PETpla.net Insider 07+08 / 2010

CAPPING / CLOSURES 29 PET planet insider Vol. 11 No. 07+08/10 www.petpla.net saved cuts CO 2 emissions by 3.01t; the same amount of PE saves 1.69 tonnes of CO2 (source: Fraunhofer / Interseroh). That North American company has reduced its CO 2 emis- sions by around 36.6t daily (or 13,357 t/a), simply by reducing the amount of raw materials it uses. That is the equivalent of a medium-sized family automobile driving 33.6 million kilo- metres (that is 3333 times around the globe) to generate this annual amount of CO 2 . Balancing weight, performance and security One of the biggest challenges for closure systems manufacturers has been achieving a balance between reduced weight and maintenance of expected performance. Building on the experience of its North American partnership, Corvaglia has developed a BTL (break then leak) design that, it says, delivers retail shelf-standard sealing performance with additional security. The system is designed so that the tamper band breaks before leakage can occur, which is an addi- tional comfort for both retailers and consumers. The Corvaglia’s CSN-26 BTL still water short-neck’ closure system was first launched by Ice River Springs Water Co. Inc. in Canada and fol- lowed by their US production, in early 2009. Attracted by this solution this trend was followed by Silver Springs Bottled Water Company in Florida US. (Fig. 4) In addressing ecological aspects, Corvaglia’s developments are always one-piece cap solutions which are moulded with a single raw material, in one production step. This reduces costs for the bottling company as well, because standard two-piece caps are produced in four production steps: impact extrusion, cutting and folding of the tamper evident band and insertion of the liner. By contrast, the one-piece cap reduces energy consumption and cuts cycle time. Efficiency and market appeal The company’s ‘still water short- neck’ closure system is now being introduced at other customers around the world. But design is not just about efficiency, it is about product differentiation as well. Packaging is about presentation but it is about convenience and functionality in the hands of the consumer, also. The plastic closure of a beverage pack- age is more than just a seal – it is an important part of the brand concept. An attractive package can have a significant impact on the decision to buy. The closure therefore plays a major part in positioning a product in the marketplace. Corvaglia’s special closure design for the Y-Water kids‘ drink, for example, provides a new product with a unique selling proposition. The neck and cap are based on the PCO Cor- vaglia closure thread design. The use of a top cap achieves a well-propor- tioned continuation of the bottle con- tour. The Vöslauer cap also helps with market positioning. The differnt look is meant to attract the attention of the consumer. As a convenience benefit Its shape makes it easy to open, (Fig. 6 and 7). The design has now been copied in other parts of the world. The company does not simply produce standard closure system designs. The system created for the North American mineral water com- pany described above was a bespoke solution, for that customer’s specific needs. It has worked with a number of major and growing companies in developing innovations that meet market needs, help to differentiate the product and assist its customers in cutting their costs and environmental footprint. Looking to the future Future developments that may soon impact the market include the introduction of bottles made from PLA (polylactic acid – a maize starch- based plastic); and a PET bottle made from 30% sugar cane and molasses- sourced monoethylene glycol compo- nents. While the biodegradability of some bioplastics is currently not at the top of the agenda, renewability cer- tainly is, because it reduces depend- ence on oil and cuts the PET indus- try’s CO 2 emissions. Corvaglia maintains that innova- tive developments are only made possible through close collaboration with its customers. Short neck threads and advanced cap geometries may offer ecological and financial benefits but the challenges involved with their implementation in high productivity cap production and filling lines – the conversion from two-component cap systems to single-component caps – is ongoing. Fig. 4 Corvaglia Short Neck / CSN-26 Fig. 6 Vöslauer cap Fig. 7 Vöslauer cap and bottle