No.9 2023 www.petpla.net D 51178; ISSN: 1438-9452 25 . 09 . 23 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 PETplanet is read in more than 158 countries MARKETsurvey It‘s all about caps! Page 27 Page 20 PACKAGING Page 36
The world leader of PET Oil free piston compressors Efficiency in sobriety AF COMPRESSORS → WWW . A F C O M P R E S S O R S . C O M → S A L E S @ A F C O M P R E S S O R S . C O M ENERGY COSTS REDUCED BY 1 5 % UNL IMI TED L I FE T IME ! MAINTENANCE COSTS REDUCED BY 50 % A F C O M P R E S S O R S A L S O P R O V I D E S S U S TA I N A B L E A N D L O N G L I F E 8 & 1 0 B A R O I L F R E E A I R BRAU BEVIALE Nuremberg, Germany 28-30/11/23 Hall 7A / Stand 7A-423
No.9 2023 www.petpla.net D 51178; ISSN: 1438-9452 25 . 09 . 23 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 PETplanet is read in more than 158 countries MARKETsurvey It‘s all about caps! Page 27 Page 20 PACKAGING Page 36
We think about your caps, so you can think of everything else. www.corvaglia.com
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. 09/23 www.petpla.net Dear readers, Today, I would like to talk about family. After having spent nearly 25 years working at PETplanet Insider, I am beginning to think about the future 10 years from now. And I do have to confess that I would like nothing more than to travel the world with Editourmobil and visit all you lovely readers! In order to ensure that the PET industry’s information pool remains in safe family hands, the time has come to gradually involve the next generation. Processors such as Alpla and Bericap are showing the way by bringing in the third generation. And so I am delighted to report that, after two years of working behind the scenes with us, my daughter, Miriam Trotter, will be joining our editorial team. She is moving from her job as a copywriter in the private sector and will initially be in charge of new media technologies. She has gained her first experiences in the industry already as a baby when vising the K fair in Düsseldorf. She was even awarded the youngest visitor of the event. A title she wears with pride to this day. Miriam became more involved in the subject at the VDMA in Kolkata, India. In supermarkets, she looks at injection points and neck rings on beverage bottles first, which tells her more about the quality than reading a list of ingredients on labels. Anyone wanting to meet her in person should call in at Brau Breviale where she will continue a trade fair career that once began in Düsseldorf and which has carried on with her involvement in several Drinktec events. Greetings from the family! Yours Alexander Büchler PS For the sake of completeness, my other daughter, Emma, was in charge of our address marketing, and my son, Valentin, is heavily involved in our brewery operations. Both are currently working with companies operating in diff erent fi elds along the PET value chain.
PETcontents 4 PETplanet Insider Vol. 24 No. 09/23 www.petpla.net 09/2023 Page 44 MATERIALS / RECYCLING 10 Launch of New Generation Dryer range BOTTLE MAKING 12 NIR heating technologies for PET bottle blow moulding 13 Stretch-blow moulding system for big bottles LABELLING 14 Analysis of modular hot-melt & self-adhesive labelling machine INSPECTION 16 Laboratory throughput – the name of the game! Agr’s Gawis 4D - a winning solution for Sipa MARKET SURVEY 27 All about caps! TRADE SHOW PREVIEW 20 Fakuma 2023 preview 32 Filtration technology for PET recycling 34 360° label inspection 35 Italian PET recycler launches new food-grade rPET brand PACKAGING/PALLETISING 36 Combined packaging machine - For the evolving food market 38 Handling of lightweight bottles - ‘Mizu To Ikiru’ philosophy meets contactless accumulation solution BUYER’S GUIDE 50 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 40 PET bottles for home + personal care 42 PET bottles for beverage + liquid food 44 Onsite 45 Products 48 Patents 49 Outer Planet Page 38 Page 13 PACKAGING
yellow.agency OUR INJEC TION MOULDS FOR PE T AND PAC FEATURE PRECISE , LONG-LASTING SWISS CRAF TSMANSHIP. OT TO-HOFSTE T TER. SWISS A FAMILY OWNED SWISS COMPANY. T OTA LLY SW I S S.
PETnews 6 NEWS PETplanet Insider Vol. 24 No. 09/23 www.petpla.net Next Generation Group invests in Hydrodyn, expanding its presence in the plastic recycling market Nex t Gene r a t i on Gr oup has acquired a majority share in Hydrodyn, a renowned technology provider specialising in plastic waste cleaning and purifying. This strategic partnership solidifies the group´s commitment to offering comprehensive plastic recycling solutions, particularly in the field of postconsumer recycling. Under the terms of the agreement, Hydrodyn will retain its operational independence while working closely with Next Generation Group, by using a high synergy potential. This collaboration will allow both companies to leverage their expertise and resources to deliver comprehensive and efficient end-to-end plastic recycling solutions that address the evolving needs of customers in the recycling machinery market. The shared objective is to prioritise the attainment of specific polymer characteristics that are essential for a diverse array of commodity applications, in order to effectively substitute virgin plastics. The acquisition provides Hydrodyn with access to Next Generation Group´s extensive global network, unlocking new opportunities for growth and expansion. The partnership is intended to reinforce their market position and benefit both companies. By leveraging their expertise and pooling resources, they aim to offer holistic solutions for post-consumer recycling. This collaboration is claimed to enable them to address the entire lifecycle of plastic materials, from product design to the recycling process. By integrating their capabilities, Hydrodyn and the Next Generation Group are at the forefront of promoting sustainable practices and closing the loop in the plastic value chain. www.ngr-world.com Berry Global appoints Kevin Kwilinski as CEO Berry Global Group, Inc, a supplier of packaging solutions for consumer goods and industrial products, announced that its Board of Directors has unanimously elected Kevin Kwilinski as CEO of Berry, effective October 2, 2023. In connection with this appointment, the Board has elected Stephen Sterrett, Lead Independent Director, as Chairman of the Board, also effective on October 2, 2023. As previously announced in February 2023, Tom Salmon will retire from his roles as CEO and Chairman, and he will remain with the company through the end of the calendar year in an advisory capacity to ensure a smooth transition. Mr Kwilinski brings to Berry nearly three decades of experience in the packaging industry. He currently serves as President and CEO of Multi-Color Corporation, a global provider of label solutions, where he successfully led and integrated multiple acquisitions, resulting in significant EBITDA and revenue growth while delivering above target commercial and operational synergies. Prior to that, he served as CEO of Fort Dearborn Company, a leading supplier of decorative labels for the beverage, food, household products, nutraceutical, paint and coatings sectors, which merged with Multi-Color in July 2021 with the backing of private equity firm Clayton, Dubilier & Rice. Mr Kwilinski previously served as CEO of Paperworks Industries, where he guided the company’s growth by supporting an aggressive go-to-market strategy and simultaneously implemented continuous improvement processes. www.berryglobal.com Neste to enable PET bottles produced with bio-based materials with Suntory, Eneos and Mitsubishi Corporation Neste has entered a cooperation agreement with Suntory, Eneos and Mitsubishi Corporation to enable the production of PET resin made with renewable Neste RE on a commercial scale. Neste RE is Neste’s feedstock for polymers production, made 100% from bio-based raw materials such as waste and residues, e.g. used cooking oil, to replace fossil feedstock in the value chain. Japanese beverage company Suntory will utilise the renewable PET resin to produce bottles for its products in 2024. A new partner for Neste in Japan, Eneos will use bio-intermediates based on Neste RE to produce bio-PX (bioparaxylene) at its Mizushima refinery in Okayama, Japan. The bio-PX will then be converted to PTA and subsequently to PET resin for Suntory to use to manufacture their PET bottles. Mitsubishi Corporation will be coordinating the collaboration between the value chain partners. “In order to tackle the imminent climate crisis and its consequences, companies are required to take responsibility now. Through partnering along the value chain, Neste can contribute to reducing the polymers and chemicals industry’s dependence on fossil resources as well as to manufacturing of products that have a lower carbon footprint,” says Lilyana Budyanto, Head of Sustainable Partnerships APAC at Neste Renewable Polymers and Chemicals business unit. A mass balancing approach will be applied to allocate the bio-based materials to the PET bottles. www.neste.com
7 NEWS PETplanet Insider Vol. 24 No. 09/23 Recyclable PET polymer incorporating furandicarboxylic acid successfully processed into preforms Origin Materials, Inc. and Husky Technologies announced a significant development in the commercialisation of PET incorporating the sustainable chemical FDCA (furandicarboxylic acid) for advanced packaging and other applications. Origin successfully polymerised the bio-based sustainable chemical FDCA into the common recyclable plastic, PET, and Husky moulded the resulting “PET/F” hybrid polymer into preforms that were then blown into bottles. The companies used Husky’s injection moulding technologies and manufacturing equipment, a commercial manufacturing-scale level of processing demonstrating the ability of PET/F, a polymer made with FDCA, to be integrated into existing PET production systems. Origin expects to develop and sell a family of 100% bio-based, low-carbon PET/F polymers offering full recyclability and superior performance compared with traditional 100% petroleum-derived PET, as the company state. Origin anticipates that PET/F will offer “tunable” performance, with properties such as enhanced mechanical performance and superior barrier properties enabling longer shelf life controlled by adjusting manufacturing conditions and the quantity of FDCA copolymer. This development demonstrates a pathway for the drop-in market adoption of FDCA to produce polymers cost-effectively from biomass using Origin technology. Origin expects to enable the production of FDCA, PEF (polyethylene furanoate), and PET/F on a commercial scale using its patented technology platform, which turns the carbon found in sustainable wood residues into useful materials, while capturing carbon in the process. FDCA is a chemical building block with diverse applications including polyesters, polyamides, polyurethanes, coating resins, and plasticisers. FDCA is also the precursor for the next-generation sustainable polymer PEF (polyethylene furanoate). By combining FDCA with PET, Origin has produced PET/F, a “tunable” hybrid polymer offering performance enhancements and full recyclability. PEF, another product derived from FDCA, is claimed to offer an attractive combination of sustainability and performance benefits for packaging. Origin’s PEF is expected to be 100% bio-based, fully recyclable, have attractive unit economics, and offer a reduced carbon footprint, with good strength, thermal properties, and barrier properties compared to today’s widely used petroleumbased materials. www.originmaterials.com www.husky.co
8 NEWS PETplanet Insider Vol. 24 No. 09/23 www.petpla.net A new rPET production unit for the SGT Group Société Générale des Techniques (SGT) is building a new recycled PET production unit in Rezé, in western France. The Group’s objective is to reach 26,000 t/a of rPET, thanks to new equipment and the performance of its teams. The new recycling unit will be located in Rezé, in the heart of the Group’s historic preform manufacturing plant and head office. This new investment reflects SGT’s determination to guarantee a continuous supply of rPET to all its customers, the majority of whom are bottlers in the food sector, 15 months ahead of the implementation of the European Directive 2019/90 which establishes a minimum recycled content requirement of 25% for PET bottles by 2025. The company had already anticipated market demand, as in 2019, the Group CEO Frédéric Mignot inaugurated his first PET recycling plant, named SGR, in Chalon-sur-Saone in Southeast France. With an annual capacity of 12,000 t, SGR produces a premium quality rPET claimed to be equivalent to virgin PET, suitable for direct food contact and approved by the European Food Safety Authority (Efsa). “We will be increasing our rPET production capacity to 26,000 t by mid-2024,” explains Frédéric Mignot. To achieve this objective, the company is equipping itself with the latest technologies, including the new LSP (Liquid State Polycondensation) process from Next Generation Recyclingmaschinen (NGR) for the treatment of post-consumer PET. In this process, all PET impurities are removed in the liquid phase to meet the requirements for food packaging. Complying with Efsa and FDA standards, this process is also claimed to offer higher energy efficiency than conventional SSP applications. In addition, the extraction of contaminants when PET is in the liquid phase enables higher levels of decontamination, particularly for NIAS (non-intentionally added substances) and bisphenol A. To support its project, SGT has been able to count on financial assistance from Ademe, the Ecological Transition Agency from western France. Work will start in December 2023, with commissioning of the new recycling unit scheduled for the second quarter of 2024. www.sgt-pet.com Lindner & Erema establish plastics recycling holding company Erema Group and Lindner Holding have established a holding company called Blueone Solutions. This newly formed entity aims to leverage both companies’ expertise and jointly execute research projects to create industry standards in plastics recycling. From waste to recycled granulate, potential new raw materials pass through several different recycling processes. These range from sorting, shredding, washing, and drying to extrusion, including filtration, compounding, and odour optimisation. The challenge for the industry lies in fine tuning these individual recycling steps – in particular when energy efficiency and high recyclate qualities are to be achieved. The founding of Blueone Solutions, a company which is owned 50:50 by the Erema Group and Lindner Holding and to which shares of Lindner Washtech were contributed, is that very starting point. The experience of Lindner Washtech will be combined with that of the extruder manufacturer Erema. They aim to increase the added value and set industry standards by adjusting and optimising processes and conducting joint research projects. Former projects, such as the pilot facilities in the LIT Factory at the Johannes Kepler University (JKU) Linz, Austria, allowed the companies to enter into a close technical exchange already years ago. www.erema.com R&D Leverage Europe expands to offer complete solution in IBM development R&D Leverage Europe, a subsidiary of Adler Industrial Solutions, announced an expansion in its services with the addition of Injection Blow Mould (IBM) capabilities. In 2023, the company has invested substantially in equipment and infrastructure to facilitate this development, including the purchase of IBM machines for mould validation and sampling. In anticipation of the increased demand for their services, R&D Leverage Europe wi l l expand i ts technical team both through numbers, and expertise through intensive training. This strategic move is intended to ensure that the company remains at the forefront of IBM technology and is well-equipped to deliver cutting-edge solutions. This expansion will enable the company to better serve its existing clients while reaching out to new customers in the IBM sector, says R&D. Employing over 80 dedicated professionals, R&D Leverage Europe operates from state-of-the-art facilities on its campus in Ashfield, Nottinghamshire, England, with a total area of 40,000 square feet. As part of its expansion plans, the company is actively developing an adjacent 15,000-squarefoot facility to house a second Product Solutions Lab, initially housing two mould validation machines for the IBM sector. This investment will further solidify the company’s position as an industry leader. www.adlertooling.com
9 NEWS PETplanet Insider Vol. 24 No. 09/23 www.petpla.net Chemical PET recycling plant under construction To strengthen its efforts in the area of sustainability, Köksan PET ve Plastik Ambalaj San. ve Tic. A.Ş., headquartered in Gaziantep, Turkiye, aims to construct a state-of-the-art rPET plant based on chemical recycling of post consumed PET waste. It is intended to commence the production of 100% food grade rPET by the end of 2024. The capacity of this plant is expected to be 110.000,00 metric tons per year; 100 % rPET content resin will be ready to use for bottle grade and textile grade application. According to the company, the process of recycling PET flakes through depolymerisation to BHET and subsequent 3-micron microfiltration results in a resin that is comparable to virgin monomer, making it suitable for food-grade applications. Köksan’s patent process to make high viscosity and lower than 1 ppm AA level in resin without any SSP process is claimed to be most suitable for bottle grade application, states the company: “This will be the first plant of this kind for 100% rPET resin for all food grade applications”. The plant is also designed to produce various qualities textile grade resin with 100% rPET or virgin resin production. Köksan states that this makes the plant most versatile, economic and environmentally friendly production process. Chemical recycling process has some advantages over mechanical or thermal recycling: the primary benefit of depolymerisation through the glycolysis process is its lower operating temperature, typically around 200 °C. This avoids the side reactions and generations of BPA and phthalates which is generally due to high temperature thermal process like mechanical recycling. The chemical depolymerisation to BHET level ensures the process is similar to virgin polycondensation reaction and product rPET is similar to virgin PET resin. Another advantage is that it can be recycled multiple times, as it undergoes depolymerisation to BHET and then follows a process similar to the standard production process. www.koksan.com
MATERIALS / RECYCLING PETplanet Insider Vol. 24 No. 09/23 www.petpla.net 10 Launch of New Generation Dryer range Italian company PET Solutions has announced the launch of a new range of dryers, branded New Generation Dryer DR-RE Series. PET Solutions says that the new range delivers improved performance across a range of parameters, including higher levels absorption capacity, while improving energy recovery by 25% and reducing consumption by around 15%. Risks of inadequate dehumidification PET is susceptible to moisture absorption from the surrounding environment, which can undermine its mechanical and optical properties. The particular issues PET Solutions lists are: Loss of mechanical strength leads to increased material brittleness. This could result in damage during handling, transport or package opening, raising safety risks and incurring higher costs. Variations in optical properties such as transparency and brilliance, caused by trapped moisture, can affect the aesthetic appearance of packaged products, influencing consumer experience and quality perception. Moisture within PET can lead to problems during the production process, such as bubble formation or surface defects. These can compromise the structural integrity of the packaging and affect its functionality. Moisture can catalyse chemical reactions and lead to degradation of polymer chains. This could impact the chemical stability of the material and even cause the formation of unwanted substances that could interact with the packaging’s contents. Effective dehumidification and proper treatment of PET will help to retain its desired strength, durability, and optical properties. A higher quality end product will result in more attractive packaging, with positive results for brand image and customer experience. Reducing moisture-related defects simplifies production processes and reduces production interruptions and the cost of downtime and repairs. PET Solutions’ New Generation Dryer DR-RE series PET Solutions says that its new range of dryers represents a significant step forward in material processing and establishes new standards for efficiency, performance and stability. The latest iteration of the New Generation Dryer series includes a brand new patented process characterised by the blowers positioned after the dessicant towers in the air process circuit. This location is said to deliver a cut of 15% in blower-related energy consumption. Reduced energy usage makes the new range suitable for environmentally responsible production facilities. What the company describes as a “sophisticated double filter system” is claimed to deliver a 47% increase in filtration capacity. PET Solutions says that this notable boost in capacity is more than just a statistic and that it indicates a substantial improvement in purity and cleanliness of processed rPET materials. In addition, the advanced filter system is claimed also to streamline maintenance operations and consequently further optimise production processes. The presence of a greater number of molecular sieves increases absorption capacity by up to 31 l per tower. This means that the number or regenerative cycles is reduced, while extending dessicant lifetime. The larger size of the exchanger within the dryer results in a 45% amplification in cooling capacity. This accelerates the drying process and ensures that PET and rPET being processed retain their optimal properties during transition from raw to finished product. PET Solutions says that the dryer offers greater throughput while maintaining material integrity, ensuring consistent quality output. The company declares that its New Generation Dryer achieves 25% overall energy recovery, which contributes to a more sustainable production cycle while eliminating the need for an oil condenser. The development is intended to raise standards for efficiency and performance in material processing. www.petsolutions.it New Generation Dryer DR-RE series The DR-RE dryer features a unique, patent-protected design.
MATERIALS / RECYCLING PETplanet Insider Vol. 24 No. 09/23 www.petpla.net 11
BOTTLE MAKING 12 PETplanet Insider Vol. 24 No. 09/23 www.petpla.net achieve uniform temperature distribution between the inner and outer parts of the preform wall with reduced heating time and corresponding energy efficiency. CEO Maxim Poliansky explained: “Not all blow moulding machines can process rPET preforms. This is mainly due to material properties like melt flow, crystallinity and molecular weight. Material contamination, for example, can also lead to premature wear of machine components. The importance of NIR heating systems for blow moulding with rPET preforms also increases with the proportion of recyclate contained in the preform. Not all machines on the market can achieve the correct melting temperature and thermal stability. Our model range of reheat stretch blow moulding machines is compatible with rPET,” Maxim Poliansky said, referring to projects completed in Europe, Asia, Africa, North and Latin America. The role of the NIR heating system in bottle blow moulding from rPET preforms increases with the percentage of recycled material in the sample. www.pet-eu.com NIR heating technologies for PET bottle blow moulding The global market for PET containers is expected to grow at a CAGR of 5.3% between 2022 and 2023. According to a report by Future Marketing Insights, it will increase from US$ 73.1 billion to US$ 122.4 billion. Currently, it is estimated that more than 500 billion PET bottles are used worldwide for packaging various products. NIR (near infrared) irradiation plays an important role in the various (processing) stages and is further fuelled by the global rPET trend. Machine manufacturer PET Technologies, headquartered in Austria and manufacturing in Ukraine, designs and installs NIR heaters and sheds light on the background and advantages of the technology. IR lamps emit a wide range of frequencies with three types of infrared radiation: wave numbers in the near IR range of 2,500-714nm (4,00014,000cm-1), medium range of 25,0002,500nm (400-4,000cm-1) and far range of 2,500.000-25,000nm (4-400cm-1). Both IR and NIR spectroscopy use spectral data to characterise matter. The main difference is the range of the electromagnetic spectrum investigated. NIR spectroscopy focuses on the range from 714nm to 2,500nm. This is just outside the range normally visible to the naked eye. Radiation in the NIR range can penetrate PET completely to a certain depth. According to the Beer-Lambert law, the amount of light absorbed by a sample (in our case a PET preform) is directly related to the volume of the sample that the light passes through and the concentration of the sample. The importance of NIR technology for PET bottle production is obvious: the heating process is faster compared to a conventional IR system, resulting in energy savings, plus space savings in the design of the heater for the stretch blow moulding machine. PET Technologies, which has been in the industry for 24 years, was an early adopter of NIR heating for its linear PET stretch blow-moulding machines, as seen in the APF Max series. The compactly designed model series is intended to APF Max SBM series
BOTTLE MAKING 13 PETplanet Insider Vol. 24 No. 09/23 www.petpla.net XtraBig machines are mainly aimed at production of big bottles for water or edible oil, as well as other sensitive products, with neck sizes up to 48mm. They can also make smaller bottles, if necessary. There are three models, with four, five, and six cavities. The smallest, XtraBig 4, can serve lines for 30-40,000 litres per hour, while with the largest, XtraBig 6, the number rises to 50,000 litres per hour. All Xtra models combine features to maximise performance while cutting Total Cost of Ownership (TCO). They feature an extra-wide active process angle, reduced energy consumption, high flexibility and ease of use, as well as compatibility with other machines upstream and downstream. The very wide process angle on Xtra machines facilitates production of bottles of high quality, even at high speeds. This makes it possible to apply high pressure air for longer, enabling accurate production of containers, even the most complex ones, said Sipa. The Xtra Big systems share many design features with their regular counterparts: machine layout, preform handling and active grippers etc. Sipa’s engineers have used finite element analysis (FEA) to create a new blowing press designed specifically for big bottles. The Italian company’s expertise in large containers extends beyond bottle blowing machines, starting with preform design, development and injection moulding, and going through to filling. The company’s fillers provide state-ofthe-art solutions for electronic filling for water, and weight filling for edible oils, with ATEX approvals for volatile chemicals and alcoholic liquids. With the SincroBloc clean and compact combined blowing and filling unit, system integration enables bottling companies to avoid transportation of empty bottles and eliminates the need for rinsing. A SincroBloc incorporating an XtraBig and the BigFill volumetric gravity-filling monobloc for formats from five to 12 litres has an hourly output capacity of 6,600 five litre containers and up to 4,000 containers in the very largest sizes. www.sipasolutions.com Stretch-blow moulding system for big bottles Sipa’s Xtra rotary stretch-blow moulding machine series, renowned for high-speed, low-cost production of top-quality containers, has been extended upwards. Xtra Big variants can blow bottles as large as 12 litres. product development caps & closures design high cavitation moulds multi-component moulds closure production systems after sales service competent – professional – inspiring +43 5572 7272-0 | sales@z-moulds.com | www.z-moulds.com z FURTHER SHOWS GULFOOD Manufacturing Dubai, Nov. 7-9th PLASTIMAGEN Mexico Mexico City, Nov. 7-10th NEXT SHOW FAKUMA 2023 October 17th-21th meet us at our booth Hall A7 - 7311
LABELLING PETplanet Insider Vol. 24 No. 09/23 www.petpla.net 14 Analysis of modular hot-melt & self-adhesive labelling machine Tech-Long Packaging Machinery Co. Ltd, Guangzhou, known for PET bottle blowing, filling and packaging equipment, also offers modular hot-melt and self-adhesive labelling machines. The hot-melt labeller can apply the label anywhere on the container by rotating the container with a label transfer system controlled by a servo motor. The modular design makes the model adaptable and flexible, suitable for various round/irregular containers and materials, and is widely used in industries such as food and beverages, cosmetics, chemicals, spices, spirits, etc. Precision positioning This device adopts servo system bottle rotation positioning technology, which can achieve labelling at any position of the container with high positioning accuracy and fast response speed. Whether it is a circular, square, or elliptical container, this device is claimed to be able to accurately locate and label, meeting the needs of containers with different shapes. The equipment’s labelling station has a multi-directional quick adjustment function, which can meet the labelling needs of irregular surfaces such as cylinder and cone. Tech-Long says that this device can be flexibly adapted to achieve precise labelling effects. In order to maximise the accuracy of labelling and reduce system vibration and noise, the modular hot-melt & self-adhesive labelling machine adopts a fully servo labelling station design. This design can ensure the accuracy and stability of labelling, improve production efficiency and product quality. Modular multi-labelling station layout The equipment adopts a modular design, and the number of labelling stations can be increased or decreased according to customer needs, meeting the requirements of multiple labelling. Customers can configure the number of labelling stations based on product characteristics and needs, achieve personalised labelling solutions. The modular hot-melt & self-adhesive labelling machine can achieve different types of combined labelling requirements. Whichever way it is used, the device can be flexibly combined to meet the labelling needs of different products. The modular hot-melt & self-adhesive labelling machine is widely used in industries such as food and beverage, cosmetics, chemical, seasoning, and alcohol. It can adapt to full bottle labelling or local labelling, such as neck labelling. This device can use various packaging materials such as OPP, BOPP, pearl film, composite paper, etc. to achieve efficient and accurate labelling operations. Operational principle The device conveys bottles to the bottle tray through the bottle inlet door, screw (or non-screw bottle inlet mode) and bottle inlet star wheel, accurately positions them through the bottle pressing head. Subsequently, the bottle reaches the labelling position with the rotation of the large plate for labelling. After being cut by a cutting knife, the label enters the labelling wheel and is coated with glue by a rubber roller. Then, it is attached to the bottle body as the labelling wheel rotates. Finally, the bottles with labels are transported to the conveyor chain at the exit through the bottle exit star wheel. The production speed of the modular hot-melt & self-adhesive labelling machine can be automatically controlled. The device can automatically adjust the bottle infeed and outfeed flow rate as needed. In addition, the bottle inlet door can ensure the minimum bottle storage capacity at the inlet and automatically stop the bottle inlet operation when the outlet is full. This control function ensures smooth operation and efficient production of the equipment. The Tech-Long modular hot-melt & self-adhesive labelling machine has been designed to demonstrate strong technological innovation capabilities in the labelling industry through its highprecision positioning and flexibility and has broad application prospects. Its fully servo labelling station design is claimed to ensure the accuracy and stability of labelling. Modular design and a combination of multiple labelling types enable the device to adapt to different products and needs. www.tech-long-intl.com
LABELLING PETplanet Insider Vol. 24 No. 09/23 www.petpla.net 15 erema.com/bottlesforever VISIT US AT: FAKUMA | Germany, Friedrichshafen October 17 - 21 2023 Booth A6-6314 New product contains up to 100 % rPET. Turn your PET flakes into recycled pellets or turn them directly into preforms: EREMA bottle-to-bottle systems stand for uncompromising food contact compliance with all the advantages of unique SafeFlake technology. Rely on highly effective decontamination, high-performance filtration, safe handling and the highest energy efficiency. For the best quality end product. Consistent quality even if the input material changes. It’s how you keep driving the bottle cycle forward sustainably. Cost effective, safe and environmentally friendly.
INSPECTION 16 PETplanet Insider Vol. 24 No. 09/23 www.petpla.net Agr’s Gawis 4D - a winning solution for Sipa Laboratory throughput – the name of the game! Sipa S.P.A., with headquarters in Vittorio Veneto, Italy, is well known in the plastics industry for its expertise in producing a range of high-end PET preform and container moulding systems. Being one of the few companies that has experience with both preforms and containers, they are uniquely positioned to offer a one-stop experience for a complete production line - from resin to finished product, including preform manufacturing, bottle and mould design and production, filling, capping and palletising. Regardless of the product supplied, quality has the highest priority, and the Sipa design, testing and qualification Laboratory managed by Roberto De Luca is tasked with ensuring that every product manufactured is to specification and meets Sipa’s strict standards. That means that every product, large or small, must be measured and tested before going out the door. And with the number of products Sipa produces, this can be a daunting task. To meet the increased demand for quality assurance measurement in the lab, Sipa recently added the Gawis 4D from Agr International, a high precision dimensional and thickness measurement system for bottles and preforms. “In the lab, we perform tests of samples from all moulds and machines to verify that they can produce finished product in compliance with customer or Sipa specifications. This includes the testing of 100% of injection, blowing and one-stage machines and moulds on delivery,” explained Mr De Luca. Keep in mind that Sipa is the second largest supplier worldwide in both preform and container moulds with state-of-the-art tooling facilities. Therefore, when it comes to testing and mould qualification, the numbers are significant. This is an important part of the business, and the testing of these moulds is a key aspect. This is where the Gawis 4D comes in. The number of cavitation on a preform mould has increased from 96 being standard to 144 to 180 and now 200 cavities in a mould set. This means more samples to test. According to De Luca, when they qualify a mould, before shipping to the customer, samples from every cavity must be measured to verify that they meet specifications including body dimensions, thread attributes for proper closure fit, perpendicularity and thickness. With the expanded number of cavities, this has dramatically increased the testing load on the lab. The Gawis 4D was purchased to help meet this increased demand. The speed of tests on the Gawis 4D system, leading to reduced cycle time, was a principal factor in the decision to add the 4D to the Sipa lab. Another “winning feature is the combination of dimensional and thickness measurement at the same time – this is important to reduce cycle time. And, of course, the accuracy of the system as well,” claimed De Luca. The fact that the Gawis 4D can measure both preforms and containers is very important. “One week we are focused on testing bottles and next week it is mainly preforms. If we had an instrument that only did one or the other, it would sit idle part of the time. With the Gawis 4D, its capability is used 100% bringing good value to our operation.” The time factors Measuring a preform by hand can take several minutes, while the Gawis 4D can perform the measurements in less than one minute. When qualifying a mould with 180 preforms, the time savings is significant, as much as 30% or more. Even if it only takes one minute longer by hand, this is 180 minutes, or 3 hours more to qualify a mould set. Also, one needs to consider the variations in measurement attributed to the technician, and of course, the time to document the data. With the Gawis 4D, measurements are performed on every container or preform, exactly the same, avoiding any type of discrepancies due to human error, all in a fraction of the time. When thousands of measurements have to be performed, this is important, and the time saving is considerable. Another reason for selecting the Gawis 4D is its ability to efficiently perform thickness measurements even of small preforms and containers. As De The Sipa Design, Testing and Qualification Laboratory relies on a number of Agr quality management products in the daily operations.
INSPECTION 17 PETplanet Insider Vol. 24 No. 09/23 www.petpla.net Luca noted, the alternative is to make hand measurements with a magnetic gauge for thickness. The Gawis 4D, with its non-contact thickness measurement, eliminates the need to do thickness manually, which takes a lot of time. This goes for large containers as well as the very small. “We need to measure both thickness and thickness variation over and around the preform or bottle wall. Material distribution analysis takes time.” The Gawis 4D captures hundreds of measurements over the length and around the circumference of the preform. This makes it quite simple to measure thickness variation as well as other attributes such as concentricity, min/max and average in a single measurement sequence. On the Gawis 4D this is performed in conjunction with dimensional measurements, in less than one minute. Additionally, the Gawis 4D is industry 4.0 compatible making it possible to easily communicate with other devices and share data. Testing, testing, testing… One of the defining aspects of Sipa is the wide portfolio of products that includes beverage bottles, preforms, jars, small and large containers and even, detergent containers. Testing and measuring are not limited to new machines and moulds. Nowadays, most of the projects coming through the Sipa lab are pretty challenging, including lightweighting or new resins testing, with the focus on sustainability. Taking measurements is not as easy as people might think. “Everything is extraordinary” – every week is a new challenge and any savings in time is welcome. AutoJob Since time and accuracy are of the essence in this facility, taking into account the wide variety of products, one of the biggest challenges typically associated with automated measurement systems is the amount of time it takes to program each job. The Gawis 4D addresses this handily with a patented feature called AutoJob. With this feature, the operator simply selects the AutoJob mode and the work of locating and identifying finish features is performed automatically and incorporated into the job within a matter of seconds. The operator can adjust the selection, add control limits, and incorporate additional measurements as necessary. AutoJob can be used to create a new job or identify an existing job template, through template matching, that most closely matches the container. Template matching, another feature associated with AutoJob, finds the closest match of a scanned bottle finish to a job template already in the template library, or published standard template. The work in this lab goes well beyond qualifying
INSPECTION 18 PETplanet Insider Vol. 24 No. 09/23 www.petpla.net machines and moulds. Typically, there are several projects running at the same time. “R&D projects are also very important as they are the future of the company” explained Mr De Luca. “A typical R&D project involves making a completely new bottle from zero. We have a department dedicated to this activity to capture ideas and feeling from the market. Sometimes these are brand new designs. We also refresh bottle designs and work through the process.” To support this work, the lab strictly interacts with the prototyping department where several machines – injection press, onestage machines, single cavity blow moulders – are dedicated to prototype new containers. This provides a realistic check before releasing the bottle for commercialisation. Whether brand new or existing, the lab supplies the testing necessary to validate the design. Long-term relationship Another important part of the decision to purchase the Gawis 4D is Sipa’s long-term relationship with Agr. The Gawis 4D is now the third Gawis measurement system working in the Sipa lab. The first was purchased in 1999, another in 2016 and the latest Gawis 4D, last year. “Before purchasing the latest system, we evaluated other devices – but we found that the Gawis 4D was the only system that had all the features we wanted, particularly the capability to do preforms and containers with the same system and simultaneous thickness and dimensional measurement ... these were most important features. The Gawis 4D was a significant upgrade over the previous systems.” In addition to the Gawis systems, the Sipa design, testing and qualification laboratory also includes the Agr PPT3000 pressure tester, Agr Combi tester for volume and top load tests and an Agr vacuum tester for qualifying vacuum strength of hot fill containers. As Sipa continues to grow and sell more equipment and moulds, the demands of the lab increase as well. According to De Luca, the new equipment has helped them keep up with these demands. Additionally, they are planning a lab expansion targeted for January of next year to aid with these increasing demands. In essence, the faster the measurements and response, the better it is for everyone. Since the work in the lab plays a critical role in the Sipa operation, it is imperative that the testing related to the qualification of moulds and equipment for shipment have no delays. “The new Gawis 4D system is essential to this effort as it has made it possible to increase our throughput and help us work faster and better. The faster we give response the better it is for everyone. The laboratory is of such importance to Sipa operation that any improvement in quality and throughput is a definite advantage.” www.agrintl.com www.sipasolutions.com The Gawis 4D from Agr International plays a critical role in the qualification process of moulds and machines for both bottles and preforms that are produced at the Sipa facility. 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
INSPECTION 19 PETplanet Insider Vol. 24 No. 09/23 www.petpla.net Be the first ... … for everyone who has to process recyclates! Get connected – with solutions from ENGEL Even flakes can be directly processed on our injection moulding machine. Bianca Gubi, Recycling Expert at ENGEL, Austria Requirements and speci f icat ions are changing. Many products already have to contain fixed amounts of recycled material. With the ENGEL recycling package or by filtering and degassing the melt in the two-stage process, your regrind can be processed directly. This means: up to 100% recycling material and as a result high cost, energy and CO2 savings. Get connected – and talk to our experts right now. engelglobal.com/circular-economy Visit us at Fakuma Hall A5 Booth 5203
20 TRADE SHOW PREVIEW PETplanet Insider Vol. 24 No. 09/23 www.petpla.net TRADE SHOWpreview 28th edition of Fakuma Wi th the approach of the 28th Fakuma International Trade Fair for Plastics Processing, taking place from October 17 to 21, 2023 at the Friedrichshafen Exhibition Centre, the stage is set for an assembly of over 1,900 exhibitors from across the world. Marked as an event of reference in the realm of injection moulding, extrusion, thermoforming, and 3D printing, Fakuma 2023 will address key themes as energy effi ciency, sustainability and recyclable design. Another objective involves the presentation of plastics processing in the intelligently networked factory of tomorrow. While the anticipation for this year’s Fakuma is rising, the following preview of some PET-related exhibits already provides an sneak peak of some innovative solutions on display. www.fakuma-messe.de Frigel - hall A5 booth 5123 Cooling and mould temperature control solutions Frigel Group wi l l be present ing their latest process cooling solutions, designed for various industry sectors. A new temperature control unit for injection moulding is the Microgel Syncro. The technology is claimed to provide a reduction in cycle time of up to 40%, while maintaining the surface quality, dimensional characteristics and mechanical performance of the finished product. The reduction of the total cycle time is obtained thanks to the reduction of the cooling time only: this result, achieved through the digital synchronisation with the moulding machine, has the advantage of not requiring modifications of the other moulding parameters. Frigel is also exhibiting its Adiabatic product family line, introducing the Ecodry MDK range, designed for flexible configuration of modular adiabatic solutions for small to large plastic factories. Industry 4.0 control platform The Netgel 3PR 4.0 product platform is a specialised solution for controlling central cooling systems. It allows processors to oversee and manage the entire cooling system from a single control point. This platform offers two versions, Lite and Premium, catering to different system sizes and equipment requirements. Frigel has also introduced MiND 2.0, a digital solution that aligns with Industry 4.0 and IIOT standards. MiND 2.0 offers supervision and maintenance tools for all Frigel equipment and accessories, both central and machine-side. Users can monitor and manage various parameters and events, track performance, and moni tor energy consumpt ion remotely via a user-friendly webpage. Single and dual zone TCUs Frigel has also introduced advances in its direct injection pressurised water TCUs up to 120 °C. The TDK units are claimed to be adaptable to any moulding condition and are equipped with features and safeties to operate over the entire temperature range. The unique single zone (RSM) and dual zone (RSD) machine-side temperature control units Microgel RS for injection moulding are designed for moulding throughputs ranging from 10 to 240 kg/h. The Microgel RS range includes important advances in temperature accuracy over the entire control range (-5 to 90 °C), functionalities, pumping performance and energy efficiency. The RS range features additional configurations specifically designed for packaging (RSP) and extrusion (RSB). www.frigel.com Getecha - hall A3 booth 3210 Production-oriented and energy-efficient grinding Equipping plastics processors and recycling companies with customised shredding and recycling solutions - that has been Getecha’s mission for many years. What this means in concrete terms and what level of process automation is achievable today will be demonstrated at this year’s Fakuma. The company will be using numerous exhibits to showcase the services it is currently able to cover as a system integrator and engineering partner. Getecha is presenting two granulators from its GRS line at the trade show as mobile and versatile size reduction solutions for use in production. The GRS 180, which is designed as a beside-the-press granulator for processing sprues and light faulty parts, is almost a classic. It is suitable for both manual and automated feeding via the handling system of an injection moulding machine. Depending on the variant and options, its feed height can be adjusted
21 TRADE SHOW PREVIEW PETplanet Insider Vol. 24 No. 09/23 www.petpla.net LOOKINGTO INCREASE ENVIRONMENTAL STRESS CRACK RESISTANCE (ESCR)? CONTACT USTODAY! info@moldmasters.com www.moldmasters.com ✓ New Sprint APEX gate seal. ✓ Increase environmental stress crack resistance for CSD caps by up to 40%. ✓ Increase your safety factor, improve product performance, and enhance customer satisfaction. ✓ Enables light weighting without sacrificing performance and durability. Cold Jet - hall B3 booth 3110 Mould and die cleaning Cold Jet, a global leader in the development of dry ice cleaning solutions and production equipment, will present surface preparation and cleaning solutions. Utilising dry ice in several applications in plastics processing is helping the industry move into a circular economy to better protect the environment, states the company and explains: The CO2 utilised for the production of dry ice is a carbon capture and utilisation process that involves using recycled CO2, and replaces environmentally harmful solvent cleaning processes. Mould cleaning remains a critical component of producing quality products. Cleaning mould cavities and vents of resin off-gasses, cured material or mould release agents can prevent numerous common moulding problems such as short shots, burns, flash, contamination, etc. Cleaning is often delayed because traditional methods cause extended downtime and often involve the use of chemicals or mechanical means that are harmful to employees, abrasive to the tooling and can wear away critical mould tolerances. Cold Jet’s Dry Ice Environmental Cleaning and Surface Preparation (ECaSP) systems are claimed to enable manufacturers to clean moulds more often, faster, cheaper and non-abrasively, in a sustainable manner. Dry ice is also utilised in the industry to deburr and deflash plastic parts. Thermoset parts will always have flash (sometimes thermoplastic parts as well), and the part geometries do not always lend themselves to tumbling. Cold Jet’s solutions are often completely automated. Lastly, Cold Jet offers solutions with on-demand dry ice production and blasting for the surface preparation/cleaning of plastic parts prior to painting. Cold Jet systems are designed for easy integration into existing automated paint line systems. They are aimed to replace aqueous cleaning methods and the associated problems that come with wet cleaning. www.coldjet.com from 800mm to 1,320mm. In addition, it can be optimally adapted to its environment with low or high frames as well as material containers (instead of free outlet) and hoppers for feeding via sprue picker (instead of manually). The GRS 180 exhibited uses a sevenblade rotor with wear-protected blades in HSS quality and is configured for connection to the customer’s extraction system. Its drive technology heart is a 2.2 kWmotor whose power requirement is effectively reduced to around 1.1kW under load thanks to the Getecha EnergySave system. The rotor variants, the drive and the blade qualities of the GRS series are always individually matched to the application. The cutting chamber can also be equipped with water cooling, which reduces the thermal load on the materials and prevents their plastification in the cutting chamber. With a fill level monitoring system, overfilling of the material container - and thus a backflow into the cutting chamber - can be avoided. Warning signals and an automatically controlled suction conveyor can be used to stabilise the production process. In addition to presenting its granulators, Getecha will be addressing important factors and trends in the field of size reduction technology. These include the question of what role a detailed requirements analysis plays or how additional savings potential can be released through the successful integration of the size reduction solution into the customer’s infrastructure. The relevance of the automation of the grinding systems, their external control and the use of modern communication and sensor technology for process optimisation and operating cost reduction will also be discussed. www.en.getecha.de
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