BOTTLE MAKING 13 PETplanet Insider Vol. 24 No. 11/23 www.petpla.net evaluates PET bottle packaging solutions and technologies, and facilitates understanding of the effects of new PET bottle innovations on recycling processes. Several test procedures can be used to assess the impact on recycling of new packaging technologies. How to use recyclate Sipa says that it has considerable expertise in how to use postconsumer recycled PET in new containers for food and drink. This means not only creating designs that take into account differences and variations in processing characteristics of rPET, but also other less obvious factors such as the increased level of powder that rPET processing creates. The company recently established the Awarpet brand to advance its environmentally conscious approach to the design and production of PET packaging. Awarpet bottles are light: for example, Sipa has been involved in a design project for a 1l water bottle weighing just 16g, far lighter than most 1l bottles currently on the market. It all starts with an idea Any design project starts with a blank piece of paper (or possibly a blank iPad screen). Working with the most basic of briefs, the design experts can create a sophisticated concept, beginning with some finetuning of the original customer idea, moving to renderings and technical drawings, finite element analysis to simulate performance of the container, through to solid mock-ups. These can be produced in a short time using appropriate additive manufacturing (3D printing) techniques, before functional prototypes and finally market-ready products can be manufactured. “The customers can share their ideas with the team in complete confidence, since it is all one-on-one, with no external agencies involved. The expression ‘one-stop shop’ may be over-used sometimes, but in this case, it truly is applicable. Everything can be resolved in a seamless, integrated progression towards market success,” says Sipa. The approach in action: successful projects The Italian company has already applied the new packaging design and development service concept to several projects, including one that involved converting a barbeque sauce bottle from glass to hot-fill PET, maintaining the “retro” look of the original; and another for a customer employing the company’s Xtreme rotary injection-compression preform moulding system, for which an in-depth study of the impact on performance of different levels of PCR was assessed. Sipa has worked for a well-known Portuguese luxury mineral water brand to engineer the existing bottle base in order to make it possible to produce this magnificent bottle at high speed on its rotary blowmoulder Xtra while before it was produced on an alternative lower speed system. Label free and lighter Sipa’s design team has demonstrated their dedication to eco-conscious packaging by creating a range of aesthetically pleasing, functional, and environmentally friendly bottles. These bottles are uniquely devoid of labels, emphasising their commitment to recyclability. This approach not only minimises waste but also bestows a clean, sleek appearance, elevating the product’s overall aesthetic appeal. Furthermore, Sipa introduced a lightweight alternative to the standard PCO 1881 with the GME 30.37 neck finish, showcasing their expertise in engineering eco-friendly solutions. This neck finish achieves a 45.5% reduction in weight compared to previous designs while maintaining structural integrity. Importantly, it complies with the SUP Directive (2019/904), ensuring adherence to tethered cap regulations set to become effective by July 2024. The company’s bottle designs not only prioritise sustainability but also adhere to evolving industry standards, exemplifying their commitment to responsible packaging. Withstanding high pressure: La Spumante La Spumante is claimed to be the world’s first PET bottle designed exclusively for sparkling wine. Its unbreakable, lightweight design enhances safety, making it suitable for diverse events and venues, from concerts to airlines. The bottle’s commitment to sustainability, crafted entirely from PET or potentially rPET, significantly reduces its environmental footprint and seamlessly integrates with traditional bottling processes. Sipa says that La Spumante’s engineering withstands high pressures, preserving the effervescence and taste of sparkling wine. Moreover, the decrease of 80% in bottle weight compared to glass counterpart, leads to more efficient transportation, reducing costs and carbon emissions, aligning with sustainability goals. It has won multiple prices around the world. www.sipasolutions.com The label free approach not only minimises waste but also bestows a clean, sleek bottle appearance.
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