PETpla.net Insider 11 / 2020

PREFORM PRODUCTION PETplanet Insider Vol. 21 No. 11/20 www.petpla.net 22 We also developed an 8-cavity mould for an ergonomic grip over the same period”. Other machines were acquired over the next few years, e.g. from Sidel and the Indian machinery builder, SAP Blowtek. Integrated Plastics also signed a partnership agreement with the well- known former boss of Sidel India, Mr Subba Bangera. Finally, from 2016 onwards, the company moved into increasingly competitive markets in terms of its production capacity by developing bigger cavities such as a 16-cavity mould for 2 l IMH bottles and the use of a rotary blower devel- oped together with South Korean machine builder, SDB. Mr Mellen went on. “We applied for several patents after 2012 but kept our marketing and public relation plans on hold until 2018 to ensure we were able to enter the market with a technology that was proven to meet customer need, as well as being environmentally-friendly. In 2018, we finally acquired B&R Industries and Sangraal, Australia who were the original developers of early integral handle patents giving us 100% control of all patents, designs and prior art globally. We then launched the tech- nology worldwide.” “Although licensing and develop- ment are Integrated Plastic’s two main business areas, in-house production currently also contributes 80% of the company’s overall turnover. Over time, the bottles came to the attention of decision-makers in Europe, Asia and the Middle East which culminated in all international patent rights being agreed in 2018. Since then, the company has held all the technology’s global patents, some of which date back to the 1990s.” The technology, process and application The exact process remains a company secret but according to Integrated Plastics, IMH preforms can be produced either on existing equip- ment with uncomplicated conversion achieved by simply changing the mould, or by purchasing a new injec- tion moulding machine for dedicated IMH production systems. “Conventional PET injection moulding machines are standard here, while compatible preform moulds can be bought from our licence partners, Classic Tools, GDXL, Husky Injection Moulding, Kisan and Sipa. A special machine developed in partnership with the South Korean firm, SDB, is now used in the blow moulding process”, said Mr Mellen. “Two-stage ISBM machines can be fitted with 1, 2, 4, 6 or 8-cavities and can produce around 4,000 1 l bph in a 4-cavity configuration using the rotary system. A 12-cavity mould is currently being developed.” The standard portfolio range includes more than 25 different bottle types for the drinks, catering and non-food industries. PET and rPET can be processed equally well within an intrinsic viscosity range of 0.76 to 0.84 decilitre/gram, including hot-fill and fast reheatable varieties. Sav- ings of up to 30% should be possible as a result of high production capac- ity compared to other processes. The fact that the handle has already been moulded during preform production should make it easier to optimise wall and handle thickness. “A 2 l IMH bottle can weigh anywhere between 69 g and 75 g, whereas the weight of the extrusion area and the subsequent handle attachment can be between 80 g and 96 g, not forgetting the gen- erally lower PET price compared to HDPE. Logistics for the converters are also made easier given IMH preforms are made centrally and can be blown either in-house or at outsourced bottle filling plants. The shape is typically based on the usual customer bottle design to minimise costs that might be incurred for any modifications made at the plant. As well as designs developed in-house, licensees can also use standard and customer bespoke bottle shapes internationally. The number of bottle designs within the IMH family is constantly expanding thanks to the efforts of everyone involved. Present and future developments In Australia, the company cur- rently has a 57% market share in the sector which, according to Mr Mellen, continues to grow steadily. “While 1 l and 2 l are the country’s most popular bottle sizes, other potential markets are on the lookout for 1.5 l to 4 l bot- tles with their own special design. Without saying too much about which companies are involved, the efforts of Managing Director Nicholas Mellen