No.11 2022 www.petpla.net D 51178; ISSN: 1438-9452 24 . 10 . 22 PETplanet is read in more than 140 countries MAGAZ I NE FOR BOT T L E R S AND BOT T L E - MAK E R S IN THE AMER ICAS, AS IA, EUROPE AND AL L AROUND THE PLANET MARKETsurvey Suppliers of recycling plants and washing units Page 23 COMPRESSORS Page 10 FILLING Page 26 Page 16
ClipAside, drink, love! Tethered ClipAside closure wins high acceptance Contact us and arrange your line trials now! www.bericap.com PET 38 PET 29/25 PCO 1881 PET 33 PET 26 PET 26 GME 30.40 A recent consumer real-life “diary study” conducted in France found a high level of acceptance among consumers for the innovative new closure. After just one or two experiences, even the youngest and oldest users could handle the smart closure without difficulty – often with one hand. What’s more, many praised the eco-friendly nature of the cap, which remains on the bottle neck and avoids creating additional plastic waste. Best of all for you, this premium product can be integrated into most lines and any popular bottle neck format without major modification of your production equipment.
No.11 2022 www.petpla.net D 51178; ISSN: 1438-9452 24 . 10 . 22 PETplanet is read in more than 140 countries MAGAZ I NE FOR BOT T L E R S AND BOT T L E - MAK E R S IN THE AMER ICAS, AS IA, EUROPE AND AL L AROUND THE PLANET MARKETsurvey Suppliers of recycling plants and washing units Page 23 COMPRESSORS Page 10 FILLING Page 26 Page 16
ENERGY COSTS reduced by 15 %? UNLIMITED life time ! MAINTENANCE COSTS reduced by 50 %? www.afcompressors.com [email protected] YES! AF Compressors can provide sustainable and long life 8 bar & 10 bar oil free air compressors! Can AF Compressors also supply 8 bar & 10 bar, oil free air compressors? AF COMPRESSORS
imprint EDITORIAL PUBLISHER Alexander Büchler, Managing Director HEAD OFFICE heidelberg business media GmbH Hubweg 15 74939 Zuzenhausen, Germany phone: +49 6221-65108-0 fax: +49 6221-65108-28 [email protected] EDITORIAL Kay Barton Heike Fischer Gabriele Kosmehl Michael Maruschke Ruari McCallion Anthony Withers WikiPETia. info [email protected] MEDIA CONSULTANTS Martina Hirschmann [email protected] Johann Lange-Brock [email protected] phone: +49 6221-65108-0 fax: +49 6221-65108-28 LAYOUT AND PREPRESS EXPRIM Werbeagentur | exprim.de Matthias Gaumann READER SERVICES [email protected] PRINT Chroma Druck Eine Unternehmung der Limberg-Druck GmbH Danziger Platz 6 67059 Ludwigshafen, Germany WWW www.hbmedia.net | www.petpla.net PETplanet Insider ISSN 1438-9459 is published 10 times a year. This publication is sent to qualified subscribers (1-year subscription 149 EUR, 2-year subscription 289 EUR, Young professionals’ subscription 99 EUR. Magazines will be dispatched to you by airmail). Not to be reproduced in any form without permission from the publisher. Note: The fact that product names may not be identified as trademarks is not an indication that such names are not registered trademarks. 3 PETplanet Insider Vol. 23 No. 11/22 www.petpla.net Dear readers, Once again, the subject of wine in PET pops up. This time from Australia. Packamama, a subsidiary of Garçon Wines, has focused totally on the subject of wine in PET. The company claims nothing less than to have re-invented the traditional glass bottle into the PET bottle of the future. The ideas are good; the wine bottle should have a significantly lower CO2 footprint, rPET is used and the exceptionally flat design of the bottle is eye-catching at the point of sale. Due to its slim shape, it is just as large as the glass bottle with the same capacity. The wine has a best-before-date of 19 to 21 months. As you can read in the report starting on page 12, the focus is not on costs, but on the target group of new buyers as well as sustainability. It is not for nothing that the company name Packamama is based on the Pachamama, the earth mother revered in South America. The London-based company not only has production facilities in Australia, but is also in the UK. So the Australians can supply Europe. But they also have their eyes on the North American market, the fourth largest wine producer in the world. The bottle particularly appeals to consumers who enjoy their wine promptly. According to the company, this accounts for 85% of the wine market. We wish the team every success. It’s late, I’ll call it a day and sit down and enjoy a glass of red wine – sadly from a glass bottle - and ponder the variety of packaging materials now used for drinks. Yours, Alexander Büchler
PETcontents 4 PETplanet Insider Vol. 23 No. 11/22 www.petpla.net 11/2022 Page 20 EDITOUR 10 Sorting, washing and grinding - Interview with Mr Ottavio Previero, Sales and Marketing Manager at Sorema BOTTLE MAKING 12 Bottles for the 21st century - Inteview with Amelia Dales, Commercial Director, Packamama 15 Wide neck containers for body building supplements BOTTLING / FILLING 16 “All the bottles that leave our production plants are 100% recycable” - Ishka, Irland’s fresh spring water 18 A unique construction - Ramseier Swiss AG invests in state-of- the-art aspectic line from KHS 22 The rise of Zambia’s Big Tree Beverages - Investment in European technology MARKET SURVEY 23 Suppliers of recycling plants and washing units COMPRESSORS 26 Reused air - A special designed compressed air recovery system 28 Shifting the energy balance with new compressor operating cost model 29 Eliminating idling times - ABC Compressors launches energy-saving Horizon Synchro range TRADE SHOW REVIEW 30 PETinar: Technical highlights at Drinktec 2022 33 Drinktec 2022, review part 1 37 Cloud computing and data analytic technologies BUYER’S GUIDE 40 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 38 PET bottles for beverage + liquid food 39 Patents 46 Outer Planet Page 10 COMPRESSORS FILLING Page 29
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PETnews 6 NEWS PETplanet Insider Vol. 23 No. 11/22 www.petpla.net Propak West Africa 2022 opens visitor registration Propak West Africa opens its doors in the end of November - with visitors now able to register for their badges. With a record number of over 5,000 visitors expected through the doors at Propak to witness the growth and innovation that the exhibition has gone through since 2021, exceeding its previous largest edition in 2019, it promises to be a catalyst for ideas across the industries served. The focus of Propak remains on the packaging, printing, plastics and processing industries and the auxiliary services and sectors that tie into them, with sustainability and green technologies having a rightfully larger presence for both the exhibitors and the conference agenda. The ninth edition is sponsored by Epson, Skysat and Neofyton and will take place from November 22-24, 2022, once again returning to the purposebuilt exhibition venue, The Landmark Centre that sits at the centre of commerce in Africa’s largest city of Lagos, Nigeria. Propak West Africa will see a large number of international companies arrive in Nigeria to showcase their product innovations and services to key buyers, business and factory owners from across West Africa. With substantial pavilions from Austria, Egypt, Italy in attendance alongside companies from 14 other countries, it is expected to be a truly international event. Not to be outdone by the international representation there is a strong and varied attendance from Nigerian companies who represent a broad range of household names and inspiring start-up companies in the sector. More than 150 brands already confirmed their participation in the exhibition. Retaining its importance more than ever is the conference theatre, where industry leading commentators and operators will be sharing their insight and experience with those who attend. With Prof Pierre Pienaar, President, World Packaging Organisation, Princess Layo Bakare, Managing Director/ CEO, FAE Limited and Amith Sukhnundan, Head, Markem-Imaje Dept, SBA Group already confirmed to speak. The sessions will cover key topics that are affecting the industries today, along with panel discussions covering green technologies, IntraAfrica trade and capital finance. These will be bolstered with presentations on specific areas of the industry including recycling, regulatory changes and industry 4.0. www.propakwestafrica.com Ceresana examines the global market for bioplastics According to the latest edition of the Ceresana report on bioplastics, the global market for “green” polymers will continue to grow dynamically: analysts expect bioplastics sales to rise to around USD 9.7 billion by 2031. Biodegradable plastics, for example polylactic acids (PLA) and starch polymers, reached a market share of 65% of the total bioplastics market in 2021. For this product group, Ceresana expects further volume growth of 10.4% per year until 2031. For bio-based plastics that are not bio-degradable, such as polyethylene, PET or PA, growth is expected to be lower at 7.5% per year. The most important application area in 2021 was the packaging industry: 58% of all bio-plastics were processed in this area. Ceresana expects the highest growth rate in the “bags and sacks” segment. www.ceresana.com Indorama Ventures opens the largest PET recycling plant in the Philippines in partnership with Coca-Cola Indorama Ventures Public Company Limited (IVL) announced the official opening of its PETValue bottle-to-bottle recycling plant in the Philippines, in partnership with Coca-Cola Beverages Philippines – the bottling arm of Coca-Cola in the country. The plant is IVL’s latest recycled PET facility as the global integrated petrochemicals company builds on its position as the world’s largest producer of recycled resin used in plastic beverage bottles. PETValue Philippines is located in General Trias in Cavite Province south of Manila. As a result of the joint venture with CocaCola, IVL will recycle about 2 billion additional used PET bottles in the Philippines every year and create about 200 new local jobs. The plant will wash and shred post-consumer bottles into flakes to produce recycled PET resin that is suitable for use in food-contact applications. Managed under IVL’s regional business lead for Recycling Vertical Mr. Anivesh Tewari, PETValue brings together an experienced leadership team led by Site Manager Mr. Joel Potian, who has nearly three decades of manufacturing and chemical engineering expertise in the Philippines and Korea. He is supported by Mr. Aris Castillo as Chief Financial Officer, formerly from Coca-Cola Beverages Philippines with more than 10 years in supply chain finance and manufacturing. PETValue will introduce advanced technology and infrastructure in the Philippines, helping to improve collection and recycling rates and prevent leakage into waterways. www.indoramaventures.com
7 NEWS PETplanet Insider Vol. 23 No. 11/22 www.petpla.net % &'() * % & ) + , ! , - $ '. / / $ ! $ # '. 0 % 1(2 * % &32 ) , ! / / .4 # 5 # $ 6 0 ! 7 '"# '. /
8 NEWS PETplanet Insider Vol. 23 No. 11/22 www.petpla.net Atlas Copco appoints Anna Sjörén as Vice President Sustainability Atlas Copco has appointed Anna Sjörén as its new Vice President Sustainability, the company announced on October 11. Anna Sjörén is currently Compliance and Sustainability Officer at Dometic Group. Between 2007 and 2019, she worked for Atlas Copco, where she last held the position as Global Sustainability Manager for the business area Industrial Technique. She will take on her new position in January 2023. Anna Sjörén has a Masters’ degree in engineering from the Royal Institute of Technology (KTH) in Stockholm, Sweden. Atlas Copco’s current Vice President Sustainability, Sofia Svingby, will leave Atlas Copco for a role outside the group. www.atlascopcogroup.com Drink Technology India 2022 India’s beverage, dairy and liquid food industry returns to Mumbai India’s biggest exposition for beverage, dairy, and liquid food technology, Drink Technology India (DTI) will take place on December 7-9 , 2022 at the Bombay Exhibition Centre in Mumbai. The trade show will be co-located with Pack Mach Asia Expo and World Tea & Coffee Expo. More than 250 exhibitors will show more than 3,000 novelties and innovations on an area of over 15,000m2. The demand for beverages and liquid foods has been steadily increasing over the past few years and is expected to grow exponentially at an average CAGR of 5.37% from 2021 to 2026. The ever-changing consumer tastes and trends have forced various brands to innovate and come up with new ideas to attract customers. The increasing proliferation of modern retail structures such as supermarkets and vending machines have fuelled the growth of the beverage industry. DTI has grown consistently over the years and has established as the preferred trade fair by the suppliers and buyers of the Indian beverage, dairy and liquid food industry. Industry decision makers, influencers and key professionals have found DTI to be the most important platform to witness innovations, engage with industry peers and exchange business ideas in the past. As in previous years, a rich supporting programme is planned during this year’s show, including knowledge-sharing conferences where industry leaders share their success stories, advise on the future outlook of the industry and discuss innovations. Brewers from across the country will meet with peers and industry leaders as part of the “place2beer” programme. From discussions on topical issues to a wide range of beer tastings, the programme is a one-stop shop for brewers. About the upcoming DTI 2022, Bhupinder Singh, CEO, Messe Muenchen India said, “The beverage and liquid foods market in India is growing at a rapid pace due to ever-increasing demand and consumption. We have received an overwhelming response from our exhibitors for our upcoming 2022 edition to be held in Mumbai. The event covers the full spectrum of the liquid food and beverage sector in India, thus enabling meaningful handshakes and unlocking business opportunities.” www.drinktechnology-india.com Alpla North America announces new Regional Managing Director Alpla Group, a global packag i ng manu f ac - turer for a wide range of industries, announced the appointment of Tasos Pourloukakis as its new Regional Managing Director North America, the top business unit leader for the region. Tasos Pourloukakis was promoted from Country Managing Director for Alpla’s UK operations and brings a total of sixteen years of manufacturing and quality experience from both Alpla and another industry leader. Prior to joining Alpla, Tasos Pourloukakis served with packaging manufacturer Crown Holdings, Inc. in the UK and in Dubai UAE, finishing as a Plant Manager at a large UK speciality packaging site, responsible for all activity including manufacturing, quality, engineering, HSE, logistics and finance. He held progressively responsible roles in quality, continuous improvement, operations and health and safety. Alpla is one of the leading companies for plastic packaging and recycling. Around 22,100 employees produce tailor-made packaging systems, bottles, closures and injection moulded parts at 177 locations in 45 countries. The areas of application for the quality packaging are diverse: food and beverages, cosmetics and care products, household cleaners, detergents and cleaning agents, pharmaceuticals, motor oil and lubricants. The company operates recycling plants for PET and HDPE in Austria, Germany, Poland, Mexico, Italy, Spain, Romania and Thailand. Other projects are being implemented internationally. www.alpla.com Tasos Pourloukakis is Alpla’s new Regional Managing Director North America. (Photo: Alpla)
9 NEWS PETplanet Insider Vol. 23 No. 11/22 www.petpla.net Interzero and Eastman reach supply agreement for planned molecular recycling facility Interzero and Eastman announced a long-term supply agreement for Eastman’s previously announced molecular recycling facility in Normandy, France. Interzero will provide up to 20,000 metric tonnes per year of hard-to-recycle PET household packaging waste that would otherwise be incinerated. Interzero Plastics Recycling, as part of Interzero, a leading service provider of circular solutions in Europe. Eastman’s planned molecular recycling facility in France is intended to become the world’s largest material-to-material molecular recycling plant. Once complete, the facility will recycle approximately 160,000 t/a of hard-to-recycle polyester waste. The project is expected to be operational in 2025. Chemical recycling is a complement to mechanical recycling to keep more raw materials in the loop. Eastman’s facility in France will process coloured and opaque PET waste that cannot be recycled mechanically to create clear and transparent rPET upon completion. Eastman’s proven polyester renewal technology is claimed to provide circularity for hard-to-recycle plastic waste that remains in a linear economy today. This material is typically incinerated because it either cannot be mechanically recycled or must be downcycled using existing technology. Eastman’s chemical recycling technology allows this hard-to-recycle waste to be broken down into its molecular building blocks and then reassembled to become first-quality material. Eastman’s polyester renewal technology enables the potentially infinite value of materials by keeping them in production, lifecycle after lifecycle. With the technology’s inherent efficiencies and the renewable energy sources available in France, materials can be produced with less greenhouse gas emissions than traditional methods, says the company. www.eastman.com www.interzero.de New dual leadership at Kiefel Packaging GmbH in Austria Kiefel Packaging GmbH, the Upper Austrian subsidiary of the Freilassing-based mechanical engineering company Kiefel GmbH, has been under dual management since September 1, 2022. Andreas Staudinger took on the duties of the previous managing director Robin Roth in spring and now heads the location as Chief Sales Officer (CSO) jointly with Christian Töscher as Chief Operations Officer (COO). Andreas Staudinger has been with Kiefel for more than 30 years and is an experienced manager with extensive market and process knowledge. He will hold the position of Managing Director at Kiefel Packaging GmbH in addition to his role as Head of the Polymer Packaging Division at Kiefel GmbH, which he has held for around two years. Christian Töscher looks back on relevant experience as COO in the management of an international company for the manufacture of machine components and tools in the metal and glass processing industry. Here he was the driving force behind, among other things, harmonisation projects at various plants, the implementation of lean concepts and strategic purchasing projects. www.kiefel.com F.l.t.r.: Christian Töscher (COO) and Andreas Staudinger (CSO) are the new dual managers of Kiefel’s Austrian site. ES PROCESS on energy consumption, PET RECYCLING PLANT Compact process, modular design equipment space. CONTACT US TO LEARN MORE ! WWW.BO-RE-TECH.COM | +86-573-85120186 | [email protected]
EDITOUR PETplanet Insider Vol. 23 No. 11/22 www.petpla.net 10 Sorting, washing and grinding Sorting, washing and grinding are vital elements in the processing of PET bottles. PETplanet insider visited Sorema the specialist company in washing and mechanical recycling plants, whose latest development is providing tailored water treatment equipment to reduce recycling plant needs. In Italy, PETplanet spoke to Ottavio Previero, Sales and Marketing Manager. Tour Sponsors: July 2022 We met: Mr Ottavio Previero, Sales and Marketing Manager at Sorema, and Mrs Chiara La Donna, Marketing More than 100 years ago, Ottavio’s great-grandfather founded the Previero company for the pre-grinding of wood. In 1974, the plastics washing division was created under the name Sorema. They initially started with a washing plant for LDPE and by 1982 had already built their first PET facility. The latest developments in Sorema’s PET washing plants is the upgrading of the bottles pre-washing system. This not only washes the bottles after dry pre-sorting but also removes the labels and sleeves. Washing removes all external contamination, which can also include sand and grit in addition to organic material. The next stage involves the grinding of bottles into flakes using wet grinders. Depending on local conditions, oil residues and other synthetic adhesions are washed off as well as any remaining organic components. After drying and sorting, the flakes are ready for further processing, hot washing, rinsing and drying. Sorema offers its customers full scale recycling and washing trials, in its pilot plant, to determine the mass balance and see the final output quality. However, for Ottavio, costs are just as important as delivery top quality flakes. “We can wash everything using our technology but a recycler must also keep an eye on costs. We therefore adapt our facilities to match the quality of the post-consumer waste stream, making them ideal in terms of costs and excellence. We have focused on wastewater treatment as a way of keeping costs in check and are offering customised solutions through our newly acquired subsidiary company Teknodepurazioni”. Teknodepurazioni Aquae is a specialist industrial wastewater treatment business, with years of experience to control the water quantity and quality between wastewater plants and washing plants for PET or other plastics. The company carries out tests, laboratory analyses and pilot plants to be able to propose the best solution for each specific application in terms of functionality, economy and ease of management. In its own analysis and research laboratory, Teknodepurazioni Aquae determine the chemical-physical and bacteriological properties of the water before and after the purification process. Depending on the requirements, wastewater is treated in three stages. These stages are mechanical filtration, followed by chemical sedimentation and finally biological treatment. Process selections is made on the client’s requirements, such as the characteristics of the area or the discharge specifications. After a final-fine treatment, the purified water can be discharged into the river, in the sewer or even reused. At the two locations Alzate Brianza and Anzano del Parco in Como, Italy, 110 workers produce Sorema equipment on an area of 11,000m2. To date, hundreds recycling plants have been installed worldwide, which recycle post-consumer and industrial plastics waste all around the year. Shortly before our visit, at the beginning this month, a bottle-to-bottle recycling plant was sold to Mexico. This turnkey plant was shipped to the Mexican recycler Envases Universales for increasing the production capacity of rPET flakes for food applications. With an output of 9,000kg/h of washed PET flakes, provided by the local municipal bottle collection of bottles, this plant helps to drive the circular economy with rPET by reintegrating the material into the production of new containers, preforms and bottles. The bottle-to-bottle rPET line contains automatic feeding, pre-washing, de-labelling, followed by the wet grinding, hot washing, flotation and finally rinsing and drying steps. The line includes colour and materials detectors for bottles and flakes as well as a Sorema Scada 4.0 digital monitoring system for an efficient local and remote control. We thank Chiara and Ottavio for their time and kind hospitality and are looking forward to meeting them again at the K’ show in Düsseldorf. www.sorema.it The Mexican plant has an output of 9,000 kg/h of washed PET flakes.
EDITOUR PETplanet Insider Vol. 23 No. 11/22 www.petpla.net 11
BOTTLE MAKING 12 PETplanet Insider Vol. 23 No. 11/22 www.petpla.net Interview with Amelia Dales, Commercial Director, Packamama Bottles for the 21st century The original impetus behind Garçon Wines was the company’s focus on e-commerce friendly wine bottles. The result was the compact bottle shape, which is flat enough to be put through a letter box, and its PET format, which is light and robust enough for easy despatch. Behind the packaging concept and its manufacture is Packamama, the brand’s spin-off. PETplanet spoke to Amelia Dales, Commercial Director, about wine in PET, customer feedback and the focus on sustainability. PETplanet: At the beginning of the year, Packamama was created as a spin-off from Garçon Wines. What is behind the brand, which parts of the business are yours and which are Garçon Wines? Amelia Dales: Packamama had been in the works since the end of 2019, but with the onset of Covid-19, we decided to hold spinning off this business line under a new brand. The timing became right at the start of 2022 with the pandemic largely behind us and soon-to-launch collaborations on the horizon. Packamama encompasses the packaging elements of Garçon Wines, supplying dry goods and processing to pioneering wine companies, that is, our IPprotected eco-flat bottles, bottling and secondary packaging. As the business increasingly became focused on business-to-business packaging and collaborating with wine companies, it made little sense to continue with a legacy name that included ‘wines’ in the title. Garçon Wines will continue to operate separately and establish itself instead as a direct-to-consumer sustainable wine brand owner of brands that use eco-flat bottles and other more sustainable packaging formats in the future. The name Packamama was inspired by the earth goddess Pachamama, with a playful change in letter as we offer Packaging Protecting Mother Earth. This name far better aligns with our vision for a lower carbon future in drinks. Additionally, the name is liquid agnostic, which is important to us as Packamama will provide packaging for more than just wine in the future. PETplanet: What was the original impetus to package wine in recycled PET? Amelia Dales: The original impetus came from wanting to make a greater success of wine ecommerce, which in our view was hampered by an inefficient primary pack that was still in use from the 19th century. If you asked a group of intelligence people today to create an optimum packaging format for wine, a product that travels vast distances across the globe through complex supply chains, they would not have come up with a round, glass bottle. It’s a logistics nightmare due to being spatially inefficient, heavy and very fragile. Challenging the base assumptions that wine bottles need to be round and made from glass led to the creation of a bottle that is a flat, cross-section design of the shape consumers knows and love, and made from recycled PET (rPET) to save weight and energy. The functional benefits of PET include being lightweight and shatterproof, while still retaining glass-like qualities such as shine and transparency. PET is also the most widely recycled plastic on the planet, with capacity to make high quality products from its recyclate. Using 100% rPET from the outset was non-negotiable from an environmental perspective because of the importance of putting pre-existing material back to good use, limiting creation of new plastic and contributing to circular economies. Most importantly, as we more frequently see and feel the alarming impacts of the climate crisis, rPET is a more climate-friendly material to be using for wine, an industry whose carbon footprint hotspot comes from the glass bottle. rPET saves energy and weight in production, transport and recycling compared to both glass and virgin PET to slash carbon emissions and so is the best-in-class material for wines that don’t require bottle aging. PETplanet: Are there plans to expand into other beverage segments such as sparkling wine or beer? Amelia Dales: We’re starting in wine because packaging represents a carbon footprint hotspot and the single greatest impact producers can make in reducing their carbon emissions is to change the bottle. We also specifically designed our bottles to pay homage to the tradition and beauty of Amelia Dales, Commercial Director at Packamama by Gabriele Kosmehl
BOTTLE MAKING 13 PETplanet Insider Vol. 23 No. 11/22 www.petpla.net the world of wine through the crosssection Bordeaux design, retaining the emotional connection and recognition of wine from a bottle. However, we do plan to expand into other beverage segments, such as spirits and bottled water and other liquid foodstuffs such as vinegar and olive oil. We would like to be able to find a solution to package sparkling wines and other carbonated beverages like beer, but the pressure exerted on the flat panels means that, for now, the bottles are only suitable for still liquids. PETplanet: The wine-buying public has a reputation for being rather traditionally-minded when it comes to purchasing and is often sceptical about wine in plastic bottles. How do you manage to convince wine producers to bottle in PET? Amelia Dales: The wine industry is steeped in a rich heritage and is generally slower to adopt innovation. But there are plenty of instances where it has adapted and continues to do so, whether that is adopting screw caps to changing perceptions about packaging wines in bag-in-box or cans. As our bottle is inspired by the traditional shapes that producers and consumers know and love, we call it an advancement to traditional bottles. It is a better bottle for the 21st century, rather than an alternative format. The main areas we highlight to producers are that our bottles will protect both their wines and our planet. We demonstrate that our packaging protects their wines through the 19-21 months shelf-life, and using PET that’s certified food-grade to FSA and Efsa standards and is a stable, inert material. For protecting the planet, the evidence is clear that we need to be reducing carbon emissions, and the evidence is also clear that in wine, recycled PET is the better option for a lower carbon, monolayer bottle which is available to scale now. Innovation is fundamental to help wine producers futureproof themselves through continuing to appeal to generations that are highly eco-conscious. These generations will have to live with the planet that we’ve damaged so badly and will not accept products with an unnecessary carbon footprint, especially if a better option is available. Previously, the bar for PET wine packaging has been set too low, using virgin material, aluminium caps that can have a negative impact on recyclability and having a bottle that looks smaller standing next to its 750 ml glass counterpart. Through shape innovation, best-in-class material and recyclability by design, we’ve changed the rhetoric. Both consumers and business customers are intrigued and interested to know more about why we do what we do, providing a platform to communicate why this packaging change is positive and needed. So far, we’ve brought on board Accolade Wines (the UK’s number 1 wine company), Château Galoupet (a Provence estate owned by luxury goods giant LVMH), Miguel Torres Chile (climate action champions in wine) and Taylors Wines (one of Australia’s first families of wine). More will follow. We engage with the larger producers as it is the largest and most respected producers that can make the greatest impact. Small/er producers are more likely to use our ecoflat bottles once they see the largest progressing. PETplanet: Do you have a few examples of consumers‘ feedback on the PET bottles? Amelia Dales: As Packamama is not a wine brand owner, we do not directly interact with consumers. However, from what we’ve seen on social media, there is a 70% positive sentiment towards our format and just a 2% negative. We also pay attention to reviews left on retailer sites. On Tesco.com, where Accolade Wines’ brand Banrock Station is available, there is a roughly 80% positive sentiment towards the bottles. Specific comments from these reviews include “I was convinced this would taste different, due to being in an ‘odd’ bottle. However, this was not the case; full bodied, fruity and really enjoyable to drink. The fact I don’t have to clink up the glass bottle bank at the top of the road is a plus, as could go directly into my own household recycling. Big thumbs up from me, and will buy more, the bottle shape also takes up less space for storage which is another bonus” and “Love the packaging too, light and compact and just the thing to take on a summer picnic, sustainability is an added bonus.” Any comments indicating repeat purchase intention is a clear sign of good consumer uptake and acceptance, so we are particularly pleased to see this. PETplanet: In which (geographical) markets are you active, which could follow soon? Amelia Dales: Packamama is active with production capabilities in the UK and Australia. The brands that use our bottles distribute them beyond just these countries though, so wines in eco-flat bottles are available in the Nordics and Canada too, and online via certain European e-retailers. Our top priority for international expansion is to establish a team and production capabilities in the USA. This is an attractive market as it is the top wine consuming country and the fourth largest wine producing country in the world. PETplanet: Oxygen ingress is more of an issue for beverages in PET than in glass. How have you solved it so that the quality of the wine does not suffer? Amelia Dales: Our bottles use
BOTTLE MAKING 14 PETplanet Insider Vol. 23 No. 11/22 www.petpla.net BOTTLE MAKING 14 an advanced barrier technology that’s introduced prior to the bottle blowing process to ensure that the format is still monolayer, which is important from a recyclability perspective. This barrier features an active oxygen scavenger and passive carbon dioxide barrier, giving the wines in our bottles a shelf-life of 19-21 months according to realtime and modelled shelf-life analysis. This is more than enough time for most wines given that around 85% of wines produced are for everyday drinking and are consumed shortly after purchase. “We tend to fi nd that our customers’ primary motivations for using eco-fl at bottles are related to sustainability targets” PETplanet: The glass industry is particularly affected by rising energy prices. Have there already been cost-driven conversions from glass to PET bottles among your new customers? Amelia Dales: You’re correct that recycled PET requires less energy than glass, as it can be produced and recycled at much lower temperatures. This also cuts costs in the supply chain. That said, 100% recycled PET is still facing the good problem of demand increase, and some price increase as a result. Resource scarcity of this nature, whether it be glass or recycled PET, goes to show the importance of keeping valuable resources in circulation and accelerating the transition to a circular economy to slash carbon footprint. We tend to find that our customers’ primary motivations for using eco-flat bottles are related to sustainability targets, staying relevant amongst their consumers bases and appealing to new shoppers, rather than cost-cutting at the moment. However, we have certainly seen an increase in enquiries related to the rising cost of glass along as well as availability and lead times, with larger industries such as beer and spirits taking priority. PETplanet: Thank you very much for these interesting insights into your business! www.packamama.com STEPS TO THE PERFECT BOTTLE. www.roeders.de www.roeders.de Idea & Design Technology Manufacturing Blow Mould 100% Service Y O U R PA R T N E R F O R B L OW MO U L D S .
BOTTLE MAKING 15 PETplanet Insider Vol. 23 No. 11/22 www.petpla.net Wide neck containers for body building supplements Two Sipa ECS SP 80 injection-stretch-blow moulding (ISMB) units have been installed this year at JSC Plastikse in Lithuania. The wide mouth jars produced on these lines are dedicated to sport nutrition powder and pills. tion. Just like the smaller ECS SP 25, it was designed with high-speed production in mind, using hydraulics when large forces are required and servo electric drives for fast movements. This combination is claimed to be very energy efficient, helping the machines achieve a small carbon footprint. Both the ECS SP 80 and SP 25 accept moulds not only made by Sipa, but also others originally designed to run on equipment from other brands. www.sipa.com happy to place on the market a new kind of product which is fully designed for recycling and manufactured with 100% green energy from renewable resources. Solar panels installed on the factory roof provide much of the energy we need.” says company GM Leonid Sterlin. The ECS SP 80 machine can produce containers with neck finishes up to 130mm in diameter. Various special features make it possible to produce containers with optimal material distribution. For example, the conditioning system provides a preform thermal profile based on the bottle specificaECS SP 80 ISBM unit with its take-out robot system Everything is on a large scale at JSC Plastikse. The company, located close to Vilnius, is one of the biggest PET converters in the Baltic region. Among the wide range of PET packaging supplied for different markets, it makes 2 l and 4 l PET jars with wide mouths, to be filled with body building supplements and sports nutrition. Both formats are being produces with Sipa ECS SP systems. The 4 l PET jars with 120mm necks, weighing 140 g as well as 2 l jars 100mm necks weighing 90 g are produced in a very short cycle time. Production of the jars from resin to the finished container is carried out without any interruption. In this way, small batches and customised jars can be produced. Designed for recycling JSC Plastikse has been in business since 2000, positioning itself at the forefront of packaging products for beverage, food, cosmetic, chemical, and medical industries worldwide. “We pride ourselves on innovation and flexibility, providing customers with high-quality customised products and services. Nowadays, packaging of a supplement product is more demanding than ever, the people are taking care about their body and health much more than before. We are The two ECS SP80 machines installed side by side at Plastikse
BOTTLING / FILLING PETplanet Insider Vol. 23 No. 11/22 www.petpla.net 16 Ishka - Ireland’s fresh spring water “All the bottles that leave our production plants are 100% recyclable” In Ballyneety, County Limerick, the luscious green, rolling landscape of the beautiful Irish countryside is the backdrop to one of the most modern bottling plants of spring water in Europe: Ishka Irish Spring Water. The company, founded in 1978 by Michael Sutton Sr. thanks to a brilliant family idea, is today a multimillion-euro company managed by Mike and Denis Sutton, sons of the founder. Every hour the plant, consisting of four fully automated lines built in partnership with SMI, produces over 40,000 bottles of spring water, with the utmost attention paid to the care and preservation of the surrounding environment. FILLING PETplanet: When and why did Ishka start bottling water? Sutton: Ishka Irish Spring Water is a family business founded in 1978 by our father Michael. Our mother, who was a great Irish speaker, invented the phonics for the trademark. The company, located in Ballyneety in County Limerick, occupies a production site of 11-acres and is one of the most modern facilities in Europe, where product innovation, production efficiency and sustainable development have been the order of the day since the beginning. In 2012, after major investments to make the site safe, we started producing bottles in PET on site, a goal that our father had always dreamed of, however, he unfortunately passed away only a few months before the start of the new business. About 60% of the water bottled in our factory, is destined for various private labels distributed in the main Irish supermarkets, while the remaining 40% concerns bottles marketed under the Ishka brand. PETplanet: In general, what position does Ishka water hold compared to the others available on the market? Sutton: Ishka is known for being “Ireland’s freshest spring water”, as it is drawn from aquifers 200 meters underground and naturally filtered through the pristine, limestone bedrock of Ballyneety - hence the distinctive taste and product refreshment. Ishka was the first Irish spring water company on the market to introduce a 100% recycled PET bottle and the first to use tethered caps anchored to the bottle, three years before the EU Directive, that made them mandatory, came into force. PETplanet: Is this innovation continual? Sutton: Naturally! Innovation is a constant element of our business. Ishka is planning a new €11 million investment, to install a new highspeed rPET bottling line, capable of producing up to 36,000 bottles per hour, by early 2023. We will also install a new glass line for the catering and hospitality sector. The presence of a brand-new kitchen will also allow us to add flavourings and develop a new range of mixers and flavoured drinks. PETplanet: What are the main factors that convinced you to invest in a new plant supplied by SMI? Sutton: SMI offered us a unique solution for filling, transporting product on conveyor belts, secondary packaging and palletising, with the consequent optimisation of management costs and time for format changes. The line designed by our Italian partner, guarantees maximum production flexibility. Furthermore, the presence of a local SMI branch that assists us quickly and efficiently, is of great importance to us. Mike Sutton & Denis Sutton the owner of Ishka Spring Water
BOTTLING / FILLING PETplanet Insider Vol. 23 No. 11/22 www.petpla.net 17 PETplanet: How important are sustainability and environmental protection to Ishka, and to your customers? Sutton: As a company we are determined to do everything possible to guide consumer behaviour towards the necessary change, to solve the global waste problem and to safeguard marine life. Many of the innovative activities at Ishka Irish Spring Water are about finding optimal solutions for the packaging of our spring water. We chose rPET because it is currently the packaging option that is the most eco-friendly. Furthermore, we are constantly striving to minimise the environmental impact of our business through a series of initiatives, including the use of recyclable plastics such as rPET and light BPA-free plastics and reducing the weight of the containers. In fact, all the bottles that leave our production plants are 100% recyclable. Further help in protecting the environment, comes from the fact that we produce rPET bottles on site, thus eliminating the need to transport them by road to our factory. Our company is also part of Repak, Ireland’s leading environmental non-profit organisation for the recycling and sustainability of packaging waste. As a member, we help fund projects for the development of fully recyclable household containers and for the creation of national recycling centers. PETplanet: How do you see the future of the bottled water industry? Sutton: The demand for bottled spring water in Ireland, is estimated to continue to grow in the coming years. Customers are increasingly interested in “premium” products, in knowing how they are produced and what they contain. At Ishka, we have great respect for the territory that hosts us and for the water it provides; for this reason, we undertake all possible initiatives to ensure the purity of our source and the surrounding environment. Every investment aimed at protecting the eco-system in which we operate, is a guarantee to maintain the quality of our products today, tomorrow, and forever. PETplanet: We thank you very much for the interview. Installed machinery: After a longstanding partnership SMI developed the production line for 5 l containers, which has allowed Ishka to increase plant capacity by over 50%. The expansion project was necessary to upgrade the existing line, this involved replacing the old linear blow moulder with a modern integrated SMI Ecobloc system, consisting of a 3-cavity rotary blow moulder, an electronic filler and a capper. The 3,600 bph bottling and packaging line for 5 l bottles consists of an Ecobloc 3-9-3 HC Ergon with a DV 500 divider & SK502T Ergon shrinkwrapper and finally an APS 1550 Ergon palletiser & conveyor belts. This system upgrade permitted the installation of a faster and more efficient stretch-blow moulding and filling system, while at the same time maintaining a compact footprint, thanks to the fact that no conveyor belts are necessary between the blow moulder and the filler. The new project also posed a challenge in secondary packaging, as Ishka required shrink film pack formats in 2x1 and 3x1 and a large (4x5) tray format to make a half pallet pack. The 2x1 and 3x1 pack sizes in film only, are made by the SK 502T Ergon shrinkwrapper, which, after the format change, is also used to create a “super” format consisting of a halfpallet display tray without shrink film. The packaging system groups 20 bottles in a 4x5 pattern, then forms a tray around the bottles, starting from a flat blank; subsequently, the package thus created, is palletised and sent to supermarkets, ready for display. For the 16,000 bph end of line for the packaging of 250ml & 500ml PET bottles a CSK42 F Ergon & LSK30F shrinkwrappers with an APS 1550 Ergon palletiser and conveyor belt has been installed. By combining a CSK42F Ergon twin lane shrink wrapper and an LSK30F Ergon shrinkwrapper to repack in film only, Ishka create “packin-pack” packages for large distribution. With the APS 1550 Ergon palletiser manages half pallets, europallets and UK pallets and has an optional system that automatically loads the half pallets, on standard pallets for storage in the warehouse. www.smigroup.it www.irishspringwater.com
BOTTLING / FILLING PETplanet Insider Vol. 23 No. 11/22 www.petpla.net 18 Ramseier Suisse AG invests in state-of-the-art aseptic line from KHS A unique construction With technology from KHS, Ramseier Suisse AG in Sursee in Switzerland recently commissioned a special aseptic line: one that is flexible, efficient and perfectly tailored to the company’s demand for quality. Established as a cider press over 100 years ago, with a gross turnover of CHF 156 million, traditional company Ramseier Suisse AG is one of the biggest beverage producers and most important independent breweries in the Swiss Confederation. At its four facilities it produces not just beer but primarily apple juice, cider and apple spritzers, fruit juice, mineral water, soda pop and soft drinks – some as exclusive own brands for retail chains such as Coop or Migros. As it processes more than half of all cider fruit in Switzerland, Ramseier Suisse AG attaches great importance to quality. Apples, pears and the apple mint used in its freshly brewed iced tea are sourced from local farmers and governed by strict specifications. The company’s high demands equally apply to its products and the methods used to make them: many of the fruit juice and tea beverages are not hot filled, for example, but instead undergo gentle pasteurisation and are filled into the bottle under aseptic conditions in order to retain the full fruity or herbal flavour. When it comes to the production technology, using standard equipment is not, for the Swiss, a satisfactory option. Ramseier Suisse AG has worked with systems provider KHS for over 30 years. The most recent product of this cooperation is an aseptic line at the production site in Sursee near Lucerne. The Dortmund engineering company has supplied the process technology, the stretch blow moulder/ filler block and a labelling machine. The new line, in which around €15 million have been invested, is part of the systematic innovation process that is intended to make the bottler technologically fit for the future. “We reckon that the variety of products and packaging will continue to increase,” explains Christoph Suter, CTO and board member of Ramseier Suisse AG. “In the future our production setup must be able to react even more flexibly to constantly changing market requirements. This calls for continuous renewal of our plant infrastructure.” FILLING Full view of the KHS aseptic line A dormer had to be built into the roof to accommodate the 9,000 l buffer tank installed on the platform.
BOTTLING / FILLING PETplanet Insider Vol. 23 No. 11/22 www.petpla.net 19 Ramseier Suisse AG’s key demands in this respect are flexibility, operational reliability, efficiency and sustainability. “Our machines have to process a broad spectrum of beverages,” says Suter. “Not only that but the PET aseptic line has to cater particularly for a variety of packaging specifications, such as different bottle shapes, sports caps or sleeve labels, all of which feature in our highly diverse product portfolio.” Limited amount of room One special challenge faced by the KHS engineers was the limited amount of room available for the new machinery. Despite the production shop being expanded, there was only a narrow space provided for the line. The answer was to construct a large stainless steel platform above the stretch blow moulder/filler block that contains all of the process engineering with a juice de-aerator, flash pasteuriser, sterile buffer tank, valve manifold, CIP system and all control cabinets for the entire line. A dormer had to be especially built into the production shop roof to accommodate the enormous tank. With a total volume of 9,000l, it allows a new batch of product to be prepared while the filler is still being cleaned. So that it runs completely empty using the natural incline, the tank was also placed on staging so that its upper edge stands at over ten metres. A practical door accessed from the roof facilitates inspection and maintenance. “The customer is not the only one enthused by the result, says Lutz Müller, Sales Manager at KHS, “This is a unique construction, a real eye-opener. Here, we can see how product preparation and product filling perfectly interact – the result of an elaborate and thorough planning process mastered together with the engineers at Ramseier Suisse AG.” “There’s absolutely nothing normal about this line” The InnoPET BloFill ACF-L aseptic stretch blow moulder/filler block from KHS is a good example of the hightech now erected in Switzerland. This includes the InnoPET Blomax Series V, the latest generation of KHS stretch blow moulding technology. It has been equipped with a box tilter which with its dosed preform infeed exerts a lower load on the preforms and For product changeovers recipes are selected on the ClearLine HMI operator panel from KHS.
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