No.9 2024 www.petpla.net D 51178; ISSN: 1438-9452 30 . 09 . 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 compressors Page 28 COMPRESSORS EDITOUR Page 39 Page 30 Page 10
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No.9 2024 www.petpla.net D 51178; ISSN: 1438-9452 30 . 09 . 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 compressors Page 28 COMPRESSORS EDITOUR Page 39 Page 30 Page 10
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imprint EDITORIAL PUBLISHER Alexander Büchler, Managing Director HEAD OFFICE heidelberg business media GmbH Hubweg 15 74939 Zuzenhausen, Germany phone: +49 6221-65108-0 [email protected] EDITORIAL Kay Barton Heike Fischer Gabriele Kosmehl Michael Maruschke Ruari McCallion Anthony Withers Editorial & WikiPETia. info [email protected] MEDIA CONSULTANTS Martina Hirschmann [email protected] Johann Lange-Brock [email protected] phone: +49 6221-65108-0 LAYOUT AND PREPRESS EXPRIM Werbeagentur Matthias Gaumann www.exprim.de READER SERVICES [email protected] 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. 09/24 www.petpla.net I started my tour through Oman, Qatar and Kuwait at the PRS Middle East & Africa 2024 in Dubai. A recycling fair in a region without recycling. It was small, but the 125 exhibitors made a pleasant show of it. For visitors from outside the Gulf States – especially those from Africa – there were many rPET suppliers and plant manufacturers from India, China and other countries represented. However, the search for regional recycling companies was fruitless. The issue of rPET is non-existent in countries that have crude oil reserves and can obtain virgin PET cheaply. At best, in-house recycling makes sense, at least for the production of plastic sheets. I spoke to recycling system providers at the PRS about why this is the case. Christoph Wöss, Business Development Manager of the Erema Group for the Bottle Application division: “We have two recycling plants at two locations in the region, each with a capacity of 1,600 kg/h, to directly recycle offcuts from sheet production. In Saudi Arabia, we also operate a preform production facility at Bariq. But in the Emirates or Oman? No, not a single bottle-to-bottle (b-to-b) system. People are not used to collecting rubbish; it all ends up in landfill. In the future, the idea of sustainability will also reach here, but I can’t tell you when that will be.” Christian Lechner, Regional Sales Manager at Starlinger: “There is no bottle-to-bottle recycling here. Virgin PET is so cheap and no consumer wants a slightly grey bottle. As there is a lack of b-to-b recycling, bottlers can also easily produce opaque bottles for energy drinks or fruit juices that are no longer suitable for b-to-b recycling due to their colour. By contrast, some manufacturers make sure that the bottles of exported drinks do not disrupt the recycling stream. It remains to be seen when the pressure for sustainability will be felt in these parts.” Peter Hartel, Head of Sales CN/MEA, Krones Recycling GmbH: “We have invested a lot of manpower in Krones Recycling GmbH in Flensburg and Neutraubling, which has been independent since July. We believe that PET recycling is a very important building block for the acceptance of the PET bottle. Only in this region has the topic not yet arrived, possibly blocked by the large local virgin PET manufacturers. One cracker after another is put into operation here.” Yours, Alexander Büchler Dear readers,
PETcontents 4 PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 09/2024 EDITOUR 10 “We want to become a key supplier for the beverage industry” - Packaging solutions from a single source MATERIALS / RECYCLING 12 From bottles to preforms to rPET - Spanish processor relies on recycling equipment from Germany 14 PEF, polyester material of the future - First PEF World Congress in Düsseldorf, Germany MOULD MAKING 16 The importance of high-quality spare parts PREFORM PRODUCTION 18 18% reduction in water flow rate - Thermoscan technology enables Sacmi to achieve water savings in injection moulding BOTTLE MAKING 20 Tennessee two-step - English Mountain Spring Water Company boosted packaging quality with the installation of a blowing line from Flexblow BOTTLING / FILLING 24 Aseptic filling system with non-heated water sterilisation 26 Hattrick in Colombia - South American beverage multi Postobón installs three KHS lines 27 Boosting efficiency and sustainability - Coca-Cola Bottlers Nepal’s journey with Sipa-supplied complete filling line MARKET SURVEY 28 Suppliers of compressors COMPRESSORS 30 Improving compressed air efficiency in PET applications 34 US market key focus for growth - AF Compressors: celebrating three decades in the United States 36 Increased monitoring capabilities - Controller improves efficiency & reliability of high-pressure reciprocating compressors 38 Oil-free high-pressure compressor series launched - Adekom introduces KSP series high-pressure compressor for bottle blowing EVENT PREVIEW 39 Fakuma 2024 preview EVENT REVIEW 46 Compact preform system for long and heavy preforms (HOD) OUTER PLANET 54 Biodegradable polymers in various environments BUYER’S GUIDE 48 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 47 Patents COMPRESSORS Page 10 Page 16 Page 39 EDITOUR
yellow.agency OUR INJECTION MOULDS FOR PET, PAC AND MED FEATURE PRECISE , LONG-LASTING SWISS CRAFTSMANSHIP. OTTO-HOFSTETTER.SWISS A FAMILY OWNED SWISS COMPANY. T OTA LLY SW I S S.
PETnews 6 NEWS PETplanet Insider Vol. 25 No. 09/24 www.petpla.net Indorama Ventures, Dhunseri and Varun beverages joint venture plans multiple recycling facilities in India Indorama Ventures Public Company Limited, through its direct subsidiary – IVL Dhunseri Petrochem Industries Limited – and Dhunseri Ventures Limited have formed a joint venture with Varun Beverages Limited, PepsiCo’s second-largest bottling company globally outside the US, to establ ish several greenfield state-of-the-art PET recycling facilities in India. The joint venture has already begun the construction of two PET recycling facilities, planned for completion within 2025, with potential for more. One facility is in Kathua within the Jammu Division of the Indian Union territory of Jammu and Kashmir, situated in Northern India, while the other is in Khurdha within the State of Odisha, located in Eastern India. The aim is to reach 100 kt/a capacity of recycled PET across all the facilities when combined. This initiative aligns with the escalating demand for rPET content in India, driven by both regulatory mandates and a collective effort towards a circular economy for PET. The surge in demand reflects a significant shift, with projected volumes increasing from approximately 400 kt in 2025-2026 to over 1 million tons by 2031. Mandates such as the Indian government’s compulsory requirement of 30% recycled plastic content in plastic packaging by 2025-2026, escalating to 60% by 2028-2029, underscores the urgency and importance of this transformation. Moreover, this move aims to effectively cater to the needs of India’s beverage brand owners, many of whom have established ambitious sustainability goals in line with regulatory directions. The amalgamation of the three industry leaders is claimed to bode well for bolstering the region’s recycling infrastructure. As regulatory frameworks increasingly advocate for heightened usage of recycled content, the joint venture is positioned to play a pivotal role in meeting these evolving requirements. Indorama Ventures is the world’s largest producer of rPET resins widely used in food and beverage packaging. Since 2011, the company has operated PET recycling facilities, gradually expanding its global footprint. www.indoramaventures.com Husky Technologies announces leadership transition: Bradley Selleck appointed CEO, John Galt to become Chairman Hu s k y Te c h n o l o g i e s announced that Chief Operating Officer Bradley Selleck will assume the role of CEO, effective October 1st. The current CEO, John Galt, will transition to the role of Chairman. This leadership change is part of a long-term succession plan designed to maintain stability and position the company for continued growth. Husky, a portfolio company of Platinum Equity, is a global provider of innovative solutions and services primarily for the beverage, consumer goods and medical device markets. “John has been preparing the company for this for several years and I commend him and the team for taking such a thoughtful and deliberate approach,” said Louis Samson, Co-President of Platinum Equity. “Brad is a uniquely talented executive and key architect of the company’s current operating model. He has made a material and multi-faceted contribution to Husky since joining approximately three years ago and has proven beyond any doubt that he’s up to the task and ready to take the reins.” Galt has been with Husky since 1985 and served as CEO since 2005. During his tenure, he played a central role in the company’s transformation into a global leader in industrial technology. In recent years, Galt has worked closely with Selleck and the management team to strengthen the company’s market strategy, with an increased focus on sustainability and essential markets. Selleck joined Husky in 2022, bringing more than 25 years of experience in operations and supply chain management. As CEO, he plans to continue advancing the company’s strategic priorities, including sustainable practices and innovation. Galt will continue to play an active role in the company as Chairman, with a focus on sustainability advocacy and supporting the leadership team in areas such as customer and investor relations. www.husky.co Yash Lohia, representative of IVL Dhunseri, and Executive President Petchem Special Projects, and Chairman of the ESG Council of Indorama Ventures
7 NEWS PETplanet Insider Vol. 25 No. 09/24 Z-Moulds Pty. Ltd. appoints David Chalmers as Vice President of new Sydney branch Z-Moulds has announced the expansion of its operations with the establishment of a new sales and service branch in Sydney, Australia. The new branch, Z-Moulds Pty. Ltd., became officially operational in September, marking a key step in the company’s growth. The expansion is aimed at enhancing service and product availability to customers across the region. David Chalmers’ experience in the closure and packaging industry spans over 30 years. His journey with Z-Moulds began in 2011, during his tenure at Coca-Cola Europacific Partners (formerly CocaCola Amatil), where he played a pivotal role in the company’s decision to self-manufacture both closures and preforms. Before joining CCEP, Chalmers had already built a strong foundation in the industry, having served as a Senior Technical Specialist at the Asahi Group for five years and as a Commercial Service Manager at the Pact Group for over a decade. During his t ime at CCEP, Chalmers col laborated wi th Z-Moulds on the Sylon closure project, an initiative that achieved recognition within the Coca-Cola system for its innovations in closure design, weight reduction, and cycle time efficiency. Under his leadership at CCEP, the company installed 11 Z-Moulds systems across Australia and Indonesia. The appointment of Chalmers is seen as a strategic move to strengthen Z-Moulds’ presence in Australia and further i ts commi tment to providing advanced solutions in the closure and packaging sector. www.z-moulds.com CREATING FUTURE STANDARDS Japan’s leading Aseptic PET Filling System Provider. Our website Our solution high quality reliable technology safe & secure
8 NEWS PETplanet Insider Vol. 25 No. 09/24 www.petpla.net Chile inaugurates first plant to produce beverage bottles from recycled plastic Chile has launched its first plant dedicated to producing beverage bottles from recycled plastic. The facility, named Re-Ciclar, is a joint venture between Coca-Cola Andina and Coca-Cola Embonor, representing a US $35 million investment. The plant aims to recycle over 350 million bottles annually and integrate food-grade recycled material into Coca-Cola’s packaging in Chile. Re-Ciclar is noted for its use of sustainable technologies and is expected to generate 25,000 indirect jobs nationwide. It is combining state-of-the-art equipment imported from Italy, Japan, and Austria. The plant is part of a broader initiative to increase the recycled content in Coca-Cola bottles, starting with 15% rPET by 2025, with plans to reach 100% in the future. Re-Ciclar has a collaborative and inclusive model through strategic alliances with all members of the recycling chain, including grassroots recyclers, small, medium, and large managers, local governments, and territorial organisations, among others. In 2024, it expects to collect around 10,000 t of PET alongside its partners, including the National Association of Recyclers of Chile, Latitud R, La Ciudad Posible, and the collective action of citizens. www.embonor.cl Corvaglia Group strengthens expertise in the Board of Directors At an extraordinary general meeting of Corvaglia Group in mid-August 2024, Marc Aeschlimann was elected to the Board of Directors. To strengthen the division operations, the sole Shareholder, Romeo Corvaglia sought to expand the Board of Directors, leading to the selection of Mr Marc Aeschlimann. The Board of Directors now consists of Romeo Corvaglia (Chairman), Karel Strub (Vice Chairman) and Marc Aeschlimann (Member). Marc Aeschlimann is CEO of the Schaffner Group. Schaffner (now part of TE Connectivity) is a global leader in electromagnetic solutions that ensure the reliable operation of electronic systems. Previously, Marc Aeschlimann was CEO of companies such as the R&S Group, Pfiffner Messwandler AG and held various leadership positions within the Franke Group. Marc Aeschlimann originally studied electrical engineering at ETH Zurich and graduated with a Master of Science. He then completed an MBA at the USC Marshall School of Business. www.corvaglia.com Factory Acceptance Test of first commercial-scale PET cap manufacturing system completed Origin Materials, a technology company focused on sustainable materials, announced the successful completion of the Factory Acceptance Test for its Origin CapFormer System, which is claimed to be the first commercial-scale system for manufacturing PET caps and closures. The system uses thermoforming, slit-and-fold technology and proprietary design elements to enable the production of PET caps at a large scale. The test demonstrated over 98% manufacturing efficiency, validating the system’s performance specifications. Origin’s Co-CEO and Co-Founder, John Bissell, noted that the system addresses long-standing industry demand for PET caps, offering a commercially viable solut ion for PET-based packaging. The CapFormer System is designed to enhance recycling efforts by enabling 100% PET container-to-container recycling for the first time. The system is poised to produce PET caps for a variety of industries, including beverages, food packaging, and medical products. Origin’s PCO 1881-compatible caps, made from either virgin or recycled PET, will be available in Q4 2024, with PCO 1881-compatible tethered caps and other cap types to follow. www.originmaterials.com
9 NEWS PETplanet Insider Vol. 25 No. 09/24 www.petpla.net Taste trends at CBB 2024 raw materials, agents and additive area 2024 China Brew China Beverage (CBB) will be held at the Shanghai New International Expo Center from October 28 to 31. A leading event for the Asian wine, beverage, liquid dairy products, liquid condiments, and edible oil industries, CBB is part of the Drinktec global network. It covers key aspects of the industry, from raw materials and auxiliary materials to processing technology and equipment, packaging technology and equipment, general equipment and parts, packaging containers and materials, and modern warehousing and logistics. It also highlights cutting-edge themes such as intelligent manufacturing, Industry 4.0, innovative packaging, food safety and health, energy efficiency management, and green and sustainable development. With rising living standards and growing health consciousness, the beverage and dairy industries are innovating to offer flavours that are both healthy and trendy. CBB 2024’s dedicated area for raw materials, agents, and additives will highlight key trends. Personalisation and trendiness: New flavours in beer, beverages, and dairy products - such as new hops and fruitinfused drinks - will inspire personalised, fashionable tastes. Natural and healthy: The focus will be on natural, healthpromoting ingredients, showcasing growth potential in craft beers, functional drinks, and plant-based beverages. A tasting journey on the tip of the tongue: Raw materials, agents and additive areas at CBB 2024 are intended to offer an interactive experience, allowing attendees to explore the diverse styles of raw materials, auxiliary materials, and additives. Visitors can sample diverse hops and explore healthy beverages, offering a hands-on experience of flavour trends. This area will serve as the starting point for a high-tech journey through the entire beverage and liquid food industry chain, including wine, beverages, dairy products, condiments, and edible oils. www.chinabrew-beverage.com
EDITOUR PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 10 Packaging solutions from a single source “We want to become a key supplier for the beverage industry” Jeddah-based company and greenfield project 3P Gulf Packaging Systems, founded in 1992, is a market leader in plastic packaging and products in Saudi Arabia and the region, serving the beverage and food, pharmaceutical, personal care and home care sectors. Its most important products include preforms, closures, tubes, disposable plastic products, plastic tableware, films and labels. Meeting with 3P Gulf Packaging System Co. February 21, 2024 We met: Mr Mohammed Najmuddin, VP Operations Mr Ali Hashim, VC & CEO Mrs Randa Hashim, Business Development Manager Mr Vipin Vellipoyil, Tooling Workshop Manager Mr Ahmed Salehi, PET Production Manager In the PET segment alone, the conversion volume in Jeddah for PET reaches 7,000 t per month. In comparison: the company started with 70 t when it was founded. A total of nine plants belong to the 3P Group in Jeddah involved in producing products in rigid and flexible packaging. Another plant in Riyadh became operational in 2023 processing around 3,000 t of PET per month in the preforms and closures segment. In addition to the MENA region, the customer base extends to over 40 countries, which is due in particular to the production of shrink and stretch film. In an interview with VP Operations, Mr Mohammed Najmuddin, VC & CEO Mr Ali Hashim and Business Development Manager Mrs Randa Hashim, we gained a comprehensive insight into the market giant’s business. With his business idea in 1960, Mr Hashim Sr, the father of today’s CEO Mr Ali Hashim, wanted to support and serve pilgrims on their journey to Makkah in the south-western Saudi region of Hejaz. He began producing footwear for them and making jerry cans for carrying the holy water from the Zamzam well. Three years later, he started the first commercial factory in Jeddah for everyday household items under the name Arabian Gulf Manufacturers (AGM). The bestknown brand that emerged from this, “Gulfmaid”, contributed significantly to the company’s success story over many years and Mr Hashim increasingly recognised the potential of plastics processing. 1992 marked the start of the Gulf Packaging System Company (GPS) that was later brought under the umbrella of Prime Plastic Products more popularly known as “3P”, which still adorns the company logo today. The current CEO, Mr Ali Hashim already knew the markets and suppliers well from previous experience and so the idea was to be able to offer a complete solution from a single source in the field of packaging, mainly for bottles and closures, primary and secondary packaging - including printing and everything that goes with it. In the 1990s, the immense construction boom in many Gulf states ensured plenty of external investment, which favoured further growth and expansion of 3P. For example, the company’s subsidiary Gulf Manufacturers was established in Egypt to produce plastic pipes. F.l.t.r.: Mohammed Najmuddin, Ali Hashim, Randa Hashim and Kay Barton Talking to Mohammed Najmuddin in his office Sacmi machinery for closures EDITOUR
EDITOUR PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 11 Mr Najmuddin, who has a master in Business Administration and is a Science Graduate, has been with the company since its inception in 1993. He has two daughters and a son, all of whom are currently in North America. “I’m probably the oldest employee here,” he said with a laugh at the small meeting table in his office. “My boss, Mr Ali Hashim, calls me the co-founder of the company because I’ve been here so long.” In fact, he is also something like the visionary backbone of the company. “When I started here, I quickly realised that PET had huge potential, but that it also needed some official qualifications if the company was to be recognised by the market leaders in the beverage industry. Just think of the high requirements of bottlers like Pepsi, for example. I then helped to drive the process of these qualifications forward and we sat down with PepsiCo and Coca-Cola to clarify what the quality requirements would be for a collaboration.” The fact that feelers had already been put out in the direction of packaging for the pharmaceutical industry as a further parallel project benefited the requirements of the multinational drinks manufacturers, as the necessary high requirements could already be more than met here. Mr Najmuddin explained: “We already had a lot of experience in injection moulding and were able to secure our first deals with pharmaceutical manufacturers for the sophisticated closures that we produced. By the start of 1995, we were already fully qualified and approved which enabled us to start producing preforms on commercial basis for Pepsi, Coca-Cola and Nestlé. On the pharmaceutical side, the company supplied bottles and closures to the Saudi Pharmaceutical Industries & Medical Appliances Corporation (Spimaco) first, and then went on to supply several other pharma companies in the region. Today, around 80% of the preforms and closures go into water applications, the rest into CSD, milk and juice. Working round the clock in day and night shifts, around 7 billion preforms and an equal number of closures are produced annually in Jeddah, and around 2 billion at the plant in Riyadh. 60% of the CSD closures are currently two-piece, but there is a shift towards more one-piece closures. For water, preforms can be produced for 200ml, 250ml, 330ml (most represented), 500ml, 600ml, 650ml and 1.5 l, for CSD for 250ml, 400ml, 500ml, 1 l and 2.25 l. 25% of the products are exported mainly in the Middle East and North Africa region. Keeping in view the circular economy, 3P is well equipped with the facilities to produce 100% rPET preforms or preforms blended with the vPET as per customer demand. Among the various support services, 3P group established an in-house inherent tooling workshop with CNC machines where prototype moulds and machine parts can be fabricated. The films division, which belongs to 3P, is mainly active in wrap-around label production for the local as well as international brand beverages, but also produces shrink film for multipacks, plastic bags including printing and the Sufra rolls, a type of disposable tablecloth. The company mainly sources its raw materials from Sabic. In fact 3P claims to be one of the largest customers of Sabic worldwide. The turnover for the entire Group in 2022 totalled USD 533.3 million, of which around 20% was attributable to the 3P flexible division which employs about 250 people. 3P setup: Jeddah plant 3 x Husky HyPET 500HPP5e 14x Husky HyPET 400/HPP4 8 x Husky G-lines still active 5 x Husky HyCAP 4 400 6 x Husky Hylectric 400 4 x Sacmi CCM 64 1 x Sacmi CCM 24 2 x Sacmi 32 inactive/for sale 3 x Blow moulding EBM 4 x ASB 70 DPH ISBM 1 x Aisa for collapsible tubes Riyadh plant 5 × Husky HyPET 500 HPP5e 3 × Husky HyCAP 4 www.3p-gulf.com Husky HyCAP closure moulding systems in action Just produced: Mohammed Najmuddin with a water preform F.r.t.l.: Mohammed Najmuddin, Kay Barton and Ahmed Salhi in front of a Husky HyPET HPP5e system
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 12 Spanish processor relies on recycling equipment from Germany From bottles to preforms to rPET The company Nosoplas, which was founded in 1996 in Bergondo, Galicia, Spain, by our interview partner Jose Carlos Piñeles, initially specialised in PET bottle blowing on the Iberian Peninsula before producing its own preforms some years later and increasingly focusing on rPET processing and production from 2012. Recycling systems from the German manufacturer Britas are used for this – the company recently added a fully automatic Britas band melt filter to the line. With an expected recycling throughput of around 43,000 t of post-consumer PET bottles this year, Nosoplas is contributing to the current massive demand for food-grade recyclate. Britas ABMF-1050-PET-C “Our original business was blow moulding PET bottles for CocaCola bottlers in Spain and Portugal,” explained General Manager Jose Carlos Piñeles in our interview. The company founder has been working in the packaging industry since 1986 and knows it like the back of his hand. “We later moved into injection moulding and started producing our own preforms in 1999, before turning our attention to sustainable packaging and rPET in 2012.” And the demand for high-quality recycled PET in Spain and Portugal proves the company right. “We definitely wanted to be one step ahead of the competition in this important area. Meanwhile, in addition to this factory in Bergondo, we have also been operating another one in the centre of the country in the city of Tarancon, Cuenca, since 2020 for logistical reasons.” The company currently sells around 42,000 t/a of rPET pellets. The corresponding post-consumer PET bottles are sourced exclusively from the EU. “Like everywhere else, we are confronted with a natural variability in the quality of the collected raw material. This is currently the major challenge for all recyclate producers who want to produce high-quality material that can ultimately be used in food contact,” explained Mr Piñeles. Legally prescribed minimum quantities of recyclate in packaging would then drive demand even higher. “We produce rPET with different viscosities, depending on customer requirements. The most common range is from 0.76 to 0.84, with 0.80 being in high demand for bottle-to-bottle.” In the process, the flakes are inspected using an inspection system before they are fed into a wet cutting system and finally a Solid State reactor via a drying, extrusion and filter melting process using Britas equipment. The ABMF-1050-PET-C band melt filter was recently added to the line and ensures that the process is characterised by a particularly high degree of filtration and that very little waste is produced during the process, which, according to the company, leads to the lowest costs for consumables. In addition to the beverage industry, which accounts for over 90% of Nosoplas’ output and whose main customers are Coca-Cola European Pacific Partners (CCEPP) bottlers, the recyclate produced is also used in the textile and detergent sectors. Nosoplas uses around half of the company space at both sites, around 1,000m2 each, for rPET production and employs a total of 110 people. And the company is growing rapidly: we were told that turnover had doubled since the Tarancon plant opened, reaching US$ 130 million in 2023. Competitors in the market include Novapet, Plastipak, Alpla and Retal. “What sets us apart is our comprehensive customer service, flexibility and adaptability to customer requirements,” concluded Mr Piñeles. Nosoplas is currently planning further investments and expansion in the areas of sustainability and energy reduction. www.linkedin.com/company/nosoplas-sl by Kay Barton
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 13 Crystal Thumb Up Our extended SportCaps range Biarritz NEW In sport, you never settle for less. That’s why we strive for the perfect closures, also when it comes to sustainability. Many closures, such as Biarritz and Monet, are made from a single material, making them easy to recycle. In addition, our sport closures are easy to handle, have integrated tamper evidence solutions and are suitable for cold, dry, or wet aseptic filling. So take the leap – and opt for more sustainability. NEW Monet Visit us at BrauBeviale Hall 4, Booth 219 Contact us and arrange your line trials now! www.bericap.com New mono-material caps for optimized recyclability Going the extra mile for you
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 14 First PEF World Congress in Düsseldorf, Germany PEF, polyester material of the future by Michael Thielen, Publisher of Renewable Carbon Plastics Magazine There is no doubt that plastics based on fossil raw materials are problematic in terms of climate change and limited resources. In many cases, plastics made from renewable raw materials already represent an interesting alternative. A comparatively new biobased plastic is polyethylene furanoate (PEF). Chemically, the aromatic polyester material is similar to the well-known commodity plastic PET, which is made from monoethylene glycol (MEG) and terephthalic acid. HO Terephthalic acid (TA) OH O O Furan- dicarboxilic acid (FDCA) HO OH O O O Figure 1: Building blocks of PET (terephthalic acid) and PEF (furandicarboxylic acid) (Source: Renewable Carbon Plastics) While biobased MEG is already being used in some cases for PET, the production of terephthalic acid from renewable raw materials has not yet been sufficiently developed. With the biobased furandicarboxylic acid (FDCA), PEF can therefore be a 100% biobased alternative for PET. Compared to PET, PEF is also characterised by improved properties, such as higher structural strength, better thermal properties and strongly improved barrier behaviour. PEF can be used for a variety of commercial applications, including bottles, films, food packaging, textiles, carpets, electronics applications and in the automotive sector. Another advantage of PEF is that it can be processed on the same equipment that is used for PET, other polyesters and often even other plastics. In many cases, only changes to the process parameters are required, as is usually the case when switching between different materials. Properties PEF is comparable to PET in many respects: It is a transparent and relatively rigid polymer. However, there are some notable differences between PEF and PET. PEF has a glass transition temperature of 86 °C, which is ~10 °C higher than PET. In the packaging industry, the remarkable barrier properties of PEF represent a significant improvement over PET. PEF has a ten times higher oxygen- and a 15 times higher CO2 barrier and two and a half times as high a water vapour barrier as PET. In addition, the strength and modulus of PEF are significantly higher than those of PET. For brand owners and packaging developers, the improved properties of PEF offer a range of innovation opportunities such as extending shelf life, further reducPET bio-PET (30) e.g. Coca-Cola plantbottle® 100% biobased MEG therephthalic acid therephthalic acid bio-MEG furandicarboxylic acid bio-MEG Figure 2: PEF can be a 100% biobased alternative for PET (Source: Renewable Carbon Plastics) Higher Tg (by about 10°C) Lower Tm (by about 30- 40 °C) Improved barrier to CO2, O2 and water vapor. Better metal adhesion 16—20x better CO2 barrier Light weighting potential (60% higher modulus &strength) Bio-based with PET-like mechanical properties 10x better O2 barrier PEF can be processed in existing PET lines PEF is complementary to PET PEF for flexible packaging PEF for CSD PEF resin General PEF for rigid packaging PEF for fibres & textiles PEF for oxygen sensitive drinks Figure 3: PEF application examples (Picture: Avantium)
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 15 MATERIALS / RECYCLING 15 ing bottle weight, smaller packaging for carbonated drinks and replacing glass with PEF for oxygen-sensitive products. Due to its similarity to PET, PEF can be recycled using the same processing steps as the many known PET recycling processes. It has also been shown that PEF has a limited impact on the rPET stream, which have led to (interim) endorsements of PET/PEF multilayer bottles to enter the PET bottle recycling stream in Europe (EPBP limited to a market penetration of 5%) and US (APR). PEF World Congress Due to the properties of PEF and its production from 100% renewable raw materials, a whole range of companies around the world are already developing FDCA and PEF production. The Dutch company Avantium (Amsterdam) is opening its flagship plant for the production of FDCA in Delfzijl, The Netherlands, in October. Reason enough for the trade journal Renewable Carbon Plastics (formerly bioplastics Magazine) to organise the first PEF World Congress together with the Horizon 2020 project PEFerence. The 2-day hybrid conference (on-site and online) will take place on October 30 and 31 in Düsseldorf, Germany. www.pef-world-congress.com Property PET PEF Density 1.36 g/cm³ 1.43 g/cm³ O2 permeability* BIF = 1 BIF = 10 CO2 permeability* BIF = 1 BIF = 15 H2O vapour permeability* BIF = 1 BIF = 2.5 Tg 76 °C 88 °C Tm 250 - 270 °C 210 - 230 °C E-modulus 2.1 - 2.2 GPa 3.6 GPa Yield strength 50 - 60 MPa 90 - 100 MPa *BIF - Barrier Improvement Factor compared to PET Table 1: Intrinsic properties of amorphous PET and PEF Digital manufacturing line for plastic caps SACMI.COM Continuous compression molding solution: digital, smart, cost-effective. Conceived, designed and produced by SACMI. DIGITAL & PROFITABLE Line ready for advanced Smart Pack and Smart Care services to provide more effective synergy with HERE M.E.S. features. SMART & RELIABLE Reliable controls and immediate overview of the process via AI-based inspection systems integrated into all the processes. COMPACT &IWX MR GPEWW WTIGMƤG IRIVK] GSRWYQTXMSR CCM maximizes output rates per bay and is the most sustainable solution. momic
MOULD MAKING PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 16 The importance of high-quality spare parts by Heike Fischer A machine should run, run, run and run... To keep it that way, the wearing parts of the machines must be replaced regularly. The Canadian company UM Inc. is a well-known manufacturer of alternative spare parts for blow moulding, filling, sealing and labelling machines for PET as well as for form-fill-seal machines, serving over 500 clients in more than 40 countries. PETplanet spoke to Arnaud Vital, President & CEO of the company, to learn more about the company’s portfolio, the market situation and high demanding spare parts. PETplanet: Dear Arnaud, may I kindly ask you to introduce your company in a few words? Arnaud: UM Inc., a premier Canadian enterprise, excels in manufacturing and supplying top-tier industrial components for the bottling industry. Our specialisation in blow moulding is complemented by our expertise in providing high-quality parts for filling, sealing, and labelling machines. Founded in 1976 as a local machine shop handling bespoke orders, UM Inc. embarked on a transformative journey in the 1990s with our strategic entry into the PET market. This pivotal move catalysed a period of strong growth, leading us to expand into a state-ofthe-art facility in Saint-Remi, QC. Three years ago, I had the privilege of acquiring UM Inc., and alongside our exceptional team, we have driven remarkable progress. This year alone, we are on a trend of a two-fold growth on our sales! We now proudly serve over 500 clients across more than 40 countries, and our global footprint continues to expand. PETplanet: Machine manufacturers provide their customers with maintenance and warranty services for machine parts. When do customers usually turn to you? Arnaud: At UM, our goal is to support our clients at every stage of the production process, enabling them to save valuable resources without compromising on quality or lead time. We aspire to be more than just a supplier; we aim to be a trusted partner, ready to assist with production issues and swiftly get machines back up and running. Our agility and proactive approach reflect our respect for time and our commitment to finding solutions. We have carefully built the UM brand around three core principles: quality, price, and lead time, all while maintaining a partnership-oriented approach. Each year, we invest significantly in expanding our product offerings to meet our clients’ evolving needs. By strategically enhancing functionality and strength, we ensure that our solutions continue to drive success for our clients. Our engineers are dedicated to making the right choices to support and improve their operations. We believe that by consistently doing what’s best for our clients, success naturally follows. PETplanet: You have published an impressive list of partners and customers from the blow moulding and filling industry on your homepage. This speaks for the high quality of your spare parts and comprehensive service. What costs do your customers save if they order spare parts from you instead of from the manufacturer of the original machine? Arnaud: Over the years, we have built robust client partnerships through a strategic and focused approach that remains at the heart of our operations. Our ability to deliver cost savings is a significant competitive advantage, with savings typically around double the industry average, all while maintaining uncompromised quality and competitive lead times. We pride ourselves on being leaders in providing alternative spare parts, but our process is meticulously strategic. We carefully select parts that offer the most potential for improvement, ensuring we deliver enhanced value to our clients. For instance, our moulds shell line is a standout success, where we consistently surpass expectations in quality, pricing, and lead times. PETplanet: Where do you produce your spare parts? Do you offer guarantees on your spare parts and have you patented them?
MOULD MAKING PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 17 Arnaud: All our spare parts are meticulously manufactured at our facility in Saint-Remi, QC, Canada, ensuring exceptional quality and consistency. We back every part with a standard one-year warranty, and for components such as oven chains and cams, we offer extended warranties due to their enhanced durability. Our team is actively focused on developing new products designed to significantly reduce operating costs, creating excitement among our clients. With our comprehensive range of alternative parts for the bottling industry and our agile approach to evolving needs, we evaluate patents strategically and innovatively to continually offer cutting-edge solutions. PETplanet: For which spare parts do you receive the most enquiries? What are your delivery times? Arnaud: Our valves and guides are unmatched in the market, delivering exceptional operating cost savings, particularly in energy efficiency, that set them apart from any other products available. We sell thousands of these units annually and ensure they are always in stock, ready to ship within a week. Additionally, we keep a selection of the most sought-after cams on hand, available for delivery within 2-3 weeks. Our moulds shells and oven chains are also standout products at UM, consistently meeting the high demands of our clients. Moreover, a crucial aspect of our business is providing personalised components such as spindle tips, grippers, and entry/ exit wheels, which are vital for the operation of blow moulding machines. We frequently receive requests for these customised parts and are fully equipped to manage and fulfill such projects with precision. PETplanet: You offer specialised spare parts & individual solutions. Format conversions are also possible with your parts. It is noticeable that you are particularly well positioned in the filling sector, (e.g. at Krones). Are you planning to expand your machine portfolio in the future? Arnaud: Looking ahead, our vision is to become the go-to partner for all our clients’ needs across the entire bottling industry production line. We are continually expanding our product catalogue to align with this vision, ensuring we offer comprehenProtecting Product Integrity With Torus gauges, you can rest assured all of your inspection requirements are covered. Would you like to know more? Email us for more information. [email protected] Wall thickness Thread, body & thickness Burst pressure Top load, weight & volume Internal diameter Total Quality Laboratory Measuring your plastic containers quickly, accurately and reliably sive solutions that cover every aspect of our clients’ operations. Stay tuned, additional service lines key to our clients will be announced in the near future. PETplanet: Your business is facing a lot of competition. How do you feel about the global market situation? Where do you see future markets for yourself? Arnaud: We remain committed to what we do best: being responsive to our clients and delivering solutions and services that offer exceptional value. Our focus on innovation drives us to continually expand our offerings, enhance our production capabilities, and invest in technology to adopt new business practices. We are confident in our abilities but recognise the challenges ahead. Adapting to the rapidly evolving environment - both within our company and in the broader market - is crucial. Technological advancements, particularly in user experience, will be key to our future success. Our primary markets include the US, Canada, and Mexico, where we continue to strengthen our presence. In Europe, we are growing, though market dynamics vary due to different client types. We are also seizing significant opportunities in the Middle East and Africa, where we see substantial demand and rapid growth, and we are pursuing these markets with strategic intent. PETplanet: Thank you very much for sharing your insides and knowledge with us! Arnaud: It is our pleasure. Thank you for your time and interview! www.um-inc.com
PREFORM PRODUCTION PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 18 Thermoscan technology enables Sacmi to achieve water savings in injection moulding 18% reduction in water flow rate Blow moulding machinery manufacturer Sacmi has significantly reduced water consumption in PET bottle production by integrating BMT’s Thermoscan technology to optimise their injection moulding cooling processes. The Thermoscan, a patented precision offline instrument developed by Blow Moulding Technologies (BMT), measures and analyses preform temperature profiles to enhance resource efficiency, reduce operational costs, and minimise environmental impact. The temperature of the preform after injection moulding plays a crucial role in both its quality and energy consumption. Optimising cooling during injection moulding offers a range of benefits, including enhanced resource efficiency, faster cycle times and reduction in energy usage, which consequently reduce operational costs per part. Scrap rates are decreased and there are savings in raw materials, too, further reducing environmental impact. BMT, based in Belfast, Northern Ireland, are pioneers of stretch blow moulding (SBM) technology for sustainable packaging solutions. It believes that data driven measurement is essential for improvement and optimisation. Sacmi identified BMT’s Thermoscan as a suitable stand-alone solution to accurately measure and digitise their cooling process. Thermoscan is a patented precision offline instrument that simultaneously measures the internal and external temperature profiles of preforms extracted from the production line and uses proprietary software to analyse and evaluate through-thickness temperature distribution. It quantifies the influence of key machine parameters on the preform temperature profile and displays their direct impact on the integrated screen. Instant feedback provides operators with the means to systematically explore various process combinations and optimise production lines. “Using Thermoscan, we can get the right data to make critical decisions,” said Francesco Macchia, PET Injection Moulding Specialist, Sacmi. In a recent case study, Sacmi methodically adjusted flow rate to optimise their injection moulding cooling process, with the intention of reducing operational costs. It first configured their machines to a preset process that produced high-quality preforms, then used Thermoscan to measure temperature distribution and establish a reference profile. Sacmi then systematically reduced water flow rate, measuring the preform temperature profile with each change, while maintaining constant cycle times and heating conditions. Thermoscan provided quantitative comparison against the target profile, enabling data-driven decisions and eliminating subjectivity from the process. The graph shown in Figure 1, generated by Thermoscan, displays preform temperature profiles of the initial (reference) and final (optimised) processes. It demonstrates nearly Figure 1: Thermoscan temperature profiles with varying flow rate
PREFORM PRODUCTION PETplanet Insider Vol. 25 No. 09/24 www.petpla.net 19 identical temperature distribution along the length for a specific preform type, despite a significant 18% reduction in water flow rate. This reduction cut costs associated with the pump and also contributed to a decrease in overall energy consumption. This significant reduction in water usage, together with Sacmi’s water treatment and recycling initiatives, energy efficient machines, clean energy utilisation and emissions reduction demonstrates their commitment to sustainable success. BMT says that Thermoscan, as part of a sustainable manufacturing strategy, offers an array of advantages for the packaging industry, including brand owners, converters and preform manufacturers. It serves as a tool for quality control, ensuring consistent high-quality production and mitigating process drift caused by oven degradation and environmental factors. It quantifies and addresses variations between sites and machines. When discrepancies arise between batches during production, Thermoscan compares their absorption behaviour. It also generates a representative temperature profile usable in simulations for efficient virtual analysis, ultimately saving time, resources, and money. BMT’s Thermoscan to measure the preform temperature profile after injection moulding led to an 18% reduction in water flow rate while maintaining the production of high-quality preforms for stretch blow moulding. www.bmt-ni.com The Thermoscan measures and analyses preform temperature profiles to enhance resource efficiency, reduce operational costs, and minimise environmental impact.
BOTTLE MAKING 20 PETplanet Insider Vol. 25 No. 09/24 www.petpla.net English Mountain Spring Water Company boosted packaging quality with the installation of a blowing line from Flexblow Tennessee two-step by Ruari McCallion Ruari McCallion, PETplanet Insider’s Editor-at-Large, spoke to English Mountain Spring Water’s founder and CEO, John Burleson, about building a brand from a small base and the big step up in quality and consistency and the reduction in costs achieved with the installation of a PET bottle blowing line from Lithuanian company Flexblow. English Mountain Spring Water Company faced a range of challenges with its bottles, which it was buying in from external suppliers. Quality issues and lack of consistency were leading to losses of product, refunds to disappointed customers and a cost base that was inhibiting profitability and growth. At the time, the decision to bring bottle blowing in-house seemed a difficult one to make but it turned out very well. The line it bought from Lithuanian company Flexblow has pretty much eliminated quality problems and thus improved relations with customers, as well as helping to cut costs and make budgeting more manageable. The story hinges on persistence by Flexblow and a willingness to listen on the part of John Burleson, CEO of English Mountain Spring Water, who smiled as he recalls how the relationship developed. “I first met Flexblow at the NPE plastics show in Orlando, Florida, in 2018. Mr Martynas, the Service Manager, had been emailing me but I’d said that I wasn’t ready for a blow moulder at that time. Well, he took it upon himself to drive all the way from Orlando, overnight and all day, and he arrived late in the afternoon, as I was getting ready to go home,” he said. He reckoned that he couldn’t turn Martynas away as he’d driven so far and listened to what he had to say. Although John Burleson wasn’t ready to invest in a blow moulding line at that time, they agreed to keep in touch, which Flexblow did, diligently but not intrusively. Meeting customer needs “In 2022, we started getting serious. Gintautas [Gin] Maksvytis, the General Manager of Flexblow, came over from Lithuania with about four staff. They toured our facility and he said he really wanted us to have a Flexblow machine. After their visit, we conducted a follow-up to gather feedback. A packaging manufacturer in Georgia assured us that Flexblow produces robust and reliable systems. I still wasn’t sure but they put together a very attractive package and, in 2022, we finalised everything,” John continued. What English Mountain Spring Water got was a Flexblow Auto Quality, a pharmaceutical grade stretch blow moulding unit that had been shown at Pack Expo 2022 . Preferential heating catered for the company’s specific bottle shapes. Installation and final commissioning in August 2023 was the latest milestone on a journey that had started in 1992, when John became interested in bottled water as a business. His original intention was to be solely a contract supplier but prospective customers themselves wanted suppliers to have a brand and market presence themselves. By 1997, he had acquired a 5,000 sq ft (465m2) facility and was soon producing with two second-hand bottling lines. A five-gallon (US) line filled 100 bph; the second line filled one gallon HDPE plastic bottles. A PET line was added in May 1998. Building a reputation “We started selling to small, Momand-Pop operations, convenience stores owned by private individuals, rather than corporates, and the like – unconventional outlets, you might think,” John said. “One of our products was distilled water, displayed in glass door coolers that we provided and installed.” A virtually non-existent marketing budget meant that English Mountain had to build its reputation by hard work and word of mouth. Fortunately, Tennessee is the kind of area where local roots and neighbourly service count for a lot. “We were growing and the home delivery side was doing very well. Customer service was what we based our business around,” he said. “Our big break came in 1999 when we won a water tasting competition in Berkeley Springs, West Virginia. It was an international competition; we competed against every Nestlé brand, Boss was there, brands from all over – some from Sweden and Belgium The Flexblow Auto Quality line was installed in August 2023
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