% of production goes to the sister company Rayyan Water. This makes Polytech half an in-house producer. We spoke to Plant Manager Nallasivam Singaraj. Interview with Polytech Plastic Industries // September 19, 2024 We met: Nallasivam Singaraj, Plant Manager The company began life in 2017 with the factory equipped with a Husky HyPET 400t system with 96-cavity moulds and a Husky HyCAP225 complete system with Husky 48-cavity closure mould and downstream IMD inspection equipment. In the wake of the embargo imposed by other Gulf states, Polytech doubled its capacity in 2019 by adding a further Husky HyPET system and a Husky HyCAP system. Capacities now stand at 1 million preforms and 1.4 million caps. Polytech also blows 5-gallon PC water containers. The standard sizes for water are 200ml, 330ml, 500ml and 1.5l. The caps for the bottles fit on 29/25 or 30/25 necks. Nallasivam Singaraj is and always has been a technician through and through. When he started at Polytech in Doha in 2017, he was also assigned to the sales division. As a technician, this was a new experience. But he clearly liked it, otherwise he would no longer be running Sales today. He looks after around 10 to 11 customers. Many of them are located within a radius of 5km. However, the company also exports to Kuwait, the UAE and India. Half of its production goes to the water bottler Rayyan. Like Polytech, Rayyan belongs to Al Rabban Holding in Qatar. The second major customer is CocaCola. He makes no secret of the fact that he worked for Coca-Cola for many years. Singaraj is therefore familiar with the internal processes there and can provide his customers with a comprehensive range of preforms and caps for water bottles. Singaraj enters into 3-month contracts with many customers. Therefore, he can take possible fluctuations in material prices into account. However, there are also always short-term contracts. With water preforms in particular, he must ensure that the acetaldehyde (AA) content does not exceed the required value. He usually uses scavengers for short-term contracts. For long-term contracts where the purchase quantities are agreed well in advance, he produces the preforms in advance and stores them for four weeks. So the AA limit also fits. To ensure that fluctuations in temperature and humidity do not affect the preforms over the four weeks, not only the production area but also the warehouses are air-conditioned. In general, the factory makes an exceptionally well-kept impression. Every last corner is clean and tidy, all the boxes are neatly positioned on the pallets and the reusable mesh boxes for preform transport look as good as new. The production area is cleaner than many a kitchen. The factory’s CocaCola past is clear to see. And who would have thought it? Here we found the first 100% rPET water bottle on our round trip! To mark the 2022 FIFA World Cup, Rayyan launched a light blue 500ml bottle (13.5g) with a 30/25 neck finish. It is still available for certain target groups, but generally consumers prefer material made from virgin material. www.polytech.qa EDITOUR Polytech has two lorries to serve the nearby customers. Mr Nallasivam Singaraj, Alexander Büchler and Vivek Chaturvedi, Quality Manager at Polytech (from left to right) took a look at one of them from the inside. The plant has a total of six bays for injection moulding machines, four of which are occupied."},{"@ID":45
"PATENTS PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 43 Beverage container Europ. Patent No. EP 3927625 B1 Applicant: PepsiCo. Inc., Purchase (US) Application date: 19.2.2020 The patent grant describes a thinwalled PET bottle that is sufficiently stable thanks to a waist and various circumferential reinforcing grooves, despite material savings. Reusable plastic containers Intern. Patent No. WO 2023 / 066830 A1 Applicant: Alpla Werke Alwin Lehner GmbH & Co KG, Hard (AT) Application date: 17.10.2022 A reusable plastic container is provided with special structures. These structures give the container stability - with reduced material usage. 90% of these structures can be seen through the container opening - so the cleanliness in this area can be checked after cleaning. Bottle made entirely of PET Intern. Patent No. WO 2024 / 223261 A1 Applicant: Krones AG, Neutraubling (DE) Application date: 4.4.2024 Bottle with cap and label - all made of PET. The use of PET for the entire bottle simplifies recycling. The label has already been printed or labelled in advance using a laser and therefore allows a higher filling or packaging speed. PET cap Intern. Patent No. WO 2024 / 200401 A1 Applicant: Alpla Werke Alwin Lehner GmbH & Co KG, Hard (AT) Application date: 26.3.2024 The structure and process for manufacturing a PET cap are registered internationally. Double-walled container Intern. Patent No. WO 2024 / 203826 A1 Applicant: Kyoraku Co. Ltd, Kyoto (JP) Application date: 22.3.2024 Double-walled container made from two preforms, in which the inner container can be easily removed from the outer container after product removal. Base attachment for lightweight bottle Intern. Patent No. WO 2023 / 101869 A1 Applicant: PepsiCo. Inc., Purchase (US) Application date: 22.11.2022 A bottle for aseptic filling is designed to be so light that it has an additional, flexible base attachment. This makes the bottle easier to handle overall. PETpatents"},{"@ID":20
"Photo: PREFORM PRODUCTION 18 PETplanet Insider Vol. 26 No. 04/25 www.petpla.net Huayan Ecosys250 and Ecosys280 target large and heavy PET bottle markets High cavitation, low energy by Ruari McCallion Chinese company Guangzhou Huayan Precision Machinery Co Ltd (Huayan) is headquartered in Guangzhou, the capital city of Guangdong province, located to the north-west of Hong Kong. It was certified as a high-tech enterprise by the government of the People’s Republic of China in 2008 and moved to its current principal production facility in 2012. It specialises in the manufacture of PET and PP preform injection systems for applications in the food and beverage, edible oil, pharmaceutical and cosmetics sectors. Its range of products include six to 176 cavity preform injection moulds and a number of injection moulding systems, under the EONE, EPioneer, Ecosys and HY-D names. Huayan’s Ecosys250 and Ecosys 280 machines are designed for the production of PET bottles for the Heavy Office and Domestic (HOD) bottle markets, with typical capacities of five gallons per 9 l. Previously a sector dominated by PC (polycarbonate), it is one where PET has made significant inroads in recent years. The 250 and 280 machines, which were originally launched in 2017, are upgrades of previous models. Huayan says that its machines offer users short cycle times, low energy consumption and high cavitation. Key to its competitive performance is a novel design of its flip-over clamping structure, which, the company says, significantly increases maximum allowable mould thickness. Clamping and ejection is also claimed to be greatly improved, compared with previous designs. The Ecosys250 and 280 models integrate a three-position cooling robot, two-stage injection unit, a servo-electric plasticisation system and a servoelectric hydraulic power system, which synchronise the injection and plasticisation systems. The inclusion of a secondary injection unit shortens cycle time and notably increases shot weight, which altogether contribute to efficient, automated production of extra-heavy preforms, the company asserts. Efficient design, lower energy consumption The machines have a compact design and footprint. Its new, flip-over clamping structure, specially designed for big stroke mould opening, significantly extends the clamping and ejection stroke, within compact overall dimensions, and also raises maximum mould thickness. The secondary injection unit both shortens cycle time and, at the same time, improves shot weight, delivering automatic and efficient production of extra-heavy HOD preforms of up to 750 g and a length of up to 423 mm. Upgraded servo-electric drives reduce energy consumption, effectively to zero during no-load periods, and rather better than conventional asynchronous motors and hydraulic drives. The machine is claimed to run more steadily and with lower running noise. The screw head rotation speed is automatically controlled, according to shot weight. Stable temperatures, fast cycle time The integrated, air-cooled removable robot is equipped with its own air blowing station, which is claimed to ensure rapid cooling of the preforms to below 45 degrees. This approach aims for a more stable preform quality and blow moulding, as well as higher dimensional consistency. The robot’s patented servo motor and gearbox are designed to ensure secure preform loading and removal. The system has a cycle time of 36s and can achieve an output of 800 preforms per hour, in eight cavity format. It is managed by a Siemens PC System. The HMI (human-machine interface) features an integrated touch screen and manual buttons and a dedicated remote diagnosis function, which helps customers discover, identify, diagnose and solve problems quickly and thus saves machine down time and maintenance costs. The main markets for Huayan’s Ecosys 250 and Ecosys 280 HOD machines are in South-East Asia, Middle East, Africa and Turkey. A total of 32 machines have been installed, including a new system supplied to Danone’s factory in Indonesia, earlier in 2024. Customised to Danone’s requirements, it produces five gallon returnable water bottle preforms. www.huayanpet.com"},{"@ID":54
"7 NEWS PETplanet Insider Vol. 26 No. 04/25 Republic Services, Blue Polymers celebrate opening of Indianapolis plastics recycling complex Republic Services and Blue Polymers celebrated the opening of North America’s first Polymer Center and plastics recycling complex in Indianapolis on March 18. The facility, designed to process over 175 million pounds of recycled plastics annually, will produce materials for food-grade packaging and other uses. Republic Services operates the Polymer Center, while Blue Polymers handles the compounding and pelletising of plastics. The Polymer Center will process recycled plastics collected from homes and businesses in Indiana and nearby states, including PET (water and soda bottles), HDPE (milk jugs or detergent bottles) and PP (to-go cups or margarine tubs). Republic Services and Blue Polymers are developing a network of plastics recycling facilities for nationwide coverage. A Republic Services Polymer Center opened in late 2023 in Las Vegas, and a second Blue Polymers facility is scheduled to open later this year in Buckeye, Arizona. Another Polymer Center-Blue Polymers complex is in development in the Northeastern U.S. The Indianapolis site spans ca. 28,000m2 (300,000 square feet) and will create 125 local jobs. The project received support through a grant from the Indiana Department of Environmental Management’s Central Indiana Waste Diversion Pilot Project; tax credits from the City of Indianapolis in conjunction with Develop Indy, the Indianapolis Department of Metropolitan Development and Employ Indy; Indiana Economic Development Corp. (IEDC) incentive-based tax credits, based on the company’s investment and job creation plans; and IEDC Hoosier Business Investment tax credits, designed to help companies invest in smart manufacturing and new technologies. www.republicservices.com CREATING FUTURE STANDARDS Japan’s leading Aseptic PET Filling System Provider. Our website Our solution high quality reliable technology safe & secure Republic Services CEO Jon Vander Ark, Indiana Gov. Mike Braun and other leaders and officials cut a ribbon to officially open the Indianapolis Polymer Center-Blue Polymers plastics recycling complex on March 18, 2025."},{"@ID":6
"PETcontents 4 PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 04/2025 EDITOUR 10 PET packaging and caps from Alexandria - From plastic motor lubricant bottles to beverages and food 13 The first rPET bottle from Qatar: Visit to Polytech 14 From preform to film BOTTLE MAKING 16 The bigger the better – and lighter - Cypet Technologies claims big savings for extra large containers PREFORM PRODUCTION 18 High cavitation, low energy - Huayan Ecosys 250 and Ecosys 280 target large and heavy PET bottle markets MOULD MAKING 20 Manufacturing blow moulds for PET bottles - Four steps, one supplier: design, manufacturing, sampling & testing 22 Why speed alone isn’t enough - Smart prototyping: De-risking bottle design with data-driven insights 24 High production level - Xform featuring 200-cavity preform mould by Sipa 29 The most sustainable label? No label at all - Label-free bottles for improved sustainability 30 Precision cap mould manufacturing 31 Precision moulding for complex shapes - FlexBlow advances mould technology with Extreme Venting solution 32 Client-centric approach - Advanced blow mould solutions 34 100% rPET lightweight bottle base for still products MARKET SURVEY 25 Suppliers of cap systems & cap moulds MATERIALS / RECYCLING 36 Simplified handling, economic efficiency - Filtration efficiency in PET recycling thanks to automated inline cleaning 38 Agglomeration, desiccation, crystallisation - Complex intermediate steps can be avoided with Plastcompactors from Herbold Meckesheim OUTER PLANET 50 Reducing heating bills and plastic waste alike - New environmentally-friendly mortar comes with recycled PET BUYER’S GUIDE 44 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 39 Products 40 PET bottles for beverage + liquid food 43 Patents MOULD MAKING Page 22 Page 29 Page 13 EDITOUR"},{"@ID":1
"No.04 2025 www.petpla.net D 51178; ISSN: 1438-9452 PETplanet is read in 159 countries Suppliers of cap systems & cap moulds MARKETsurvey 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 14 . 04 . 25 MOULD MAKING EDITOUR Page 10 Page 25 Page 20"},{"@ID":26
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 24 Xform featuring 200-cavity preform mould by Sipa High production level The first Sipa 200-cavity preform mould in Asia is now in operation at Sappe, a major Thai beverage manufacturer. F.l.t.r.: Siwapong Muendetch, Technical Operation Manager SEA, Ponlawit Lamprasert, Senior Plastic Supervisor, Suvidhean Dhirakaosal, Vice President - Performance Optimisation, Romeo Grava, Sales & LCS Manager SEA & Oceania, Weera Eiamrattanawong, Sipa Thai Branch Director, Payao Nuson, Section Manager - Plastic and Powder Maintenance and Ubontip Raveetip, Project Manager SEA. Sappe: innovative beverages Sappe PCL, a renowned leader in functional drinks in Thailand, has been driving the beverage industry with its commitment to “better people’s lives through our innovative spirit.” The company’s dedication to innovation is reflected in its products and corporate culture, evident in popular brands such as Mogu Mogu, Sappe Aloe Vera, and capacity, this mould retains the same external dimensions, allowing it to be seamlessly integrated into an Xform 500 GEN4 injection moulding machine. This 200-cavity mould enables the production of over 140,000 preforms per hour. This production level is intended for large packaging companies. Sipa says that a very high output system results in lower enegry consumption per preform produced, improved labour efficiency and optimised space utilisation. One preform production system with a 200-cavity mould can supply two bottle production- and filling lines operating at 81,000bph. Sipa designed the 200-cavity mould according to the same principles as its well-known 180-cavity mould. The company’s GEN4 hot runner concept offers good balance, extended maintenance intervals and easy access for necessary interventions, according to Sipa. Sipa’s Preform Tooling Manager emphasises the company’s ability to create wellbalanced hot runner systems that transcend geometrical limitations. Sappe’s success Sappes’ successful implementation of Sipa’s 200-cavity mould demonstrates the role of advanced technology and collaboration in beverage packaging. This achievement aims to pave the way for a more sustainable and efficient future, benefiting both producers and consumers alike. www.sipasolutions.com www.sappe.com All Coco. With a presence in over 100 countries, Sappe is determined to establish itself as a global brand. Sipa’s largest preform mould Sipa has developed a mould with 200 cavities for preforms with necks up to 28mm, ideal for mineral water and beverage bottles. Despite its massive MOULD MAKING"},{"@ID":24
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 22 Smart prototyping: De-risking bottle design with data-driven insights Why speed alone isn’t enough In the world of fast-moving consumer goods (FMCG), brands and converters operate under immense pressure to launch new packaging quickly. Rapid prototyping has become an industry norm, yet simply producing a bottle faster is no longer enough. Advances in virtual simulation, 3D-printed moulds, and lab-scale testing are reshaping how bottle designs are refined and optimised, ensuring better performance and reducing risks before mass production begins. BMT’s method of a data-driven approach to bottle development combines virtual simulation, 3D printed moulds, and lab-scale stretch blow moulding. Their methodology - measure, digitise, execute - focuses on gathering insights rather than relying solely on iterative testing. By capturing critical information about material behaviour, blowing dynamics, and final bottle performance, the design process can be refined, reducing lead times and mitigating risks associated with production. Engineering confidence before production begins At the core of this approach is BMT’s proprietary SBM simulation, which uses advanced material models to virtually assess the preform to bottle design before any physical prototype is made. This allows engineers to predict bottle formation, identify areas for optimisation, and verify performance virtually - long before production tooling is considered. By making smarter decisions at this stage, costly modifications down the line can be avoided. Advanced testing capabilities Using Blowscan, BMT’s lab-scale SBM machine, small batches of bottles are produced under controlled conditions. Integrated with Thermoscan technology, the full temperature profile of the preform is captured. Simultaneously, pressure data and material distribution are tracked in real time, providing a detailed picture of exactly how the bottle is formed. This level of analysis provides engineers with precise information to optimise preform geometry, material selection, and processing parameters for efficient scale-up. 3D-printed mould tools Traditionally, creating prototype bottles required expensive metal mould tools and access to an industrial SBM machine, adding time and cost to the development process. By 3D printing the mould tool, BMT reduces the time from concept to prototype from weeks to days. The tooling is designed to work seamlessly with Blowscan, so engineers can test and iterate designs rapidly, all while generating performance data that informs final production decisions. Performance validation To assess the viability of 3D printed mould technology, BMT conducted a comparative study, forming two sets of bottles using the same blowing recipe – one from a 3D printed mould, the other from a traditional metal tool. The results confirmed equivalency across all critical parameters. Geometrically, both botMOULD MAKING MON TUE WED THU FRI BMT OUTPUTS Physical Bottles Process Qualification Performance Qualification SIMULATION PRODUCTION Build Simulation Virtual Investigation Define Process Window Mould Design Mould Print Mould Build Process Qualification Bottle Production Physical Validation 3D PRINTING CLIENT INPUTS Preforms Bottle Design"},{"@ID":4
"9 NEWS PETplanet Insider Vol. 26 No. 04/25 www.petpla.net New leadership chapter at Sumitomo (SHI) Demag North America Sumitomo (SHI) Demag North America has announced leadership changes. Effective April 1, 2025, Liam Burns became President, bringing 36 years of industry experience, including two years as Senior Manager for Sumitomo Demag’s Northeast Regional Sales. Burns will focus on customer value, partnerships, and expanding the company’s market presence. John F. Martich III, previously Executive Vice President, took on the role of Chief Operating Officer (COO) on the same date. Martich will oversee internal operations, driving efficiency and innovation in line with the company’s global strategy, working closely with Corporate Controller Beth Belay. www.sumitomo-shi-demag.eu Sidel’s Octeville site earns EcoVadis Gold Sidel’s Octeville site has been awarded the Gold Medal by sustainability assessors, EcoVadis following a comprehensive review of its supply chain strategy at both local and corporate-group level. The company was positioned in the top five per cent of reporting companies in 2024 by EcoVadis. Sidel partnered with EcoVadis in 2017 to assess and improve its environmental, social, and ethical performance. Sidel’s latest achievement follows a comprehensive review involving more than 300 questions covering critical areas such as environmental impact, labour rights, health and safety, ethics, and responsible procurement. www.sidel.com From left to right: John F. Martich III, Liam Burns and Beth Belay Peter McLellan, Director Global HSE at Sidel"},{"@ID":39
"MATERIALS / RECYCLING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 37 Continuity and process stability thanks to automation As a continuous filter, Cobra has two filter inserts: one is always active in production mode, the other in stand-by or in intermediate cleaning mode. The automated switchover has been designed to ensure a smooth changeover between the inserts. The system automatically checks the status of the filter inserts and initiates cleaning and switchover when needed, requiring only operator confirmation. This facilitates smooth, uninterrupted operation without manual intervention or errors. Automated inline cleaning The Cobra filter features the integration of BBE’s White Filter Cleaning technology (WFC). This process is claimed to enable chemical-free and environmentally friendly intermediate cleaning of the filter inserts using hot steam alone and extends the filter’s service life many times over. BBE has already had WFC in its product portfolio as a stand-alone solution for several years. Now, for the first time, the cleaning system is integrated directly into a filter, bringing additional advantages, like cleaning speed and wear-reduction. Production and cleaning become an alternating interaction. Only after multiple operating/cleaning cycles (the exact number depends on product and degree of soiling) is it necessary to completely remove the filter insert for a service check and full cleaning. According to the company, the WFC cleaning process takes around 10 hours, whereas conventional cleaning takes several days. Filtration and cleaning form a selfcontained, automated system that is designed to ensure both process and operating safety in equal measure: The operator does not have to handle melt or chemicals. BB Engineering designed the Cobra filter to tackle rising contamination in recycling while streamlining filter changes, automating cleaning, and reducing operating costs. Comparing the Cobra with other fine filters with a throughput of 2,000 kg/h reveals savings of 40% in direct operating costs, says the company. Savings stem from reduced melt loss in backflush cycles, extended service life through steam cleaning, and lower energy use due to minimised heating and cooling. The Cobra filter is claimed to cut costs on spare parts, consumables, and chemicals while automation reduces labour expenses. Its closed, chemical-free system enhances safety by eliminating risks like injury and fire. Additionally, its efficient cleaning aims to minimise process interruptions and downstream efforts. The new filter made its public debut at the PRSE in Amsterdam in early April. www.bbeng.de .PSF UIBO KVTU 7*4*0/ */41&$5*0/"},{"@ID":29
"MARKET SURVEY 27 PETplanet Insider Vol. 26 No. 04/25 www.petpla.net Moulds for caps/closure production Company name Sacmi s.c. Plastisud Sas Postal address Telephone number Web site address Contact name Function Direct telephone number E-mail Via Selice 17/A, 40026 Imola (BO) - Italy +39 0542 60 7111 www.sacmi.com Mr Iacopo Bianconcini Marketing Manager +39 0542 60 7880 [email protected] 5 rue Joseph Jacquard, 1400 Castelanudary, France +33 4 68 23 15 57 www.plastisud.com Ms Nathalie Fabbro Sales & Marketing Coordinator +33 6 08 43 42 78 [email protected] Filling good: - beverages Water CSD and sparkling water Juice, RTD, tea, isotonic, cold filled / hot filled Still water, carboted drinks, hot fill, diary... - other Edible oil, soy sauces dairy, pharma & food and other filling goods Edible oil, CRC - individial cap solutions Possible on request Possible on request Possible on request Possible on request Yes, in mould closing Closure: -type Flat top, one/two pieces, sportcaps, flip-top Flat top, one/two pieces, sportcaps, flip-top, Flat top, one/two pieces, sportcaps, flip-top, Flat top, one/two pieces, sportcaps, flip-top, child proof 1-pces, 2-pces, 3-pces closure, tethered, with / without safety band -material HDPE HDPE, PP HDPE, PP HDPE, PP and TPE PE BD - PE HD - PP -weight From 0.8g and above From 0.8g and above From 0.8g and above From 0.8g and above 0.7 to …. g - whatever mentioned by customer Moulds: Clamping dimensions/Cavities From 12 to 64 cavities From 12 to 64 cavities From 12 to 64 cavities From 12 to 64 cavities Up to 144 cav Preferred hot runner suppliers No need of hot runner No need of hot runner No need of hot runner No need of hot runner Plastisud Special features Closure designs, including tethered solutions, validated by major brand owners, worldwide Closure designs, including tethered solutions, validated by major brand owners, worldwide Closure designs, including tethered solutions, validated by major brand owners, worldwide Closure designs, including tethered solutions, validated by major brand owners, worldwide IMDvista BOCO SCAN - Line Scan Technology Inline Bottle Inspection One system for opaque and transparent bottles No size parts needed - quick product change Reflection-free bottle inspection Endless geometries and shapes PETplanet's Market Surveys are now also available online at www.petpla.net"},{"@ID":27
"MARKET SURVEY 25 PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 04/2025 MARKETsurvey Suppliers of cap systems and cap moulds With this overview of the manufacturers of capping systems and moulds, we are concluding the topic of closures that was started in the last market overview in issue 3. We are very pleased to present the latest systems and moulds from Sacmi, Netstal, Corvaglia, Sumitomo Demag, Z-Moulds, Plastisud and GDXL. Although the publishers have made every effort to ensure that the information in this survey is up to date, no claims are made regarding completeness or accuracy. Resins & additives Cap manufacturer & cap inspection Cap systems & cap moulds Preform production & inspection Preform systems & moulds Two stage SBM machinery Filling equipment Compressors Shrinkfilm & palletising machinery Recycling machinery"},{"@ID":49
""},{"@ID":33
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 31 FlexBlow advances mould technology with Extreme Venting solution Precision moulding for complex shapes MOULD MAKING FEATURING REAL WORLD DATA BY Unparalleled accuracy from Industrial Physics Scan to access our exclusive guidebook FlexBlow provides a full in-house mould design, prototyping, and manufacturing capabilities tailored to the most demanding container geometries. Whether it’s stackable containers, lateral handles, deep grips, or heat-set jars, FlexBlow moulds are engineered to give converters more flexibility, better performance, and lower production costs. The new development Extreme Vent technology is a proprietary venting solution developed to solve one pressing challenge in stretch blow moulding: trapped air and uneven material distribution in sharp-edged or complex PET designs. Traditional mould venting has its limits, especially when forming tight angles or shoulder zones. Air pockets can form during the blowing process, resulting in weak spots, cosmetic flaws, or the need to overcompensate with heavier preforms or higher pressure. The new Extreme Venting system uses electro-discharge machining (EDM) to create precise venting channels in critical areas of the mould. This allows trapped air to escape more efficiently during the moulding process, ensuring an even material flow and reducing the risk of defects. As a result, manufacturers benefit from better part integrity, less material stress, and a reduction in blowing pressure by up to 25%. This technology is claimed to allow for the creation of sharp, detailed shapes with improved surface quality, while minimising the need for excess material or energy. Sharp-shouldered PET jar for cosmetics A recent application of this technology was seen in the development of a 500ml PET jar for the cosmetics sector, featuring a sharply defined shoulder design. The Extreme Venting solution helped eliminate surface imperfections and achieve the intended geometry with minimal stress on the material. The sharp bottle shoulders, a distinctive visual feature of this design, were precisely formed without distortion, says Flexblow. The selected closure complemented the shoulder profile, resulting in the required clean, uninterrupted silhouette and seamless overall appearance. The final 500ml container is made from 100% PET, features a 90mm neck size, and is fully recyclable. Its material clarity, defined contours, and overall design consistency make it suitable for moisturisers, toners, lotions, and other personal care or chemical products. www.fl exblow.com FlexBlow has recently introduced a new mould technology, Extreme Venting, designed to address the challenges of stretch blow moulding, particularly with sharp-edged or complex PET container designs. Extreme Venting mould Sharply defined corners"},{"@ID":13
"EDITOUR 11 PETplanet Insider Vol. 26 portfolio, as well as various bottles, IML packaging and closures. The 29/25 water preform is the best-selling preform here. In terms of closures, the company specialises in special closures, e.g. multi-part, more complicated closure types. “We were the first manufacturers in Egypt for juice and milk packaging in PET and PE and were thus able to offer alternatives to multilayer cardboard packaging for the first time. We also produced the first Sports and milk caps. We are the main suppliers for multinational lubricating customers in Africa and the Middle East such as Shell, Total, Ola Energy, Castrol and BP, while in the PET market we have supplied customers such as PepsiCo, Nestle, Froneri, SC Johnson, Harvest, Mansour and other well-known companies”, he said. ACIP currently produces around 400 million preforms annually, which equates to approximately 85-90% capacity utilisation. 8,500 t of PET material are processed. On the closure side, around 200 million units are produced, which corresponds to 350 t of PE and 500 t of PP. For preform moulding, the company uses HyPET 225 and 300 injection moulding systems from Husky, most of which run with 48- and 72-cavity mould capacities. Bottle blow-moulding is carried out with a Sidel SBO 6. Mr Awad pointed to the SBO during the tour: “Thanks to Sidel’s Preferential Heating Technology, we can offer complex and oval bottle shapes, depending on customers’ requirements.” Smaller stretch blowing and preform systems are also in operation for shorter production runs. In the IML and cap segment, two Husky Hylectric and four Zhafir systems are working along with Ilsemann and other Automation equipment. Two further Zhafir systems for IML and cap productions are to follow soon within the next few months. There are also F.l.t.r.: Samy Awad with ACIP factory management next to one of the Husky HyPET systems"},{"@ID":7
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 20 Four steps, one supplier: design, manufacturing, sampling & testing Manufacturing blow moulds for PET bottles For half a century, Röders GmbH is manufacturing PET blow moulds, delivering high-precision solutions. With its experience the company offers solutions for a wide range of blow moulds, applications and designs. The moulds are produced for all 2-stage PET bottles for various industries all over the world. As the industry continues to evolve, packaging manufacturers face increasing demands for lightweight, sustainable, and cost-effective solutions. Röders has continuously adapted to these challenges, ensuring that their moulds meet market expectations, and exceed them with their innovations and in-house developments. The company develops customised mould solutions, optimising bottle performance and production efficiency. A seamless process Efficiency is critical in today’s fastpaced beverage industry. That’s why Röders offers a complete solution from design, manufacturing, sampling, and testing. This integrated approach is claimed to ensure short reaction and lead times and to eliminate compatibility concerns. Röders’ moulds are engineered for rotary or linear stretch blow moulding machines, eg. from KHS, Krones, Sidel, or Sipa and others. In its ISO 9001-certified bottle testing laboratory, Röders analyses every bottle to meet the high industry standards. Equipped with state-ofthe-art machinery, Röders offers a comprehensive range of tests, including: top load resistance, drop impact, carbonation retention, thermal stability, wall thickness and section weight distribution. Röders has been certified by PepsiCo for many years and more recently also authorised by Coca-Cola. If needed, customised tests are carried out to meet individual requirements. Speed and flexibility In the competitive PET packaging industry, time-to-market is everything. Thanks to Röders’ modern production and in-house high-speed machining technology, moulds can be delivered in short time. According to Röders, the mould change systems combined with specialised coatings for durability, provide added value by reducing downtime and extending mould lifespan. Röders actively supports its customers with on-site process optimisation and machine conversions for a smooth transition to new bottle designs. Whether working with standard PET or rPET, Röders helps to fine-tune blowing parameters for weight reduction (lightweighting to cut material costs), energy efficiency with low-pressure blowing, or stretch ratios for improved material distribution. This work supports customers achieving their sustainability goals and helps brands to reduce their carbon footprint. MOULD MAKING Andreas Cordes (left), Mould Engineer, and Helge Heuer (right), Technical Sales Manager, work closely together to develop a customised mould design that meets all requirements for the final application."},{"@ID":10
"8 NEWS PETplanet Insider Vol. 26 No. 04/25 www.petpla.net Engel opens new plant in Mexico Engel has opened a new production site in Querétaro, Mexico, to strengthen its presence in the Americas and enhance manufacturing capacity. The goal is to offer customers in North and South America faster delivery times and greater availability of injection moulding machines. The site allows for significant production expansion and future growth, with space for additional capacity. Engel plans to ramp up production of injection moulding machines, including the e-mac and Wintec t-win series, while also modernising the plant to meet high production standards. Mexico is an important industrial and manufacturing hub for Engel. The country is claimed to offer ideal conditions for production companies and skilled labour, making it a prime location for long-term investments. Additionally, Mexico and Latin America represent key and growing markets for injection moulding technology. www.engelglobal.com Arca Continental boosts investments to drive growth in 2025 Arca Continental announced an investment of approximately US$896 million for 2025 to expand production, boost digital tools, introduce new beverage categories, and enhance sustainability efforts. The investments aim to strengthen its operations and community impact. In 2024, the company achieved a strong performance, including record volume in Mexico and historic margins in the U.S. Consolidated volume reached 2,466 million unit cases, with net sales growing by 10.9% to US$11.79 billion. Net income rose by 11.8%, totalling US$973.26 million. Arca Continental also made significant progress in sustainability, becoming the first Mexico-based company in the Dow Jones Sustainability World Index and being included in the S&P Global Sustainability Yearbook for the third consecutive year. www.arcacontal.com New Global Sales Director at Erema The Austrian specialist in plastics recycling systems and components, Erema, has appointed a long- t ime employee as Global Sales Director: Christoph Wöss, previously Business Development Manager for the Bottle division, took over the newly created position within the Erema management team on April 1, 2025. Christoph Wöss has been part of the Erema Group for 24 years and possesses in-depth market knowledge. With his extensive experience, he is well-versed in the international markets and the specific requirements of the plastic recycling industry. In his new role, he will manage the company’s global sales activities and drive the company’s strategic development in the global market. In this context, Christoph Wöss will lead the international sales team and work closely with Erema’s global subsidiaries to strengthen the company’s market presence. www.erema.com | www.agrintl.com | +1.724.482.2163 Featuring AutoJob® 6LPSOLȴHG DQG DXWRPDWHG MRE VHWXS LQ VHFRQGV 3DUWQHU ZLWK $JU WR DFKLHYH VLPSOLȴHG GLPHQVLRQDO PHDVXUHPHQW IRU \\RXU SODVWLF FRQWDLQHUV DQG SUHIRUPV Prepare for tomorrow... HQKDQFH HɝFLHQF\\ WRGD\\ F.l.t.r.: Kalojan Iliev, Managing Director at OOO Erema and Christoph Wöss, new Global Sales Director at Erema, at the PRS Europe in Amsterdam, NL"},{"@ID":51
"MOULD MAKING PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 35 MOULD MAKING 35 sures. This bottle base can also be blown at lower pressure, only requiring 16 bars - a reduction of up to 20% on standard air blowing operations, translating to a further saving of 51t/a of CO² equivalent. The bottle base is also compatible with a wide range of weights, including very lightweight bottles as low as 7g for 500ml format. Versatility with StarLite-R Still Sidel’s StarLite-R bottle base is claimed to provide manufacturers with increased versatility as it is compatible with round, square-round and rectangular shaped bottles as well as suitable for single or multi-serve sizes from 0.25l up to 2.5l. It can be used with transparent or white PET. It supports single-serve production rates of up to 2,700bph per machine and multi-serve rates of up to 2,400bph per machine. The StarLite-R Still can be used with virgin PET as well as rPET and be produced utilising Sidel’s EvoBlow, Universal, and Series 2 blow moulders. Expanding StarLite-R range The streamlined bottle base is the latest addition to Sidel’s StarLite-R range, joining the ranks of advanced designs like the StarLite-R for carbonated soft drinks (CSD), StarLite-R Nitro and StarLite-R Premium. The original StarLite-R for CSD, was Sidel’s first solution dedicated to rPET, offering enhanced protection against deformation, improved stability, and increased resistance to bursting. In 2024, Sidel released the StarLite-R Nitro, a high-resistance bottle base specifically engineered for still nitrogen-dosed products in 100% rPET bottles and the StarLite-R Premium, a sleek, high-performance bottle base for distinctive, 100 % rPET bottles. www.sidel.com E N D L E S S I N N O V A T I O N S I N C E 1 9 1 9"},{"@ID":28
"MARKET SURVEY 26 PETplanet Insider Vol. 26 No. 04/25 www.petpla.net Moulds for caps/closure production Caps Systems Company name Sumitomo (SHI) Demag Plastics Machinery GmbH Netstal Maschinen AG Sacmi s.c. Postal address Telephone number Web site address Contact name Function Direct telephone number E-mail Altdorferstrasse 15 90571 Schwaig, Germany +49 91150610 www.sumitomo-shi-demag.eu Mr Arnaud Nomblot Director - Bus. Dev.-Packaging +49 911 5061 625 [email protected] Tschachenstrasse 1, 8752 Näfels, Switzerland +41(0)55 618 6111 www.netstal.com Mr Pascal Müller Product Manager CAP +41 55 618 61 92 [email protected] Via Selice 17/A, 40026 Imola (BO), Italy +39 0542 60 7111 www.sacmi.com Mr Iacopo Bianconcini Marketing Manager +39 0542 60 7880 [email protected] Systems for cap/ closure production CAP-Line (based on Elion and Elios platform depending on clamping force) Model intElect / PAC-E / El-Exis SP Elion series, Elios series CCM24SD CCM24SF CCM32MC CCM48SD CCM64MD Procession technology Injection moulding Injection moulding Compression Compression Compression Compression Compression Clamp force 100 - 10,000kN 2,200 - 6,500kN Not applicable Not applicable Not applicable Not applicable Not applicable Cycle time (guaranteed 98% closure system efficiency for): 26/22mm - up to 2,800 caps/ min < 2 sec - High speed production: closure type/weight/cavities: caps/min 29/25mm - up to 2,300 caps/ min 26mm (GME 30.39); 0.75g; 128 cav.; 4,042 caps/min 28mm CSD / 2g / 24 cavities: 600 caps/min 26mm water 0.9g / 24 cavities: 1,000 caps/min 28mm CSD / 2g / 32 cavities: 980 caps/min 26mm water / 0.9g / 48 cavities: 2,000 caps/min 26/22 CSD / 1.6g 64 cavities: 2,850 caps/min - Individual cap solution: closure type/weight/cavities: caps/min PCO1881 - up to 1,800 caps/ min GME30.40 - up to 1,800 caps/min Flip Top; 8.12g; 48+48; 524 caps/ min (IMC) 38mm CAF/ 2.6g / 24 cavities: 600 caps/min 29mm water/ 1.2g / 48 cavities: 2,000 caps/min 38mm CAF/ 2.6g / 64 cavities: 2,400 caps/min Drive concept All-Electric / Hybrid Electric and hybrid Electric / hydraulic Electric / hydraulic Electric / hydraulic Electric / hydraulic Electric / hydraulic Energy consumption (kwh/kg) 0.30 - 0.40kWh/kg, varying upon application Product specific, as low as 0.37kWh/kg ±10% Product specific, equal or more than 0.35kwh/h Product specific, equal or more than 0.35kwh/h Product specific, equal or more than 0.35kwh/h Product specific, equal or more than 0.35kwh/h Product specific, equal or more than 0.35kwh/h Preferred mould makers Customer & project specific selection for best performance fit Sacmi Sacmi Sacmi Sacmi Sacmi Special features Spindle-free high-speed toggle lever clamp, adaptive system pressure reduction (ASPR), responsive filling control (RFC), Axos 9 controller, Smart Operation, eService, Netstal Remote Control (NRC) Technical & technological complete service for moulds, machines and closures; moulds, machines and technological knowledge, providing complete solutions for closures manufacturing Company name Z-Moulds - z-moulds GmbH Corvaglia Mould AG GDXL Precise Machinery Co., Ltd. Postal address Telephone number Web site address Contact name Function Direct telephone number E-mail Dr.-Walter-Zumtobel-Strasse 9, 6850 Dornbirn, Austria +43 5572 7272-0 www.z-moulds.com Mr Michael Fink CEO +43 5572 7272-610 [email protected] Hörnlistr. 14, CH-8360 Eschlikon, Switzerland +41 71 973 77 77 www.corvaglia.com Mr Albert Brunner Director Sales & Service +41 71 973 77 52 [email protected] No. 18 Changjiang Road, Guicheng, Nanhai, Foshan city, Guangdong Province, China. Postcode: 528251 +86 757 8677 7168 www.gdxl.com Mr Billy Ay Marketing Specialist +86 757 8677 7168 ext 8681 [email protected] Filling good: - beverages Carbonated and non-carbonated drinks, water, juices, beer, coffee & teas, dairy, etc. CSD & Carbonated Bottled Water, Still Bottled Water (pressurised & non-pressurised), Sensitive Drinks (juices, teas, flavoured waters, ...), Sports & Energy Drinks, Others (dairy, edible oil and liquid food) Closure moulds for various beverage applications including water, CSD, aseptic and hot-fill, etc. - other Edible oil, soy sauces and other filling goods possible on request. Laundry & Household products. Coffee, beer, detergents; other contents/applications are possible upon request Closure moulds for food, edible oil, cosmetics, personal care, pharmaceuticals applications and other industries - individial cap solutions Possible on request Individual cap solutions are possible upon request R&D service and mould fabrications for individualised single-pc or multi-pc closures; tethered closure solutions available Closure: -type All single-piece standard closure dimensions for all neck finishes, sports closures, flip-tops, pushpulls, multi-component closures… Flat top & sports closures for neck finishes from 25 to 48mm, e.g. all CETIE standard necks GME 30.21 to GME 30.43 Closure moulds for one-piece cap and two-piece cap for various neck finish standards including 26/22, 1881, 1810, 29/25, 30/25, 38mm, etc.; tethered closure solutions available -material HDPE, LDPE, PP, TPE, … HDPE (PP for transparent parts) HDPE -weight Lowest from approx. 0.7g Starting from 0.7g Closure moulds for: 26/22 CSD tethered: 1.77g; 1881 Aseptic / hot-fill: 2.15g; 1881 CSD: 2.35g; 48mm neck water: 4.2g; 38mm neck water: 2.8g; 30/25 neck: 1.65 - 1.85g; 29/25 neck: 1.2g Moulds: Clamping dimensions/Cavities 16 to 144 cavities 24 - 96 cavities From 12 to 72 cavities Preferred hot runner suppliers MHT, Mold Masters and others various GDXL ( suppling hot runner as well) Special features Several patented technologies for most efficient closure production, with lowest downtimes and spare parts usage. Closure design approvals from all major beverage brand owners. Most economical closure designs for private labels. Tethered cap solutions for carbonated and non-carbonated drinks according to requirements of EU Directive 2019/904"},{"@ID":21
"PREFORM PRODUCTION PETplanet Insider Vol. 26 No. 04/25 www.petpla.net 19 PREFORM PRODUCTION 19 \" \"ĸrĸ ĸ ň (b- -7ࢼ 7;Ѳ -ouoĶ Ɛ ň ƐƎƍƏƔ (boubo (;m;|o Ŏ$(ŏ ň |-Ѳ ň $;Ѳĸ ƱƐƔ ƍƑƐѴ ƔƎƎƒƎƎ ň vbr-Şorr-vĸ1ol ň ĸvbr-ĸb| SIPA’sXFORMGEN4XP ru;=oulňloѲ7bm] |;1_moѲo] 7;Ѳb;uv |_; lowestconversion 1ov| -Ѳom] b|_ unmatched ;m;u] ;L1b;m1 -m7 ease of useĸ | umv b|_ loѲ7v =uol Ə |o Əƍƍ 1-bࢼ;v -v ;ѲѲ -v legacy tooling. $_; b7; HMI b|_ v;Ѳ=ňv;࣌m] ruo1;vv v;|ňr -m7 |uo0Ѳ;v_ooࢼm] ||oub-Ѳv 0ubm]v -m ;@ou|Ѳ;vv v;u ;r;ub;m1;ĸ *\r ! bv built to last ث |_bv l-1_bm; _-v 0;;m ;m]bm;;u;7 |o 1om; |_; _b]_;v| rѲ-oul uo0v|m;vv -Ѳom] b|_ less than1%of total investment om maintenancecostsĶ l-hbm] bu]bm PETandrPET ru;=oul l-m=-1|ubm] |_; 0;v| ;r;ub;m1; ;;uĸ <200 Wh/kg energy 1omvlrঞom 100% rPET pellets 1-r-0bѴbঞ;v 1 million cold half cycles guaranteed 100% 1olr-ঞ0bѴb| with legacy tooling <1% maintenance cost of total investment : an extraordinary preforming experience"}]}}
