PETpla.net Insider 06 / 2024

No.6 2024 www.petpla.net D 51178; ISSN: 1438-9452 24 . 06 . 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 preform-, cap- & SBM moulds Page 23 EDITOUR FILLING Page 12 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. 06/24 www.petpla.net The time has now come; as from “...3 July 2024, singleuse plastic beverage containers may only be placed on the EU market if their plastic closures and lids are firmly attached to the containers for the entire period of use.” This is what EU Regulation 2019/904 says somewhat cumbersomely. It cost the beverage industry a lot of effort and money to implement this. Money and effort that bottlers would have loved to invest in more meaningful projects. The preamble “...but its increasing use in short-lived items that are not intended to be reused or recycled cost-effectively means that the associated production and consumption habits are becoming increasingly inefficient and linear...” is – at least when it comes to PET bottles and their closures – way off the mark. No plastic has a higher recycling share than PET. And since the closure almost always comes with it, the polyolefin component is also in the recycling loop. But what’s the good of crying? The industry has tried to change the committees’ minds with factual arguments, but to no avail. Now we have a mess, or rather the tethered cap. Simply because the locking ring on the previous closure is cut differently or manufactured with new moulds, which is very complex, the sensitive closure now gets stuck in the feeders, and is a challenge for quality assurance as well as being extremely unpopular with consumers. The many good sides of the EU are overshadowed by these and other regulations that are difficult to understand. This plays into the hands of the EU sceptics and right-wing populists, who gained 10% more seats in the recent EU election with 370 million eligible voters, increasing their number of seats to 131 (out of a total of 720). May the future regulations make more sense and perhaps involving experts when they are drawn up. Yours, Alexander Büchler Dear readers,

PETcontents 4 PETplanet Insider Vol. 25 No. 06/24 www.petpla.net 06/2024 EDITOUR 10 30 million preforms daily - Visiting one of the largest plastics processors for PET in the region BOTTLING / FILLING 12 Advanced filling in a water world 13 Increased speed 14 Handling high-value liquids INSPECTION 16 Tethered Caps: From regulation to implementation 18 In step with AI: intelligent computer vision - Sacmi’s 24/7 virtual assistance for rigid packaging AUXILIARY EQUIPMENT 19 Controlled loss-in-weight gravimetric dosing unit MATERIALS / RECYCLING 20 The recycling rate for beverage cartons is only half as high as is being claimed - Deutsche Umwelthilfe has been investigating recycling streams MARKET SURVEY 23 Suppliers of preform, cap & SBM moulds EVENT REVIEW 26 Chinaplas review - Chinaplas returned to Shanghai 27 Sustainability and new technologies 28 Food-safe rPET on the increase, now also in the textile industry 30 The future of sustainable packaging solutions European Food & Beverage - Plastic Packaging Summit 31 From “maybe” to “definitely” - PET cap and closure manufacturing system 32 NPE review - part 1 BUYER’S GUIDE 40 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 38 Products 39 PET bottles for home + personal care 46 Outer Planet FILLING Page 31 Page 13 Page 10 EDITOUR INSPECTION

yellow.agency OUR INJEC TION MOULDS FOR PET, PAC AND MED FEATURE KEEN, SOLID SWISS CRAFTSMANSHIP. OT TO-HOFSTET TER.SWISS A FAMILY OWNED SWISS COMPANY. T OTA LLY SW I S S.

PETnews 6 NEWS PETplanet Insider Vol. 25 No. 06/24 www.petpla.net Nadeem Amin is the new President for Netstal Americas Netstal has appointed NadeemAmin as its new President for the Americas Region, effective since June 1, 2024. He reports directly to Netstal CEO Renzo Davatz. NadeemAmin joins Netstal with over 30 years of experience in collaborating with customers in the plastics industry. After 25 years in various roles at Husky, he joined Sacmi USA in 2020 as Vice President PET Sales and Business Development. In his new leadership role, Nadeem Amin will continue to drive market share expansion throughout the Americas Region from the Netstal Technical Center located in Hebron, KY. This technical centre currently supports customers with sales, service, and training. His focus will be on maximising production efficiency for customers in the strategic application areas of PET preform, beverage closures, thin-wall packaging, and medical moulding. www.netstal.com Origin Materials and Bachmann Group to mass produce PET caps and closures Origin Materials and Bachmann Group announced a strategic partnership to mass produce PET caps and closures. In Bachmann’s existing world-class European manufacturing facilities, Bachmann and Origin will operate the lines to convert virgin and recycled PET into caps, including tethered caps, using high-speed equipment and automation. Origin’s caps are developed to be the first commercially viable PET closures to reach the mass market. Origin Co-CEO and Co-Founder John Bissell said: “Bachmann Group will help us produce billions of caps, taking pellet or flake all the way to finished closures. We share a commitment to sustainability and look forward to a productive partnership.” Origin’s PCO 1881-compatible caps, which can be made with virgin or recycled PET, will be available beginning in Q4 2024, with PCO 1881-compatible tethered caps and other cap types to follow afterwards. www.originmaterials.com

7 NEWS PETplanet Insider Vol. 25 No. 06/24 www.petpla.net Alpla and Re-Purpose form strategic partnership to strengthen the plastics cycle in South Africa The Alpla Group and Re-Purpose have announced a strategic partnership that will advance sustainable packaging solutions and strengthen the feedstock value chain of Alpla’s very first PET recycling facility in Africa. Alpla is investing 60 million euros in the construction of a state-of-the-art recycling plant in Ballito in the South African province of KwaZulu-Natal. Construction of the plant on the 90,000m2 site is well advanced. From the beginning of 2025, the plant is expected to produce over 35,000t/a of rPET. Durban-based Re-Purpose is one of the market leaders in the reverse logistics of post-consumer plastic waste through sourceoriented collection programmes. With four material recovery facilities around KwaZulu-Natal, Re-Purpose is developing and empowering local communities and buy-back centres to collect and divert a significant volume of plastic waste. The model is also creating hundreds of jobs and income for previously disadvantaged people.The partnership combines the recycling expertise of Alpla and the reverse logistics of Re-Purpose. By joining forces, the two companies aim to develop solutions and promote the circular economy. At the same time, a large number of jobs will be created in KwaZulu-Natal, neighbouring provinces and potentially throughout the country. As part of the collaboration, Re-Purpose will maximise the utilisation of its current baling centres and set up new centres to make it easier for people to collect PET bottles. Re-Purpose will also assist Alpla in building a strategic supplier base for PET bottle bales and work with key stakeholders to expand community reach and separation at source programmes. The aim is to contribute to the collection of 5,000t of PET per month. This volume is expected to be required for the full capacity operation of Alpla’s recycling plant from 2026. www.alpla.com CCL Industries completes acquisition of 100% of Middle East Venture C C L I n d u s t r i e s I n c . announced it has completed the acquisition of the remaining 50% equity interest in its Middle East joint venture, PacmanCCL (“PCCL”), from its partner, Albwardy Investment LLC, headquartered in Dubai. PCCL, headquartered at its Dubai manufacturing facility in the UAE, operates label production facilities in Oman, Egypt, Saudi Arabia and Pakistan. Sales for the first four months of 2024 were approximately $34 million with $14 million of adjusted EBITDA. The debtfree, all cash purchase consideration is approximately $143 million, net of cash acquired, subject to customary closing conditions. The business will immediately commence trading as CCL Label with results fully consolidated. www.cclind.com

8 NEWS PETplanet Insider Vol. 25 No. 06/24 www.petpla.net Erema Group achieves EUR 380 million revenue in 2023/24 The Erema Group, headquartered in Ansfelden, Austria, achieved a revenue of EUR 380 million for the financial year 2023/24. The group, which now includes eight subsidiaries such as Erema, Pure Loop, Plasmac, and Lindner Washtech, expanded its portfolio through a joint venture with the Lindner Group, adding washing technology to its offerings. CEO Manfred Hackl highlighted the company’s role in advancing the circular economy for plastics, recycling over 25 million tonnes annually. In the past year, Erema produced 290 plastic recycling extruders and over 100 add-on components. The group operates approximately 8,500 machines worldwide and employs 950 people. Despite economic challenges, such as competition from low-cost virgin materials and high energy prices, Hackl remains optimistic. Erema is focusing on process optimisation and increasing investment in R&D to enhance customer value and prepare for future growth. Significant investments include a new R&D Centre in Ansfelden and new machinery at the Customer Technology Center in North America. Over the past five years, Erema has invested more than EUR 110 million in expanding and modernising its facilities. Erema has also seen success with new technologies such as Duafil Compact for high-contamination applications and Refresher technology for odouroptimised recycled pellets. The DischargePro control system, which reduces melt loss by up to 50%, has been nominated for the Plastics Recycling Awards Europe. For bottle applications, Erema’s Vacurema systems boast a capacity of over 4.5 million t/a. PET recycling is also becoming important in the textile industry, supported by Erema’s FibrePro technology and a new fibre technical centre at its headquarters. Given the global plastic production of around 400 million tonnes annually with only 9% recycled, Erema sees substantial potential for growth in plastics recycling. www.erema-group.com The Erema Group with its eight subsidiaries is managed by CEO Manfred Hackl (right) and CFO Horst Wolfsgruber. Sidel expands Central Asian presence with new office in Kazakhstan Sidel, a leading provider of equipment, services and complete line solutions for packaging liquids, foods, home, and personal care products, established a new office in Almaty, Kazakhstan on June 12, 2024. The strategic decision aims to bring Sidel’s expertise closer to its customers and support their growth in the region. Sidel has been serving the Central Asia and Caucasus (CCA) region for more than ten years. The region is a significant market with Kazakhstan, Uzbekistan, Azerbaijan, Tajikistan, Turkmenistan, Kyrgyzstan, Georgia, and Armenia exhibiting growing GDP and disposable income levels. Building upon the strong relationships Sidel has already developed with fast moving consumer goods producers in CCA, the company will continue to significantly invest in this region, providing its solutions and services while supporting the local market needs. The new office will give producers direct access to Sidel’s regional expertise, including local project management, advanced engineering solutions and on-the-ground support services that understand and respond to local market nuances. Sidel is also committed to investing in the local labour market, leveraging local talent, and developing skills in all core operational functions, including sales, project management and services. www.sidel.com

EDITOUR PETplanet Insider Vol. 25 No. 06/24 www.petpla.net 10 Visiting one of the largest plastics processors for PET in the region 30 million preforms dailyby Kay Barton In the Al-Kharj industrial zone, around 100 km south of Riyadh, the Zahrat Al Waha For Trading Company produces preforms and closures under its Oasis brand as one of the largest converters in Saudi Arabia. With an enterprise value of US$270 million and a process volume of 300 tonnes of PET and 40 tonnes of HDPE per day, the giant, which has been listed on the stock exchange since 2016, is of immense importance in the plastic packaging sector not only nationally, but also in the entire Gulf region. Now the company is completing a new production facility for the manufacture of flexible film and labels, which is due to go live in three months. Plenty of reasons to take a look and ask some questions. EDITOUR Meeting with Zahrat Al Waha For Trading Co. (Oasis) We met: Mr Ahmed Hassan Ahmed Ali, Quality Director The Al-Kharj industrial area near the administrative district of the same name in Riyadh province is characterised by expansion. The large red buildings, four in number, stand out visually from the others. They are the Oasis factories. When the processor began its activities in 2012, preform and cap production were still under one and the same roof, exactly where we met Quality Director Ahmed Hassan Ahmed Ali for an interview. “We started with a Husky HyPET HPP 4.0 line back then,” he recalled. Mr Hassan, a qualified chemistry graduate has been part of the company for nine years now and has been working in the plastics sector since the millennium,” explained Mr Hassan with a smile. Since then, he has been responsible for ensuring quality at Oasis, which is achieved primarily through significant investments in well-known suppliers. What once took place in the same factory is now separate. The preform and closure production sections are meanwhile in separate buildings in the industrial estate, as is a warehouse and, more recently, a factory for the production of film and labels, which is about to be commissioned. As a result, the packaging producer soon wants to position itself as a turnkey supplier for the beverage market. A total of 18 Husky HyPET 400 and 500 systems with 96 and 144 cavities process 300 tonnes of PET daily to produce 30 million preforms, i.e. almost 110,000 tonnes of material per year. On the HDPE side, around 14,400 tonnes are processed into closures on eleven Husky HyCap 3.0 systems with 96-cavity moulds from both Husky itself and Corvaglia. During the plant tour, we see a Packsys Global slitting-folding machine for 29/25 closures. The inspections are carried out by IMD Vista Equipment. “For the preform area, further IMD Vista inspection systems are to follow in the future. At present, we only have one here,” says Mr Hassan. The current capacity utilisation is 85%, we were told. The portfolio includes 42 different preform and six cap versions. PET and PE raw materials are sourced entirely from Sabic, while masterbatch suppliers are Polyone and Colormatrix. “Everything we produce goes exclusively into the water bottling sector,” says Mr Hassan. The annual turnover is US$160 million with an average annual company growth of 10%. The company employs 250 people and has a total area of 80,000m2, of which around 20,000m2 is used for production. View into the cap factory Next to the Editourmobil with Mr Ahmed Hassan (right) and Kay Barton

EDITOUR PETplanet Insider Vol. 25 No. 06/24 www.petpla.net 11 Packsys Global equipment for slitting and folding Quality Director Ahmed Hassan with preforms produced on HyPET systems for the water industry One of two areas specifically for preform production PETplanet interview: Quality Director Mr Ahmed Hassan (left) and Kay Barton

BOTTLING / FILLING PETplanet Insider Vol. 25 No. 06/24 www.petpla.net 12 Advanced filling in a water world based on an article by Tommaso Tegoni, Product Manager Filling, Sidel The beverage industry has expanded rapidly over recent years, and bottled water represents the fastest-growing category driving PET growth – driven particularly by countries such as China, India and Turkey. FILLING To meet the rising demand, packaging solutions provider Sidel introduced Evofill PET at the start of this year, a compact new filling machine technology for water and still beverages. The new design is claimed to offer enhanced hygiene and quality while also reducing water and chemical consumption. Sidel designed the first PET filler in 1987. The evolution in filling design has been influenced by a range of factors. Starting with the end consumer, packaging choices are mainly influenced by lifestyle preferences, sustainability claims and budget constraints. Health and price remain key considerations for bottled water. “However, customers often have also other considerations unique to the individual markets that they operate in, such as local legislation, for example,” stated Tommaso Tegoni. “Packaging expertise and extensive knowledge of customers’ industries have led Sidel to develop the Evofill PET system, which provides enhanced water quality in a reduced footprint and is changing the way that manufacturers utilise filling machines”, he added. Enhanced optimisation & design As optimum hygiene is extremely important for all customers, the Evofill PET has been designed to be easier to operate, maintain and clean. To achieve this, Sidel has created a simplified configuration with fewer transfer star wheels and a more compact front table and process unit. In addition, the company has simplified the format changeover in both manual and automatic mode, which can be completed in less than five minutes. The filler can be integrated within Sidel’s Combi and Super Combi complete systems and can also be fully embedded into Sidel’s Evo-On digital intelligence platform to monitor and improve all aspects of the filling parameters and performance. Ease of use Tommaso explained that the ergonomic design of the new development ensures a consistent and repeatable performance that can be used by operators of all skill levels. The reduced filler enclosure is a controlled environment that keeps the water safe during production. The flowmeter contactless filling is claimed to ensure product safety and quality, while preserving bottle integrity with gentle neck handling. Starting at 24 and ranging up to 144 filling valves, with various pitch and filler diameter sizes, Evofill PET can handle bottle sizes from 0.1 to 10 l. The spacesaving filler can handle high production speeds of up to 90,000bph with a footprint that is 15 per cent smaller compared to previous generations. Reduction in water and chemical consumption “There is no doubt that improved sustainability and reducing resource consumption is a huge priority now, both for consumers and governments, with new legislation and directives coming into force around the world. Evofill PET’s integrated CIP system reduces energy by around 25 per cent, while also cutting both water and chemical consumption by 12 per cent for external cleaning. Additionally, its compact size means fewer components and less maintenance operation,” Tommaso proudly announced. Striving for a lower total cost of ownership Tommaso summarised: “While bottle designs and filling technologies have evolved over time, goals for packaging solutions has remained constant: to benefit from the lowest possible total cost of ownership (TCO). Evofill PET has been designed to enhance productivity on PET water bottling lines. The improved accessibility enables faster format changeovers and cleaning operations, reducing downtime. Combined with lower operational costs, it all adds up to a lower TCO. Evofill PET is robustly built for an extended lifespan, enabling customers to count on its reliable operation – with efficiency rates of up to 99 per cent – for years to come.” www.sidel.com

BOTTLING / FILLING PETplanet Insider Vol. 25 No. 0/24 www.petpla.net 13 Increased speed KHS has introduced three improvements to its modular Innofill PET DRV filler, enhancing its capability for faster and more effective filling of still and carbonated beverages into PET bottles - even under extreme conditions. The new Innofill PET DRV HC (high capacity) filler option provides the flexibility needed for filling large containers of 1.5 litres or more, says KHS. Two technical optimisations allow the machine output to increase by up to 15% for these sizes. The product bowl has been raised, increasing the static height between the tubular ring vessel and filling valve, resulting in a higher filling speed. Additionally, a pneumatic switching valve now features three switching steps instead of two, offering three different filling speeds. This enables optimal filling quality and time for both, small and large containers. CO2 consumption is minimised: whereas 150 g of carbon dioxide per hectolitre are needed for a 300ml bottle, as the volume rises this amount gradually decreases, reaching about zero for a 1 l container. For larger containers, no CO2 is needed at all. Manfred Härtel, Product Manager Filling at KHS, explains that the reason for this exceptionally low consumption is that KHS has dispensed with the nozzle technology in the filling valve, which was previously used to control the filling speed in the bottle. “On our new modular platform, this is regulated on the product path between the tubular ring bowl and filling valve so that gas is no longer lost.” KHS has increased the speed of its DRV fillers to meet the growing demands of markets such as Asia. With an output of up to 90,000 bph for CSDs, the system is claimed to ensure gentle and safe conveyance of beverage containers to prevent damage and spillage. Using advanced simulation technology, KHS computes the impact of centrifugal force on beverage sloshing. In CFD (Computational Fluid Dynamics) calculations the bottle contour, fill level and diameter plus the star geometries and capacities are used to determine precisely how the liquid in the bottle behaves and moves during the filling and capping process. To facilitate a reliable production process, machine geometries are adjusted on the container conveyor and stars, for example. Bottle base cooling The newly developed bottle base cooling function is part of the energyefficient and compact block system. This feature is essential for PET bottles filled with carbonated beverages, as they need to withstand the required filling pressure. The bottles, which leave the stretch blow moulder at about 80 °C, must be quickly cooled to become solid and stable. This is particularly important for bottles with complex base designs. The previous method of convection cooling with air and water often reached its limits in tropical regions with high temperatures, risking damage to the bottle base material. To address this, KHS has implemented a bottle base full jet cooling procedure that ensures containers achieve adequate stability before pressurised filling. This method reduces the risk of damage and improves the bottle’s stability and leak tightness. Water consumption is efficiently regulated by a filtered cooling water circuit. www.khs.com FILLING New SCAN Technology for your Bottle Inspection IMDvista BOCO SCAN One system for opaque and transparent bottles No size parts needed - quick product change Reflection-free bottle inspection Endless geometries and shapes Bottle base full jet cooling is claimed to be effective and gentle, ensuring stability and improving hygiene. (Source: Frank Reinhold)

BOTTLING / FILLING PETplanet Insider Vol. 25 No. 06/24 www.petpla.net 14 Handling high-value liquids Sipa’s Flextronic W filling system has been upgraded to handle personal care and homecare liquids as well as edible oils. In today’s fast-paced production landscape, precision and adaptability are essential for success. Sipa, an industry leader in PET bottle production, handling and filling, has announced the launch of an upgraded version of its Flextronic W weight filler, which it describes as a ‘groundbreaking addition’ to its existing range of monobloc filling machines. The Flextronic range was originally designed for high-value products such as edible oils; the latest version of the FlextronicW has undergone an evolutionary design upgrade to make it capable of handling a diverse range of products including salad dressings, ketchup, several types of sauces, detergents and other applications in home and personal care, such as cosmetics. Sipa says that the latest version of the Flextronic W offers higher standards of product performance and emphasises the need, in today’s production landscape, for precision and adaptability, while delivering at pace. In order to achieve these goals, Sipa has invested the Flextronic W with advanced technology and customisable features intended to deliver excellent operational performance, efficient production processes and superior product quality. These features are claimed to meet the needs and demands of businesses in the food and toiletries industries. The company says that its range of monobloc filling solutions featuring Flextronic W offer premier quality and exceptional sanitisation capabilities, while minimising operational expenses. Main features The Flextronic W’s features include a pressurised central tank for efficient product handling. Its draining frame is made entirely of grade 304 stainless steel, to achieve high standards of hygiene. For operations that require the strictest standards, an ultra-clean configuration featuring nitrogen pressurisation of the filling tank is available, along with automatic insertion of dummy bottles during CIP. Changeover times have been cut, which helps to boost productivity, and operations are made as simple as possible by a user-friendly touchscreen HMI, with intuitive control and monitoring of filling processes. In order to minimise waste, the Flextronic W is equipped with a recovery tray for rinse or cleaning oil, which enables complete product recovery at the end of production. Sipa says that the Flextronic W’s comprehensive set of features are designed to raise its performance in a number of areas. The capacity for the flexible handling of a variety of products eliminates any need for additional equipment and simplifies the production process. Likewise, its adjustable filling speed is designed to ensure the efficient handling of a wider range of FILLING products, with different consistencies, than previous models. Automatic filling engagement is designed to deliver precision and consistency, for uniform product quality through multiple fills. Its design, including the use of high-grade stainless steel, mean that the machine is ideal for industries and operations with strict hygiene standards, Sipa maintains. The improved design helps to minimise downtime and boost productivity by enabling faster changeovers and transitions between products, and easier access for simplified maintenance. The filler, available with 20 to 96 valves, can achieve output rates ranging from 6,000 to 36,000 bph in case of 1.5 l formats. Advanced weight-filling technology Flextronic W seamlessly accommodates various types of products, says Sipa. This versatility allows producers to expand their offerings without the need for multiple filling machines, thus helping to boost operational flexibility and cost-effectiveness. Its advanced weight-filling technology enables higher levels of accuracy, which minimises product waste while maintaining quality and consistency. As its design incorporates features for quick adjustments and thus cuts downtime, higher production rates and improved efficiency can be achieved, especially

BOTTLING / FILLING PETplanet Insider Vol. 25 No. 06/24 www.petpla.net 15 when configured in synchrobloc with a blow-moulding machine. Sipa’s stated commitment to reducing running costs in the latest Flextronic W helps manufacturers to better control and manage costs. At the same time, the company says that its quality standards ensure production consistency and compliance with product specification. Safety has not been overlooked. Modular element guards prioritise safety and convenience, providing operators with added peace of mind during operation. www.sipasolutions.com Filling flammable liquids Sipa’s Flextronic W Atex version has been specifically designed for the safe filling of flammable liquids, such as 70% alcohol hand sanitisers. This specialised configuration adheres rigorously to Atex compliance standards, for mitigation of risks and safe operation in environments with hazardous atmospheres, such as explosive gases and vapours. The version incorporates features to eliminate of potential ignition sources and the integration of micro isolators around the filling valves to contain hazardous areas. Specially-designed ventilation and aspiration systems further minimise risks. The Atex version of Flextronic W caters to industries requiring the safe and efficient handling of highly flammable liquids and features safety and precision engineering. It is claimed to ensure compliance with the most stringent safety standards and provides reassurance to manufacturers operating in hazardous environments.

INSPECTION 16 PETplanet Insider Vol. 25 No. 06/24 www.petpla.net Tethered Caps: From regulation to implementation In July of this year, EU Directive 2019/904 on Single Use Plastics will finally come into force. One of the consequences of this directive is the widespread introduction of tethered caps in the European Union. We spoke to Marius Pötting, Product Manager Caps and Closures at Intravis GmbH, and asked him: What impact will the directive have on the industry in general and on inspection systems for closures in particular? PETplanet: Mr Pötting, EU Directive 2019/904 comes into force on July 3. In your opinion, what are the main objectives of this directive? Marius Pötting: In general, the directive aims to reduce the impact of certain plastic products on the environment. The focus here is on reducing plastic waste, improving the recycling loop, reducing material consumption as well as using resources more sustainable. The introduction of tethered caps (plastic closures that must remain permanently attached to the packaging) is also intended to prevent the careless disposal of closures in the environment. All these measures obviously have a huge impact on the plastics and packaging industry. PETplanet: So what exactly does the directive mean for the packaging industry? Marius Pötting: The effects on the packaging industry are diverse and require adjustments to the entire process chain. In order to meet the requirements of EU Directive 2019/904, considerable investment in research and development was and still is required. However, the directive also offers opportunities for companies that can position themselves as pioneers for sustainable packaging solutions. In concrete terms, the introduction of the directive means that adjustments have to be made at various points in the manufacturing process: For example, to the injection moulding machine tool, the injection speed and injection pressure, as well as the inspection system all the way to the filling line. PETplanet: You mention that these changes will also have an impact on the inspection of objects. Can you tell us what exactly is changing for inspection systems? Marius Pötting: The introduction of tethered caps has ensured that new, asymmetrical geometries and designs have been established on the market. As a result, both the feeding and the handling of the inspection system had to be adapted. In addition, material savings mean that closures are becoming thinner and thinner and are therefore more vulnerable to process-related defects. Accordingly, the feeding system must be carefully adapted to the thinner material thickness. One example of this is the Intravis form-fit star wheel separation, which ensures perfect positioning of the closures thanks to its lateral movement. The star wheel separation does not exert any pressure on the closures and there is no friction compared to conventional separation methods. In addition, the introduction of the new tethered caps has changed the inspection approach, which means that the software must also be adapted. Intravis has implemented a holistic software solution based on Deep Learning: It does not require time-consuming “screening” and “teaching” of different defect patterns. With the new approach, you can train the system on the basis of a few good parts in a quick and intuitive process. Deviations from the defined “good” closures are automatically ejected based on the sensitivity settings you choose. The inspection system thus ensures that even minimal defects are detected and only flawless products find their way to the end consumer. PETplanet: Talking about the inspection approach: More and more suppliers in the mechanical engineering sector are now offering their systems with the addition of Artificial Intelligence. Can you tell us what customers can expect from Intravis? Many customers are certainly afraid that their data will disappear into a black box and that they cannot understand what exactly is being verified. Marius Pötting: At Intravis, the customer always retains full control over the inspection system. As already mentioned, the AI is the foundation for empowering our customers INSPECTION

Inspection 17 PETplanet Insider Vol. 25 No. 06/24 www.petpla.net to teach the system which product should be accepted as a good part and which should not. Intuitive reference creation allows the customer to define inspection areas in which all defect criteria are inspected. The customer uses tolerance values to independently define which closure he wants to evaluate as a good or bad part. Based on a large number of successfully completed projects, Intravis has already gained extensive experience of typical defects (such as flashes or short shots at the warranty band) that can occur during tethered cap production. This allows the best possible, customised solution to be found for each project. The cavityrelated data analysis enables precise monitoring and analysis in order to be able to react to potential problems at an early stage. This means that our customers always retain full control over their production quality. PETplanet: Intravis was one of the first providers to offer an inspection system that is “Tethered Caps Ready”. How much experience have you gained in this area in the meantime? Marius Pötting: For many years now, Intravis has been actively involved in Cetie (International Technical Center for Bottling and related Packaging), making a significant contribution to the further development of tethered caps and, thus, supporting the optimisation of safety and sustainability standards in the packaging industry. Since then, we have dedicated ourselves intensively to the inspection of tethered caps and have successfully adapted to meet the new requirements. By using the latest image processing technologies and machine learning algorithms, we are able to inspect tethered caps quickly and precisely - regardless of whether they are produced using the injection moulding or compression moulding process. As a leading provider of image processing solutions in the packaging industry, we are proud to have already successfully implemented a large number of inspection systems for closures on the market, and to be able to offer our customers high-quality and reliable solutions for tethered caps. PETplanet: Finally, let’s imagine a customer who wants to convert his existing line to tethered caps. He has already updated everything and is now confronted with the final task of adapting his inspection. How complicated will this be for the customer? Marius Pötting: Of course, I cannot speak for other providers on this issue, but Intravis took all the necessary measures early on when developing and refining the CapWatcher. So, an uncomplicated and rapid changeover is definitely possible. It is advisable to involve the inspection system provider in the changeover as early as possible. If you are interested, you can contact us at any time. We will be happy to support you with the transition of your production. PETplanet: Thank you very much Mr Pötting. www.intravis.com

INSPECTION 18 PETplanet Insider Vol. 25 No. 06/24 www.petpla.net Sacmi’s 24/7 virtual assistance for rigid packaging In step with AI: intelligent computer vision The evolution of ‘vision’, from quality control to process control, systems designed to ‘think’ like a human being, providing immediate and useful information to even the most experienced operator. Sacmi provides a wide range of vision systems for rigid packaging in the beverage industry. INSPECTION Caps, preforms, right up to the full, labelled container: today, Sacmi systems are evolving under the banner of artificial intelligence and deep learning. This is achieved thanks to the new release of the Computer Vision software (CV) suite, a set of tools that - in the name of interoperability, cybersecurity, and data availability- project quality control within a collaborative vision between man, machines and systems. Sacmi says that the GildaAI, a real ‘virtual colleague’ provides answers, further simplifies system management and troubleshooting. Quality first Sacmi seized the opportunity from the early days of software engineering to complement its range of machines with the development of data-based systems to support quality control. More recently, the radical paradigm shift in the digitalisation of systems has made these solutions a tool for quality control and a strategic tool for making the production process more efficient. The new CVs software suite The range of vision systems for the rigid packaging sector is based on the Sacmi software suite. This is the starting point of the development to train operators in their use, making process data management simpler, more useful and more immediate. In this logic, CVs includes software (CVs23) integrated into the machines and common to all systems, the remote data logging and analysis platform (CVsWeb) and the Classy AI system that improves and simplifies system operation by automatically categorising the types of defects detected, says Sacmi. In addition to the technical interface, which is always available, the Classy AI presents an advanced dashboard, trained to ‘think’ like a human being, classifying and associating each defect with its possible cause, intercepting and anticipating any process drift. Gilda-AI, the 24/7 digital assistant Sacmi’s approach to the factory of the future is based on the idea that technologies should increase productivity and ensure the safety and well-being of operators. This concept is reflected in CVS machines and devices that detect defects and offer unparalleled virtual support through Sacmi’s new 24/7 digital assistant, Gilda-AI. Gilda-AI is a ‘virtual colleague’ that speaks the language of the operators and provides immediate and intuitive solutions to any problem. Thanks to Gilda-AI and the CVs software suite, there is no need to consult manuals or search for complex solutions. The range for bottlers As part of its vision in the production of rigid packaging for the beverage industry, Sacmi offers the proven CHS solution for the in-line quality control of caps. In addition, there are the new cut and tamper-evident band inspection systems integrated into the cap line in view of the changeover to the new tethered standard. Sacmi range extends to preform production, with PVS systems for both in-line and laboratory quality control, and with the first press on the market, the IPS 300 and IPS 400, to integrate this system directly into the machine as an option for process control. For bottling lines, Sacmi develops dedicated label quality control (LVS) and filled and labelled container (BVS) quality control systems, which are designed to work with advanced software packages. Digital & on-site services Intelligent on-board machine systems complement the ability to support customers throughout the service life of the machine and plant with a timely after-sales, remote and on-site service. From this point of view, too, solutions such as Gilda-AI and the remote control of data, together with the possibility of sharing it in the cloud with the Sacmi team, are the beginning of a new approach to customer service. www.sacmi.com

AUXILIARY EQUIPMENT PETplanet Insider Vol. 25 No. 0/24 www.petpla.net 19 Controlled loss-in-weight gravimetric dosing unit The DUG series of loss-in-weight gravimetric dosing unit by PET Solutions, part of the Pegaso Industries S.p.A. group, based in Borgoricco, Italy, has been developed as a cutting-edge advancement in the automatic dosing of masterbatches, additives, and regrinds in granules. Designed to optimise production process efficiency, the DUG feeders are claimed to combine innovative design with advanced technology, offering flexibility for various applications on injection moulding machines, blow moulders, and extruders. The DUG dosing unit is notable for its inclined axis configuration, ensuring precision and stability. Paired with a brushless motor, it offers precise and reliable dosing control, minimising errors. The intuitive control system features an LCD display that can be installed on the feeder or remotely. A key solution is the patented dual load cell system: The first load cell handles dosing from the hopper to the mixer, while the second provides additional precision control, ensuring maximum accuracy. Six screw sizes are available, from 8 to 30mm in diameter, and three hopper versions, ranging from 10 to 60 l. The feeder’s self-learning calibration and adjustment system, which uses data exchange between the two load cells, allows for automatic and continuous adjustment. This, combined with a bottom shutter for residual material discharge, is claimed to enhance efficiency and ease of management. The central flanged base of the DUG allows for the installation of one or two units, offering versatile configurations. An integrated static mixer ensures homogeneous material mixing, and a Modbus RS485 interface facilitates integration with other systems. Additional features and options include a remote control panel, touch LCD display, a centrally polished stainless steel hopper, capacitive sensors with a buzzer for material shortage alerts, and a remote controller kit. Other available accessories are a paddle mixer body, a Venturi loader for air-compressed material loading, and a screw cooling system for low melting point materials. PET Solutions says that the DUG dosing unit allows for efficient replicability of dosing processes, quick colour changes, and fast cleanings due to the unit’s complete accessibility, reducing downtime. The interchangeable stainless steel screws offer operational flexibility for different materials. The advanced technology of the DUG series minimises material waste during the weighing process, contributing to a more sustainable and economical production. www.petsolutions.it www.agrintl.com +1.724.482.2163 ȏ $FFXUDWH )DVW ΖQWXLWLYH ȏ 3RZHUIXO 6LPSOH -RE &UHDWLRQ DQG (GLWLQJ ȏ 3UH 'HȴQHG &RQWDLQHU 0HDVXUHPHQW 5RXWLQHV ȏ $XWR-RE® ȃ $XWRPDWHG )HDWXUH 5HFRJQLWLRQ DQG -RE 6HWXS LQ 6HFRQGV High Precision Dimensional Measurement for Plastic Containers — 6LPSOLȴHG ® The easily transferable weighing and dosing station makes the system suitable for dynamic production environments.

PETplanet Insider Vol. 25 No. 06/24 www.petpla.net 20 MATERIALS / RECYCLING Deutsche Umwelthilfe has been investigating recycling streams The recycling rate for beverage cartons is only half as high as is being claimed The German environmental organisation Deutsche Umwelthilfe (DUH) has calculated a recycling rate of 38% rather than 75% for beverage cartons, once again casting an unfavourable light on the use of controversial cardboard packaging. However, the new EU Packaging Regulation plans to do something about this. The current draft text calls for a mandatory deposit scheme for containers which, for technical reasons, are made almost exclusively from virgin material. CONVEYING PALLETIZING PACKAGING BLOWING FILLING LABELLING The DUH organisation is always challenging and questioning the environmental-friendliness of drinks packaging in Germany. Their research and findings can also be applied to other countries, even though Germany is different with its small-scale bottling industry and special waste system (Yellow Bag). For the German small-scale market, the DUH has concluded that returnable glass bottles are the most environmentally-friendly option for short distances between the consumer and bottler. The fact that municipal water in Germany is of drinking water quality was not taken into account, which is why no packaging is actually required for water. It is equally evident that the non-returnable PET bottle is the most eco-friendly form of beverage packaging when distances between the consumer and bottler are greater, as is the case in nearly every country. The current DUH study on drinks cartons is extremely interesting. The official recycling rate of 75% for drinks cartons claimed by FKN e.V., the association that represents the interests of beverage carton manufacturers, is far too high – in fact it is only around 38%. The 75% quoted by the FKN is based on the cartons collected in the yellow bag, the 38% recycling quota of the DUH is based on cartons produced or sold. Barbara Metz, Federal Managing Director at DUH, said “Contrary to the promises made by Tetra Pak and Co., beverage cartons have an incredibly poor recycling record. This is mainly due to the fact that more than a third of their drinks cartons do not end up in yellow recycling bags but in residual waste, a paper bin or in the environment. The Federal Environment Minister Steffi Lemke must therefore introduce a one-way deposit of 25 cents on drinks cartons as soon as possible. This would allow around 2.3 billion more units to be recycled each year. The best thing to do is to dispense with environmentally harmful drinks cartons altogether and use regional reusable bottles instead.” In addition, the EU Packaging Regulation explicitly recommends introducing a deposit scheme for beverage cartons. Drinks cartons have tended to be less eco-friendly in recent years. The paper fibre content has decreased while the plastic ratio has increased, with composite packaging having become 35% heavier during the last 20 years. They are only filled at a few locations and distributed over long distances throughout Germany. Thomas Fischer, Head of the Circular Economy at DUH, continues: “Beverage cartons are a burden on our environment due to their plastic-moulded packaging. Tops made from plastic, long-handled pouring aids or oversized screw caps are evidence of the increasing plasticisation of this short-lived

PETplanet Insider Vol. 25 No. 06/24 www.petpla.net 21 MATERIALS / RECYCLING disposable packaging. What’s more, drinks cartons are made almost entirely from new rather than recycled materials. Thousands of trees have to be felled for the packaging. This is because slow-growing wood with long fibres is required for production purposes, most of which is imported to Germany over long transport routes.” www.duh.de right- /Quellenangaben 1 UBA, Federal Environmental Agency (2023) 2 Calculation according to sources 1, 3 and 4 3 ifeu gGmbH, Institute for Energy and Environmental Research (2020) – 11.2 % of beverage cartons not sorted for recycling 4 FKN e.V., Association for Beverage Cartons (2008) – approx. 12.5 % other external materials, approx. 17 % moisture and contaminants 5 Market information – approx. 70 % paper, 25 % plastic and 5 % aluminum content of beverage cartons 6 FKN e.V. (2019) – annual processing capacity of the Palurec plant in Cologne Knapsack of around 18,000 tons 7 bifa Umweltinstitut GmbH, Environmental Institute (2020) – approx. 22 % loss during paper recycling Actual recycling rate 2021 according to DUH e.V. Alleged recycling rate 2021 according to FKN e.V. 37.9 % 75 % Total use of beverage cartons in 2021 (empty weight)1 179,700 t Paper content (not recycled)5,7 14,603 t Plastic content (not recycled/incinerated)5,6 10,206 t Aluminium content (not recycled/incinerated)5,6 1,831 t Other external materials (e.g. plastic foils, corrugated cardboard) 16,813 t Moisture and contaminants4 22,865 t No collection via the Green Dot system (e.g. due to disposal in residual waste/paper waste, littering; empty weight)2 69,699 t (Empty weight without other external materials, moisture and contaminants) 94,823 t Recycled beverage cartons (empty weight)5,6,7 68,183 t Sorting residue (beverage cartons not sorted for recycling, incl. moisture and contaminants)3 14,843 t Status: February 2024 Collection via the Green Dot system in bins for recycables (without other external materials, but incl. moisture and contaminants)2 132,531 t (empty weight without moisture and contaminants)2 110,001 t Paper content (recycled)5,7 51,773 t Beverage cartons for recycling (after sorting, incl. other external materials, moisture and contaminants)1 134,500 t Aluminium content (recycled)5,6 2,910 t Plastic content (recycled)5,6 13,500 t Recycling of beverage cartons in Germany in 2021 (source: DUH)

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