No.7+8 2025 www.petpla.net D 51178; ISSN: 1438-9452 PETplanet is read in 162 countries Suppliers of 2-stage SBM machinery MARKETsurvey 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 11 . 08 . 25 FILLING Page 27 Page 20 Page 50 Page 31 EDITOUR Page 12
UNL IMI TED L I FE T IME ! MAINTENANCE COSTS REDUCED BY 50% ENERGY COSTS REDUCED BY 1 5% AF COMPRESSORS ALSO PROVIDE SUSTAINABLE AND LONG LIFE 8 & 10 BAR OIL FREE AIR Drinktec September 15 - 19 Munich HALL C5 - BOOTH 401 Meet us at AF COMPRESSORS ENERGY SOBRIETY The world leader of PET oil free piston compressors WWW.AFCOMPRESSORS .COM SALES@AFCOMPRESSORS .COM
No.7+8 2025 www.petpla.net D 51178; ISSN: 1438-9452 PETplanet is read in 162 countries Suppliers of 2-stage SBM machinery MARKETsurvey 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 11 . 08 . 25 FILLING Page 27 Page 20 Page 50 Page 31 EDITOUR Page 12
We think about your caps, so you can think of everything else. www.corvaglia.com Visit us at the Trade Fair Munich, Germany September 15-19, 2025 Hall C6/Booth 561
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 Miriam Trotter 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. 26 No. 07+08/25 www.petpla.net This drinktec will be a special one for me - and for many others. Petra Westphal, a long-standing colleague and influential personality at drinktec, left Yontex GmbH on June 30 and is returning to Messe München in a new role. After more than 30 years full of energy, ideas and tireless commitment to the beverage industry, a new chapter is beginning for Petra - and I am very happy for her. Of course we will miss her at the trade fair - no question about it. But I’m sure that the conversations, laughter and a glass or two in the evening will not be denied to us in the future. When I think of drinktec, I think of Petra. For over a quarter of a century, she, PETplanet and the trade fair were a solid unit. She was the one who brought our PETpoint from the Interpack environment to Munich. We travelled to India together in 2007, where we developed the idea for drink technology India - a project that is now an integral part of the global trade fair portfolio. Petra has shaped the beverage industry network over decades with foresight and passion. Under her leadership, the former Interbrau has developed from a specialised brewing trade fair into the leading international trade fair for the entire beverage and liquid food industry - today’s drinktec. By her side: Markus Kosak, who is now taking over responsibility. Markus knows the industry, the people and the vision - and I am convinced that he will continue the success story in his own individual way. All the best on this exciting journey, Markus! For me, Petra remains a formative face of this industry. Her enthusiasm, commitment and network are real strengths that will continue to accompany her in the future - no matter where her new tasks take her. And even if in the future she no longer thinks about drinktec every day, we at PETplanet will think that ‘PET’ reminds us a little of PETra. Dear Petra, I wish you all the best, lots of joy and success for what lies ahead. And I look forward to many new moments together - with a smile, good humour, and with a glass in my hand. Yours, Alexander Büchler Dear readers,
PETcontents 4 PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net 07+08/2025 TOP TALK 10 A legacy in PET - 40th anniversary of PTI EDITOUR CIRCULAR ECONOMY 12 Mastering complexity in pharma packaging 14 Producing your own rPET: A sustainable advantage MOULD MAKING 16 Advancing mould engineering BOTTLE MAKING 18 One bottle, one material BOTTLING / FILLING 20 RefPET ready 22 Synchroblock for sensitive bottling & canning products INSPECTION 24 Optimally applied PET bottle closures 25 Modular inline bottle inspection MATERIALS / RECYCLING 26 Oxygen scavenging additive enhances recyclability MARKET SURVEY 31 Suppliers of 2-stage SBM machinery EVENT PREVIEW 27 drinktec 2025 preview, part 2 34 Interaction of all components within a line 36 Quality control and productivity improvement 38 Caps for circularity 40 Performance-oriented approach 43 Designed for low operating costs and mould compatibility 44 1.5-step moulding live on display 46 From sketch to smart bottle designs 47 Continuous drying, clean results 48 Advances in large-format PET bottle production 49 Injection moulding for lightweight closures 50 The power of plastics! Green – Smart – Responsible 52 Edvanced plastic recycling solutions 54 Extrusion efficiency OUTER PLANET 62 Microbes transform terephthalic acid into paracetamol BUYER’S GUIDE 56 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News Page 16 Page 18 Page 44 Editour
A FAMILY- OWNED SWI SS COMPANY. >P[O WYLJPZPVU LɉJPLUJ` HUK K\YHIPSP[` V\Y TV\SKZ LTIVK` [OL SLNLUKHY` :^PZZ X\HSP[` (SS V\Y 7,; 7(* HUK 4,+ TV\SKZ HYL KLZPNULK HUK THU\MHJ[\YLK PU :^P[aLYSHUK >L OH]L ILLU OLSWPUN V\Y J\Z[VTLYZ HJOPL]L [OLPY NVHSZ MVY `LHYZ -PUK V\[ ^OH[ ^L JHU KV MVY `V\ V[[V OVMZ[L[[LY Z^PZZ L i ght i l l umi nates peak per formers. yellow.agency 4LL[ \Z H[ +YPUR[LJ ! /HSS * Booth 339
PETnews 6 NEWS PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net Plastics Recycling Show Asia announces new Shanghai location for 2026 In response to exhibitor and visitor feedback – and to further expand the event’s regional reach – the organisers of the Plastics Recycling Show Asia (PRS Asia) has announced that the 2026 edition will take place at the Shanghai World Expo Exhibition and Convention Centre, Shanghai, China from November 3–5, 2026. The move to Shanghai, one of Asia’s most dynamic industrial and innovation hubs, is intended to enable even broader participation from key players in the plastics recycling sector across China and Southeast Asia. Organised by Crain Communications and Min Metals and supported by Plastics Recyclers Europe (PRE) and the China Polyurethane Industry Association (CPUIA), PRS Asia brings together professionals from every part of the plastics recycling value chain – from machinery and equipment suppliers to recyclers, raw material suppliers, brand owners, government representatives and NGOs. The free-to-attend exhibition and conference provide a platform to showcase innovation, share best practice, connect with industry leaders and explore new business opportunities in plastics recycling. PRS events are held around the globe in Europe (Amsterdam), Middle East & Africa (Dubai) and India (Mumbai). www.prseventasia.com drinktec on a three-year cycle Even before the doors of drinktec 2025 open, trade fair organiser Yontex has already announced the date for the next edition: from September 11 to 15, 2028, the Munich exhibition grounds will once again become the global hub of the beverage and liquid food industry. With this change, drinktec is moving away from its previous four-year cycle. Figures from VDMA, the conceptual sponsor of drinktec, clearly show that the industry remains on a growth trajectory. By 2028, market research institute Euromonitor forecasts global growth of 15.8 per cent for soft drinks and 7.8 per cent for alcoholic beverages, based on 2024 figures. The Asia-Pacific, Middle East/Africa, and Latin America regions are among those expected to see the highest growth rates. Global megatrends such as connectivity, the circular economy, and hyper-personalisation are claimed to accelerate the industry’s pace of innovation. As a result, investment cycles are becoming shorter. “Yontex is closely following these developments and is continuously evolving its portfolio. We are in close dialogue with our stakeholders, who have fully confirmed our assessment. By rescheduling drinktec to 2028, we are laying the foundation to provide the beverage and liquid food industry with the optimal platform,” explains Rolf Keller, Managing Director of Yontex. www.yontex.com RecyClass validates Avantium’s PET/PEF multilayer bottle as fully recyclable in PET stream Avantium N.V. announced that its PET/PEF multilayer bottle has been recognised as fully compatible with the PET recycling stream following an evaluation by RecyClass, the European non-profit initiative dedicated to advancing plastics circularity. Avantium’s PEF (polyethylene furanoate), branded as releaf, can be used in fully plant-based monolayer PEF bottles, but is also claimed to have advantages in combination with PET. For example, PEF can be used in multilayer PET bottles as a barrier material when the required shelf life cannot be guaranteed by a single layer of PET. The RecyClass PET Technical Committee evaluated Avantium’s PET/PEF multilayer bottle – containing 10% PEF releaf RP90N – through lab tests by PTI Europe and Plastics Forming Enterprises. Results confirmed full compatibility with PET recycling stream under the conditions outlined in the RecyClass Approval Letter. RecyClass collaborates with the US-based Association of Plastic Recyclers (APR) to harmonise recyclability recommendations and testing procedures. Avantium’s PEF received APR Critical Guidance Recognition in 2023. With both approvals, brand owners can confidently adopt PEF as a recyclable barrier layer. Additionally, RecyClass validation supports favourable acceptance by national producer responsibility organisations (PROs), which oversee compliance with Extended Producer Responsibility (EPR) regulations and determine packagingrelated EPR fees. EPR is a policy mechanism that requires producers to, amongst others, pay fees based on recyclability and environmental impact. www.avantium.com
7 NEWS PETplanet Insider Vol. 26 Erratum Unfortunately, an error has crept into the printed issue 6/2025 of PETplanet: In the Market Survey, the Otto Hofstetter AG is incorrectly named not only for the manufacture of preform moulds, but also for the PET machine systems. However, the PET machines are distributed by Otto Systems AG, whose contact details are as follows: Otto Systems AG, Zürcherstrasse 73, 8730 Uznach, Switzerland. Mr Reto Bamert is Division Manager PET and can be contacted at: reto.bamert@ otto-systems.com. The European PET Bottle Platform (EPBP) introduces the PET Circularity Test The European PET Bottle Platform (EPBP), a leading industry initiative dedicated to advancing the circular economy within the PET bottle value chain, announced the launch of its Circularity Test Protocol. This new protocol is intended to provide industry stakeholders with a tool to meet ambitious environmental targets. EPBP’s Design for Recyclability Test Protocol already aligns with the EU’s Packaging and Packaging Waste Regulation (PPWR), and the Circularity Test Protocol can be seen as the next evolution towards true circularity. The Circularity Test Protocol is designed to simulate multiple recycling loops and better address the evolving needs of the PET industry as the content of recycled PET (rPET) increases under EU policies and associated legislation. EPBP will initially offer both test protocols to applicants seeking a recyclability or circularity assessment. EPBP will collaborate with relevant stakeholders to establish a transition period for the newly developed PET Circularity Protocol and its associated design guidelines. This transition period will enable the industry to prepare for the new design-forcircularity guidelines. These will be announced by EPBP in the near future. During this transition period, applicants may choose whether to validate their packaging innovations based on either the recyclabi l ity or circularity protocols. However, EPBP strongly encourages applicants to begin adopting the circularity protocol. Innovations successfully validated under the recyclability protocol may face challenges when reassessed against the circularity protocol, emphasising the importance of early adoption. EPBP is a liaison organisation with the Technical Committee on Packaging within the European Committee for Standardisation (CEN) and actively contributes to the development of standards and the exchange of best practices across the industry. Evolving the PET test protocol from recyclability to circularity aims to provide the value chain with a clearer direction in the future, considering the reality of multi-loop recycling. www.epbp.org CREATING FUTURE STANDARDS Japan’s leading Aseptic PET Filling System Provider. Our website Our solution high quality reliable technology safe & secure Hall B4 Booth 533
8 NEWS PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net Otto Hofstetter AG marks 70 years of innovation and family continuity This year, Swiss mould-making specialist Otto Hofstetter AG celebrates its 70th anniversary – a milestone that reflects decades of innovation, precision engineering and international success. Founded by Otto Hofstetter Sr. in 1955 as a small workshop in Uznach, the company has steadily evolved into a leading global manufacturer of high-performance injection moulds, particularly in the field of PET preforms and thinwall packaging. Throughout its history, Otto Hofstetter AG has demonstrated a strong pioneering spirit. From producing its first thin-wall packaging moulds in the early 1960s, to developing the world’s first PET preform moulds in 1977, at a time when no one else dared, the company has consistently embraced technical challenges. With the creation of the holistic Otto Systems brand and the launch of its own PET injection moulding machines, the company took a bold step towards vertical integration, securing independence and long-term competitiveness. The 70th anniversary held in June was marked with a campaign that looked back on key milestones, celebrated the achievements of its employees, and set the stage for the future. A special highlight was the introduction of the third generation of the Hofstetter family: Lea Hofstetter, daughter of Otto Hofstetter Jr., has joined the company and is gradually taking on a more active role. Her involvement signals the continuation of family leadership and a clear commitment to long-term development. With around 200 employees and 23 apprentices, the company places strong emphasis on training and talent development – a commitment that has earned it recognition as a “TOP training company” in Switzerland. The opening of the new TechCentre in 2024, featuring multiple assembly and demonstration stations, further underlines the company’s forward-looking approach. www.otto-hofstetter.swiss [email protected] USA Toll Free +1 888 459 2412 l Canada +1 905 879 1100 Europe +44 1827 338 280 l Asia +65 6848 7117 l Taiwan +886 4 2658 1535 Maguire delivers real data, real savings, real results. See how ULTRA Dryers can: Slash energy consumption Boost production Reduce maintenance Shrink your carbon footprint ASK ABOUT OUR FREE TRIAL! 30 SECONDS OF YOUR TIME = Ɣ <56 ƕ PROVE IT GO TO ULTRA.MAGUIRE.COM Hall 10 Stand C41 October 8 - 15, 2025
9 NEWS PETplanet Insider Vol. 26 Veolia to close recycling facilities MultiPet and Multiport GmbH in Bernburg, Germany Veolia has announced that it will shut down its plastic recycling facilities MultiPet and Multiport GmbH in Bernburg at the end of 2025. The decision comes in response to persistently challenging market conditions in the plastic recycling sector. The company has pledged to support the 122 employees affected by the closure. “From our sites in Bernburg, we have supplied customers across Europe with recycled HDPE and PET plastics,” said Guido Adomßent, CEO of Veolia Umweltservice. “However, high processing costs for plastic waste and consistently low prices for virgin plastics have severely impacted the profitability of these facilities. Under current conditions, continued operation is no longer economically viable.” Founded in 1991 and 2001 respectively, Multiport GmbH and MultiPet GmbH were key players in the recycling of HDPE and PET plastics. They have been part of the Veolia Group in Germany since 2017. With an annual capacity of around 70,000 t, the Bernburg site was one of the largest plastic recycling locations in Europe. Veolia will enter negotiations with the relevant works council and explore opportunities to offer affected employees positions within other Veolia companies, depending on their qualifications and personal circumstances. Material flows from Bernburg will be redirected to other Veolia sites, particularly in the Netherlands and France. Shipments from Veolia Germany to these facilities will be increased to support their operational capacity. Looking ahead, Veolia Germany plans to expand its successful PET recycling operations in Norway, Sweden, and Switzerland. The company is also investing in the digitalisation and efficiency of its facilities and is strengthening partnerships with municipalities and industrial stakeholders. www.veolia.de
TOP TALK PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net 10 PTI celebrates 40 years by revitalising the profi le of its light Dromo bottle and raising awareness of its breadth of services A legacy in PET Plastic Technologies, Inc (PTI) in 2025 celebrates the 40th anniversary of its foundation in 1985 by Thomas E. Brady, PhD, who led development of PET bottle technology from 1971 to 1984 at Owens-Illinois Inc. He also led the transformation of the iconic Coca-Cola bottle from glass and was, initially, the drinks giant’s only expert on PET. On the occasion of the company’s anniversary, PETplanet spoke with Marketing Manager Erica Hartmann about PTI’s evolving role in sustainable packaging, its analytical and prototyping services, and the renewed push to showcase its Dromo e-commerce bottle. Headquartered in Toledo, Ohio, USA and with a facility in Switzerland, PTI has built a reputation as an innovator and developer of leading edge solutions in the PET packaging industry, across food and beverage, personal care and household. It designed the ketchup bottle for Heinz that is now a common sight in food cupboards across the world; Kraft Heinz remains an important client, along with Coca-Cola, PepsiCo, Mars, Mondelez, SC Johnson, Diageo, Carlsberg and many more. The company works with resin producers, additive suppliers, recyclers and converters, as well as manufacturers. PTI has collaborated with DePoly to create a closedloop recycled PET bottle; sustainability and the development of products using higher proportions of rPET are a current priority for the company, Marketing Manager Erica Hartmann explained. Recycling and sustainability “We are heavily engaged in researching and testing several different types of post-consumer recycled (PCR) resins, in exploring chemical and advanced recycling technologies and analysing how recycled resins compare to virgin materials,” she said. Analysis extends to comparing recycling process chains: curbside against collection, reverse deposit schemes and recovery from general waste collection. “We have been involved in developing sustainable packaging solutions for years. Dromo, a lightweight e-commerce bottle, uses 75% less material than similar PET bottles.” The 16 fl oz (one US Pint; 443ml) bottle, which weighs less than 10 g, was first introduced at Pack Expo in 2018 so it is quite well established but Erica says that the time is right to raise its profile and remind the market what a versatile and effective solution it is. Despite its exceptionally light weight, Dromo is a refillable bottle, designed to be inserted into rigid, reusable containers of the kind typically used for personal care products. As it is squarely aimed at the e-commerce segment, it does not have to meet requirements for on-shelf packaging, which is how the designers to cut out so much weight. The walls are thin but the opposing flat side panels provide sidewall strength and enable stacking, prior to shrink wrapping. The bottles can be sealed with a threaded closure or a foil seal. Lightness does not come at the cost of robust performance; the Dromo bottles comfortably pass burst tests up to 173 psi (just under 12 bar) and drop tests from six feet (183 cm). It can be made with up to 100% PCR. Small company with a big impact PTI employs just 65 people across its two locations, so it isn’t a huge producer of preforms or bottles, itself. It collaborates with clients to design and develop packaging solutions that meet their particular needs. At any time, a lot of its ongoing work is confidential, so Erica could not go into details about new launches we could expect to see this year or next but she was able to talk about the capabilities that the company’s two offices have. “We work with different packaging types, including flexible, thermoform and HDPE packaging, as well as PET, for standard, hot-fill and aseptic applications, and provide testing and validation for all of them. Our analytical services lab is probably the biggest part of our activities. We do a lot of testing to make sure that our clients’ products work right,” said Erica. “We also have a production lab here in Toledo so we have the ability to cut and make injection and blow moulds, internally. So, if a customer needs something for a trial or even a small run, we can do that.” She showed an example of what PTI can do in this context: a wide-mouth bottle, specially produced for the company’s 40th anniversary. The beginnings: Thomas E. Brady (right) and AI Uhlig (left) measure new container sizes. Erica Hartmann, Marketing Manager PTI by Ruari McCallion
TOP TALK PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net 11 Anniversary bottle “This started with a drawing on a piece of paper, which our CAD department took forward and developed to something that could be evaluated in our FEA (finite element analysis) capability. We figured it would work, so we cut the moulds and blew the bottle right here,” she said. The bottle in question features a section of the PTI logo embossed onto the surface, with a green closure and wide opening. It was filled with green M&Ms. Three hundred bottles were made for the 40th anniversary party, held on June 12, and handed to honoured guests as souvenirs. “We aren’t doing Coca-Cola sized production, we aren’t making thousands of bottles a day, but we can undertake a production run to allow brands to get a viable product to use and fill. Choosing the wide mouth format also made clear that we have that capability here.” Green for go The choice of green for the closure and the M&Ms was deliberate. PTI makes a point of helping clients to understand sustainable material transitions, the implications of transition and the opportunities, including the provision of analytical services to validate sustainable packaging performance. “We help clients to better understand environmental packaging footprints and we can demonstrate that sustainable packaging can be used without in any way compromising product safety,” she explained. Transition from one material to another has been a significant element in PTI’s work since it was founded. Customers have come to the company for help and advice on moving from glass to aluminium, to PET and to assess various solutions against each other. “We also offer a lot of training and education. There’s a lot of growth on the horizon for PTI and we’re very excited about it.” Investing for the future PTI is so optimistic about growth opportunities that it has invested in three new machines. “We have a Sipa SFL Flex, which is the only one of its type in the USA and is what we used to produce our anniversary bottles,” said Erica. “We have a Sipa SP80, which is brand new and just being fully set up although we were able to undertake our first run HDPE items on that, during our 40th anniversary event. We can also run PET and PP materials on this machine, and our moulds and products on Husky and Sidel, of course.” PTI has come a long way in the 40 years since it was founded. It has built itself and its reputation on providing advanced and innovative solutions that the market is seeking and being able to become involved at any point in the production process. The company will have a presence at this year’s drinktec but not in the form of a booth or stand. Representatives from the Swiss facility will be there, meeting existing clients and building new relationships. “A lot of people know us only for small parts of what we do; maybe they know us for our analytical lab, or for validation, or for preform design but PTI is really a full-service partner,” she concluded. “We look back on 40 years but we are really excited about how we will continue to grow within the industry.” www.plastictechnologies.com The 40th birthday bottle features a section of the PTI logo embossed on the surface, with a green closure and a wide opening filled with green M&Ms. PTI’s headquarter in Toledo, Ohio USA
EDITOUR PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net 12 Editour Mastering complexity in pharma packaging Alpla and Inden Pharma have had a joint venture Alpla Inden Pharma since 2023. The focus is on the production of pharmaceutical packaging for oral liquids, solids, ophthalmic, nasal, topical, buccal and parenteral applications. We met CEO and owner of Inden Pharma Juan Guillem González. Sponsors to date Interview with Alpla Inden Pharma // March 24, 2025 We met: CEO Juan Guillem Gonzáles Pharmaceutical packaging undergoes an approval process, sometimes lasting several years, so that the packaging remains unchanged for many years. On the one hand, this is a good basis for a lasting customer relationship; on the other hand, it is a challenge in production. Because part of the authorisation is also a precisely specified material. Depending on the barrier requirements, polyolefins or PET are used. And these margins must be used in exactly the same way over the entire life cycle. In addition, different guidelines have to be observed depending on the region. For Europe the EMA, FDA for North America, MHRA for Great Britain, PMDA for Japan, CDSCO for India, to name but a few. And so not only a large number of moulds are stacked up in the factory, but also an equally large number of different materials as bagged goods. The batches are too small to feed the plants with silage. It goes without saying that the design of the packaging, once approved, will not be further developed. The same applies not only to the bottle, but of course also to the caps, some of which are very complex. The situation is somewhat different in the standard range from Inden Pharma. The company offers containers in a wide range of sizes and neck finishes. This packaging is also produced on different materials depending on the required barrier properties. 75% of production is classic pharmaceutical packaging and around 25% is for veterinary medicine. Production is carried out using extrusion-blow moulding, traditional injection moulding, injection-blow moulding and injection-stretch-blow process. The last procedure in particular is probably hardly known anywhere in the world. Here, the injection mould is not only injected, but also blown directly. The production facilities are located in 6 large cleanrooms, most of which run automatically. Employees are only permanently present in the cleanrooms to shrink-wrap the bottles in large bags. In front of the rooms are chest-high pellet conveyors that transport the pellets from the bags into the plasticising units. With the JV, both companies can now demonstrate an even stronger global presence. Together with the Poland, Greece, and Germany, they will produce 1.500 million units in 2025. www.alplapharma.com by Alexander Büchler
PETplanet Insider Vol. 26 No. 06/25 www.petpla.net 13 EVENT PREVIEW
EDITOUR PETplanet Insider Vol. 26 No. 06/25 www.petpla.net 14 Editour Sponsors to date Hertex observes a widening price gap between recycled PET (rPET) and virgin PET (vPET) - a trend the company considers critical for the industry. Producing your own rPET: A sustainable advantage With a global presence in the plastics trade since 1979, Hertex specialises in PET and recycled materials. CEO Jerry A. Herculeijns, who has led the company since 2005, has extensive insight into market dynamics and pricing trends in both virgin and recycled materials. Now featuring Virtual Navigator – achieve sustainability in every cycle XVLQJ VPDUW HɝFLHQW SURFHVV FRQWURO Process Pilot+® Agr’s Process Pilot+ system delivers an automated, predictive response tailored to your unique bottle design and blowmolder characteristics ensuring optimization, consistency and repeatability. Start producing your best product today as we push to change global packaging technology one solution at a time. | www.agrintl.com | +1.724.482.2163 ™ Visit us at 15-19 September 2025 Münich, Germany Stand C6-521 Interview with Hertex // June 17, 2025 Due to low oil prices, virgin PET is currently available for around 1,000€/t, while rPET remains significantly more expensive - reaching up to 1,800€/t. “In Europe, many bottlers are reverting to the legally mandated minimum of 25% rPET content,” explains Herculeijns. “Even with a virgin plastics tax - such as the 450€/t levy in Spain - vPET is still more cost-effective than rPET as of June 2025.” Seasonality is another influencing factor. By June, bottlers have typically secured their annual supply contracts. Subsequent orders for the autumn and winter months tend to be smaller, given the seasonal decline in beverage consumption. They doen’t expect the market to stabilise before autumn at the earliest. Currently, Hertex’s sales are evenly split between virgin PET and rPET, with an annual turnover around 150M €. Since 2022, the company has been producing a significant portion of its own rPET. Three years ago, Hertex acquired STF Recycling’s flake-to-granulate production site in Aicha vorm Wald, Germany, and consolidated operations under the newly formed Eco Polymers GmbH. The facility includes polycondensation and extrusion systems from Viscostar (Starlinger) and Erema, enabling efficient production of bottlegrade rPET with an intrinsic viscosity (IV) of 0.82 dL/g in approximately 6 h. Over the past three years, Hertex has made substantial investments in its subsidiary, including the installation of advanced laser-based flake sorting systems from Unisensor, which ensure the reliable removal of contaminants such as PVC. With a production capacity of up to 36,000 t/a, approximately 95% of Hertex’s rPET output is used in the bottle sector. Further investments in capacity and technology are expected soon. www.hertex.ch F.l.t.r.: Marcel Illien COO at Hertex and Jerry A. Herculeijns, CEO of Hertex & Eco Polymers GmbH by Alexander Büchler
PETplanet Insider Vol. 26 No. 06/25 www.petpla.net 15 EVENT PREVIEW Working with us bears a risk RI VWDUWLQJ D ORQJ WHUP SURƓWDEOH UHODWLRQVKLS IRU \HDUV yellow.agency Swiss-engineered Preform Systems At Otto Systems we focus on solutions for special applications in PET preform production. We provide you with the most economical answers to your needs. Our unique system concept is based on smart modularity, proven performance, IXOO LQWHJUDWLRQ DQG PD[LPXP ŴH[LELOLW\ )URP LGHD WR RSHUDWLRQ 2WWR 6\VWHPV JLYHV \RX D GHFLVLYH FRPSHWLWLYH HGJH with your satisfaction as our guiding principle. Jump-start your PET preform production with us. RWWR V\VWHPV FRP DRINKTEC 2025 SEPT 15–19 Meet us in Hall C6 Booth 339
MOULD MAKING PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net 16 Redefi ning blow mould design through precise kinematic integration and clever mechanics Advancing mould engineering Reducing blowing pressures alone is insufficient for today’s demanding PET bottle production. Moldintec introduces a three-dimensional mould partition line for the petaloid base, precisely synchronised with the machine’s mechanical motion. This holistic engineering approach is claimed to achieve reliable low-pressure bottle formation, to enhance mould performance, reduce moving mass, and to deliver superior product aesthetics. In the dynamic and competitive world of PET bottle manufacturing, continuous innovation is essential for maintaining market leadership and sustainable growth. Moldintec, recently introduced KnetMold. This technology aims to redefine traditional stretch-blow moulding processes, particularly for PET bottles featuring petaloid bottoms used primarily in carbonated beverages. Historically, the production of robust PET bottles has necessitated blow moulding operations at pressures around 25 bar or less. Moldintec has established itself as a known player in this field by successfully developing its ultra-low-pressure BaseMax moulds. These moulds reliably achieve petaloid base formation at pressures as low as 16 to 20 bar, even accommodating large containers up to 3 L. With KnetMold technology, Moldintec advances the mechanical engineering aspects of mould construction rather than merely focusing on blow pressure reduction. Current mould construction methods often rely on simple planar or cylindrical partition lines. While effective, these traditional approaches present limitations, particularly in the precision and efficiency of air evacuation, cooling management, and overall mould durability, says Moldintec. Recognising these constraints, the company’s expert team implemented a unique three-dimensional partition line that aligns with the mould’s mechanical and kinetic interactions within the blowing machine. The distinctive feature of KnetMold technology is this three-dimensional partition line, meticulously engineered by carefully studying the exact trajectories and mechanical movements of mould segments during the opening and closing cycles of the machine. This sophisticated approach is intended to ensure mould segments move synchronously without interference, facilitating optimal interaction between the mould and the preform throughout the blowing process. Consequently, the PET preform expands uniformly and accurately, closely replicating the intended bottle geometry, even at significantly reduced blowing pressures, achieving reliable performance below the critical threshold of 14 bar. “Every petaloid base needs a unique 3D parting line that is linked with the blower kinematics. Our engineers must find the optimal curve that improves the air venting, the machining process, and the minimum mass as possible. At the beginning of the project all the analysis was made using the engineering software tools, but today they are training an AI agent to help them to optimise the curve design in a fraction of the time.” emphasises Alexis Martin, Principal Eng. at Moldintec’s Buenos Aires TechCenter. “Our approach strategically leverages advanced mechanical engineering principles, which deliver energy savings, reduced manufacturing costs of the moulds, moving mass of the base subassembly, and enhanced product quality.” This mechanical solution helps to optimise the venting process. “KnetMold design strategy eliminates the previously necessary small perforations or complex 3D laser-machined pathways required to evacuate trapped air by directly integrating specifically engineered venting channels into the three-dimensional partition line,” comments Diego Taboada, Chief Operations Officer based at Moldintec’s Headquarters in Buenos Aires, “This evolution simplifies mould manufacturing, reduces production time, and minimises long-term maintenance needs, further boosting economic efficiency.” Beyond air evacuation improvements, KnetMold technology enhances thermal management, says the company. By strategically distributing petaloid geometry between the lateral mould segments and the bottom insert, Moldintec has opti-
MOULD MAKING 17 PETplanet Insider Vol. 26 mised cooling circuits to achieve more efficient heat removal. This precise thermal control ensures uniform and rapid cooling, substantially reducing internal stress variations and enhancing the bottle’s resistance to stress cracking - a crucial factor for maintaining the structural integrity of carbonated beverage containers. Nevertheless, innovations inherently come with new technical challenges. The intricate geometry associated with the threedimensional partition line makes some areas of the mould thinner than conventional designs. Moldintec proactively addresses this concern by employing carefully calculated curvature radii and using specialised protective fixtures specifically developed for mould storage and handling outside production machines. These measures protect the integrity and durability of the moulds, underscoring Moldintec’s dedication to overcoming challenges through continuous innovation and technical know-how. In addition to operational and mechanical advantages, KnetMold technology also improves the aesthetic quality of PET bottles. The innovative three-dimensional partition line creates smoother transitions and less visible seam lines, enhancing the finished product’s visual appeal and perceived value - an essential factor for brand positioning and consumer satisfaction. Ongoing R&D to simplify mould mechanics Latest developments also point to a potential simplification of the mechanical system. Moldintec is now considering eliminating the third movement - the vertical displacement of the base subassembly - since the mould can open even when the base remains stationary. The team is currently working on methods to separate the base insert and the bottle without losing alignment with the mould centre line. This could represent another step forward in reducing mechanical complexity, wear, and cycle time. KnetMold technology is claimed to offer benefits such as decreased energy consumption, enhanced mechanical durability, and consistently high-quality output. To further validate its approach, Moldintec has applied for patent protection (patent pending) for the KnetMold technology. The company continues rigorous industrial validation programs, inviting potential collaborators and interested parties to engage directly with Moldintec’s technical experts. www.moldintec.com
BOTTLE MAKING 18 PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net Integrated Plastics Pty Ltd’s Integrally Moulded Handle (IMH) technology includes PET closures for recyclability One bottle, one material Australian firm Integrated Plastics Pty Ltd has developed a patented Integrally Moulded Handle (IMH) technology creating fully recyclable, single-material PET bottles with built-in handles. By partnering with nviro1 to develop an all-PET closure, the company now offers a 100% PET packaging solution that is intended to simplify recycling and to meet the demands of a circular economy. Australian company Integrated Plastics Pty Ltd, based in Sydney, New South Wales, offers a patented technology that integrates the handle of largercapacity PET bottles, creating a singlematerial PET or rPET bottle. This single material design of the IMH (Integrally Moulded Handle) technology integrates the handle into the bottle and eliminates separate production equipment and also means that the need to separate polymers for recycling is eliminated, enabling total recyclability within existing PET streams, supporting closedloop recycling and the circular economy, and helping to streamline global waste management. The company has collaborated with a fellow Sydney-based company, nviro1, to develop a PET closure as well, which means that it can offer an entire 100% PET IMH package. Integrated Plastics’ achievement has been recognised with two Worldstar 2025 Awards for Packaging excellence: one from South Africa and the second from Australia and New Zealand. Patented and unique features Integrated Plastics’ design features a number of advanced, patented and exclusive characteristics. The company has been offering handled bottle designs since 2006, which, unusually, use standard bottle-grade PET, with IV (intrinsic viscosity) values of 0.76 to 0.84dL/g. Injection moulding equipment requires no modifications in order to produce IMH preforms. Standard injection moulding machines can be equipped with dedicated moulds from Husky, Sipa, GDXL, Kisan, Petform, and Classic Tools. On the blowmoulding side, systems from Sipa and SDB-Korea incorporate special features to handle IMH preforms - where the handle is integrally moulded—while still operating within established PET processing platforms. Today’s IMH offer is an evolution of existing moulding technology by Integrated Plastics. The company says that dispensing with separate handles across its current range 1-5 L bottles offer a number of advantages. Eliminating mixed materials from recycling streams “Mixed-material bottles require manual or robotic insertion of HDPE handles, which reduces production speed and increases handling complexity,” said Nick Mellen, Managing Director of Integrated Plastics. “The IMH process avoids this step entirely. It by Ruari McCallion
BOTTLE MAKING 19 PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net eliminates handle insertion errors, streamlines the blow-moulding operation and reduces weight by 25 to 30% in the 2 L and 5 L formats.” It also eliminates any possibility of seal breakdown at the interface of the handle and the bottle itself, improving product security. It also makes recycling easier. “Our aim was to simplify the recycling stream by removing the need for separation, altogether,” he continued. PET/HDPE separation is improving but it still carries contamination risk and processing inefficiency is inevitable. “A fully PET-based package ensures purity in rPET feedstock, improves recycling yields and aligns with global EPR (extended producer responsibility) circularity regulations, which favour monomaterial packaging. It also means that brands using our solution are positioned to exceed upcoming legislation, rather than just comply.” Higher performance from PET There are other benefits, as well. PET outperforms HDPE in a number of areas that are particularly crucial for food and beverage packaging. PET offers up to 50 times higher oxygen barrier than HDPE, which means extended shelf life for sensitive products, such as juices, dairy and flavoured drinks: between 40 and 60% longer, in controlled trials of cordial juices and dairy products packaged in PET, HDPE and hybrid bottles. PET can be clear or coloured, as the producer requires, which can make the product more appealing on the shelf, as well. Similar capacity PET bottles are significantly lighter than HDPE equivalents: a 2 L PET bottle will weigh 69-75 g, while HDPE will weigh 90-135 g – a saving of 20% or more and with better barrier performance. And the PET bottle is fully recyclable. Adding a PET closure The addition of a PET cap makes the monomaterial picture complete. Integrated Plastics has been collaborating with nviro1, a design company also located in Sydney, New South Wales. “Nviro1 is finalising a PET cap mould design that includes a unique demoulding system and improved tamper-evident band,” Nick Mellen said. The finished product is dualbore seal cap that compresses and expands to form two seals, which strengthen under CO2 pressure. The closure is designed for low torque and easy moulding; an imminent set of tests will validate long-term performance. Target markets “We are initially targeting the nonalcoholic beverages, dairy, edible oils and household liquids categories. They stand to benefit most from enhanced barrier properties, ergonomic handling, and full recyclability,” he said “The robust, mono-material design also makes IMH bottles ideal for e-commerce ready packaging, where durability and shelf presence are critical.” IMH technology bottles are being manufactured and distributed through a growing global network of licensed partners. In the home market of Australia, Refresco Australia produces applications for cordial juices. In South Korea, Sempio Foods bottles soy sauce and vinegar and Piskopack produces Asian cooking sauces. MPACT Plastics of South Africa specialises in bottles for edible oil, dairy and fruit juice and Raya Plastics at the opposite end of the continent, in Egypt, produces 1-2 L edible oil, liquid detergent and other household chemical bottles. In Saudi Arabia, Highgate Plastic Company makes 2-5 L bottles for edible oil, while Bottle One – Handle Preforms supplies bottles for fruit juice, edible oil and water, across the Americas. www.integratedplastics.com.au PET closures 26mm water (source: nviro1)
BOTTLING / FILLING PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net 20 One monobloc for glass, PET, and refi llable bottles RefPET ready SIPA’s Isotronic G filling monobloc is designed to accommodate the production of a variety of bottle types. Designed to handle single-use and refillable (refPET) PET bottles as well as glass bottles, it accommodates screw tops, crown caps, and a wide variety of still or carbonated beverages. One notable feature is its capability to fill both glass and refillable PET bottles without mechanical changes, provided the bottles are the same height. This translates to faster transitions, fewer interventions, and no downtime. Built as an isobaric electro-pneumatic level filler, the Isotronic G incorporates a wide range of advanced design features that are claimed to deliver top-tier performance and flexibility. Available in configurations from 20 to 100 valves, it supports output rates of up to 50,000 bph. At the heart of the system is a stainless steel central tank equipped with mobile filling and vent tubes. The design allows operation without vertical movement of bottles, minimising wear and maintenance. Automatic engagement of dummy bottles during the washing cycle, along with easy-tosanitise valves and reliable mechanical components, further enhance the system’s simplicity and hygiene. Streamlined changeovers The Isotronic G simplifies adjustments when switching between different bottle materials, neck sizes, or formats, says SIPA. Centralised filling level adjustments eliminate the need to swap vent tubes. Handling is done through the base for glass bottles and by the neck for PET bottles, and when switching between glass and PET bottles of the same height, no monobloc height adjustment is needed. AccordFILLING ing to the company, neck changeovers are fast and tool-free, centring cups can be replaced quickly, and all parameters are controlled via a modern touchscreen HMI, keeping operations smooth and user-friendly. Smart features for high per-formance The system includes product deflection via a swirl device, intended to enable smooth filling without turbulence or foam, as well as automatic dummy bottle engagement. A dry pressurisation circuit minimises foaming, while the air return is separated from the product path to preserve product integrity. The system includes built-in protections in case of bottle burst, and eliminates the need for a pneumatic lifting cylinder, simplifying maintenance and improving hygiene. The swirl device, integrated within the valve, spreads the product evenly along the bottle walls in a thin, controlled film. Unlike conventional systems, this design doesn’t require adjustments when changing formats, reducing downtime and simplifying cleaning. Combined with fully automated sanitation, triggered directly from the operator panel, the Isotronic G is claimed to ensure consistent hygiene, with cleaning solutions flowing through all internal parts of the filler. Cleanliness and durability Dry pressurisation keeps liquid particles out of the pressurisation circuit, reducing foam and improving cleanliness. No sliding gaskets or lubrication are needed, and the bottle handling system ensures bottles move along a single, flat plane, thus further reducing the risk of contamination. The mobile vent tube allows real-time adjustments to the filling level, enhancing flexibility and efficiency. It also contributes to cleaner decompression (snifting), reducing product loss and foam. “Our system is equipped with advanced capabilities to effectively manage an occasional bottle burst,” says Sipa.When such an event occurs, sensors instantly identify it, and separators actively protect crucial components like the filling valve and swirl device. The single gasket in contact with the bottle, found within the centering cup, is ingeniously designed for swift and easy cleaning using high-pressure water. “This thoughtful engineering not only mitigates potential impact, but also guarantees a quick and seamless recovery process without requiring manual intervention”. SIPA Hall C6 – Booth 301
BOTTLING / FILLING PETplanet Insider Vol. 26 No. 07+08/25 www.petpla.net 21 Configurable and connected The Isotronic G can be customised to suit virtually any production need. Optional CIP systems can be integrated either on the filler or the carbo/mixer, helping reduce footprint, energy consumption, and investment cost - particularly useful for water filling operations. The monobloc can also be connected with SIPA’s rotary or linear stretch-blow moulding units in a Sincro Bloc configuration, forming a compact and efficient blowing-fillingcapping line. The system is compatible with a wide range of capping solutions, from plastic caps to aluminium crown and ROPP caps (roll-on pilferproof caps), with optional cap decontamination for added hygiene. A clean, controlled environment To maintain high hygiene standards, the Isotronic G supports a range of environmental control solutions. These include ISO Class 7 cleanroom integration - upgradable to Class 5 - sterile air cabins with Hepa filters, and minienclosures using isolator technology. These measures are intended to reduce the controlled area, to improve sanitation efficiency while keeping operating costs low. www.sipasolutions.com JOIN THE OFFICIAL REVEAL: Tuesday, September 16th 12:00 PM Hall B5 — Stand B180 Get ready to rethink compression.
RkJQdWJsaXNoZXIy NTY0MjI=