PETpla.net Insider 07+08 / 2022

EDITOUR PETplanet Insider Vol. 23 No. 07+08/22 www.petpla.net 12 we try to do is to embrace it from outset. When we buy new equipment or start new projects, is much better to get it right from the very start of that project, rather than try and introduce it later. It’s rarely as efficient as a bolt on as it is as an integrated process.” “Our new rHDPE line has been set up from day one to mould, assemble and pack all in one stream,” said Nick Hill, Plant Manager. In February 2022, Paccor announced that the Mansfield production team are now able to offer caps with a minimum 30% rHDPE. That proportion is important; any less and the products would be subject to the Plastic Package tax, which will be levied at £200/t (EUR240/t). Paccor expects to see the minimum percentage rise in future, along with the tax on noncompliance. It is ahead of the game by, in fact, being able to offer 40% rHDPE content already, with a cast-iron guarantee of 30% minimum. At the same time, it is reducing the amount of material needed for each cap, thus achieving a double benefit. “It’s like everything when it’s first introduced, because there isn’t the availability, then it has to be set at a level that’s realistic for industry. Once the availability is there, investments then be made in in the kerbside collections and everything else,” Steve continued. “The same applies to reprocessing. There should be no issue for people to use progressively more material and the more that you have going through the system, the more there will be investment in recycling and the material quality consequently improves.” The Mansfield site is now producing around 45 million rHDPE caps a week. It has been able to get there after an extensive development programme that included the testing of various extrusion nozzle diameters and cutter holder profiles, getting the pellet size and head pressures right, to ensure the right cap, full cap or flush. “The biggest investments have been in changed part. We have invested in new nozzle diameters, in hoppers and a new central blender, to ensure that we have a constant distribution of material,” said Nick. Improved accuracy in the setup of the machinery enabled Paccor to deliver consistent forming of the caps, without any impact on filling at customers’ premises. It is estimated that the inclusion of rHDPE at these levels reduces the company’s use of virgin material by more than 1,000 t/a and will save an estimated 1,300 t of CO2 annually. Wastage has been target for several years already and they may have reached the point where the investment to drive down further would be difficult to recoup. “We think we are at about 2.5%,” said Nick. “We don’t actually have the facility to catch and put back into the process. The challenge is that, while it may be, say, a certain amount nominally is being lost, if you’re having to spend half that amount upfront, plus the monitoring and paperwork, it becomes difficult to achieve ROI in a reasonable time.” After the conversation in the boardroom, I was taken on a tour of the production floor by Nick, with a particular focus on the rHDPE lines. One thing caught my eye: different bags for packing the caps. Some of Paccor’s customers like to have their caps delivered packed as tightly as possible but some like to have them ‘air packed’. The split seemed to be about equal but it illustrated that, despite its dominant market position, Paccor is still committed to meeting customers’ own special needs. www.paccor.com Paccor’s Mansfield plant uses a range of machinery to produce closures, including this Sacmi CVS 2000. Its closures are made using either virgin or recycled PE.

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