No.04 2023 www.petpla.net D 51178; ISSN: 1438-9452 17 . 04 . 23 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 preforms & preform inspection systems Page 27 PREFORMS Page 14 Page 31
The all-new PET-LINE comes with a variety of advantages to maximize output and minimize costs: • Maximum compatibility with legacy molds and PMC • Shortest cycle times for increased output • Lowest level of energy consumption to minimize the ecological footprint • Improved 100 % rPET processing to enable the circular economy • New control unit including Smart Operation to ensure easy, fast and safe start-up and production • Available with 3000, 4000 and 5000 kN clamping force More details on www.netstal.com FLIPPING THE WORLD OF PET UPSIDE DOWN AND EVEN SIDEWAYS THE ALLNEW PETLINE WITH SIDE ENTRY. SCAN ME
No.04 2023 www.petpla.net D 51178; ISSN: 1438-9452 17 . 04 . 23 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 preforms & preform inspection systems Page 27 PREFORMS Page 14 Page 31
% 2 * % &8 )( $ 7 7 9 '. : % ;7<2 * % ; ! " # $ % # # )+ $ '. 7 =# $ #
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 info@petpla.net EDITORIAL Kay Barton Heike Fischer Gabriele Kosmehl Michael Maruschke Ruari McCallion Anthony Withers WikiPETia. info petplanet@petpla.net MEDIA CONSULTANTS Martina Hirschmann hirschmann@petpla.net Johann Lange-Brock lange-brock@petpla.net phone: +49 6221-65108-0 fax: +49 6221-65108-28 LAYOUT AND PREPRESS EXPRIM Werbeagentur | exprim.de Matthias Gaumann READER SERVICES reader@petpla.net 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. 24 No. 04/23 www.petpla.net Dear readers, After the lockdowns, China is now also opening up again to travellers and tourists. The country can now be visited without any quarantine formalities. From our plastics perspective, Chinaplas in particular should benefit from this, which is about to start. With a gross area of 380,000m², it has grown by 8.6% compared to 2021. 3,900 national and international exhibitors will be present on the grounds of the Shenzhen World Exhibition & Convention Center, PR China (SWECC). China is impressively back on the international stage. As everywhere else in the world, sustainability dominates the industry in China. Smart and green are the key words in plastics and rubber industries: Many manufacturing companies are demanding high production efficiency, cost reduction, low pollution, and low energy consumption. In addition to the Injection Moulding and Smart Manufacturing Solutions Zone, visitors at Chinaplas can find the latest all-round sustainable solutions for environmentally friendly materials, processing technologies, and products in various theme zones, including Recycled Plastics Zone, Bioplastics Zone, and Recycling Tech Zone, and the newly established Innovative Products Zone. Relevant trade fairs on the European continent are now also on the agenda: the Interpack trade fair in Düsseldorf, Germany will open its doors to the international experts of the packaging industry from May 4-10. After the suspension of the fair in 2020, 2,700 companies have now registered and will present their innovations. Equally relevant, the established recycling trade fair PRS Europe in Amsterdam, Netherlands will open its doors to recycling industry professionals from May 10-11. This year, the event is expanding to include another exhibition hall. An extensive conference programme forms the perfect framework for the exhibition. As a small preview: Also new is this year’s PRS Middle East and Africa from September 5-7 in Dubai. Yours Alexander Büchler
PETcontents 4 PETplanet Insider Vol. 24 No. 04/23 www.petpla.net 04/2023 Page 38 MATERIALS / RECYCLING 10 PET recycling in East India - Food-grade rPET project and smart waste bins in Bengal 12 Colourful solutions - PCR colour prediction service & colourants for beverage closures PREFORM PRODUCTION 14 Always in tunes with the times - Sustainable development of required preforms 16 Preparing rPET for preform production - Continuous vacuum drying technology 18 Minimising waste - Status quo and developments in preform manufacturing 19 The PET wine bottle - Increasing interest in a sustainable alternative to glass BOTTLE MAKING 20 Increased efficiency and sustainability for large-capacity bottles BOTTLING / FILLING 22 Climate-neutral juice factory MARKET SURVEY 27 Suppliers of preforms & preform inspection systems TRADE SHOW PREVIEW 24 Plastics Recycling Show Europe 2023 preview 31 Interpack 2023 preview 43 Track, trace & protect TRADE SHOW REVIEW 44 Petcore Europe Annual Conference, review part 2 BUYER’S GUIDE 48 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 46 On site 47 PET bottles for beverage + liquid food 54 Outer Planet PREFORMS Page 22 Page 10
yellow.agency A FAMILY OWNED SWISS COMPANY. OUR INJEC T ION MOULDS FOR PE T AND PAC FE ATURE CRAF TSMANSHIP THAT IS UNIQUELY SWISS . OT TO-HOFSTE T TER . SWISS T OTA LLY SW I S S.
PETnews 6 NEWS PETplanet Insider Vol. 24 No. 04/23 www.petpla.net Chinaplas 2023: first-time use of all 18 exhibition halls of the Shenzhen World Exhibition & Convention Center Chinaplas 2023, to be held at the Shenzhen World Exhibition & Convention Center, PR China (SWECC), on April 17-20, 2023, will be the first world-class plastics and rubber industry event held in China after the relaxation of pandemic controls. “Over the past year, the uncertain and unpredictable environment has increased the difficulty of organising the exhibition. However, this year the exhibition can still set a new record in terms of scale, with a total area of 380,000m2, an increase of 8.6% from the 2021 exhibition. It is the first time for us to use all 18 exhibition halls of SWECC. It is encouraging and reflects the high confidence and expectations of the industry. Together with more than 3,900 prominent renowned exhibitors from all over the world, the show will follow the themes of high-quality development and vigorous development of advanced manufacturing, join hands together with the industry towards high-end manufacturing, smart manufacturing, and green manufacturing,” said Ms. Ada Leung, General Manager of organiser Adsale Exhibition Services Ltd. at a press conference held in Shenzhen on March 29. Over 3,900 exhibitors from China and abroad are showcasing a full array of solutions, including over 200 world / Asian debut technologies. It is expected that more than 1,400 materials suppliers and 3,000 sets of machinery exhibits will be on the same stage. Industry development At the press conference, the leaders of the exhibition organisers and co-organisers shared their insights on the current situation of plastics industry and made predictions and suggestions. In 2022, the total production of plastic products in China was 77.716 million tons, a year-on-year decrease of 4.3%; the revenue and profit of China’s plastics machinery industry decreased by 7% and 11% respectively compared to the previous year. The profit margin remained at 10%, which was higher than the overall machinery industry’s profit margin of 6% during the same period. Since the start of 2023, China’s economy has achieved a stable and upward trend, and all sectors have started to strive for economic development. This year, the “Government Work Report” proposes a target for the expected growth of China’s gross domestic product (GDP) of around 5% in 2023, focusing, amongst other things, on expanding domestic demand, accelerating the construction of a modern industrial system, strengthening the support of scientific and technological innovation for industrial development, promoting energy conservation, carbon reduction, and pollution reduction in key areas. www.chinaplasonline.com Aptar Closures acquires majority stake of Gulf Closures Aptar Closures, a global player in dispensing closures and active material science solutions, announced the acquisition of majority stake in Gulf Closures, a closure manufacturer for beverage products in Bahrain. With the acquisition, Aptar Closures intends to leverage its global business capabilities and Gulf Closures’ manufacturing expertise, regional network, and experienced team to better serve the company’s existing customers in the Middle East, while opening new market opportunities and strengthening its presence in the region. Gulf Closures employs approximately 60 people at its facility in Bahrain and holds ISO and FSSC certifications. Gulf Closures is a partner to several global and other major local beverage brands in Gulf Cooperation Council (GCC) countries, Levant, and Africa. www.aptar.com sidel.com COMBINING ROBOTICS WITH COBOTICS High palletizing performances in a compact footprint. With RoboAccess_Pal S, Sidel delivers an agile robotic palletizing unit ensuring fast Return on Investment with higher speed and payload.
7 NEWS PETplanet Insider Vol. 24 No. 04/23 www.petpla.net
8 NEWS PETplanet Insider Vol. 24 No. 04/23 www.petpla.net Packamama and Vinventions have launched a collaboration to serve the packaging needs of the French wine industry Packamama and Vinventions, producer of sustainable closures for the global wine industry, have joined forces with Vinventions to sell Packamama’s eco-flat bottles in France. This exclusive sales agreement will see Vinventions offering these PET wine bottles to their winery customers and to the wider French wine industry, too. Stéphane Vidal, Head of Innovation at Vinventions, said the following about this collaboration, “[…] By partnering with Packamama, we can help wineries suffering from the shortage of glass bottles by proposing a PET bottle alternative. Moreover, the eco-flat bottle made from 100% recycled PET plastic will help wineries improve their CO2 footprint.” Santiago Navarro, CEO & Founder at Packamama, explained that France is currently experiencing two concurrent crises: wine bottle supply pressures, with shortages and price rises, and declining wine consumption from younger drinkers. “We offer an innovative bottle packaging solution that is readily available and which is not impacted by the challenging energy crisis. Furthermore, our low carbon footprint solution contributes meaningfully to emissions reduction and climate action, appealing to a younger audience who actively seek out sustainable products,” he commented on the collaboration. Vinventions is a provider of a diverse portfolio of wine closure solutions. www.vinventions.com www.packamama.com BrauBeviale 2023 After a pandemic-related four-year break, preparations for BrauBeviale 2023, one of the leading capital goods trade fairs for the beverage industry, are in full swing. Organisers now finetuned the profile for the exhibition which will take place from 28–30 November in the Exhibition Centre Nuremberg, Germany. The new slogan “We stand for variety” points the way for BrauBeviale. The trade fair has its origins in the beer and brewing segment. The sense of community in the sector has always been palpable at BrauBeviale, say the organisers. At this year’s event, wine and sparkling wine will also be put under the spotlight. The alcohol-free drinks segment is also well represented at BrauBeviale, with around 70 per cent of the exhibitors already registered also offering specific products and solutions for manufacturers of alcohol-free drinks. Ahead of the event, interested trade visitors can filter and display a selection of exhibitors for individual beverage industry segments, to get suggested contacts in advance and plan a visit that is as efficient as possible. Exhibitors are arranged around the exhibition park to represent the process chain for beverage manufacture, from raw materials to machinery and equipment, and from packaging and marketing to components. Supporting programme Established elements of the supporting programme like the Craft Drinks Area or the European Beer Star competition are combined with new formats, developed with and for the entire sector. For the BrauBeviale Forum, the exhibitors will be involved in designing the programme to a much greater extent this year. Some of the key topics that affect all segments are sustainability, energy, raw materials, export, prohibitionist policies, and the European Packaging Directive. Details of the individual items on the programme agenda will be provided in good time prior to the event. www.braubeviale.de
9 NEWS PETplanet Insider Vol. 24 No. 04/23 www.petpla.net NPE2024: Over one million square feet of exhibit space sold The Plast ics Indust ry Associat ion announced that NPE2024: The Plast ics Show has sold 1,024,462 sq.ft (95,176 m2) of exhibit space at this year’s in-person Space Draw event - a new record high with 982,000 sq. ft. (91,230m2) sold in 2018. More than 1,100 exhibitors selected space across 1,259 booths in preparation for the return of the trade show on May 6-10, 2024 in Orlando, Florida, USA. Space Draw was held as an in-person event where exhibitors select their booth location for NPE2024. “We are thrilled to see this level of commitment 14-months ahead of the show opening,” said Matt Seaholm, President and CEO of Plastics Industry Association. “The plastics industry has undergone an incredible amount of change over the last few years and industry leaders are eager to showcase their latest innovations. The swift pace of floor space selections is a testament to NPE’s significance as the largest plastics products, materials and manufacturing show in the Americas. NPE2024 will represent the full plastics ecosystem and supply chain – and servicing key markets like automotive, consumer, recycling, packaging, medical and building and construction. It’s an incredibly positive indication for NPE2024 and for the plastics industry as a whole.” NPE is regularly held every three years as a five-day focal point event for the plastics industry. It is designed to help organisations leverage innovations, drive business growth and build a more sustainable economy. The trade show feature new plastics, materials and manufacturing solutions. The latest product and service advancements will be highlighted in seven technology zones including: Advanced Manufacturing Zone, Bottle Zone, Business Solution Zone, Materials Science Zone, Mouldmaking Zone, Recycling & Sustainability Zone and the Packaging Zone. www.npe.org
MATERIALS / RECYCLING PETplanet Insider Vol. 24 No. 04/23 www.petpla.net 10 Food-grade rPET project and smart waste bins in Bengal PET recycling in East India On Jan 24, 2023, Magpet Polymers Pvt Ltd, Eastern India’s largest PET processing company in Kolkata announced a bottle-to-bottle project to manufacture food-grade rPET. The announcement was made in the presence of Janab Firhad Hakim, Mayor and MIC for Urban Development and Municipal Affairs, Dr Shashi Panja, MIC, Ministry of Industries, Commerce and Enterprises, Public Enterprises and Industrial Reconstruction, Government of West Bengal, and Dr Kalyan Rudra, Chairman, West Bengal Pollution Control Board. For Magpet, Managing Director Mr Devendra Surana, and Mr Indroneel Goho, President & CEO were present at the event. Looking at the future trend of using rPET in food packaging, Magpet will set up the bottle-to-bottle rPET project in Bengal. The project aims to ensure recycling of used PET bottles in Bengal and adjoining states, thereby reducing the consumption of virgin resins and promoting sustainability in the region. The project is also expected to be a step towards integrating the informal recycling sector in Bengal into the regular recycling sector. The project will use European technology and an investment of more than €11 million. The project is divided into three phases. “In the first phase, we will initially install a state-of-the-art European washing plant for the production of food-grade rPET flakes,” Managing Director Devendra Surana told PETplanet. “The capacity will be around 17,000-18,000 t/a and flake production will start by the end of December 2023. The second phase will be followed by an extruder line to produce food-grade pellets from the flakes. Here, commissioning is planned by December 2024 with the same production capacity. So we are also preparing for the emerging demand for food-grade rPET raw material, which will come from the government’s target of 30% recycled content in solid packaging in 2025 and up to 60% content in subsequent years.” The final third phase will see the commissioning of a second integrated rPET pellet line by December 2026. “With the commissioning of the second integrated line, our annual rPET pellet production capacity will double to about 36,000 t/a,” Mr Goho said. The company chose a washing line from the German machine builder Herbold Meckesheim, the manufacturer’s first ever in the Indian market, we were told. For the sorting, the order was placed with Sesotec, also a German manufacturer. For the extruder lines, active discussions are being held with leading European equipment suppliers. A supplier is to be selected shortly and the order placed. On the same day, Magpet also presented the “Smart Bins”, unveiled by the City Mayor, which are to be installed in the city for the disposal of PET bottles. The ‘Smart Bin’, according to the company, is a technologybased and cost-effective solution for plastic waste collection. It is said to have been specifically designed for Indian conditions to provide a wider reach. The size of the bin is said to be designed for collecting large quantities of used plastic bottles. It uses a sensor to report the fill level to a data management centre to ensure a timely and optimised collection route. Around 1,000 of these bins are to be installed at high-traffic locations in Kolkata, such as shopping malls, grocery shops, marketplaces, amusement parks, hospitals, and so on. Discussions on this are in full swing. In addition to collection through this channel, Magpet intends to use regional waste recycling companies for sourcing of post-consumer bottles. The project launch was followed by the Ecologue 2023 symposium, where experts from leading petrochemical manufacturers and global FMCG brands presented their views on the future of PET packaging and its recycling. The main theme of this event is to promote recycling, reduce waste and achieve a clean, waste-free India. www.magnumgroup.in Presentation of the Smart Bin Impression of the Ecologue Symposium
vbr-voѲࢼomvĸ1ol SFL v_b[v |_; 0om7-ub;v bm |_; ;oѲࢼom o= Ѳbm;-u 0ѲoloѲ7bm]Ķ o@;ubm] l-bll Y;b0bѲb| 1ol0bm;7 b|_ bm1u;-v;7 o|r|. 1omvoѲb7-|;7 |;1_moѲo] b|_ |_; Ѳo;v| |o|-Ѳ 1ov| o= om;uv_br Ŏ$ ŏ om |_; l-uh;|Ķ 7;vb]m;7 |o or;u-|; b|_ Ǝ |o Ѵ 0Ѳobm] 1-bࢼ;v -m7 |o u;-1_ - l-bll ruo71ࢼb| o= ƏĶƍƍƍ 0oѲ;vń_ouń1-b|Ķ b|_ |_; Ѳo;v| ;;u ;m;u] 1omvlrࢼomĸ $_; u;=;u;m1; =ou |_; $ r-1h-]bm] l-uh;|Ķ ml-|1_;7 bm |_; bm7v|uĶ v_ov ml;uov |;1_moѲo]b1-Ѳ 7;;Ѳorl;m|v bm |;ulv o= vr;;7Ķ t-Ѳb|Ķ ;uv-ࢼѲb|Ķ 1-r-1b|Ķ ;m;u] ;L1b;m1 -m7 o;u-ѲѲ vv|-bm-0bѲb|ĸ | bm1ourou-|;v _b]_Ѳ bmmo-ࢼ; 7b]b|-Ѳ voѲࢼomv |o C| bm |_; lov| bvbom-u "l-u| -1|ouĸ ѲѲ |_;v; mbt; =;-|u;vĶ |o];|_;u b|_ |_; Ѳo l-bm|;m-m1; 1ov|vĶ l-h; " |uѲ - ļ0;v| bm 1Ѳ-vvĽ -lom] Ѳbm;-u vv|;lv. FLEXIBLE packaging and extreme stretching capabilities SUPERIOR productivity & performance EASY to use and to maintain ECO energy saving & sustainability focused TCO SAFE & CLEAN no hydraulics, operator and food safety LINEAR BLOWMOULDER: SIMPLY THE BEST IN CLASS.
MATERIALS / RECYCLING PETplanet Insider Vol. 24 No. 04/23 www.petpla.net 12 PCR colour prediction service & colourants for beverage closures Colourful solutions Based on articles by Sandrine Reboux, Sr. Marketing Manager Personal & Home Care Markets, Avient & Marco Schaefer, Senior Marketing Manager Food & Beverage Packaging EMEA, Avient Corporation Avient’s PCR Color Prediction Tool is a service that digitally illustrates the colour possibilities or limitations of certain types of PCR before sample development. This can help brand owners and technical colourists simplify the process of transitioning to higher levels of PCR content, shorten the time-to-launch of new product ranges, and create global colour consistency. For the caps and closures sector, the company‘s portfolio include specifically developed colourants for the colouration of organoleptic-sensitive applications. Supporting use of recycled content Avient’s recently launched PCR Color Prediction Service (CPS) is a digital tool developed to help recyclers, converters, and brand owners to have a fast and reliable colour assessment prior to initiating sample development in recycled resins. PCR packaging. Using the CPS, recycled resin colouration was simplified and the time to launch was shortened by avoiding lengthy lab trials, says Avient. Organoleptic colourants for beverage closures “Organoleptic” describes anything involving the senses: taste, sight, touch, smell and sound. Organoleptic influences are especially important when offering a product consumers expect to have a neutral taste, such as water. The beverage market has, for some time, recognised the importance of organoleptic influences in the buying process and is paying increasing attention to it. Most consumers can detect even minute traces of substances that cause off-taste and/or unpleasant odour in mineral water. Any unwanted organoleptic experience associated with the product and the associated brand can lead consumers to reject it. In worst-case scenarios, expensive product recalls and claims for damages can result. Every step in the value chain, from raw material producer to the retailer, has the ability to help to reduce the risk and avoid negative organoleptic influences within their respective areas of control.Caps and closure systems can be a source of tiny quantities of contaminants that can compromise taste and odour. Avient’s SenseAction colourants for caps and closures have been specifically developed for the colouration of organoleptic-sensitive info@petsolutions.it www.petsolutions.it THE rEVOLUTION IS HERE rPET continuous vacuum drying technology follow us DRVseries First introduced in June 2022, Avient’s CPS can digitally illustrate, in real-time, the colour possibilities or limitations of certain types of postconsumer recycled content (PCR), simplifying the overall colour decision-making process during product development and launch. The tool helps optimise the ratio of virgin resin to PCR in order to achieve the best acceptable rendering, proven by scientific data. It can be utilised on a coloured resin of any given shade and aims to decrease complexity when different mixed grades of PCR, both polyolefins and rPET resins, are used. It is particularly powerful in rPET as a slight undertone variation can have a dramatic impact on the final rendering of a transparent-coloured bottle. At K 2022, Avient showcased its success with the CPS in working with L’Oréal, helping the beauty products brand overcome PCR colouring challenges for its Redken line, enabling global colour consistency across all Redken
MATERIALS / RECYCLING PETplanet Insider Vol. 24 No. 04/23 www.petpla.net 13 MATERIALS / RECYCLING 13 applications. They are characterised by three pillars: A dedicated raw material portfolio used for colour development; An ISO 22000 certified production site; A sensory test result provided to customers. SenseAction colourants are formulated with specific carriers and selected pigments within a dedicated raw material portfolio. They comply with the three pillars in the following way: All raw materials are food contact compliant and subject to special handling and storage to help avoid cross-contamination. The SenseAction portfolio is produced on dedicated production lines at an ISO 22000-certified production site. Special cleaning procedures minimise contamination risks. SenseAction colourants are subjected to regular testing by an independent lab. The short sensory test method is efficient and based on a standard method that is also used by the mineral water industry. The test results are included in the certificate of analysis. www.avient.com L’Oréal was able to overcome the challenges of PCR colouring for their Redken line with Avient’s Color Prediction Service CPS. More recently, Avient’s CPS was announced as one of the shortlisted finalists of the Plastics Recycling Awards Europe 2023 in the category Product Technology Innovation of the Year.
PREFORM PRODUCTION PETplanet Insider Vol. 24 No. 04/23 www.petpla.net 14 Sustainable development of required preforms Always in tune with the times The last stop on our Editour takes us to PDG Plastiques. The PET converter is for more than 30 years active in the PET industry, being one of the pioneers in Europe. As a family-owned company, integrity, reliability and partnership are key to PDG Plastiques. The company is located south of Paris and has a subsidiary plant in Algeria. It is producing approx. 2 billion preforms consolidated. Blowing activities represent approx. 70 million bottles per year. We met: Philippe Blonda, Business Development PDG-Plastiques (left) and François Desfretier, CEO (right) In a packaging world dominated by large companies, PDG-Plastiques seeks its place by dedicating itself to special challenges. PDG produces special solutions for the dairy industry, e.g. for barrier containers. Also especially small and very large complex preforms. Two years ago, for example, PDG launched a range of large containers with 5, 10 and 20 l capacities and mouths of 48 and 63mm. Light base technology In the constant struggle to save material, PDG has developed a light base technology, Mint-Tec, together with a partner. By applying this technology, PDG removes more than 10% material from the bottom of the preform. Especially for heavy preforms it is a very interesting technology and being implemented for a new 20 l preform. Recently PDG introduced this technology for a 5 l container for a wellknown French mineral water company. Mint-Tec enables 10% material savings in the bottom of the preform. Alternatives to HDPE or carton packaing A two-layer preform blocking light entrance: Prelactia light barrier for sterilised milk PDG Plastiques and its partners also developed Prelactia, a special injection process, leading to a 2-layer preform, where the inner layer blocks the light entrance. The outer layer covers and gives the bottle a nice white appearance. Since the introduction of the Oxy Block barrier, PDG provides also a barrier against oxygen ingress. Prelactia is offering a solution to the dairy industry in finding alternatives to aseptic HDPE and carton solutions, for any kind of dairy products. It can be combined with recycled PET material as well. The technology used enables PDG Plastiques to comply with European directives requiring a 25% recycling rate for PET bottles by 2025 and 30% by 2030. A different mindset in the green economy, as one of the first in Europe, PDG introduced one and a half years ago the 26/22 light neck finish for carbonated and still beverages, saving almost 2 g as a total package solution towards the standard 1881 finish. The current material price increase led to the fact that brand owners now introducing this new neck finish on large scale. Enhancing material functionality As a researching and forwardlooking company PDG is involved in a project with Keiryo Packaging. Keiryo Packaging technology for plastic processing integrates molecular ordering into the polymer melt, triggering “flowenhanced morphological changes” in the polymer mass with the aim of enhancing material functionality. The KP technology combines a software and a hardware component. It triggers a phenomenon called Flow-Enhanced Nucleation and Induced Crystallisation (Fenic). The hardware is a 3D printed insert – the physical component of the technology, that is retrofitted on standard injection machinery. The inside Keiryo Packaging technology integrates molecular ordering into the polymer melt, triggering “flow-enhanced morphological changes” in the polymer mass. PREFORMS
PREFORM PRODUCTION 15 PETplanet Insider Vol. 24 of the insert is made of microchannels generating a well-defined friction when the polymer passes through the hot runner into the preform mould. Higher level of order of the molecules improve the overall material functionality and can be advantageous for barrier applications – the ordered morphologies can act as an obstacle that delays the gasses permeation. As a result, also less material is required. Keiryo are running trials in PDG’s industrial facility as technology partner. PDG is still in the process of fully scoping these differences, but the demonstration that morphological changes are carried over in the bottle is an important milestone. PDG Plastiques is ISO 22000 FSSC certificated. The company carries out the necessary controls on the injection process using state-of-the-art technologies to ensure that quality targets are met and that customers can market their products with a clear conscience. The laboratory, which is equipped with the modern measuring instruments, monitors the quality of the final product. PDG Plastiques contributes in its own way to the planet by caring for the integrity of its products and the well-being of the planet. www.pdg-plastiques.com The blowing division of PDG Plastiques produce standard PET bottles, flasks and containers and special PET bottles, from 5ml to 10 l.
PREFORM PRODUCTION PETplanet Insider Vol. 24 No. 04/23 www.petpla.net 16 Continuous vacuum drying technology Preparing rPET for preform production Preform production is a critical step in the manufacturing of PET bottles. One key aspect of preform production is the drying of PET granules or flakes prior to injection moulding. The DRV vacuum dryer by PET Solutions is designed specifically for drying PET flakes or granules, using a combination of heat and vacuum. The machine was built on the basis of three registered patents which allows it to treat amorphous material through a continuous vacuum dehumidification process. When using rPET for preform production, some issues may arise that need to be kept in mind to ensure its long-term viability as a material. Although superior to virgin PET in terms of sustainability aspects, a number of problems may arise associated with rPET when being processed. So can for example the quality of rPET vary significantly depending on the source and the recycling process used. Contamination, such as food residue or other type of plastic, can also affect the quality of the recycled material and make it less suitable for certain applications. When preparing the material for injection moulding, vacuum drying has become an increasingly popular method for the drying process. Vacuum drying is claimed to offer several advantages over other drying methods, particularly for materials that are sensitive to heat or that require gentle handling: One major advantage of vacuum drying for preform production is that it can help to prevent degradation of the PET material. Vacuum drying also leads to a uniform drying of the material, as the reduced pressure helps to remove moisture evenly throughout the PET. This can help to ensure consistent quality of the final preform product. Furthermore, vacuum drying can be more energy-efficient than other methods, as the reduced pressure requires less energy to remove moisture from the PET. Overall, vacuum drying is regarded as a reliable and efficient method for drying PET material in preform production. Its advantages in terms of temperature control, speed, uniformity, quality and energy efficiency make it an increasingly popular choice in the beverage industry. Heat/vacuum combination One vacuum dryer solution for PET preform production is the DRV vacuum dryer by PET Solutions. This specialised piece of equipment is designed specifically for drying PET flakes or granules using a combination of heat and vacuum. The combination of heat and vacuum in vacuum drying allows for faster drying times, which can help to increase production efficiency. PREFORMS Continuous vacuum drying technology by PET Solutions
PREFORM PRODUCTION 17 PETplanet Insider Vol. 24 The machine was built on the basis of three registered patents which allows it to treat amorphous material through a continuous vacuum dehumidification process. The DRV vacuum dryer uses vacuum technology to create a low-pressure environment that allows moisture to evaporate from the material at a lower temperature. The dryer also incorporates a hot air circulation system to speed up the drying process and ensure even drying of the material. It features an advanced control system that allows for precise temperature and vacuum pressure control, as well as a range of safety features for safe operation. The machine is constructed with high quality materials, such as stainless steel and high precision sensors, to ensure reliability and durability, says PET Solutions. Additionally, the DRV is designed for ease of maintenance, with a touch screen control panel and a simple interface that allows for easy operation and monitoring. The machine also features an automatic cleaning system and easy access to key components for routine maintenance. The DRV vacuum dryer can be customised to meet the specific needs of the customer, taking into account factors such as production volume, material type and required drying time. This allows for a more tailored solution that can maximise efficiency and quality. Changeover time reduced by 65% According to PET Solutions, the series’ technology allows the material changeover time to be reduced by 65% from 6 hours (standard drying) to 2 hours (vacuum drying). As there is no need for an oil condenser – the removal of residual oil contaminant generated by recycled plastic from the process air can be managed without one – energy consumption could be reduced. www.petsolutions.it interpack 2023 Düsseldorf, 4-10 May Hall 13, Stand A73
PREFORM PRODUCTION PETplanet Insider Vol. 18 No. 0/17 www.petpla.net 18 Status quo and developments in preform manufacturing Minimising waste Based on an article by Gaurav Saraogi, Managing Director Chemco Plastics Industries Limited Chemco Group, a supplier of PET preforms with its headquarter in India, announced that it currently has a global capacity in PET processing of 95,000 t/a and it will expand to 110,000 t/a in 2024. It also processes over 20,000 t/a of other polymers, such as PE and PP. PET preforms have gained traction in the packaging industry because of their characteristics and material properties, including strength, impact resistance, dimensional stability and light weight along with its barrier properties and processability. The development of biodegradable and bio-based PET are leading to more environmentally friendly preforms, reduction in fossil fuel dependency and growth of circular manufacturing solutions, have further boosted PET’s appeal. Its range of markets and applications have been extended with innovations such as nanocomposite materials, multilayer structures and specialised coatings for sensitive products. Chemco Group operates manufacturing facilities equipped with machinery from leading providers such as Husky HyPET Systems, Krauss Maffei, Nissei ASB, Ferromatik, Chen Hsong and Toshiba and more. Its R&D team focuses on material science and engineering and exploring new formulations and additives that enhance PET preform properties. Currently, it has teams working on the development of high-performance barrier materials, lightweighting techniques, and biodegradable or bio-based PET formulations. The main thrust of most of the companies is towards sustainability in terms of reduction of materials, use of postconsumer recycled (PCR) materials and strengthening the networking of the collection mechanism of PCR plastic packaging waste materials. Chemco has got in-house dedicated recycling facilities which allow the company to control the quality of input materials. The high-quality machines and an attached laboratory ensure the recycled materials are safe and can be used for food packaging applications. PREFORMS PET preform markets In the PET preforms market, Asia Pacific is the fastest expanding region. PET preforms are in significant demand in growing economies like China, Japan, and India. Amongst all these countries, China is the primary market for PET preforms. Due to the rising demand for carbonated soft drinks, purified water, food, beverages, and medicinal liquor in economies such as India and China, the need for plastic goods and industries has expanded, boosting the PET preform market in this area. The PET preforms market in the Asia Pacific is predicted to develop with a CAGR of over 6% in-between 2016 and 2026. www.chemcogroup.com
PREFORM PRODUCTION PETplanet Insider Vol. 18 No. 0/17 www.petpla.net 19 Increasing interest in a sustainable alternative to glass The PET wine bottle Economic and supply pressures are driving bottlers to look for alternatives to glass to sustain packaging volumes and differentiation in a highly competitive market. French company Société Générale des Techniques (SGT), which has been making and supplying PET preforms for several decades, says that wine bottlers are expressing increasing interest in PET for their product. SGT has been offering BVS 30H and 22H30 PET necks for wine and spirit bottles for several years. While PET has been used for entry-level wines for some time, bottlers of higher quality and premium brands are also investigating its suitability. Enquiries are being driven by problems in the glass supply chain. Energy costs have pushed up prices and some suppliers have even shut down completely. PET preforms offer a number of advantages to wine bottlers. Their size means that storage requirements are greatly reduced, saving warehouse costs. PET wine bottles are much lighter than glass, typically weighing 50-60 g, compared to glass equivalents of 330 g-1 kg. At the same time, they are more robust than glass. PET bottles are much less likely to break during transport, filling or palletising. As well as saving costs, PET has a lower carbon footprint than glass. It is fully recyclable and rPET can be incorporated in preforms. PREFORMS Meet us at Plastics Recycling Show Europe Amsterdam | Booth H 10 | 10 – 15 May 2023 RECYCLING SOLUTIONS HIGH PERFORMANCE CLEANING ADDITIVES & SUPPORT How can your recycled product meet permanently increasing demands? With the CHT range of high performance process solutions with environmental relief for the wet cleaning and recycling process. We support you directly on site and ensure your quality controls in our laboratories with state-of-the-art equipment. Thus, your strong position in the growing market is confirmed day by day. More about us at www.cht.com In addition, SGT states that wine quality can be conserved within mono and multilayer PET bottles, equipped with UV and oxygen barriers. www.sgt-pet.com SGT’s BVS 30 H wine preform in PET
BOTTLE MAKING 20 PETplanet Insider Vol. 24 No. 04/23 www.petpla.net Increased efficiency and sustainability for large-capacity bottles High-capacity containers, such as 5, 8 and 10 l bottles, are attracting growing interest, especially among companies seeking ‘green’ and efficient solutions. Large volume bottles require fewer containers for particular product volumes, which means that logistic, handling and disposal costs can be reduced, according to SMI S.p.A. The company’s advanced centre for 3D design specialises in devising solutions for rPET bottles of different sizes and shapes that are 100% recyclable, resistant, light and energy efficient. PET containers of up to 10 l produced and filled on a single machine are, increasingly, seen as an optimal solution for mineral water and edible oil manufacturers. SMI’s Ecobloc Ergon KL HC groups the whole wet section of the bottling line into a single system that performs stretch-blow moulding, filling and capping. The system does not need conveyor belts between the blow moulder, filler and collection area, which helps to ensure a controlled and flexible production process, the company says. The entire wet section, which does not require a rinser, can be managed by a single operator, reducing energy consumption and thus improving sustainability. SMI’s machine also integrates preform heating and stretch-blow moulding sections into a single module, which occupies a more compact footprint than other integrated systems currently available. The design is easily adaptable to small bottling lines, helps to reduce transport costs and cuts installation and start-up to just a few days. Ecobloc Ergon KL HC systems can produce and bottle liquid food and beverages at up to 7,200 bph, depending on bottle size and features. Features and characteristics The preform heating tunnel is equipped with thermo-reflective panels, made of energy-efficient composite material, placed to the front and rear of its IR lamps, to ensure high reflection and more uniform distribution of heat over preform surfaces. An aluminium diffuser, integrated into the tunnel, is claimed to ensure optimal temperature control and to avoid overheating. The stretch-blow moulding section is equipped with an AirMaster double-stage air recovery system. The standard air recovery system is accompanied by a second circuit, which recovers and recycles air from the blowing process, which saves energy consumption by the compressor. The blow moulding unit is equipped with motorised stretch rods, controlled by a cam-free electronic drive, for precise management of their path, accurate positioning, and improved energy performance, compared to traditional solutions. This system allows stretch speed modification without mechanical intervention. The mould’s mechanical unit has its own motorisation, to precisely control vertical movements of the base and the holder unit opening and closing. Low dead-volume valves optimise energy and compressed air consumption. Isolation between the dry section of the blower and the wet section of the filler ensure the perfect separation between the two modules. The introduction and return of the washed product take place in the lower part of the machine, by means of a ceramic collector equipped with two gaskets (sealing and a safety) with inspection light. This maintains separation between wet collectors (product and CIP return) and dry collectors (electric and pneumatic), as well as high durability. Filling and capping modules have a modular, unwelded frame, equipped with highly resistant, long-lasting tempered glass access doors. The filling module is equipped with electronic meters, for precise filling. Machine areas in contact with the product to be bottled are made of stainless steel and glass, for hygiene. Optimisation of carousel placement inside the frame has enabled reduced dead angles, which helps productivity. The filling module is equipped with automatic insertion dummy bottles, for fast format changeover and reduce operator intervention. The Ecobloc Ergon KL HC is designed to reduce plant maintenance and management costs. www.smigroup.it
Our consultants aren’t good sales reps but they’re great at problem-solving. yellow.agency 3(7 SUHIRUP SURGXFWLRQ OLQHV HQJLQHHUHG E\ 2WWR 6\VWHPV URXWLQHO\ VHW LQGXVWU\ EHQFKPDUNV IRU SHUIRUPDQFH DYDLODELOLW\ HQHUJ\ HIƓFLHQF\ and lowmaintenance costs. This is because the consultants and engineers at Otto Systems meet your production challenge with open minds, decades of experience and deep knowledge about PET production processes and techniques to ensure high quality at the best possible price. That’s why they are able to plan and implement production systems that are uncompromisingly tailored to your needs, independently selecting the best components from experienced manufacturers to achieve your goals. Call +41 55 285 22 11, otto-systems.com
BOTTLING / FILLING PETplanet Insider Vol. 24 No. 04/23 www.petpla.net 22 Climate-neutral juice factory European manufacturer Innocent Drinks, which is 90% owned by Coca-Cola, has opened a new bottling plant that will be 100% electrically operated and totally carbon neutral. It is fitted out with four Krones PET bottling lines and corresponding IT infrastructure. Drinks manufacturer Innocent Drinks’ new facility in the Port of Rotterdam, Netherlands, named “the blender”, is one of the world’s first carbon neutral factories. Krones has delivered and installed four speciallydesigned PET lines for it. Innocent, which is the European market leader for smoothies, has a healthy, sustainable and environmentally responsible image and aims to set an example in the food industry. Sam Woollett, Site Director of “the blender”, says that the business is aiming to be climate neutral by 2025 and the new plant will play a key role in reaching that target.” Innocent Drinks has made minimising its carbon footprint a primary goal. Its efforts were recognised in 2018, when it was officially certified as a B Corp – a private certification of for-profit companies for their “social and environmental performance” – demonstrating that a successful business can also be responsible. The company has used contract fillers for many years but decided to build its own filling plant in order to better manage the sustainability of its production. The blender, one of the first carbon neutral factories in the world, is equipped with a combination of technological innovations and clever designs, all in the interest of reducing emissions in every area of operations. The plant was built from sustainable, locally sourced materials and incorporates heat recovery and solar panels, will have its own wind turbines from 2024 and will then operate as a carbon neutral facility. A fleet of newly designed electric trucks transport bulk orange juice from a nearby storage facility to the factory. The location in the Port of Rotterdam was chosen deliberately; it helps Innocent to reduce the total mileage in its value chain by 20 percent, which also helps to reduces its emissions, Sam Woollett explained. As well as building an environmentally compatible facility, the company wanted to create a pleasant environment for the 200 employees on the site. The building has been designed to provide plenty of natural daylight, room to move around and space for working together, and a safe and inclusive company culture. Adaptable, quick changeover PET lines The four PET lines supplied by Krones are used primarily filling juices and smoothies. Innocent Drinks has left enough room in the plant to add a fifth line if needed. The main criteria for awarding the contracts for the greenfield project were: sustainability, including minimised consumption of operating supplies and water; safety and reliability of the equipment; and the quality of the product and its packaging. Innocent sells a wide range of different drinks in different sized bottles, made to very different recipes, so the systems have to be flexible and capable of producing high output volumes per hour but they also have to be easy to change over to another product or size. “Two to three different bottle formats and around ten different drinks are filled on each line,” says Sam Woollett. “That’s why we ultimately chose Krones. They offered the best solutions for our needs.” Production began in July 2022, after the four PET lines were delivered, installed and tested in early 2021. Although the lines are identical, they are currently filling at different output rates. One is operating at 22,000 containers per hour, a second at 27,000 and the other two operate at 32,000 containers per hour. The Contipure AseptBloc DA blow-moulder-filler block consists of a Contipure AseptBloc DA Innocent’s product range extends from orange juice to vitamin smoothies and ginger shots. Topmodul labeller KRONES Hall 13 Booth A73
BOTTLING / FILLING PETplanet Insider Vol. 24 No. 04/23 www.petpla.net 23 Contiform 3 Pro stretch blow moulder and a Modulfill Asept aseptic filler. The Contipure D preform sterilisation module features a sustainable design that uses very little hydrogen peroxide, steam and energy, and requires very short preparation times, thereby helping to ensure a low total cost of ownership (TCO). After filling, all containers are provided with a tamper-evident seal and – depending on the bottle – either a wrap-around or a pressure-sensitive label. Packing is handled by the Variopac Pro FS, just downstream of the Topmodul modular labeller. Filling under aseptic conditions ensures a longer product shelf life and preserves the product’s flavour. The lines are cleaned every 72 hours or as needed between products. A complete CIP process takes around 90 minutes. The Contipure AseptBloc DA at a glance: Suitable for up to 70,000 containers per hour; High acid products; Round and square PET containers; Standard and lightweight containers; Only one sterilising medium: gaseous hydrogen peroxide (H2O2). Trust-based collaboration Innocent Drinks especially appreciated the reliability and flexibility that the Krones team brought to the project. “We’ve been very lucky with the Krones team on site. When they arrived, we were behind on the actual construction of the building. They were very flexible and supportive and helped move the project along,” says Sam Woollett, Site Director, Innocent Drinks. “What I appreciate most about Krones is that they do what they say they’ll do. We’ve never had an incident throughout the whole project where they said they would do something and not delivered. All the lines went in on time, they started running on time and the performance tests all happened on time. Being able to actually just trust in Krones has made it so easy to work with them across this whole project.” Digital technology Krones is also helping the project go digital. Its digital technology experts developed for innocent a turnkey manufacturing execution system (MES) concept that integrates the new plant’s enterprise resource planning (ERP), process control, and warehouse management systems using the appropriate interfaces. Various IT solutions from Krones’ SitePilot portfolio, including the Planning production planning system, the Line Contipure D preform sterilisation module Sam Woollett, Site Director, Innocent Drinks 2023 Training Schedule Technology&Application of PET Plastic Packaging for Hot-Fill &Aseptic Beverages Join our expert team for small group training on a variety of subjects - frommaterials to recycling. Scan to learn more & register for classes! ©2023 Plastic Technologies | 1440 Timberwolf Drive, Holland, Ohio USA 43528 www.pti-usa.com info@pti-usa.com info@pti-europe.com Management order and material management system, and Line Diagnostics for data acquisition and analytics are included. Innocent Drinks will use Connect from Krones’ Share2Act Services, which means that all information, such as shift schedules, can be made available digitally to all employees. www.krones.com
RkJQdWJsaXNoZXIy NTY0MjI=