No.12 2024 www.petpla.net D 51178; ISSN: 1438-9452 09 . 12 . 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 Suppliers of recycling plants and washing units MARKETsurvey MATERIALS / RECYCLING EDITOUR Page 15 Page 9 Page 21
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No.12 2024 www.petpla.net D 51178; ISSN: 1438-9452 09 . 12 . 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 Suppliers of recycling plants and washing units MARKETsurvey MATERIALS / RECYCLING EDITOUR Page 15 Page 9 Page 21
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. 12/24 www.petpla.net Acetaldehyde in PET bottles: an unsolved problem? Acetaldehyde (AA) has been classified as carcinogenic by the World Health Organisation, although the human body produces small amounts of this molecule itself. Nevertheless, its presence in our environment is an issue that cannot be ignored. AA is found in relatively high concentrations in spirits in particular, such as liqueur wines - sherry or port wine. Its fruity flavour is even appreciated there, especially in sweet wines. However, AA is much less welcome in PET bottles, especially when bottling flavour-sensitive liquids such as water. The PET industry has been working for years to reduce the acetaldehyde content in bottles to a level that is not perceptible in terms of flavour. Numerous technological improvements have been developed and implemented for this purpose: from optimised plasticising processes and advanced hot runner systems in the preform injection moulding process to special AA-reduced virgin PET materials. Additives, so-called blockers, which bind the acetaldehyde in the bottle, were also introduced. These measures have led to considerable progress in the past, and for a long time the issue seemed largely resolved. Personally, I had the impression that the problem was under control in most markets - until I travelled through the Gulf States recently. In this region, where extreme temperatures of up to 45 degrees Celsius are not uncommon, I repeatedly encountered complaints about the bland taste of PET water bottles. Despite state-of-the-art plant technology, the use of so-called ‘water grade’ PET materials and the implementation of all known AA reduction methods, consumers repeatedly report flavour impairments. A local manufacturer told me in an interview: “We have found that this is the case with many water brands on the market.” To illustrate this, he handed me a bottle of water from a competitor - and indeed, the flavour was unpleasant. “As long as we have control over the storage of the bottles, everything is fine. But we can’t prevent consumers from storing the bottles in the blazing sun, for example.” Extreme conditions such as direct sunlight at high temperatures seem to push previous technical solutions to their limits. Despite intensive efforts by the industry - from the development of innovative materials to the improvement of logistical processes - the problem persists. The challenge of keeping the flavour of water in PET bottles stable even under extreme conditions is still unresolved. It remains to be seen what new approaches the industry will find to tackle this issue in the long term. Yours, Alexander Büchler Dear readers,
PETcontents 4 PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 12/2024 EDITOUR 9 Converter for water preforms and closures reaches out to Africa 10 Bottle-to-bottle recycling in Egypt - rPET pioneer from the Greater Cairo region focuses on huge capacity expansion 12 German joint venture closures in Saudi Arabia - How the growing demand for beverage, food and non-food products is being met in Jeddah 14 Close to customers in the Middle East and beyond - Service and sales of injection moulding systems and moulds MATERIALS / RECYCLING 15 PEF: A bio-based alternative to PET with lower environmental impact 18 UV protection additive for rPET packaging 20 Turning dairy PET bottle-to-bottle recycling into reality 24 Material and long-term properties in recyclates 26 And a pinch of graphene - Fractal graphene enhances PET bottles’ performance and sustainability 27 Meeting the needs of an ever-evolving sector 28 High-quality rPET granules from mixed streams - Mission PET and Next Generation Recycling GmbH collaborate on LSP PET recycling in food and non-food applications MARKET SURVEY 21 Suppliers of recycling plants and washing units BOTTLE MAKING 29 Flexible hot-fill bottle production - Leading the Greek market with ketchup containers hot filled with Sipa’s ECS SP system 30 Environmentally friendly packaging for the pharmaceutical industry - Italian company focuses on special sustainability strategy EVENT REVIEW 31 Experience a new dimension of plastics recycling - Coperion and Herbold Meckesheim host two-day recycling conference OUTER PLANET 42 Renewable carbon feedstocks - Building a net-zero chemical industry in 2050 BUYER’S GUIDE 36 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 32 PET bottles for home + personal care 34 On site EDITOUR Page 10 Page 29 Page 18 MATERIALS / RECYCLING
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6 NEWS PETplanet Insider Vol. 25 No. 12/24 www.petpla.net Husky’s PET closure wins Packaging Europe Sustainability Award Husky Technologies, a technology provider enabling the delivery of essential needs to the global community, announces that its PET closure has won the Packaging Europe Sustainability Award in the Driving Circular Economy category. This award, presented at the Sustainable Packaging Summit that took place in Amsterdam on November 12, reflects Husky’s commitment to enabling true circularity in the beverage packaging industry. In a market traditionally dominated by two-material bottleand-closure solutions, Husky’s PET closure aims to transform industry standards. By creating a fully PET-based monomaterial solution that integrates seamlessly with existing PET recycling streams, Husky is streamlining the material sorting process, reducing environmental impact, and unlocking new efficiencies in recycling and lightweighting. “At Husky, our commitment to enabling the packaging industry to transition from a linear to a circular economy is taken seriously. Winning the Packaging Europe Sustainability Award for our PET closure reflects this commitment to delivering innovative, sustainable solutions that meet global demands for more circular packaging,” said Robert Domodossola, Husky’s President of Systems and Tooling. “Our PET closure is designed to advance the recyclability and functionality of beverage packaging by providing a mono-material solution that represents a significant step forward for the industry and consumers alike.” Unveiled earlier this year at NPE 2024 in Orlando, Florida, Husky’s PET closure has already garnered strong industry support, with select early adopters preparing for commercial production in 2025. www.husky.co PETnews ? SEE HOW MUCH YOU CAN SAVE 70% LESS ENERGY MAINTENANCE COSTS 90% LESS 70% REDUCTION IN CO2e 50% MORE PRODUCTIVITY The savings will vary based on your circumstances and should be reviewed with our sales team. [email protected] www.maguire.com Discover your potential savings. With just a few clicks, you’ll gain valuable insight into how ULTRA will positively impact your bottom line. 1. Go to ultra.maguire.com 2. Input your data. 3. Receive your customized PDF report of potential savings via email. 7 R
7 NEWS PETplanet Insider Vol. 25 No. 12/24 Amcor and Berry to combine in all-stock transaction Amcor Plc has announced an USD 8.43 billion all-stock acquisition of Berry Global, creating a global leader in consumer and healthcare packaging with combined revenues of USD 24 billion. Berry shareholders will receive a fixed exchange ratio of 7.25 Amcor shares per Berry share, giving them a 37% stake in the merged entity. The boards of both companies have unanimously approved the deal, which values Berry’s stock at USD 73.59 per share, a 9.75% premium over its prior close. The merger combines complementary strengths in flexible films, containers, closures, and healthcare packaging. The combined company will invest USD 180 mi l l ion annual ly in R&D, leveraging 1,500 professionals and 10 global innovation centres. This will enhance offerings in high-growth markets, with an expanded focus on sustainable solutions such as recycled materials and lightweight designs. Amcor CEO Peter Konieczny emphasised the strategic benefits, including stronger customer focus, enhanced sustainability efforts, and improved cash flow and earnings growth. Berry CEO Kevin Kwilinski highlighted the merger’s alignment with Berry’s transformation goals, a complementary geographic coverage and shared commitment to innovation and sustainability. The merger is expected to yield USD 650 million in cost and growth synergies within three years. Financially, the combined entity targets USD 3 billion in annual cash flow and a strong balance sheet, with plans for sustained dividend growth and further portfolio optimisation. Subject to regulatory and shareholder approvals, the transaction is expected to close by mid-2025. The merged company will retain Amcor’s name, headquarters in Zurich, and primary NYSE listing while maintaining a significant presence in Evansville, Indiana, USA. Leadership will include Peter Konieczny as CEO; Graeme Liebelt will serve as Chairman and Stephen Sterrett will serve as Deputy Chairman of the combined company. www.amcor.com www.reuters.com CREATING FUTURE STANDARDS Japan’s leading Aseptic PET Filling System Provider. Our website Our solution high quality reliable technology safe & secure Repi’s UV absorbers receive RecyClass recyclability approval Repi’s UV absorber formulations ‘Remap 00395’ and ‘Remap 00561’ received a RecyClass rRecyclability approval. Independent test ing was carried out by the Institut für Kunststofftechnologie und -recycling e. V. (IKTR), following the RecyClass Recyclability Evaluation Protocol for PET bottles. The results showed no adverse effects on the recycling process, confirming its compatibility with state-of-the-art PET recycling processes in Europe. Specifically, the approval is valid as long as the amount of additive used does not exceed 0.15 wt % of the total weight of the packaging. www.repi.com
8 NEWS PETplanet Insider Vol. 25 No. 12/24 www.petpla.net Bericap takes full ownership of Bericap North America Bericap, a leading manufacturer of plastic and aluminium closures, has announced an agreement to acquire the 50% stake in Bericap North America (BCNA), held to date by Amcor Rigid Packaging. This means that familyowned global manufacturing company Bericap will acquire 100 per cent of the shares in BCNA. The joint venture, founded in 1997 as a 50:50 partnership between Bericap and Amcor in Burlington, Ontario, has grown to become a successful business with annual revenue of USD 200m. BCNA operates three production facilities located in the USA (Cowpens, South Carolina), Canada (Burlington) and Mexico (Mexico City) and offers the complete Bericap closures portfolio for the food, beverage and industrial markets. The acquisition of the shares in BCNA is the most significant investment in the company’s almost 100-year history and demonstrates its strong commitment to the North American market. www.bericap.com Opening of PET bottle processing plant in Latvia On October 23, the new factory of AS Iterum (formerly PET Baltija) was opened in Olaine – one of the largest in Northern Europe with a planned processing capacity of 80,000 t/a, or about 30% more than it was possible to provide at the company’s previous production facility in Jelgava. Iterum has invested more than USD 10 m (€10 m) in the creation of the new factory, while the total investment reaches more than USD 37 m (€35 m). Iterum’s newly opened factory will be one of the largest and most modern PET processing plants in Northern Europe and one of the largest industrial buildings in Latvia, with a total indoor area of approximately 30,000m2 and an outdoor area of approximately 40,000 m2. The building complies with the sustainable construction standard Breem, it will fully use energy obtained from renewable resources. Wastewater treatment equipment, unique in Latvia, has been installed in the factory, which allows the consumption of chemicals in the process of wastewater treatment to be reduced. An efficient air recuperation system has been created, which also provides for the excess thermal energy generated in the PET melting process to be used for heating the building. The new factory will provide more than 250 jobs, with a special focus on employee well-being and the sustainability of the working environment. Jūlija Zandersone, the chairman of the board of JSC Iterum, says that sustainability is one of the main pillars of the factory’s operation, while at the same time prioritising the quality of the final product, which the Latvian manufacturer can offer on the international market: “Almost 100% of our production is exported. The main sales countries are Lithuania, Germany, Finland, Poland and other regions of the world. Although Latvia is territorially small compared to other European countries, we can be proud that in terms of PET processing with high-quality production, we are able to reach up to 5% of this market share. We believe that the new Iterum factory is a new step for the further development of PET recycling, aiming to increase its market share even more.” The Eco Baltia project was implemented with the support of INVL Baltic Sea Growth Fund and in cooperation with domestic industrial park developer SIA Piche. In turn, equipment suppliers are among the distributors of the most modern solutions, one of which is the Austrian manufacturer Starlinger. www.iterum.lv www.agrintl.com +1.724.482.2163 • Accurate. Fast. Intuitive. • Powerful, Simple Job Creation and Editing • Pre-Defined Container Measurement Routines • AutoJob® — Automated Feature Recognition and Job Setup in Seconds Partner with Agr to achieve simplified, dimensional measurement for your plastic containers and preforms! ®
EDITOUR PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 9 Converter for water preforms and closures reaches out to Africa by Alexander Büchler Oman Industrial Investment Co. (OIIC), strategically located near Salalah port, southern Oman, stands out as a principal manufacturer in the PET preform and HDPE cap and handle. A key entity of Al-Mehdar Group, OIIC was founded by Mr Mohsen Ali Al-Mehdar, the Chairman. The company significantly expanded its capabilities five years ago post the acquisition of a major converter. OIIC’s product range encompasses preforms with 29/25 and 30/25 neck sizes, available in various sizes and colours, specifically tailored for water applications. EDITOUR F.l.t.r.: Shaik Mynuddin, Dr Omar Mohammed Bashatahil, Alexander Büchler and the Production Manager The company’s commitment to quality is underscored by its adherence to low acetaldehyde PET production, aligning with its FSSC 22000 and ISO 9001 certifications. Under the leadership of CEO Eng. Omar Mohammed Basharahil, OIIC has made remarkable advancements, increasing its production capacity by 350% within five years. This expansion has positioned the company as the largest PET converter in Oman, boasting a robust production capability and a diverse product portfolio. In the previous year, 75% of OIIC’s production was exported, highlighting its strong international market presence and competitive edge in the PET manufacturing industry. A landmark achievement in 2022 was OIIC’s evolution into a multi-national company with the establishment of several branches in Yemen and Africa, enhancing customer proximity and engagement. Pioneering sustainability and cost-efficiency, OIIC has achieved a reduction in preform weights, producing 250ml bottle preforms at 7.8 g and 500ml bottle preforms at 11.5 g, marking a first in its markets for these lower grammage sizes. To enhance production capabilities, OIIC has invested in cutting-edge technology, employing the Husky HyPET 300 system with 96 cavities, and the Sipa Xform 250 t preform system. These systems facilitate efficient handling of preform weights ranging from 7.8 g to 28 g with cycle times as low as 6.7 s, all while maintaining strict acetaldehyde content limits. Furthermore, OIIC has integrated the latest Sacmi machines for HDPE closures, specifically serving packaged drinking water companies. Mr Shaik Mynuddin, the Plant Manager, with over 25 years of industry experience, plays a vital role in maintaining production efficiency and quality. He leads a skilled technical team, dedicated to upholding high standards and ensuring customer satisfaction. OIIC is poised for further expansion, actively planning to diversify its product portfolio and enhance its regional market presence. A new, larger production hall is underway to address the growing demand for carbonated soft drink (CSD) preforms and closures. Additionally, the company plans to produce labels, offering a comprehensive packaging solution to its clients.
EDITOUR PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 10 rPET pioneer from the Greater Cairo region focuses on huge capacity expansion Bottle-to-bottle recycling in Egypt by Kay Barton The recycling plant of rPET producer Bariq is located in the west of the 6th of October City, the largest industrial and business city in Egypt and part of the Greater Cairo region. On 23,000m2 of production space, the pioneering PET recycler in the MENA region currently creates a total capacity of 35,000 t/a of food-grade rPET material, which is FDA, EFSA and Reach & Health Canada regulation compliant. And while we were still watching the whole thing live on site at the Middle East Road Show, the final adjustments were already being made to a recently acquired third line, which is also due to start production next month, increasing capacity to 55,000 t. EDITOUR Meeting with Bariq September 8, 2024 We met: Mr Ahmed Abdel Fattah, CCO Mrs Nour El Gammal, Marketing Manager Mr Abdul Rahman, Production Engineer The company was officially founded and built in 2011 as the first recycling plant for PET in the country. It began operations in 2012, at that time still as part of the Egyptian investment conglomerate Raya Holding and with a Starlinger RecoStar PET 165 iV+ with ViscoStar 150 SSP reactor. “At the time, we simply wanted to be the first on the market to tackle the issue of rPET,” explained CCO Ahmed Abdel Fattah in an interview. Having been in office for just two months, he is still very new to the company. He previously worked in the gas and oil industry for almost two decades, specifically in LPG trading and operations. The first sales markets were initially outside Egypt. Ten years its foundation, Raya Bariq sold the company in 2021 to the Egyptian Intro Group, which also invests in various industrial segments. The group includes the Intro Sustainable Resources (ISR) and Intro Resource Recovery (IRR) segments, under whose umbrella Bariq plays the central role in the closed loop: IRR’s ‘Dawar’ app, a digital waste management system, can be used to report waste for collection, for example. The ‘Environ Adapt’ business unit offers the tracking of collected waste, which ultimately ends up at Bariq for processing. Since the sale to Intro, Bariq has been aiming for massive expansion. In 2022, the plant received its second Starlinger line, a RecoStar PET art line iV+ which is the first and only art line installed in the region and the second in the world with ViscoStar 350 SSP reactor, and has now managed to triple its capacity in less than three years with the new, third recycling line, a RecoStar PET 215 iV+ with ViscoStar 350 SSP reactor. In addition to the Starlinger lines, grinders from STF, autosort systems from Tomra, washing lines from Amut and sorting equipment from Bühler and Sesotec are also in use. An estimated 60% of the PET bottles required come from the company’s own market, the rest is imported, for example from the EU, as we learn during the tour. Bariq is the only non-European recycling company that is registered with the Spanish organisation Ecoembes and is therefore part of the tendering process for bottle recycling. As in many parts of the world, the collection of PET bottle waste in Egypt is, with a few exceptions, still heavily dependent on the unorganised sector. Bottles are taken to collection centres and then end up at Bariq for processing, often with better initial quality than the imported bales. F.l.t.r.: CCO Ahmed Abdel Fattah, PETplanet Editor Kay Barton and Marketing Manager Nour El Gammal in the entrance area F.l.t.r.: Nour El Gammal, Ahmed Abdel Fattah and Kay Barton in front of the Editourmobil
EDITOUR PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 11 EDITOUR 11 The recyclate, around 90% of which ends up back in packaging such as PET bottles, is sold worldwide. Customers include Pepsi, Niagara, Nestlé, Coca-Cola, Retal and Alpla. The remaining material ends up in non-food applications, such as at Henkel or L’Oréal. “Our main markets are the EU and USA with over 90% exports,” explained Mr Fattah. “The rest remains in the Middle East and Egypt, where rPET is still in its infancy in bottle production. At present, recycled material in contact with food is still often perceived by the population as contaminated and therefore anything but positive. But awareness of this is gradually changing, so that we are slowly but surely seeing positive signals in the handling of recycled PET. We would like to contribute to recycling processes and the circular economy for plastics being perceived as a kind of ‘social plastic.” The company is currently building another plant in Jeddah, Saudi Arabia, which is expected to be completed in early 2025. An Erema Vacurema Prime will be used there together with an initial annual capacity of 15,000 t before plans are made to increase this to 55,000 t in the medium term, as in Egypt. www.bariq-eg.com Production Engineer Abdul Rahman (back) shows Editor Kay Barton the recycling stations at the plant All areas at Bariq are clearly marked Shall we? %X 7%'1- TEVXRIVWLMT MW JSVIZIV Choose everlasting excellence for your tethered cap production plant. With SACMI ]SYƅPP ƼRH E JYXYVI VIEH] WSPYXMSR XLEXƅW designed to stand the test of time. sacmi.com E N D L E S S I N N O V A T I O N S I N C E 1 9 1 9
EDITOUR PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 12 How the growing demand for beverage, food and non-food products is being met in Jeddah German joint venture closures in Saudi Arabia by Kay Barton In the well-known holiday area of Jeddah, on the west coast of Saudi Arabia, the Saudi Can Company produces cans and plastic containers for food and non-food segments, such as lubricating oils, home and personal care applications. Founded in 1979 as a manufacturer of three-piece printed lubricating oil cans, the company has undergone a steady transformation in recent years to become a supplier of packaging of all kinds. Interview with Saudi Can Closure Ltd (SCCL) April 29, 2024 A long-standing business relationship with closure manufacturer Bericap eventually led to a joint venture to meet market demand through local closure production. We spoke with Mr Muntasir Alireza, Chairman of Saudi Can Closures Co. Ltd, and Mr Peter Loffler, Operations Manager and the General Manager of Saudi Can Closures Ltd, at the Middle East Road Show about the milestones and strategy that led to the current success. According to Muntasir Alireza, the idea for the joint venture arose from the growing demand in Saudi Arabia for beverage and lubricating oil closures. The Saudi Can Company had already been purchasing closures and caps from Bericap in Germany for many years and so the company finally decided to intensify the collaboration and promote Bericap closures on the market through local production and to be able to offer customised closure designs. The result was SCCL, which is now managed by an international team. He explained: “We are now targeting a market that requires closures for water, soft drinks, lubricants, personal care, household and industrial uses, as well as food segment. Saudi Can Co. initially provided an area within its facility, which allowed for a shorter ramp-up time for production. The initial production started with three injection moulding machines as well as a cutting and printing machine.” Production initially began with the manufacture of soft drink closures, which was switched to the production of water closures due to lower demand, and significant growth potential in the water segment. A short time later, additional machines to produce new water, lubricating oil and customised closures found their way into the plant. “The market for water closures has undergone several changes over the years,” said Mr Löffler. “Initial production met the demand for 28mm closures, followed by 30/25 closures. The last change to weight-reduced 29/11 closures dates back to 2014. And recently a high-grip version of 29/11 closure has been introduced” At the end of 2017, SCCL began building a separate and future-proof site of 10,000m2, as the space available at the Saudi Can Company had been exhausted by the constant expansion. In 2022, all relevant closure production lines were finally relocated to the new site and the portfolio was expanded considerably. The company now has 85 employees. “SCCL can offer available cap designs via Bericap and, if necessary, develop new cap designs,” Peter Löffler explained further. Depending on customer requirements and application, the necessary moulds are procured from Bericap in Europe or other regions. The majority of the closures remain in Saudi Arabia, while the rest are distributed in the GCC region, via Bericap Middle East established in UAE. The annual output is over one billion closures and, as we learned, the total material input in 2023 was just under 3,500 t of HDPE and PP. The customer base in all business sectors includes a good mix of global players as well as local leading brands. Commenting on trends and markets with particular potential, Mr Löffler said: “We are seeing very good growth in the food segment, edible oil, personal care and household chemicals segments. The local market is the largest in the region with high growth opportunities and is therefore our target area.” F.l.t.r.: Mr Peter Loeffler, GM of Saudi Can Closures Ltd. and Mr Muntasir Alireza, Chairman of Saudi Can Closures Ltd. EDITOUR
EDITOUR 13 PETplanet Insider Vol. 25 As Saudi Arabia is gradually opening up to international tourism and the annual Umrah and Hajj season, further growth is expected for water and soft drinks closures, whereas growth in the lubricating oil sector is expected to be limited and demand is likely to decline with the trend towards synthetic oils. “In recent years, a localisation process has been initiated in the foods, personal care and household goods industries at critical times,” said Mr Löffler. “Demand for these products has increased significantly and is expected to continue to grow.” Topics such as tethered caps have not yet been prioritised in local requirements, while areas such as shortneck and lightweight preforms are omnipresent, especially for margin-limited products such as water. On the other hand, higher closures that are easy to open with grip are being prioritised in certain areas. And what does the near future hold for SCCL? “We will be making investments this year to launch new closures for the food and water markets and new process equipment for labelling closures, particularly for the lubricating oil sector, We will also invest in Anti-Counterfeiting technologies, in order to protect both the product and the brands of our customers” commented Mr Alireza. “As a joint venture partner of Bericap, we can principally offer closures that meet the latest standards and environmental trends.” www.saudican.com.sa www.bericap.com The 1-pc ClipAside tethered closure with 72 knurls is equipped with an olive bore seal and provides a tight seal for PET oneway bottles with 29/25 neck finish.
EDITOUR PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 14 Service and sales of injection moulding systems and moulds Close to customers in the Middle East and beyond by Kay Barton The Canadian injection moulding system manufacturer Husky Technologies operates its sales and service office directly at Dubai Airport within the DAFZA (Dubai Airport Free Zone) office complex. We were able to make an appointment with the team around Mr Wassim F. Labban, Vice President, Systems & Tooling, EEMEIA, SEA, ANZ. The GM Middle East Mr Abdallah El Kharboutly, GM of Business Development Mr Philip Parubets, and Regional Manager Mr Zaher Azzam welcomed us for a brief insight into the local market and the company activities in principle, managed from this strategic hub. Interview with Husky Technologies December 8, 2023 We met: Mr Abdallah El Kharboutly, General Manager, Middle East Mr Philip Parubets, General Manager, Business Development Mr Zaher Azzam, Regional Manager, Middle East The Husky base here in Dubai has existed since 2004. Evolving from a modest start with only two employees, the machine manufacturer has grown significantly since and is currently serving as a pivotal hub in the Middle East and Africa, South and Southeast Asia, and Australia and New Zealand regions. Abdallah El Kharboutly is the General Manager of Middle East including Egypt, Turkey, the Gulf Countries and beyond. He has been with Husky since 2007 and has been instrumental in growing the business in the region. Philip Parubets has been part of the company since 2006 and brings a wealth of experience, having previously served in various technical and managerial capacities across multiple global locations. Prior to his tenure in Dubai starting in 2020, he held roles in Husky’s Shanghai and Bangkok offices as well as at the company’s global headquarters located in Bolton, Ontario, Canada. Husky is a frontrunner in injection moulding across the Middle East, but what is the secret of its success? “One key factor contributing to our success in the region is our comprehensive system offerings encompassing machines, moulds, and hot runners, all available directly from us without intermediary agents,” says Mr El Kharboutly. “Moreover, our commitment to innovation drives the continuous introduction of new solutions for preform and cap production, coupled with the proactive approach of our Advantage+Elite remote, proactive monitoring program, wherein we analyse real-time equipment performance and efficiency, promptly addressing any potential risks or concerns,” he adds. And there are also many legacy Husky systems in the market that are still running and being maintained by the local service teams, which is clearly being well received by customers. In the local UAE market, the company estimates that its own market share for preform systems is around 80% in the high-output space, with the rest being accounted for by machines from competitors Netstal and Sipa. In the UAE, there is approximately 160 kt of Husky PET processing capacity. Mr El Kharboutly anticipates an annual addition of 8 to 12 kt of additional capacity is being added to the market each year. The bestseller for preforms in the UAE is the HyPET HPP platform and for closures the HyCAP 4. The growth rate of Husky’s throughput capacity in the Middle East region has averaged 6.5% CAGR annually over the last ten years, while the PET preform unit has grown by an average of 6.2%. Due to the Covid situation, investment in new capacity fell significantly for the entire region in 2020 and 2021, but has since recovered, particularly evident in good investment growth in 2023. www.husky.co EDITOUR Interview meeting with Abdallah El Kharboutly (left), Philip Parubets (right) and Kay Barton
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 15 PEF: A bio-based alternative to PET with lower environmental impact by Gabriele Kosmehl PETplanet: At the nova-Institute you are part of the EU-funded PEFerence project. Could you briefly describe the project’s goals and your specific role within it? Dr Puente: The PEFerence project aims to establish a sustainable value chain for producing polyethene furanoate (PEF), a 100% bio-based and fully recyclable plastic developed by Avantium (NL). PEF offers a renewable carbon-based alternative to fossil-based plastics like PET in applications such as bottles, films and fibres. My role in the project is to assess the environmental advantages of PEF using the established ISO LCA methodology. PETplanet: You have assessed various products made from PEF, such as monolayer bottles and PET/ PEF multilayer bottles. Are bottle applications the primary focus for PEF? Dr Puente: PEF is indeed an excellent material for bottle applications. Its superior barrier properties — especially against oxygen and carbon dioxide — make it an ideal choice for monolayer and multilayer bottles, ensuring extended shelf life for beverages and reducing food waste. Additionally, its fully bio-based and recyclable nature aligns perfectly with the growing demand for sustainable packaging solutions. However, bottles are just one of the many applications where PEF can excel. Thanks to its remarkable mechanical strength and thermal stability, PEF can also replace traditional materials like ABS in certain application and is well-suited for films used in flexible packaging, which can replace conventional plastics in snack wrappers, pouches, and more. In textiles, PEF fibres can offer a biobased alternative to polyester, catering to industries aiming to reduce their dependence on fossil-based materials. PETplanet: How do the barrier properties of PEF compare to PET, and what other characteristics make it particularly suitable for bottle applications? Dr Puente: One of the standout features of PEF is its exceptional barrier performance. PEF offers up to 10 times better oxygen barrier and approximately 16-20 times better carbon dioxide barrier compared to PET. These properties significantly extend the shelf life of beverages, making it an ideal material for packaging sensitive products like carbonated drinks, juices, and even beer. This advantage also helps reduce food and beverage waste, aligning with global sustainability goals. Another advantage is that PEF can be processed in existing PET processing lines, therefore no additional investment is needed. PETplanet: When you compared the environmental impact of PEF to PET, what did the profiles reveal? What environmental impacts were most relevant, and how did they differ? Dr Puente: As an example, in monolayer bottles application, the LCA showed that the use of PEF would result in significant reductions (up to -73%) in greenhouse gas emissions (GHG) over the bottles’ life cycle compare to those of PET (Fig. 1). PEF bottles would also contribute to remarkably less finite resource consumption of fossil fuels (-45%), largely due to the use of 100% renewable feedstocks and the good barrier and mechanical properties of PEF enabling light-weighting designs. These MATERIALS / RECYCLING At the PEF World Congress in Düsseldorf this October, Dr Ángel Puente, Senior Expert at the nova-Institut GmbH, presented on the topic “PEF – A circular bio-based plastic with improved properties and environmental performance.” As part of the EU-funded PEFerence project, Dr Puente is evaluating the environmental impact of polyethylene furanoate (PEF). PETplanet caught up with him to discuss how PEF compares to PET and examine its potential advantages.
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 16 results are remarkable, since these impact potentials are two of the most relevant environmental impact categories in the current political agenda driving the transition from fossil to renewable feedstocks. PETplanet: In comparing endof-life scenarios like incineration and recycling with respect to climate impact, you project that PEF bottles could reach a similar recycling rate as PET bottles, which could offer up to an 86% advantage for PEF (Fig. 2). Given that PEF currently lacks established recycling streams, how would a comparison look between a recycled PET bottle and an incinerated PEF bottle? Dr Puente: PEF has proven fitfor-purpose with existing sorting and recycling facilities and can be recycled mechanically in a similar way using the same equipment used to recycle PET. The European PET Bottle Platform (EPBP) has provisionally approved the recyclability of PEF in the European recycling market for bottles, although in the future a separate recycling stream would have to be set up for final recycling. In this respect, PEF can easily be distinguished from PET and other plastics using nearinfrared technology. This will allow PEF to be sorted from any PCR or deposit system waste streams once the market has grown sufficiently to enable an individual PEF material recycling stream. Our study showed that a rPET bottle would need to contain approximately 85% recycled content to match the carbon footprint of a virgin PEF bottle. PETplanet: By 2030, PET bottles in Europe must have an average of 30% recycled content. How does the carbon footprint of a PET bottle with this 30% recycled content compare to a vPEF bottle? Dr Puente: Based on our assessments, a virgin PEF bottle would still have a 48% lower carbon footprint than a PET bottle with 30% recycled content. As PEF enters the market and recycling streams for PEF are further developed, its carbon footprint could decrease even further, reinforcing its role as a 100% bio-based and recyclable packaging solution. PETplanet: The production of PEF requires intermediates such as fructose and other plant-based feedstock. In 2022, EU demand for bottle-grade PET was 3.4 million tonnes. If this demand were fully met with plant-based PEF, what would that mean in terms of agricultural land requirements? Dr Puente: To make the change to a fully sustainable future we need to switch to sustainable carbon sources. With recycling alone, we will not be able to meet the full demand. Therefore, next to recycling we need to switch to plantbased materials. Materials that have a good fit with the feedstock (efficient conversion) and a performance that can, at least, compete with the current incumbent. PEF is a material that fulfils these criteria. The feedstocks required for PEF production is sourced from sustainably grown, high-efficient crops. In any case, the focus should not be solely on land use but on integrating any bio-based material production into landscapes in a way that balances environmental, social, and economic priorities. Today, plant-based plastics only make up a miniscule land use. Ultimately, there is a need to shift away from fossil feedstocks to achieve climate change mitigation and bio-based materials are part of the solution. With thoughtful planning, policy support, and technological MATERIALS / RECYCLING Fig. 1 Impact Assessment (all figures: nova-Institute) Fig. 2: Recycling rate
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 17 advancements, bio-based feedstocks and materials can contribute to a more sustainable future without compromising food security or ecosystems. PETplanet: How significant do you see the role of government policy in supporting the adoption of PEF? Dr Puente: Government policy plays a crucial role in supporting the adoption of PEF by setting clear regulations and incentives that promote sustainability. Policies that encourage the use of bio-based and recyclable materials such as regulations on eco-design and product standards, extended producer responsibility (EPR) schemes, and stricter recycling and renewable carbon content targets for materials can accelerate PEF’s market penetration. PETplanet: Thank you very much! www.nova-institute.eu PEFerence receives funding from the Bio-based Industries Joint Undertaking (JU) under the European Union’s Horizon 2020 research and innovation programme. The JU receives support from the European Union’s Horizon 2020 research and innovation programme and the Bio-based Industries Consortium. www.peference.eu
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 18 UV protection additive for rPET packaging Repi has introduced UV-R Remap 00561, a new UV protection additive engineered specifically for recycled PET. Designed to enhance UV resistance without compromising recyclability, this development aligns with RecyClass protocols, supporting sustainable packaging solutions. UV protection is critical for preserving the quality of products packaged in PET, as exposure to UV radiation can degrade taste, smell, colour, and biological properties. Many products contain light sensitive ingredients, and a PET barrier alone is not enough to protect them from degradation. Repi, well known in producing liquid colours and additives, addresses this challenge with its comprehensive portfolio of liquid UV additives tailored for diverse applications, including food contact and non-food sectors. As a globally active company, Repi provides products in full compliance with European directives, FDA, and regulations of other countries and regions. The Remap UV absorber range provides several grades that cover different protection specifications set by final product needs, allowing customers to select the most appropriate additive, optimising the cost/benefit ratio, while increasing shelf-life. Remap UV absorbers, benzotriazole-free, claimed to capture UV radiation from 300 to 400nm, providing different levels of protection, depending on the LDR and packaging wall thickness. In addition, they do not impact the shade of final product, allowing the user to be independent and flexible. The latest addition of UV-R Remap 00561, is optimised for the use with clear rPET bottle flakes. It fulfils RecyClass recyclability protocols as it is increasingly important to consider the impact of additives in recycling streams, with the aim of safeguarding future feedstocks characteristics for an even more intensive use of rPET. Over the years, Repi engineered high performance and reliable dosing units to support the needs of customers who use colours and additives in preform injection processes and beyond. The company’s equipment team is constantly engaged in developing new solutions to make the dosing process user-friendly and performing, to answer all technical needs, from a high dosing precision to a full bundled data collection. This last feature allows the sharing of data logs for a comprehensive control of dosing devices. Beyond additives, Repi supports precision in production with its internally engineered dosing systems. The U2023X dosing unit, their latest release, features advanced capabilities such as dosing precision at low addition rates using a gear pump and brushless motor; easy cleaning to accommodate various colours without frequent pump changes or functionality alarms and Modbus TCP/IP for data sharing and control. Repi also offers the Light Meter Plus (LMP), a patented analytical instrument that measures the intensity of the signal emitted by an RGBUvIR light allowing to correlate it to colour and additive content and giving the user the chance to monitor the consistency of preform production for MATERIALS / RECYCLING
The U2023X dosing unit The Remap UV absorber range provides several grades that cover different protection specifications set by final product needs. MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 19 real-time monitoring of UV protection and opacity in PET preforms. By correlating light intensity with additive content, it ensures consistency and provides a reliable alternative to manual inspection. These innovations reflect an ongoing dedication to enhancing performance, sustainability, and user-friendliness in the plastics industry, says Repi. www.repi.com viscoZERO – processing PP, PE, PET & PS! ZERO contamination. ZERO odour. ZERO limits. foodgrade without compromise viscoZERO Upgrade your existing recycling plant with viscoZERO technology.
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 12/24 www.petpla.net 20 Turning dairy PET bottle-to-bottle recycling into reality The chemical industry plays a key role in plastics recycling, where advancing bottle-to-bottle recyclability for rPET is crucial to closing the loop on plastic waste. Sukano, known for its commitment to sustainable plastics solutions, will support the industry with new technologies to create a circular future for plastics. MATERIALS / RECYCLING Global demand for opaque white PET bottles is rising continuously, particularly in dairy applications. As with all beverage PET bottles, these are fully recyclable. In order to maximise their recyclability and enhance waste sorting and recycling rates, it is essential that opaque PET products adhere to design for recycling guidelines provided by the European PET Bottle Platform (EPBP). Achieving enhanced bottle opacity and whiteness The Sukano White Opaque masterbatches for monolayer PET bottles were submitted for recycling trial simulations at PTI’s certified packaging performance testing labs, following the conditions specified by the EPBP protocol. The results proved that the masterbatches can be used in PET monolayer bottles, and still be processed at the same machine throughput, with no impact on colour, material properties, functionality or production rates. The melt also showed a very stable colour, with the end material remaining white at all levels, says Sukano. The integrity of the light barrier was also confirmed for extreme conditions, such as less than 0.1% light transmission at 550 nm wavelength. Sukano offers the White Opaque masterbatches to increase the whiteness of the surface while maintaining the opacity and specific light barrier properties that every brand owner needs for fresh and flavoured milk, extended shelf life (ESL) and UHT PET milk bottles. They are suitable for monolayer or multilayer/co-injection ISBM technology. In-house recyclability testing Sukano is equipped with advanced analytical and machinery capabilities to replicate essential steps of the rPET mechanical recycling process in-house. This includes flake shredding, flake drying and crystallisation, extrusion and filtration, pellet crystallisation, solid-state polymerisation (SSP) of pellets, and film extrusion. Also, analytical measurements such as yellowing, haze, and intrinsic viscosity (IV) development on pellets can be proceeded in-house to ensure all requirements are met. Stay ahead of mandatory recycling targets Sukano’s expertise and solutions support dedicated food-grade PET bottle streams for clear and light blue rPET, as well as white opaque rPET (rPETo), allowing bottles to return to their original application while enhancing the recyclate quality of each stream. When virgin PET is partially replaced with rPETo, the whiteness of the bottle surface significantly drops. Sukano addresses this by offering tailored light protection and whiteness for bottles using up to 50% rPETo. With expertise in clear rPET, rPETo, and customised solutions for light protection and whiteness, the company is committed to helping converters and brand owners realise their circularity goals with closed-loop recyclable white dairy bottles. This will help to heightened recycling rates, improved recyclate quality, and a lowered carbon footprint of packaging possible. www.sukano.com
MARKET SURVEY 21 PETplanet Insider Vol. 25 No. 12/24 www.petpla.net Suppliers of recycling plants and washing units Company name Krones AG Herbold Meckesheim GmbH Postal address Telephone number Web site address Contact name Function Direct telephone number E-Mail Boehmerwaldstr 5, 93073 Neutraubling, Germany +49 9401 70 0 www.krones.com Mr Peter Hartel Head of Sales - Recycling Solutions +49 9401 70 5448 [email protected] Industriestrasse 33, 74909 Meckesheim, Germany +49 6226 932 0 www.herbold.com Mr Achim Ebel Vice President Sales +49 6226 932 0 [email protected] Frontend Sorting Section Input variable: collected pressed bottles, various colours Yes, with different qualities Yes Output: sorted bottles, treated sidestreams Yes, separation in several valuable streams if necessary Yes Capacity range output [t/a] 10,000-45,000t/a; higher ranges also possible if necessary 500-6,000kg/h Floor space [m²] Starting with 1,500m² and more; will be designed to fi t the needs of the customer; depending on the scope of supply Variable Fresh water consumption per tonne output [m³/t] (if necessary) Only necessary if whole bottle washing is required 1-4m³/t Consumption kWh per tonne output [kWh/t] Designed to fi t the needs of the customer; depending on the scope of supply Variable Grinder included Yes, with high quality suppliers, mainly from Europe Yes Additional information Krones can act as turnkey-supplier and offers frontend from preferred partner Stadler Anlagenbau Equipment for bale opening, delabelling, prewash drums Sorting technology (NIR, laser, optical etc.), effi ciency in % OEM equipment, integration Washing Section MetaPure W Input variable: Flakes, coloured proportion max 5%, not much chlorine Yes Yes Output: Hot washed fl akes Yes, washed with hot caustic, rest humidity < 0,8% Yes Capacity range output [t/a] 7,000-42,000t/a; higher output possible by multiplying sections Up to 6t/h Floor space [m²] 450-2,100m²; higher output reqires more space ≈ 1,800m² Fresh water consumption per tonne output [m³/t] 1.5-2.0m³, depending on input quality 1-4m³ Consumption kWh per tonne output [kWh/t] Designed to fi t the needs of the customer; depending on the scope of supply Depending on individual scope Kind of polymer (PET, PP, PS, HD-PE, LD-PE etc.) PET, PP, PS , PE-HD, PE-LD All Additional information Krones own manufacturing Hydrocyclone technology for density separation Decontamination section MetaPure S Input variable: Flakes or Pellets Flakes Output: Flakes or Pellets Flakes, pellets Capacity [t/a] 7,000-12,600t/a per decontamination unit Floor space [m²] 450-520m² per decontamination unit Approvals (FDA, Efsa, others) FDA, Efsa, various brands Consumption kWh per tonne output [kWh/t] Designed to fi t the needs of the customer; depending on the scope of supply Additional information Krones own manufacturing Periphery Fresh water treatment Yes Yes Waste water treatment Yes Yes Heating systems Yes, with partner Yes Nitrogen generator Yes, with partner Compressed air Yes, with partner Chemical dosing Yes Yes Kind and quantity of detergents Caustic soda 8.0-12.0 ml/kg output Yes Additives 0.5-1.0 ml/kg output Yes Defoamer Depending on infeed quality Yes Acid for neutralisation 1.2-1.8 ml/kg output Yes Removal of the organic residuals up to which size [μm] As needed to achieve higher fl ake quality Presetting residence time in the process Yes, according to desired fi nal product quality Yes, batch reactors with controlled residence time Company also offers systems for Yes, in cooperation with partners Bottle-to-preform Yes, with partner Yes Bottle-to-fi lm Yes, with partner Yes Bottle-to-fi bre Yes, with partner Yes Bottle-to-strapping Yes, with partner Yes Bottle-to-tray Yes Tray-to-tray Yes 12/2024 MARKETsurvey
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