PETpla.net Insider 10 / 2020

PREFORM PRODUCTION PETplanet Insider Vol. 21 No. 10/20 www.petpla.net 20 Sipa’s Xtreme up and running with customers Revolution, not evolution by Alexander Büchler Sipa introduce the injection compression process for preforms. Still in its secretive housing and with a limited view of the technology. Now, we have been allowed to put our heads in the machine in Italy and check out every screw. Interview with Mr Gianfranco Zoppas, Chairman PETplanet: Hello Mr Zoppas. We are standing here in front of an opera- tional Xtreme. You have been coaxing this project along for six years. Finally the machines are with satisfied cus- tomers. How does that feel? Mr Zoppas: In these difficult times, it is great to see that our ideas really work. This is not one of those typical technical evolutions where we are making progress in the region of 1/10 of a gram. It is a revolution where we have completely reinvented the entire preform production. PETplanet: Revolution sounds a little bit extravagant. Mr Zoppas: Revolution is not just about technology; revolution is expensive but the result is what counts and I am very proud of what we have achieved. PETplanet: With the concept of the integrated Xtreme system from recycling through to the filled bottle, the so called Xtreme Renew Sincro Cube, the inefficiencies of the indi- vidual components add together so that overall efficiency would have to suffer. Mr Zoppas: We heard the same argument when we started around twenty years ago with integrated stretch-blow moulding systems, fill- ers, labellers and cappers. Today, it is impossible to imagine the market without these synchronised systems. Our investigations show that the technology runs in such a stable way that the overall efficiency of the entire line is above 90%, and the advan- tages of significantly lesser logistics and enormous energy savings from working with a single thermal cycle are overwhelming. PETplanet: Bottling systems are usually sold without profit and money is made on the subsequent servicing; preform systems usually contribute to company stability when sold. How have you placed the concept of the Xtreme? Mr Zoppas: At my age I think the money should flow right away but of course we tried to take other factors into account. PETplanet: Many thanks, Mr Zoppas. Interview with Antonio Narder, General Manager PETplanet: Hello Antonio. The first three Xtreme went to Japan. Two are with a flake recycling system from Erema. Why did the customer want this combination? Mr Narder: The customer is a PET recycler in Japan already pro- ducing PET flakes. He has expanded his supply chain from the process- ing of waste PET bottles to include preform production. Now, with the Xtreme Renew technology he bought, after the flakes have been decon- taminated to food grade quality and the IV raised to the required level, the melt from the extruder goes straight into the hotrunner of the Xtreme for the production of preforms. As the flakes are only plasticised once, this saves energy and reduces the material degradation. Therefore the production cost of a recycled preform with 100% rPET from flakes is greatly reduced. PETplanet: Why is there a melt pump installed between the recycling extruder and the hotrunner? Mr Narder: Because it is important that entry to the Xtreme is at equal melt pressure. In contrast to classic injection moulding, this is very low at max. 300 bar. And that is one reason why the material is not placed under great stress and the IV drop is kept to a minimum. F.l.t.r.: Alexander Büchler and Gianfranco Zoppas in front of the Xtreme Renew System The Xtreme Renew System at Sipa’s factory in Italy