PETpla.net Insider 10 / 2010

BOTTLING / FILLING 54 PET planet insider Vol. 11 No. 10/10 www.petpla.net 200ml bottles can be capped with a normal closure or with sportscaps. Antartic has noted the rising sales of 330ml PET packages and intends to include that size in its private-label filling range when volumes are right in its customers’ own-brands, accord- ing to Manuel Machado. “The asep- tic line will also enable us to try out new products, such as smoothies in 0.15l bottles, for example,” he said. Antartic now handles ten different PET containers, ranging from 200ml to 2l. While non-Intermarché contract bot- tling currently represents only 5% of the facility’s output, third-party orders on the aseptic lines account for 10%. The company’s original aseptic line handles 15 different products, run- ning the same one for three to twelve hours and with formats changed about three times a week. Aseptic line 2 runs 20 different products, from two to eight hours continuously. “We’re trying to run this line for a whole week with just one or two bottle sizes,” Machado said. “Weekly format change-over times for the two aseptic lines account for approximately 25%, including disinfection, sterilisation and product and format change-over routines. That’s a good figure, even comparable to the times we’re getting for the non-aseptic soft-drinks lines - but we’re trying to improve on this by means of SMED (single-minute exchange of die) steps.” Legacy and modernity combined Antartic opted for an air conveyor on its new line, rather than a blow- moulder/filler monobloc, as it is the same system it has on Line 1. The company is comfortable with the buff- ering provided by the air conveyor; it believes it makes the line more flexible. The two lines run four to six days a week in three shifts, each with two operators and one technician. As well as the new line itself, Krones also supplied an AquaAsept sterile-water treatment unit and a VarioDos hygiene centre. Antartic is able to recycle per- acetic acid from the bottle sterilisation process and to re-use it for cleaning the bottle exteriors, which reduces total chemical consumption. Fewer parts, faster handling On Line 1, Antartic can assemble two-, three-, four- and six-bottle shrink- packs, for promotional purposes, or use a Robogrip, plus appropriate gripper tools, to load the containers on sales pallets without prior shrink-wrapping. Loading on Line 2 is restricted to full pallets; it is handled by robots from the Modulpal family. In the new Line 2, Antartic uses two Variopac Pro units; its Variopac Pro FS produces four- or six-packs, which a Variopac Pro TFS assembles into 24-bottle trays as needed. The new Variopac Pro has turned out to be an important compo- nent for the company. Its original model had more handling parts, which slowed down changeovers. The new unit ena- bles everything to go faster. In addition to its Contiroll wrap- around labeller, Antartic also integrated an inline Sleevematic in the second line for bottle sleeving, with a downstream Shrinkmat. Sleeving is used for 1l, pre- mium squash (cordial) containers. The sleeves have lifelike pictures of straw- berries, bananas, lychees, apricots in lifelike pictures printed on them. “Compared to the first aseptic line, the new PET-Asept line has shorter changeover times and peracetic-acid treatment is more reliable, Machado said. The company is also focusing on operator and maintenance staff training, which it has recognised as an important element in continued performance. “We will intensify operator training on a con- tinuous basis. Our goal is efficiency.” In the new Line 2, Antartic uses two Variopac Pro machines. “We opted once again for an air con- veyor, and not a blow-moulder/filler monobloc, simply because that’s the same system we have in Line 1”, says Machado. Antartic is the only producer of juices, syrups and soft drinks in the Inter- marché Group.