No.1+2 2024 www.petpla.net D 51178; ISSN: 1438-9452 05 . 02 . 24 M A G A Z I N E F O R B O T T L E R S A N D B O T T L E - M A K E R S I N T H E A M E R I C A S , A S I A , E U R O P E A N D A L L A R O U N D T H E P L A N E T PETplanet is read in 159 countries MARKETsurvey Suppliers of resins and additives Page 24 EDITOUR CAPS & CLOSURESPage 16 Page 10
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No.1+2 2024 www.petpla.net D 51178; ISSN: 1438-9452 05 . 02 . 24 M A G A Z I N E F O R B O T T L E R S A N D B O T T L E - M A K E R S I N T H E A M E R I C A S , A S I A , E U R O P E A N D A L L A R O U N D T H E P L A N E T PETplanet is read in 159 countries MARKETsurvey Suppliers of resins and additives Page 24 EDITOUR CAPS & CLOSURESPage 16 Page 10
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 info@petpla.net EDITORIAL Kay Barton Heike Fischer Gabriele Kosmehl Michael Maruschke Ruari McCallion Anthony Withers Editorial & WikiPETia. info petplanet@petpla.net MEDIA CONSULTANTS Martina Hirschmann hirschmann@petpla.net Johann Lange-Brock lange-brock@petpla.net phone: +49 6221-65108-0 LAYOUT AND PREPRESS EXPRIM Werbeagentur Matthias Gaumann www.exprim.de 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. 25 No. 01+02/24 www.petpla.net Credit: Cover illustration by Anja Stiehler-Patschan Dear readers, Sometimes two pieces of information fit together even though they actually have no connection with each other. This is definitely the case with my story today: the first happened in Mexico, the second in Lithuania. Both have to do with our new favourite topic, the Tethered Cap. In Ciudad Obregon, Mexico, my son visited the traditional restaurant El Bronco and, among other things, ordered water. A PET bottle came with a tethered cap. My son was puzzled. OK in Europe, maybe even in California but in Obregon? Upon closer inspection, he discovered that it was just a badly slit cap, so nothing to do with a tethered cap. And then we had a message from Retal in, Lithuania. When slitting, they removed just part of the knife and therefore the cap was only partially slitted. So actually the production error - found in Mexico - was dealt with in an orderly fashion. Retal has now found an EasyTether solution that costs practically nothing (photo below). Details can be found on page 33. Yours, Alexander Büchler
PETcontents 4 PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net 1+2/2024 EDITOUR 10 Multinational brand on course for expansion in the UAE - Soft drinks, water and more snacks in the future MATERIALS / RECYCLING 12 Shifting focus - Starting with the end in mind for sustainable plastics packaging PREFORM PRODUCTION 14 Combined strengths for new wine packaging MOULD MAKING 15 Converting mould - 96-cavity mould from Engel to Netstal CAPS / CLOSURES 16 128 cavities in a 1.85 seconds cycle time - Where is the limit? 17 Navigating the transition 18 Weight savings combined with high performance - Boosting sustainability by lightweighting closures while maintaining performance and structural integrity 20 New challenges in sport caps making 22 New standard cap in Eckes-Granini portfolio - The Clip Aside tethered cap solution by Bericap 26 Secure down to the last drop - Practical, intuitive, and child-friendly new closure solution 27 Compact feeding solution 28 Consistent cap quality - Calibrated and validated in-line inspection 30 Closing the loop on bottle caps - Greenpath and Tomra pioneer mechanical sorting solution for separating polyolefins by polymer type and colour MARKET SURVEY 24 Suppliers of resins and additives EVENT PREVIEW 34 CBST & Chinaplas 2024 preview 37 From AA reducers to UV blocking EVENT REVIEW 38 PETinar: PET blow moulds and machinery BUYER’S GUIDE 40 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 32 Products 39 Patents 46 Outer Planet CAPS & CLOSURES Page 15 Page 10 EDITOUR Page 22
yellow.agency A FAMILY OWNED SWISS COMPANY. T OTA LLY SW I S S. OUR INJEC TION MOULDS FOR PET, PAC AND MED FEATURE ROCK-SOLID, GENUINE SWISS CRAFTSMANSHIP. OT TO-HOFSTET TER.SWISS
PETnews 6 NEWS PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net ArabPlast 2023: A showcase of innovation and sustainability in the plastics and petrochemical industry ArabPlast, the Dubai trade fair for the plastics, recycling, petrochemical, packaging & rubber industry, opened its doors from December 13-15, 2023. The three-day fair not only celebrated the latest advancements, and innovations, but also delved into sustainable solutions. A defining feature of ArabPlast 2023 was the participation of more than 750 exhibitors, representing 35 countries across the globe. The exhibition served as a stage for presenting the latest products, showcasing advanced technologies, and exchanging invaluable know-how. The diverse and global representation emphasised the interconnectedness of the plastics and petrochemical sectors, fostering collaboration and crossborder exchange of ideas that are vital for the industry’s evolution. In addition to the comprehensive displays, ArabPlast 2023 featured machine displays that captivated the audience. Cutting-edge machinery was showcased, providing attendees with a firsthand look at the latest innovations in plastic processing. In addition, on-the-spot machine sales added an element of practicality to the event, allowing industry professionals to acquire state-of-theart equipment right on the exhibition floor. The event also witnessed the unveiling of patented technology in plastic processing. This technology is claimed to represent a significant milestone in the global plastic industry, tick marking the first-time introduction of such advancements. Aligning with the global transition towards a more sustainable and environmentally conscious economy, exhibitors showcased eco-friendly solutions, sustainable practices, and innovations aimed at reducing the environmental footprint of the plastics and petrochemical industry. The commitment of these industries in the Middle East and beyond to sustainability was evident in the initiatives and products unveiled during the event, solidifying ArabPlast’s role as a driving force in fostering environmental responsibility. www.arabplast.info Krones announced it is to discontinue its digital container-decoration business The Krones Group has chosen to cease its activities in the field of digital container decoration by the end of 2023. The decision to cease the activities of the group’s subsidiary Dekron GmbH is the result of a careful review of Krones’ business strategy and the current market situation. Dekron informed its staff, customers, suppliers and business associates accordingly in November. Dekron GmbH has developed and manufactured machines from the DecoType series used for digitally decorating containers made of glass, PET and HDPE since 2018, with the group’s subsidiary KIC Krones supplying the matching UV inks. Krones has synergised in Dekron its own development activities and the business operations of Till GmbH, in which the company has had a majority holding since 2014. The subsidiary has been liquidated effective December 31, 2023 and the facility in Kelkheim closed down as part of the phase-out. A reconciliation of interests has been negotiated with all members of staff. www.krones.com La Spumante shines bright: triumphs at Worldstar 2024 Sipa’s La Spumante has secured two prestigious accolades at the Worldstar 2024. The popular awards were bestowed upon La Spumante in two significant categories: Alcoholic Beverages and Packaging Materials and Components. This success follows an important year for La Spumante in 2023, where it garnered widespread acclaim. In April, it clinched the Best Packaging Award in Italy, a testament to its exceptional design and functionality. Later in October, the PET bottle won at the SPE Blow Moulded Part Competition in Chicago, USA, showcasing its technological prowess and manufacturing excellence. Additionally, La Spumante earned a place as a finalist at the Food Bev Beverage Awards in November. La Spumante is lightweight, offers convenience to consumers and contributes to lower transport costs and a reduced carbon footprint. It is fully recyclable to meet environmental sustainability targets, emphasising its commitment to environmentally friendly packaging solutions. Sipa says that the PET bottle’s easy filling process streamlines production for manufacturers, ensuring efficiency without compromising on quality. Moreover, its remarkable 24 months shelf life adds a layer of practicality and convenience for both producers and consumers alike. Receiving the Worldstar 2024 award is not only a recognition of past achievements, but also a testament to the ongoing commitment to push boundaries and redefine standards in the world of packaging. The future looks promising for La Spumante as the company continues to make waves and set new standards in the industry, according to Sipa. www.sipa.com
7 NEWS PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net ColorMatrix™ AAnchor™ Acetaldehyde Control Technology for PET can help you achieve sustainable and high-quality PET packaging by: • Reducing Acetaldehyde • Reducing Regulatory Risk • Improving Recyclability • Enhancing Bottle Quality Visit www.avient.com for more information about ColorMatrix™ AAnchor™ Acetaldehyde Control Technology for PET and our full range of innovative polymer solutions for PET packaging. PET PACKAGING HOOKED ON SUSTAINABILITY
8 NEWS PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net Petcore Europe – Annual Conference 2024 The conference, being held in Brussels from February 7-8, 2024, will take place against the background of the finalisation of the EU’s landmark Packaging and Packaging Waste Regulation (PPWR). Day One will consider the impact that the regulation will have on businesses operating both upstream and downstream, with industry experts and representatives from the European Commission. This year Petcore Europe will gather three DGs: DG Sante, DG Grow & DG Env, namely, Bastiaan Schupp – Legislative Officer – Food Contact Materials for the European Commission (DG Health and Food Safety), Stefano Soro – Head of Unit – Green and Circular Economy at European Commission (DG Grow) and Wolfgang Trunk – Policy Officer at European Commission (DG Environment) are coming together to debate and explore market developments shaping the sector. The agenda will cover reams of legislation and impending regulation, and address the challenges and opportunities facing those in the PET industry. Petcore Europe is launching a new working group, Advocacy, to cope with these challenges. The President of Petcore Europe, Antonello Ciotti, explains that the association has “a lot to say” on these issues and adds that Petcore Europe needs to be more agile in promoting its ideas when it has a common position among all its members. On Day One, the latest updates on textile and the ongoing PET Communications Campaign 2024 will be revealed. “Communication is important, and we must show how the PET bottle is being recycled,” says Antonello. “It can only be done if the consumer takes the first step. In countries without deposits, we do campaigns to increase the consumer’s understanding that recycling starts with them. The value of rPET is important and there must be an incentive for companies to start collecting.” During Day Two the experts from the entire PET value chain will share their updates on LCA, reuse, labels and other insightful topics, covering all the challenges and innovations, embraced by Petcore Europe Technical WGs throughout 2023. www.petcoreeuropeannualconference.org Reliance Industries becomes first in India to use chemical recycling for circular polymers Reliance Industries Limited (RIL), operator of the world’s largest integrated refining and petrochemical complex, has become the first Indian company to chemically recycle plastic waste-based pyrolysis oil into International Sustainability & Carbon Certification (ISCC)-Plus certified circular polymers. RIL shipped its first batch of ISCC-Plus certified circular polymers, named CircuRepol (Polypropylene) and CircuRelene (Polyethylene). RIL paves the way in India by using new technology to recycle plastic by converting plastic waste into special circular polymers, thereby making a positive impact on the environment. RIL’s commitment to sustainability is demonstrated through its innovative methods like chemical recycling which help create a circular economy. The company firmly believes in finding smart solutions to reduce plastic waste and inspire others to join in this journey towards a greener future. CircuRepol and CircuRelene have been designed to lead the way in circular economy practices. RIL’s Jamnagar refinery became the first refinery to get the important ISCC-Plus certification, proving that it can produce circular polymers through chemical recycling. The ISCC-Plus certification guarantees that traceability and rules are followed in making circular polymers. RIL has developed a technology that turns different types of plastic waste, including single-use and multi-layered plastics, into pyrolysis oil. The company is working with trusted partners to increase the production of this oil and turn the yield into circular polymers. Chemical recycling has many benefits, including turning plastic waste into high-quality materials for new plastic. These materials can be used for packaging that comes into contact with food. www.ril.com Hungary launches new deposit return scheme for drink container recycling Starting from January 1, 2024 Hungary has implemented a new deposit return system (DRS) for recycling singleuse drink containers. Manufacturer of reverse vending machines Tomra has partnered with Mohu (MOL Hulladékgazdálkodási Zrt.), the central system administrator for the DRS, to roll out a collection infrastructure aimed at making drink container returns as convenient as possible for recyclers. This DRS covers ready-to-drink or concentrated beverages (except milk and milk-based beverages), in singleuse aluminium cans and glass/plastic bottles, ranging from 0.1 l to 3 l in size. Consumers pay a deposit of 50 Hungarian forint (approximately 0.13 €) when purchasing an eligible drink, which is refunded to them once they return the empty drink container for recycling. Drink containers in Hungary can be returned to grocery retailers over 400m2 in size, and the growing number of voluntary and manual sites. This initiative aims to integrate recycling into consumers’ existing shopping routines. Tomra has installed more than 1,000 high-volume reverse vending machines (RVMs) for medium and large locations like supermarkets and hypermarkets in urban settings across Hungary, with the roll-out of further RVMs to continue in 2024. When a consumer inserts drink containers into an RVM, it automatically identifies and sorts the containers, and pays out the correct refund, more efficiently and securely than with a manual return of containers. Hungary’s DRS follows closely after a new deposit return systems launched in the Australian state of Victoria on November 1 and in Romania on November 30, and comes ahead of Ireland’s launch next month on February 1, 2024. www.mohu.hu www.tomra.com
9 NEWS PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net ClipAside, drink, love! On an exponential growth path: Tethered ClipAside passes the 6 billion mark. Contact us and arrange your line trials now! www.bericap.com PET 38 PET 29/25 PCO 1881 PET 33 PET 26 PET 26 GME 30.40 A consumer real-life study conducted in France found a high level of acceptance among consumers for our innovative new closure. After just one or two experiences, even the youngest and oldest users could handle the smart closure without difficulty – often with one hand. What’s more, many praised the eco-friendly nature of the cap, which remains on the bottle neck and avoids creating additional plastic waste. Best of all for you, this premium product can be integrated into most lines for any popular neck finish without major modification of your production equipment - proven by more than 70 successfully converted filling lines across Europe.
EDITOUR PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net 10 Soft drinks, water and more snacks in the future Multinational brand on course for expansion in the UAE In 2016, the bottler Dubai Refreshment, franchisee for PepsiCo products, relocated to its new plant in Dubai Investment Park 2, just over 30 km south of the city centre. The new site, a greenfield project that currently employs around 700 people, was deliberately designed for continuous capacity expansion and, in addition to the state-of-the-art setup of European machine builders for its water and soft drinks bottling, not only offers plenty of space for additional equipment in the future, but has also taken a number of sustainability and environmental measures into account during construction and implemented them in a future-proof manner. In the foyer of Dubai Refreshment with Wael Nehme (left) and Kay Barton Interview meeting with Dubai Refreshment Company (DRC) December 5, 2023 We met: Mr Wael Nehme, VP, Supply Chain And Projects The history of Dubai Refreshment goes back to the late 1950s. It all began in 1959 with the establishment of a glass line for returnable Pepsi bottles and 20 employees in Deira in northern Dubai. In 1962, the company became an official Pepsi franchisee and delivered its drinks to customers with five trucks. Over the decades, many other products from the multinational brand’s range were added. One main product, Aquafina still water, has been bottled here since 2004 and was listed on the stock exchange in 2007. Five bottling lines are now in operation in the new factory, an investment of around US$ 200 million. A total of 15 different beverage brands roll off the production line here: Pepsi, 7Up, Mirinda, Shani, Lipton Iced Tea, Mountain Dew, Aquafina, Mathieu Teisseire, Ceres, Rockstar, Robinsons, London Essence, Evervess, Britvic, Gatorade, Life WTR and Ceres Juice. Pepsi and Aquafina make up the majority with more than 90%. In addition, the snacks Dofreeze Cakes, Edita Wafers and, more recently, Lay’s Crisps are also sold. The plant comprises two turnkey KHS lines for PET with 40,000bph capacity for 0.33 l to 2.25 l bottles, two turnkey KHS lines for cans with 90,000cph each for 0.15 l to 0.33 l, as well as a Simonazzi glass line with 24,000bhp for 0.25 l CSDs as well as for 0.33 l and 0.75 l Aquafina. These, as well as one of the PET and one of the canning lines, were taken over from the previous site and modernised. In addition to water and CSD, the two newly added lines can also hot fill. Preforms (PCO1881 in clear and green for CSD, 29/25 in clear for Aquafina) are bought in from various sources, and bottle blowing takes place on Sidel blow moulding lines (SBO12 for Aquafina, SBO8 and SBO14 for CSDs). The latest technologies in the range include 100% rPET bottles for the Pepsi, Pepsi Diet and Pepsi Black brands, which the company launched in October 2023 with the new legislation on the use of recyclate in food contact. PET accounts for 47% of total production. The plant currently has over 300 stock keeping units and produces over 60 million crates annually. “We are talking about one of the most modern production facilities in the Middle East,” explained Mr Wael Nehme, BSc and MBA graduate from American universities in Cairo & Dubai respectively, at the meeting. He has been working in operations and supply chain for more than 30 years. His personal career led him via Pepsi Société Moderne Libanaise Pour Le Commerce (SMLC) in Lebanon, Pepsi United Beverages in Kuwait and Pepsi Al Qahtani in Saudi Arabia to Dubai Refreshment in 2001. Here he started as Operations Manager and became responsible for the entire supply chain, from procurement, production, maintenance, quality control and 1.5 l bottles of Mountain Dew on their way to the palletiser EDITOUR
EDITOUR PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net 11 safety to warehousing, logistics and the delivery fleet. His responsibilities also include sustainability and project planning, as well as the planning and implementation of this factory, where we met for the interview, and the company’s own distribution centres in various parts of the Emirates. He has 300 employees working under him. “This factory,” Mr Nehme continued, “is Industry 4.0-capable and a number of precautions were taken during construction to ensure that it also meets future sustainability and energy-saving requirements.” Several processes and filtration steps are used in the water treatment plant with a capacity of 150m3/h, including ultra filtration, carbon purification, reverse osmosis, microfiltration & UV disinfection. Aquafina also receives ozone treatment. For the water source, Dubai Refreshment mainly uses municipal water from the Dubai Electricity & Water Authority (Dewa). Cochran boilers can use gas or diesel fuel for steam generation, Gea ammonia compressors for the central cooling system, Atlas Copco compressors for low pressure air and AF Compressors for high pressure air. Krones equipment can be found in the syrup room. Here, the sugar and water is mixed with the concentrate and pumped directly into the bottling line. The water is treated using Veolia technology. “The production process and the lines are fully automated and run at 86% efficiency,” said Mr Nehme. The site covers a total of 140,000 m2, of which only around 50% - 50,000 m2 - is used for production and delivery and 20,000 m2 for waste water treatment, administration and staff areas. Five more lines could be added at any time. Syrup room with Krones equipment The company has a waste water treatment system and large-scale solar thermal and photovoltaic panels. The wastewater treatment plant has a nominal capacity of 1,100m3/h and is reused in utilities and for watering the outdoor greenery. Mr Nehme explained: “We can currently reuse around 85-90% of the wastewater produced in this way, around 500-600m3. Our solar system creates a capacity of 70m3/h for hot water and with the photovoltaic system, consisting of 11,000 panels, we cover more than 30-40% of the plant’s energy requirements with a capacity of of 3.7MW.” An optimised system for transporting and delivering goods is also used in logistics, with automatic route planning, digital mapping and utilisation of the 150 trucks, which reduces emissions and increases efficiency. In addition to this main plant and hub, there are also four warehouses in Sharjah, Ras Al Khaimah, Fujairah and Abu Dhabi. In total, the company has more than 1,000 employees and serves over 15,000 customers. The company’s expenditure has been recognised many times, both nationally and internationally. A hall of fame of these awards and certificates can be seen in the foyer, including the recently added Leeds Platinum Award, presented by the US Green Building Council (USGB) in recognition of the company’s sustainability achievements. “We also want to be more active in the snacks sector in future in order to develop from a pure beverage manufacturer into a beverage and food company,” said Wael Nehme, looking to the future. Format overview PET CSD: 0.3 l, 0.5 l, 1.25 l, 1.5 l, 2.28 l PET water (Aquafina): 0.33 l, 0.5 l, 1.5 l www.pepsidrc.com Plenty of space for further filling lines, currently used as an additional warehouse IMPROVEYOUR PRODUCTIVITY CONTACT USTODAY! info@moldmasters.com www.moldmasters.com Featuring ✓ High-performance 2-stage hot runner system. ✓ Enhance preform quality and productivity. ✓ Lower injection pressures to allow for faster cycle times and lightweighting.
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net 12 Starting with the end in mind for sustainable plastics packaging Shifting focus based on an article by Andrea Smith, Avient Increasing the amount of rPET can affect the processability, quality, and food safety of packaging. During the recycling of PET, it undergoes several remelting processes, which can cause thermal degradation and side reactions, resulting in rPET that is of a lower quality than virgin PET. This article will discuss the latest challenges and efforts from Avient to improve additives’ performance through recycling and design technologies with circularity in mind while maintaining functional performance. Today’s challenges Additives are added to PET to provide many functional advantages that can be particularly beneficial when using and processing rPET. However, as PET is recycled, it becomes increasingly important that these additives are designed to remain helpful and not adversely affect the quality, safety, and processability of rPET during the recycling process. This concept is of greater significance in closed-loop recycling systems, which are commonly used across Europe. Any negative impact from an additive could be enhanced due to the potential for accumulation in the closedloop system. Accumulation-related risks could be of particular concern, especially regarding regulatory or food safety. The accumulation of additives in recycling processes can lead to two potential issues. The first one is related to manufacturing and processability. For example, anthranilamide (ATA) based acetaldehyde (AA) scavengers are problematic due to high levels of sublimation. This issue manifests as deposition on the surface of the moulds in an injection moulding process, leading to downtime for cleaning the moulds, reducing efficiency and throughput. Deposition also occurs during the solid-state polymerisation (SSP) stage in the rPET manufacturing process when high levels of sublimation cause deposition on equipment, again leading to downtime for cleaning and reduced efficiency. If the levels of ATA in rPET keep accumulating, the processing issues related to ATA will also increase. The second issue is of higher concern and relates to regulatory compliance; the accumulation of ATAbased AA scavengers increases the risk of exceeding regulatory migration limits of ATA. This risk is well known and understood. However, when using ATA, there is a possibility of side reactions forming non-intentionally added substances (NIAS) components. These compounds also tend to accumulate over time despite being present at minimal levels and being undetectable until recently. As technology advances, the detection limits on analytical equipment have lowered, revealing the increasing concentration of these compounds due to the accumulation effect. This issue is now quickly becoming a concern for ATAbased products. Starting from September 2022, regulatory amendments have been imposed by Commission Regulation (EU) No 2020/1245 on Commission Regulation (EU) No 10/2011 regarding primary aromatic amines (PAAs). These compounds are present at minimal levels in PET-containing ATA-based scavengers and can now be detected by modern analytical devices. To remain compliant with the new regulations, it is necessary to provide additional toxicology data and migration testing for PAAs in PET articles containing ATA. PAAs are the first in a fast-growing list of other compounds detected in ATA-containing articles. Additional toxicology data and migration testing are crucial for these products to remain compliant. However, there is a significant risk of non-compliance that could result in a withdrawal of these products from the market in the future. Developing a solution To tackle today’s sustainability challenges, simulating the mechanical recycling process is necessary to design new additive technologies. Standard testing protocols at the European PET Bottle Platform (EPBP) and the Association of Plastic Recyclers (APR) are based upon one full recycle loop. However, as the use of rPET increases, the impact of two or more recycle loops is becoming increasingly significant. Therefore, it is more realistic to screen additive performance through at least two
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net 13 MATERIALS / RECYCLING 13 full recycle loops. Avient has developed the “Heat Stability Protocol,” which involves screening new additive solutions for PET packaging for impact on colour and NIAS through two full recycle loops at 100% recycled content. With the use of high-tech analytical equipment for minimal impact on colour shift, so there are no adverse effects on impurities or product safety. In the case of AA scavengers, replacing ATA was essential to avoid processing and regulatory issues caused by recycling and product accumulation. A new molecule had to be designed to provide effective acetaldehyde reduction and full circularity. After stringent performance validation testing, extensive recycle and NIAS testing using the heat stability protocol, and multiple beta customer tests, Avient is offering a new patented AA scavenging technology called ColorMatrix AAnchor. It is designed with recycling in mind and is claimed to have much lower levels of sublimation than ATA-containing products. Furthermore, it does not cause deposition on moulds or equipment, and the potential for migration of this molecule is much lower than ATA, reducing the risk of exceeding regulatory migration thresholds, even in closed-loop recycling systems. Being ATA-free, ColorMatrix AAnchor does not cause the formation of PAAs. It is a liquid dispersion that can be added to an injection moulding or extrusion process using standard ColorMatrix liquid dosing systems. Implementing sustainable solutions for plastic packaging As the European Union sets new, mandatory targets to increase the amount of recycled content in plastic packaging and ensure its recyclability, new measures to safeguard the quality of rPET will also be required, especially for its use in food contact packaging applications where, besides being easy to process and having good mechanical properties, it’s important to avoid the creation of unwanted substances during repetitive processing. Further optimisation of the process and packaging composition will help the industry to overcome these challenges. It’s also necessary to develop existing solutions further to ensure the suitability of packaging for specific applications. The primary focus of new developments should be on eliminating gaps that limit the circularity of packaging. These criteria have become mandatory for packaging design in recent years. Understanding these gaps also requires a robust development process for new solutions. This process should involve simulating the recycling process multiple times to identify any potential accumulation of unwanted substances. Ultimately, this will help eliminate critical substances before a product launches and becomes part of the rPET stream. www.avient.com
PREFORM PRODUCTION PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net 14 Combined strengths for new wine packaging In the ever-evolving landscape of plastic packaging, creativity remains a driving force behind transformative change. Sipa, the well-known plastic packaging specialist, designed the world’s first PET bottle specifically for sparkling wine. This new PET bottle has garnered significant attention within the wine industry and beyond. PET bottles for sparkling wine provide, in fact, numerous advantages, including lightweight design, durability, and sustainability. The pioneer PDG Plastiques: Forcing the packaging business in Europe The first player to recognise the potential of Sipa’s PET bottles for sparkling wine was the French preform, bottle and container manufacturer PDG Plastiques. The company converted Sipa’s new packaging solution into reality. Recognising the advantages the PET bottles offered, PDG Plastiques made a strategic investment in Sipa’s preform moulds with 32 cavities designed to produce sparkling wine preforms. PDG Plastiques invested in Sipa’s preform moulds as well as in the preform systems and blowing moulds. Their commitment to serving the wine packaging markets across Europe and their adoption of this sustainable packaging solutions exemplify their dedication to excellence. Expanding reach PDG Plastiques’ vision has enabled them to serve the wine packaging markets not only in their home country of France but also in Spain, Germany, and Italy, where the appreciation for fine wines runs deep. Their commitment has allowed them to make a significant impact on the wine packaging landscape. A sustainable future In addition to the advantages that PET bottles bring to wine packaging, PDG Plastiques produced the preform on Sipa’s XForm 350 GEN 4 preform system. The XForm platform, available in 250, 350, and 500 t, represents cost efficient PET preform production through conventional injection moulding. It boasts the capability to run moulds with up to 200 cavities, making it a versatile choice for various packaging needs. Sipa said that the advantages of the XForm are the high energy efficiency, low maintenance costs, and its ability to accept moulds from any manufacturer, showcasing its adaptability and value in the PET preform manufacturing industry. As the demand for available and sustainable packaging solutions continues to grow, Sipa and PDG Plastiques are offering PET bottle solutions that combine quality, sustainability, and design freedom. Together, they are redefining wine packaging, in a new, exciting, and eco-conscious way to enjoy the finest wines from around the world. www.sipasolutions.com www.pdg-plastiques.com The Sipa team and PDG management celebrate their success. The World Star-winning PET bottle for sparkling wine is launched on the international packaging market.
MOULD MAKING PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net 15 96-cavity mould from Engel to Netstal Converting mould The faster the preform production, the more yield. The more durable the mould, the more the investment makes sense. This is even more the case if the tool can also be used on another machine. MHT Mold & Hotrunner Technology AG converted a 96-cavity mould from an Engel system to Netstal for Deltaplast, a Hungarian preform manufacturer, saving three seconds of cycle time. MHT manufactures high-cavity preform moulds for all PET lines on the market. The company has the expertise to adapt moulds from one machine type to another. MHT’s 96-cavity tool has been running reliably on an Engel macPET 330 at Deltaplast (Kecskemét, Hungary) since 2015. When this preform manufacturer purchased a Netstal PETline 4000 Side Entry model, it was worthwhile to rebuild the mould after 6.5 million cycles. Mr Zsolt Csengery, Deltaplast’s Chairman of the Board, commented: “We are happy to have MHT as a partner who not only supplies us with top moulds, but is also able to support us with special orders like this.” MHT has a wide range of adapter kits that can be used to convert moulds from one machine generation, machine brand or clamping force size to another. In some cases, it makes it possible to produce with more cavities after a conversion, with its upgrade kits. PROCESS PILOT+TM 2SWLPL]H %ORZPROGHU 3HUIRUPDQFH DQG 3URȴWDELOLW\ ZLWK $XWRPDWHG &ORVHG /RRS &RQWURO Maximize rPET usability and processing Improve bottle performance and downstream operations Maintain lightweight, targeted material distribution Increase consistent production yield Overcome environmental and process variation 5HGXFH scrap with accelerated start-up +1.724.482.2163 agrintl.com In this particular case, MHT used an adapter set for the cold side and reconstructed the hot runner. MHT builds its own hot runners. The preform post-cooling (Post Mould Cooling) was brought up to date in Hochheim/Main, Germany. It includes a new removal plate as well as the patented CoolMax cooling solution, which combines the cooling and preform removal functions. CoolMax directs air flow efficiently to the thread and perform body, thus saving cycle time. The 96 prefoms at Deltaplast are now produced three seconds faster than before. The long-term use of PET moulds is not only financially attractive, it also reduces CO2 emissions, which is increasingly important in all areas of plastics processing. www.mht-ag.com
CAPS & CLOSURES 16 PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net Where is the limit? 128 cavities in a 1.85 seconds cycle time Today’s packaging requirements in the beverage sector are highly demanding, especially for still water. The packaging shouldn’t cost anything more, that’s why the requirements for the design, especially the weight, are enormous. But the requirements for the output of closure systems are also high, because the production costs can kept low. The Austrian company z-moulds has risen to this challenge and designed a 128-cavity closure mould system with a cycle time of less than 2 s. The existing 96-cavity moulds on the market operated with a cycle time of around 2 s, approaching their physical limits. The most important technical limitation was the dimensions of the mould in terms of height and mass, which reached the physical limits of the injection moulding machines. Gregor Degasperi, Business Development Manager of z-moulds, said: “Our initial idea was to stick with our existing pitch size of closure moulds at 70mm. However, this would have required a larger machine solely due to the mould size, although a 420 t injection moulding machine has sufficient clamping force. The second approach was to circumvent the laws of physics in order to decrease the closures fall time and reduce the weight of the moving half.” By introducing the 55mm pitch with the existing patented z-slides, z-moulds was able to build a mould with 128 cavities and a width of 696mm and a height of 1,196mm. This reduced the closure’s fall height, compared to the market standard, by 500mm, resulting in a 0.12 s decrease in fall time. In addition, the weight of the moving half was reduced by 45% compared to market standards, which contributed to a further reduction in opening/closing times of 0.08 s. These advances enable z-moulds to achieve a cycle time of 1.85 s. z-mould’s machine partner Netstal used its highspeed Elios model to achieve these results. A supplementary developPatented smart tool for cavity removal from the front ment was a smart tool to enable the removal and replacement of cavity inserts from front of the cavity plate within the machine, eliminating the need of pulling over the cavity plate to the cold side. This enhances efficiency and productivity. The development of these two patented innovations was made possible by the will to solve problems, to go beyond physical limits and to be inventive. They not only address specific challenges but also set a new standard for efficiency and productivity in mould development and plastic closure manufacturing. www.z-moulds.com 128 cavity z-slides mould for cap 26/22 with new 55mm pitch CAPS & CLOSURES z-moulds became its own legal entity in October 2023. The former Vice-President of Sales and Marketing, Michael Fink, was appointed as CEO.
CAPS & CLOSURES 17 PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net Navigating the transition In an era marked by evolving standards and sustainability imperatives, the shift towards new cap and neck formats can be a daunting challenge for producers. Balancing innovation with the need to protect investments requires a strategic approach. Sacmi asserts that a seamless, profitable, and future-proof transition is achievable through a triad of strategies. The ongoing transition towards new neck and cap formats, designed to comply with standards and sustainability requirements while keeping pace with consumption habits, can be bewildering for producers as they strive to innovate while safeguarding their investments. Sacmi suggests that a simple, profitable, and future-proof transition can be accomplished in three ways: by providing complete product solutions via the Rigid Packaging Lab, through close collaboration with major international certification bodies such as Cetie, and by adopting a win-win approach that expedites the uptake and diffusion of new standards. The 26/22 mm neck/cap transition Globally, there is an installed capacity of 39 billion caps for 26/22mm necks per year. From Africa to the Americas, from Europe to South-East Asia, an increasing number of producers are seizing this opportunity or planning to do so. This change commenced with the transition from the PCO1810 to the PCO1881, currently the world’s most commonly used cap. Over the last 10-15 years, this transition has resulted in raw material savings of more than 50%, enhancing plant profitability and environmental sustainability. Now, Sacmi is aiming higher with new solutions that are already on the market and certified by the major international brand owners. Future-proofing (tethered) The enforcement of the EU Directive on single-use plastics, which imposes the new tethered standard on European markets, raises questions about what manufacturers who operate in parts of the world where tethered caps are not (yet) mandatory should do. The technological approach Sacmi is offering involves slitting the tamper band in post-processing, downstream from compression moulding (CCM); this is claimed to allow the transition to be completed swiftly, flexibly and with limited investment. Secondly, Sacmi says that the switch to tethered caps can be combined with new neck standards. All the latest caps in the 26/22mm ‘family’ are available in both tethered and non-tethered versions. This enables producers to prepare themselves for future regulatory changes and adapt production setups to a variety of market contexts, countries and consumption styles. The Rigid Packaging Lab In addition to substantial installed output capacity globally, the company has chosen to pursue its business goals through technical-technological dissemination. The UAE, Nigeria, South Africa and India are just some of the places where Sacmi has organised country-specific seminars and provides comprehensive consultancy services. Ranging from the product and the technology to design, these services draw on a database of over 1,000 cap-neck designs that the lab has created for customers worldwide in recent years. 35% less plastic Every solution in the new 26/22mm family, for example the new multi-purpose caps such as the AB26 CSDT-5 for GME 30.40, is claimed to offer a specific advantage with respect to the ones already in use. The first, most general benefit is a reduced need for virgin resins while maintaining equal functionality, strength and sealing performance. On the tethered front, according to the company, there is no need for heavy investment in the mould, which would, among other things, lower line productivity and jeopardise the anticipated sustainability benefits. From a technological perspective, extensive digitalisation of each stage simplifies and upgrades the production process, with all the intrinsic bonuses of compression technology. www.sacmi.com CAPS & CLOSURES GME 30.40 neck finishes 26/22 AB26 CSD15
CAPS & CLOSURES 18 PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net Boosting sustainability by lightweighting closures while maintaining performance and structural integrity Weight savings combined with high performance Beverage brand owners and/or packaging manufacturers are working to reduce the impacts their businesses have on the environment. The motivations for these efforts can legislative, or to better align with the values of their stakeholders (e.g. ESG compliance). Husky’s beverage closure business is helping to enable the circular economy with its manufacturing technology. While significant focus on lightweighting is placed on the PET bottle, the closure can also make a meaningful contribution to further improve the sustainability of the overall package. Husky has developed a leading portfolio of closures in terms of weight and performance. Weight optimisation is achieved using sophisticated simulation tools backed up with a deep knowledge base. The basic concept of lightweighting is simple. Remove as much resin from specific closure features as possible without impacting performance or the user experience. A lower part weight requires less time to manufacture thereby improving productivity. Reducing the amount of resin used in each closure may involve the modification of feature specific geometry. These geometric modifications are subject to multiple simulations, to ensure performance is at least maintained or improved. An iterative simulation approach is applied until the performance criteria are satisfied. Fig 1: A 29/25 still water closure broken out into its fundamental elements. Simulation tools are used to predict how much material can be removed from each feature without negatively impacting performance/usability. Husky says that it has developed a leading portfolio of ultra-lightweight closures leveraging extensive use of mechanical and melt flow simulation tools. The process involves breaking the closure down into its specific features (Fig. 1), and focusing on material removal without compromising performance or usability. Simulation tools are used to predict performance behaviour. The features are modified accordingly until the target weight is achieved and simulation outcomes are favourable. Fig. 2: Popular neck finish options (CSD) The introduction of new industry standard neck finishes presents an opportunity to develop higher levels of performance at a lighter weight. Fig. 2 identifies the most common neck finishes used for CSD applications. While other CSD neck finishes exist, these tend to have a regional focus and are not as widespread on a global level (e.g. PCO1873). The recently introduced 26/22 CSD family (GME30.37, GME30.40, & GME30.41) of neck finishes offers opportunities for weight savings combined with a high level of performance. PCO1881 (3.81 g) is the most common CSD finish globally. The next generation 26/22 CSD neck finishes range in weight from 2.30-2.70 g. Fig. 3 identifies the critical dimensions of PCO1881 compared with the new 26/22 CSD options. All three 26/22 CSD finishes feature the same inner bore diameter of 21.7418mm (same as PCO1881), thereby preserving the drinking experience. The GME 30.40 and GME 30.41 finishes offer a higher performance rating for gas carbonation at 5.2 vol, compared with 4.5 vol for the PCO1881 finish. GME 30.37 offers an even lower rating at 4.2 vol. but with a slight weight savings benefit. GME 30.40 is compatible with tethered caps; GME 30.41 is designed for non-tethered applications. Fig. 4 identifies the most widely used neck finishes for still water. The 25/22 (GME 30.39) and 26/22 3-Start (GME 30.28) have emerged as viable alternatives to the 29/25 (GME 30.26) standard in recent years. The 25/22 and its variants have expanded beyond North America and have seen brand adoption in other regions including Europe, Middle East, SAARC, and Southeast Asia. The key drivers for this adoption are both enviCAPS & CLOSURES Fig. 3: PCO1881 & 26/22 CSD neck finish variants
CAPS & CLOSURES 19 PETplanet Insider Vol. 25 ronmental and commercial. The 25/22 variants offer reduced cost of production and weight savings of up to 1.85 g, compared with 29/25 (GME 30.26). Husky has developed a portfolio of 25/22 solutions that enable brands to achieve weight savings without compromising the consumer experience (see Fig. 5). An extended height 25/22 (~8.7mm) offers more grip than the typical 29/25 (~8.2mm) closure. This extended grip offers a good balance between weight savings and preserving the consumer experience. The above example is one of many innovative closure designs that Husky offers to help brand owners and closure manufacturers improve their sustainability efforts while improving profitability. The company says that all of this can be realised without compromising the consumer experience. www.husky.co Fig. 5: 29/25 & 25/22 dispensing system (neck + closure) comparison Fig. 4: Popular neck finish options (still water)
CAPS & CLOSURES 20 PETplanet Insider Vol. 25 No. 01+02/24 www.petpla.net New challenges in sport caps making Attention to the environment, complex closures and ergonomics: the caps manufacturers are more and more raising the bar in their new developments. In this scenario, the Italian company Maca Engineering offers a complete range of automatic machines and systems for the production and assembly of aluminium and plastic caps and closures. capable of assembling up to three components with an output of up to 36,000 pph. The first flywheel is dedicated to folding body flap, the second flywheel for inserting ring and the third flywheel for inserting spout. For greater efficiency the ARV model provides some features such as ejection of defective pieces (for example, not assembled pieces), that occur without the machine stopping its process. Rejecting defective parts stations are located after each flywheel and consist of a sensor. If it detects an error (non-compliant piece for colour or incorrect assembly), it discards the piece, and this can happen at any stage of assembly. Model ITVE: continuous rotary slitting machine (also for tethered caps) The second model, ITVE, is a machine that cuts the bottom part of the cap. Thanks to the exit conveyor belt with the integration of a vision system, it checks for possible deformation of caps and ensures the correct presence of the components inside caps. Finally, it provides a straight end-line conveyor for cardboard boxes (four boxes in accumulation, one box in the filling position, and three boxes in discharge). Maca has the ability to assemble up to four components (body, ring, spout and valve) using the 3-Flywheel ARV and an additional ARV for inserting the valve. The machines can be supplied at low, medium and high speed, based on individual requirements. www.macaengineering.com CAPS & CLOSURES Maca Engineering has experience in tailor-made solutions to realise complex closures through fast, reliable and fully automated machines for over 30 years. Maca supports its customers with feasibility studies and design proposals in order to find the best possible solution in the initial phase of research or the market launch of a new product. Around 80% of key components and structural assemblies (including machine units, dies, etc.) are produced in-house and countermarked with an identification number. One of Maca’s main production areas is the assembling lines and slitting/folding machines for plastic caps and closures: not only pre-threaded flat plastic caps, but also pre-threaded sport plastic caps, complex closures for alcoholic drinks or pre-threaded agrochemical caps. One example, is a line for folding, assembling “TE ring” and spout and slitting for the production of sports caps. In particular, it is a flexible continuous rotary assembly machine model ARV and a continuous rotary slitting machine model ITVE. Structurally the ARV machine consists of three flywheels with 24 punches each Since a few years Maca Engineering became part of the Arol Group, which includes: Arol Closure Systems, the global point of reference in the design, manufacture and distribution of capping machines & capping turrets, caps feeding systems, caps orienting systems and caps sorters; Unimac-Gherri the specialist in filling and capping of glass, metal and plastic containers with twist-off and pre-threaded caps for dense, semi dense and pasty products and Tirelli, which develops and produce filling, capping and labelling systems mainly for home and personal care industry. Model ARV: continuous rotary assembly machine with an output of up to 36,000 pieces per hour Complex plastic closures (ex: sport cap)
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