PETpla.net Insider 05 / 2025

No.05 2025 www.petpla.net D 51178; ISSN: 1438-9452 PETplanet is read in 159 countries Suppliers of preforms & preform inspection systems 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 19 . 05 . 25 Page 23 COMPRESSORS Page 27 EDITOUR Page 10 Page 16 AI

AF COMPRESSORS EFFICIENCY IN SOBRIETY UNL IMI TED L I FE T IME ! MAINTENANCE COSTS REDUCED BY 50% ENERGY COSTS REDUCED BY 1 5% The world leader of PET oil free piston compressors WWW.AFCOMPRESSORS .COM SALES@AFCOMPRESSORS .COM AF COMPRESSORS ALSO PROVIDE SUSTAINABLE AND LONG LIFE 8 & 10 BAR OIL FREE AIR Drinktec Hall C5 - Booth 401 But also Propak Asia • Fispal Tecnologia • ... and many others Meet us at

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. 26 No. 05/25 www.petpla.net Our Gulf tour is coming to an end, and in this issue you can read our last on-site stories. It was a very interesting tour for me, as we visited an above-average number of processors. This is the only way to get a really good feel for the local market and a lot of background knowledge about the equipment and raw materials used. To summarise, the Gulf region is a very strong water market that has so far been supplied by many smaller local bottlers. However, we are finding more and more high volume bottlers in the region which are squeezing out the smaller ones. These large local bottlers boast the latest stretch blow moulding and filling technology. They have also brought some of the preform and cap production in-house. The markets are saturated, and no-one expects demand for bottled water to increase significantly. Nevertheless, the large local suppliers have excess capacity that cannot be accommodated in the local market. As a result, there is a fierce price war at the point of sale for the consumer’s favour. Another strategy to deal with overcapacity is for bottlers to export to neighbouring countries. Dubai and the African states are particularly popular export countries. However, the markets there are also reaching saturation point. There are no new drinks on the horizon that could boost consumption and thus reduce local overcapacity, and consumers are focussing on still water. And, according to the bottlers, the consumer dislikes bottles made with rPET - the grey shimmer of rPET bottles carries the aura of unclean packaging. Attempts to encourage bottleto-bottle recycling are therefore the exception rather than the rule. Things are different in Europe, where our sustainability tour has now started with many sustainability projects - and not just B-to-B. Enjoy the current issue and look forward to the next one. Yours, Alexander Büchler Dear readers,

PETcontents 4 PETplanet Insider Vol. 26 No. 05/25 www.petpla.net 05/2025 EDITOUR 10 The waste converters 12 “We create solutions” - Almannai, driver for rPET bottles in Kuwait 13 Mastering cost control in a competitive market - United Factory for Preforms and Packaging (UFPP) adjusts cost screw for preforms 14 Not all water is the same - Malavilla with sophisticated water treatment ARTIFICIAL INTELLIGENCE 16 How digitalisation and AI advance the plastics sector 18 Measure the shift - How digitisation is driving sustainable packaging innovation 20 The digital twin: a virtual reality - Sipa’s AI systems for PET packaging machinery 21 AI-powered material sorting - Boosting efficiency in plastic recycling 26 Multiple material streams on a single sorting line - AI-powered sorting system with deep learning technology MARKET SURVEY 23 Suppliers of preforms & preform inspection systems COMPRESSORS 27 “Plug-and-play design brings speed and simplicity to compressor installation 28 Sustainable savings - Heat recovery saves money and benefits the environment 30 Automatic learning and management - A compressed air system monitoring and control network EVENT REVIEW 32 Brazil recycled 410,000 t of PET packaging in 2024 - Unprecedented memorandum will encourage the recyclability of packaging based on the “design for environment” principles 34 PRSE 2025 review OUTER PLANET 46 From field to fibre to form - Papacks positions industrial hemp as the circular raw material of the future and delivers an answer to EU packaging regulations BUYER’S GUIDE 40 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 37 PET bottles for home + personal care 38 Products 39 Patents Page 13 Page 34 Page 21 EDITOUR COMPRESSORS AI

T OTA LLY SW I S S. OUR INJECTION MOULDS FOR PET, PAC AND MED FEATURE ACCOMPLISHED, TRADITIONAL SWISS CRAFTSMANSHIP. OTTO-HOFSTETTER.SWISS A FAMILY OWNED SWISS COMPANY. O F P R E C I S I O N 70 YEARS yellow.agency

PETnews 6 NEWS PETplanet Insider Vol. 26 No. 05/25 www.petpla.net DePoly to launch 500 t/a showcase plant DePoly, a PET-to-raw-material recycling company, announced the upcoming launch of a 500 t/a showcase plant in Monthey, Switzerland this summer, representing a critical step in the company’s journey from laboratory breakthrough to industrial-scale implementation. The facility will demonstrate DePoly’s proprietary process that converts PET and polyester waste into virgin-quality raw materials without fossil fuels. The technology has already demonstrated its commercial impact through collaborations with some leading companies in fashion, cosmetics and the broader consumer goods industry, including innovators such as PTI, says DePoly. Through these partnerships, the company has validated the quality of its recycled monomers by transforming PET waste into new bottles, highperformance textile fibres, and cosmetic packaging. The company is planning to build a commercial plant in 2027 that will process significantly larger volumes of PET and polyester waste – a major leap in redefining recycling and advancing the circular economy, as DePoly strives to become the global leader in sustainable, circular plastics. www.depoly.co The Association of Plastic Recyclers (APR) and RecyClass mark a second year of progress in driving global harmonisation of Plastic Recyclability The Association of Plastic Recyclers (APR) and RecyClass published the second progress report of their collaboration, which aims to accelerate the global harmonisation of plastic recyclability. Key updates include streamlining the measurement of intrinsic viscosity variation for PET bottles and harmonising the filter pack used in extrusion during HDPE and PP rigid packaging recyclability tests to facilitate future common assessments. Over the past year, APR and RecyClass conducted extensive test campaigns. The main areas of investigation included inks and laminating adhesives for PE films, additives that cause yellowing in recycled PET for PET bottles, and metallised labels. Following the results, the two associations actively participated in the respective Technical Committees to align the benchmarks of the APR Critical Guidance Test Protocols and RecyClass Recyclability Evaluation Protocols. Moving forward, APR and RecyClass are set to conduct further test campaigns to enhance the Design for Recycling Guidelines for various packaging solutions. These efforts will help ensure better alignment and effectiveness of recyclability standards worldwide. www.recyclass.eu www.plasticsrecycling.org Indorama Ventures divests indirect subsidiary in Portugal Indorama Ventures Public Company Limited (IVL) has announced the divestment of its indirect subsidiary, Indorama Ventures Portugal PTA - Unipessoal, LDA. (IVPPTA), which operates a PTA manufacturing facility in Sines, Portugal. According to a resolution passed on April 7, 2025, the Management Board of Indorama Netherlands B.V. (INBV), an indirect subsidiary of IVL, approved the sale of its entire 100% equity stake in IVPPTA to an unrelated third party. The transaction was completed on April 11, 2025. The company stated that the decision followed a review of market conditions and economic pressures, including high costs of raw materials and energy, inflation, and increased competition from low-cost PTA imports. The facility had ceased operations two years prior. IVL noted that the divestment aligns with its broader asset optimisation strategy. The sale, valued at EUR 100,000 (approximately THB 3.82 million), includes the transfer of all future obligations associated with IVPPTA to the purchaser. As IVPPTA’s assets had already been impaired in 2024, the company indicated that the transaction would not have a material impact on its operations or financial position. www.indoramaventures.com Maag Group to acquire Sikora AG Maag Group is pleased to announce that it has entered into a definitive agreement to acquire Sikora AG, a recognised leader in measuring and control technologies. This acquisition accelerates Maag’s innovation capabilities in machine learning, industrial IoT, and AI-driven technologies. Headquartered in Bremen, Germany, Sikora is well-known in the market in measuring and control systems for various applications such as cables, tubes and plastics production. From non-contact measurement control to automatic sorting systems, the company is developing innovative and sustainable solutions, with considerable investment in research and development. With this acquisition, Maag aims to achieve a new milestone in its growth strategy. The company offers a wide range of equipment and integrated systems for the polymer and recycling industries, and is broadening its capabilities to address a wider set of applications and processes. The combination of Maag and Sikora is expected to support the development of smart, self-driven, and energy-efficient systems, in response to evolving market demands. The transaction is subject to customary closing conditions, including receipt of regulatory approvals and is expected to close in the second quarter of 2025. www.maag.com  www.sikora.net

7 NEWS PETplanet Insider Vol. 26 No. 05/25 Blow Moulding 2025: Conference on innovations and sustainability in plastic bottles and containers According to research by Nortal Consulting, circa 36 million tonnes of polymer (mostly PET and HDPE) have been processed by blow moulding around the world in 2024, mainly to make consumer and industrial packaging valued at c. 97 billion US dollars. Widely employed as a packaging solution, blow moulded plastic bottles and containers present very specific challenges and opportunities, both in terms of the supply chain and from a sustainability perspective. Fortunately, those can all be debated at this industry’s dedicated meeting place. Already in its 9th edition, the International Conference / Exhibition / Networking Event Blow Moulding 2025 which will take place from December 10-11 at Brussels, Belgium, is well-established as the annual forum for this industry. It brings together the entire supply chain: from producers of raw materials, additives, machinery and tooling to suppliers of packaging systems and components, as well as brand owners and retailers; not forgetting of course recyclers and sustainability experts. The two full days comprise absorbing presentation sessions and panel discussions, interspaced with exhibition visits and lots of networking opportunities. It will be an opportunity to get an update on the latest trends, developments and innovations, to promote products, services and capabilities, as well as to meet key experts and industry leaders. The event covers plastic bottles and containers viewed as complete packaging solutions – i.e. including Caps & Closures, Labels & Sleeves, Dispensing Systems, Seal Films, as well as secondary packaging. All aspects of the product cycle are within the scope – from choice of raw material and design to post-use stewardship. So are all the various blow moulding technologies and materials. www.blow-moulding.com CREATING FUTURE STANDARDS Japan’s leading Aseptic PET Filling System Provider. Our website Our solution high quality reliable technology safe & secure

8 NEWS PETplanet Insider Vol. 26 No. 05/25 www.petpla.net New study reveals progress and challenges in meeting recycled content goals for packaging A new report fromAmeripen, prepared by Circular Matters and funded by PLASTICS’ Recycling is Real initiative, highlights significant progress by consumer-packaged goods (CPG) companies toward recycled content goals in packaging while also exploring critical gaps in infrastructure, collection systems, and supply to meet targets. Following a recent member exclusive release webinar, U.S. Packaging Recycled Content Goals Analysis is now freely available for individuals and organisations to use in sustainability efforts. Success in goals for post-consumer recycled (PCR) content will require coordination across this value chain; understanding where and why challenges may be occurring can provide further insight into effective interventions to ensure success. This new resource provides an update and expands onAmeripen’s 2021 report that explored the relationship between packaging recyclability and recycled content goals, domestic supply, and reprocessing capacity, and what, if any, additional policies or program supports could be supported to close potential gaps. A lot has happened in recycling and packaging since 2021, including new goals, new investment, and increased PCR usage – with this progress, Ameripen and Recycling Is Real felt quantifying impact again would provide value to many stakeholders. The updated U.S. Packaging Recycled Content Goals Analysis is the most comprehensive assessment to date of how voluntary corporate commitments, trade association targets, and state and federal laws align with the current and projected capacity of the U.S. recycling system. The study includes detailed data from 46 CPG companies, state legislation, and national trade associations covering paper, plastic, and aluminium packaging. Key findings include: Progress being made: The average post-consumer recycled (PCR) content in plastic packaging more than doubled (from 5.3% in 2019 to 10.7% in 2023) among companies with stated goals. Supply gaps remain: despite added reclamation capacity, the U.S. will still fall short in meeting 2025 plastics packaging goals, especially for PET, unless collection rates and advanced recycling capabilities increase significantly. State policies are gaining influence: since 2020, at least ten states have enacted laws mandating recycled content in packaging, adding new external pressures across the supply chain. Barriers persist which could benefit from intervention: companies continue to cite limited availability of food-grade PCR, inconsistent material quality, and higher costs compared to virgin resins as primary obstacles. Increased capacity: between the 2021 and 2025 reports, U.S. plastics reclaimers have more than doubled their capacity to supply PCR to the packaging market. The report also cautions against policies that give preferential access to recycled materials, advocating instead for open, competitive markets that balance all end-uses of recovered materials. As pressure mounts to increase the use of recycled content, it is critical to understand how voluntary corporate goals and state legislation align with the realities of U.S. material supply and recycling infrastructure. When informed by objective current data, goals for recycled content in packaging will be more effective and achievable. www.ameripen.org Chinaplas 2025 review Chinaplas 2025 successfully wrapped up on April 18 with 281,206 visitors, an increment of 13.29% compared to Chinaplas 2023 in Shenzhen. Chinaplas 2024 in Shanghai welcomed 321,879 visitors. Among them, visitors from overseas countries and Hong Kong, Macau and Taiwan region of China rocketed to 68,542, accounting for over 24% of total visitors, a 141.1% increase compared to Chinaplas 2023 held in Shenzhen. This trade fair saw over 4,500 superior plastics and rubber suppliers from 39 countries and regions, more than 3,800 machine exhibits, and over 1,600 raw material suppliers. Numerous trade deals were concluded between distinguished exhibitors and global buyers, proving the trade fair’s 2025 edition an effective sourcing platform that cultivated new partnerships and paved the way for industry growth and success. Showcasing of full industry chain The exhibition released industry breakthroughs of more than 120 global/Asian debut technology projects and brought many new, effective landing solutions for plastics and rubber production. The industry chain in full scope was exhibited – from advanced material innovations, intelligent manufacturing solutions to tried-and-true products, covering automotive, electronics and electric, packaging, medical and healthcare, building materials, new energy, sports and leisure, as well as other downstream applications, catering to diverse needs from various industries and sectors. Concurrent events A series of concurrent events surrounding circular economy were organised and received participants’ support. Over 800 industry elites joined “Plastics Recycling & Circular Economy Conference and Showcase”, where over 60 international experts and leaders of renowned enterprises shared insights on plastics recycling market and technologies contributing to sustainable plastics development. In “Sustainable Plastic Packaging Forum”, experts from prominent packaging institutions and companies addressed the latest solutions and sustainability blueprint from an international perspective, while representatives from renowned brands shared difficulties they faced in daily operations of innovative packaging, realising efficient docking between upstream and downstream of the industry chain. PET food-grade and PE high-quality recycling production lines were demonstrated at “The Plastics Circularity Journey” Production Line Live Demo, showcasing high-value utilisation of plastics recycling. Chinaplas 2026 will be held at National Exhibition & Convention Center (NECC), Hongqiao, Shanghai, PR China on April 21-24, 2026. www.chinaplasonline.com

9 NEWS PETplanet Insider Vol. 26 No. 05/25 ICS Egypt joins Wisecap Group to lead the next phase of growth across Egypt and Africa ICS Egypt is a closure producer for carbonated soft drinks across Egypt and Africa. Wisecap Group is proud to announce the beginning of a new chapter as Integrated Cap Solutions Egypt (ICS Egypt). ICS Egypt is the result of a strategic partnership between CSS Group, the previous owner of CSI Egypt, and Wisecap Group. “By joining Wisecap Group, ICS Egypt gains access to a broader product portfolio, cutting-edge technologies, and extensive commercial know-how developed over more than four decades. This will allow ICS Egypt to better serve its existing customers while expanding into new product segments such as closures for water and noncarbonated beverages,” said Alessandro Delfanti, Chairman and CEO of Wisecap Group. “This powerful partnership unites CSS Group’s centurylong legacy in beverage closure excellence with Wisecap’s decades of industrial—leveraging ICS Egypt’s strong local footprint and reputation across Egypt and Af r ica, ” said by Miquel Batlle and Andre Bianchi, co-owners of CSS group. ICS Egypt sees itself now ideally positioned to accelerate i ts growth journey. The continuity of the local team and operations are claimed to ensure uninterrupted service for existing clients, while the integration into Wisecap Group unlocks new opportunities for innovation, performance, and regional expansion. www.wisecap.eu

EDITOUR PETplanet Insider Vol. 26 No. 05/25 www.petpla.net 10 The waste converters by Ruari McCallion Establishing an organisation to promote a circular economy for plastics sounds simple but making it a reality in a country that has not given much thought to waste and sustainability is a major challenge. Interview with Omniya PET Recycling // October 27, 2024 We met: Mrs Sanaa Al Ghemlas, Founder & CEO Historically, there has been no recycling in the Gulf States, from Kuwait to the United Arab Emirates. Mrs Sanaa Al Ghemlas has a clear environmental vision: to build a circular economy for plastics in Kuwait. Omniya, the vehicle to realise her goal, is raising awareness of the impact of plastic packaging with a variety of initiatives, including the involvement of schoolchildren. “We started as an NGO (nongovernmental organisation) in 2015, initially with the intention of spreading awareness about plastics in Kuwait, going out with messages about the importance of segregating plastics and recycling,” said Mrs Sanaa Al Ghemlas, founder and CEO of Omniya Collection System. “We approached the Kuwait National Fund for SMEs and we were awarded funding to build the first PET recycling plant in the whole Gulf region.” Omniya started producing PET hot washed flakes in 2017. Its market was primarily Europe and its quality was high enough to be approved by Dow Chemical. The end of the beginning “Unfortunately, supply of post-consumer PET in Kuwait turned out to be minimal,” Mrs Al Ghemlas continued. “Along with the high cost of renting the premises, it became clear that the project was not viable and we had to close down, at the end of 2021.” Omniya had been the first to seek to recycle PET in the whole Gulf region, it had acquired unequalled expertise and insight into the needs and logistics of waste management, collection and recycling. When it reopened as a not-for-profit company, in March 2023, it was with a clear focus on collection and waste management. It has attracted sponsorship from the private sector and from the National Bank of Kuwait and Equate Petrochemical Company. “When we were operating previously we established a collection system, with containers across all the governorates (districts) of Kuwait. They aren’t like dumpsters; they are small rooms, 2m x 2m and 2.5m in height,” Mrs Al Ghemlas explained. Omniya redoubled its efforts in the country’s schools, both private and public sector. Changing culture with technology “The schoolkids had got to know Omniya and had started to collect for us. They wanted to continue what we had begun previously. While we were recycling, we collected over 2,000 t of postconsumer PET bottles and produced around 1,500 t of washed flakes. We managed that without any incentive at all. The people did it because they thought it was the right thing.” Omniya has now introduced competitions between schools to collect the most PET, and it is working. “Last year, we had about 48 schools involved and collected about 150 t. This year, we have over 100 schools,” Mrs Al Ghemlas said. The project has been embraced by youngsters of all ages, from the most junior grades to high schools. “We now have all our containers located on Google Maps, so people know where to put their waste once it has been collected and segregated, and have an app linked to it to record activity. We are working with private sector companies to encourage them to offer people the chance to earn discounts against services or on products.” The app has now been downloaded over 20,000 times and activity is running at around 1,000 interactions a day. The International Alliance to End Plastic Waste has approved a grant to enable Omniya to increase the number of collection points and to acquire two new compactors. It is supplying segregated waste to partners like Almannai, which manufactures preforms. Closing the loop “Manufacturers in Kuwait who produce PET preforms from 100% recycled PET, which we then put into schools to use as their water bottles, means that we are showing the schoolchildren what they have done and that we are achieving our objective of closing the loop,” she said. “I hope that, soon, plastic will be seen as valuable a resource in Kuwait as oil.” www.omniya-kw.com EDITOUR

P E R M A N E N T M A G N E T M O T O R R E L I A B I L I T Y S U S TA I N A B I L I T Y I N D U S T R Y 4 . 0 V A R I A B L E S P E E D D R I V E V E R S AT I L E & A D A P TA B L E Check it more here! abc-compressors.com

EDITOUR PETplanet Insider Vol. 26 No. 05/25 www.petpla.net 12 Almannai, driver for rPET bottles in Kuwait “We create solutions” by Alexander Büchler Almannai Plastics, a Kuwait-based manufacturer of PET preforms and closures, has partnered with PepsiCo to launch the MENA region’s first bottles made entirely from recycled PET (rPET). The initiative reflects growing interest in sustainable packaging solutions, even in regions where formal recycling regulations are still emerging. Interview with Almannai Plastics // September 23, 2024 We met: Yousef Al-Mannai, Founder at Almannai Plastics Actually, this could have been a completely normal story of a converter. Almannai has been producing water preforms on two Husky HyPET systems since 2015 and caps on Husky HyCAP systems since 2018, mainly for the local market. Normal, that is, if it weren’t for Yousef Almannai, who is always looking for new ideas. In his opinion, sustainability in the bottle sector is not just about optimising weight, but also about using rPET in preform production. He sees no other way of producing the PET bottle in an environmentally friendly way. He trialled the production of a 100% rPET bottle with the local Pepsi-Cola people in multiple formats (200ml, 330ml, 500ml, and 1.5 L). The result was good: no grey or yellow haze, a clear neck finish. He posted the bottle without a label on LinkedIn, with hashtags of all internationally known water brands. Hardly was it online when Pepsi got in touch. At first they were surprised that EDITOUR FEATURING REAL WORLD DATA BY Unparalleled accuracy from Industrial Physics Scan to access our exclusive guidebook he had publicised the small internal project so widely. The story reached senior management and they decided to give it a try after all. The Aquafina bottles went into production in 2022, and the fear that consumers would only drink water from virgin material bottles was groundless. The Husky lines for the bottles are now running at 5,000 t/a rPET. There is still no collection or even processing of PET bottles in Kuwait, so Almannai has to import the rPET from various countries. To ensure that the quality remains the same, the acetaldehyde content is low and transparency is guaranteed, all rPET batches at Almannai undergo extensive tests in their own laboratory. Only when all values are correct does the batch go into production. The next step will be to produce the CSD preforms for Pepsi also in rPET to other beverage and FMCG brands throughout the MENA region. “If it works with sensitive water, it should be even more possible with CSD products, which have a more stable flavour,” believes Almannai. However, with Pepsi in Kuwait, the production capacity of its Husky systems with 72-cavity moulds is not fully utilised. So he is looking around for other partners who need rPET bottles. He has set his sights on international airlines such as Kuwait Airways and Qatar Airways. If they serve Europe, they must use rPET bottles to meet EU directives with 25% rPET by 2025. And so he is pleased that he does not sell preforms, but solutions for companies. www.almannaiplastics.com

EDITOUR PETplanet Insider Vol. 26 No. 05/25 www.petpla.net 13 United Factory for Preforms and Packaging (UFPP) adjusts cost screw for preforms Mastering cost control in a competitive market by Alexander Büchler With a focus on lean management and strategic production planning, Ashok Arumugam, Factory Manager at UFPP ensures the factory’s efficiency, balancing demand fluctuations and optimising capacity to maintain a competitive edge while keeping prices low. Interview with United Factory For Preform And Packaging (UFPP) // September 22, 2024 We met: Ashok Arumugam, Factory Manager “Here in the region, sales are mainly based on price,” reports Mr Ashok Arumugam, Factory Manager. Consequently, he has to move heaven and earth to ensure that the costs do not get out of hand. From lean management to plant utilisation and weight reduction, he is working to keep costs low. The factory was opened in 2017 and went into full production in 2019. Ashok produces the classic water preforms for the region. The secret of his success is to keep costs low in order to offer customers a good price. This also includes lean management, for example. He manages the company with just four group leaders, each responsible for quality and production. Oman has a capacity of 10 million preforms/bottles per day. However, only a maximum of 5 million are needed. In addition, consumption drops significantly during the summer school holidays, as pupils drink from family bottles or dispensers at home rather than taking disposable bottles with them. Ramadan also has an impact on consumption, as devout Muslims do not eat or drink during the day at this time. So Ashok thinks about how he can utilise his production capacity. Due to its favourable pricing, the company exports to Tunisia, Jordan and Bahrain. Now he would also like to deliver to the Emirates. Ashok also restricts itself to longterm orders for cost reasons. Shortterm small batches do not fit into his thought process. He is also considering a product expansion in the form of CSD preforms, even if the market here only accounts for a fraction of still water sales. The CSD preforms are currently imported. To keep costs in check, it is also necessary to reduce the preform weight. He has therefore now developed new preforms that are thinnerwalled but longer. For example, the weight of the 200ml preform can be reduced from 8.22 g to 7.5 g; for the 300ml preform from 10.72 g to 9.98 g. The bottler needs less energy to heat up the new variants. He produces three shades of blue: dark blue for Oyses and two shades of sky blue. The bottles can easily be returned to the recycling cycle with the colours. What is important here in the Gulf States is a low acetaldehyde content, which he keeps in check with scavengers even at the 45 degrees that prevail here in summer. Despite all the discussions about costs, one thing is very important to Ashok. If the customer has problems with their preforms or systems, he is there for them. He goes over to see them and can usually solve the problem. All these products are manufactured on a top-entry Netstal 600 t with Otto Hofstetter 128-cavity mould. In another Netstal system, we find a Z-moulds mould for producing caps for 29/25 standard preforms. Ashok is convinced that these are the best solutions from a technological and economic point of view, even if the purchase costs are higher than those of comparable moulds from other manufacturers. www.ufpp-qatar.com EDITOUR Fl.t.r.: Alexander Büchler and Ashok Arumugam in front of the top-entry Netstal system with Otto Hofstetter moulds View into the Z-Moulds mould Long, thin, light - this is the new preform generation from Ashok

EDITOUR PETplanet Insider Vol. 26 No. 05/25 www.petpla.net 14 Malavilla with sophisticated water treatment Not all water is the same by Alexander Büchler At Malavilla Water in Doha, Plant Manager Ahmad Al Natour, a former PepsiCo executive, runs an impressively hygienic and efficient facility where every detail, from custom-coloured machinery housings to precise water treatment, reflects his passion for quality and control. Interview with Malavilla Water // September 19, 2024 We met: Eng. Ahmad Al Natour, Plant Manager We meet the Plant Manager Ahmad Al Natour. He used to work for PepsiCo. Today, he manages the production of Malavilla Water in Doha. The outstanding tidiness and high standard of hygiene are immediately noticeable during operation. For example, he enclosed the dispensing area around the octabins for his Krauss-Maffei preform system from 2017. As a perfectionist, he painted the housing in the colour of the machine. At least as careful is his water treatment from Grewa. The system achieves 40m³/h. The municipal water first passes through various filters, such as sand and carbon filters. He adds his own mineral formula to the demineralised water, supplements it with O3 for hygiene and fills it 27,000 times an hour into 225ml, 350ml, 500ml or 1.5 L bottles on a Krones line. 48 filling valves and 12 capping stations do the work. Several inspectors ensure that only flawless bottles go into the drying section. The efficiency in pure filling mode is 93%. The Krauss-Maffei system is even higher with its MHT 48-cavity mould. With the Krauss-Maffei system, he achieves an average efficiency of 97%. Although he uses scavengers, he stores the preforms for 24 hours at controlled ambient temperatures to minimise the acetaldehyde content. 80% of its bottling goes to its own brand, 20% of its production to private labels. He would like to have the systems running around the clock, but the overcrowded market in Qatar does not allow it. Ahmad does not see generating additional volumes through exports as a solution, as the costs would be so high that it would be a loss maker at best. Its bottle weights are 8.5 g for the 225ml. He has now reduced this to 7.8 g, as well as the weight of the 350ml from 11 g to 9.2 g. The compressed air is supplied by a threestage AF compressor. It works oil-free, just like the compressor for the working pressure of 10 bar. For Ahmad, oil-free compressed air is essential in beverage production, even at low pressures. And the outlook? The mother company Gulf Center Holding Company, which strives for the quality and innovation of its factories, looks forward to starting operations in Syria, as soon as sanctions are lifted. www.mvqatar.com EDITOUR Ahmad Al Natour in front of the labelling station at the Krones system The in-house enclosure for the octabins at the preform output blends seamlessly into the machine design of the Krauss-Maffei system. Water preparation is the core area for Ahmad. This is where the flavoursome water for Malavilla is created.

BIG ON BOTTLES. EXPERIENCE XTRA FLEXIBILITY. 7KLV LQWHJUDWHG ERWWOH EORZLQJ DQG ĆOOLQJ V\VWHP FRPELQHV WKH ZHOO NQRZQ DGYDQWDJHV RI WKH ;75$ URWDU\ EORZPROGHU ZLWK WKH DGYDQFHG WHFKQRORJ\ RI WKH %,*),// ĆOOHU D YROXPHWULF HOHFWURQLF JUDYLW\ ĆOOHU ,W VWUHDPOLQHV WKH EORZLQJ DQG ĆOOLQJ SURGXFWLRQ SURFHVV RI ODUJH FRQWDLQHUV WR OLWHUV IRU KLJK YROXPH DSSOLFDWLRQV OLNH VWLOO ZDWHU DQG HGLEOH RLO ;WUD %LJ EORZPROGHU DQG %,*),// ĆOOHU ZRUN VHDPOHVVO\ WRJHWKHU PD[LPL]LQJ HIĆFLHQF\ DQG PLQLPL]LQJ GRZQWLPH 2XU XQLTXH K\JLHQLF GHVLJQ HQVXUHV QR FRQWDFW ZLWK WKH ERWWOH SUHVHUYLQJ SURGXFW LQWHJULW\ :KHWKHU LWèV VWLOO ZDWHU RU HGLEOH RLO WKH 6LQFUR ;WUD %LJ DGDSWV WR \RXU SURGXFW JXDUDQWHHLQJ SUHFLVH DQG FOHDQ ĆOOLQJ HYHU\ WLPH %XLOW ZLWK $,6, VWDLQOHVV VWHHO YDOYHV VDQLWDWLRQ LV D EUHH]H

ARTIFICIAL INTELLIGENCE 16 PETplanet Insider Vol. 26 No. 05/25 www.petpla.net ARTIFICIAL INTELLIGENCE 16 How digitalisation and AI advance the plastics sector based on an article by Dr Cornelia Jokisch, K’ show PR The plastics industry faces major economic and regulatory disruptions worldwide. Rising competitive pressure, stricter environmental regulations and higher demands made on circularity increase the pressure to innovate. On-going digitalisation offers new opportunities for producing more efficiently and sustainably. Automated processes, data-based control systems and smart connectivity already ease adaptation to stricter requirements in many companies today. Artificial Intelligence (AI) is considered a key milestone in this. According to a Bitkom study, 78% of the industrial companies polled view AI as decisive for their competitiveness while more than half are waiting to see how others get on first. At the same time, 48% lack the necessary AI skills and 91% demand fewer regulatory obstacles so as not to hamper AI innovations. These figures underline that there is a broad consensus on the relevance of digitalisation but many firms are hesitant to implement it in practice. Digital key technologies: connectivity and IoT The digital control and connectivity of machines forms the basis for new technologies. Cyber-physical systems (CPS) and the Internet of Things (IoT) make it possible to capture and evaluate production data seamlessly in real time. Sensors monitor temperature, flow rate or inmould pressures, for example, and transmit the values to Cloud applications. An important communication standard for this is OPC UA, which makes for safe and cross-manufacturer data exchange. Rising data volumes lead to questions of data use. In the European Union, the so-called “EU Data Act” is one example of how this issue is being addressed. This new Data Act obliges machinery manufacturers to provide machine users with the data generated during operation in a simple and understandable, machine-readable way. At the same time, predictive maintenance moves into focus because real-time analyses can detect deviations early on and reduce unplanned downtimes. Artificial Intelligence and automation AI adds new dynamism to digital processes as self-learning algorithms analyse large data volumes and optimise processes flexibly. In addition, machine learning accelerates development cycles and improves [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 AI

ARTIFICIAL INTELLIGENCE 17 PETplanet Insider Vol. 26 No. 05/25 www.petpla.net ARTIFICIAL INTELLIGENCE 17 process control. Digital twins go even one step further: they depict real production lines virtually and deliver structured data on the complete machinery utilisation. Furthermore, they offer the possibility to save machine data and information in a structured and machinereadable format over the complete lifecycle. Digital twins are said to also comply with the requirements of the Digital Product Passport (DPP), which was introduced with the EU’s Ecodesign for Sustainable Products Regulation (ESPR) entering into force in July 2024. These virtual twins of real manufacturing plants accelerate development cycles and ease maintenance strategies. Optical quality control & AI-assisted sorting In the field of quality assurance camera systems and AI-based image processing support manufacturing processes. They detect shape deviations, surface defects or material impurities during production and ensure consistent quality levels. These technologies allow early defect detection thereby reducing rejects and ensuring a more efficient use of resources. In the wake of stricter environmental regulations and rising customer expectations the fitness of plastics for circularity is also moving centrestage. AI-assisted sorting systems with near-IR sensors (NIR) identify different plastic types, separate high-quality recyclates from impurities and improve the recycling quality. This increases reuse rates and contributes to compliance with regulatory requirements. What’s more, digital systems are closely linked with the DPP, which features comprehensive information about the used raw materials, production processes and recycling paths. These technologies support companies in establishing closed material cycles, reducing environmental burdens and complying with the ESPR. Challenges and skilled labour shortage Despite numerous flagship projects, progress is stalling in many companies, especially SMEs, due to a lack of investment. Another obstacle is the shortage of skilled staff. Those wanting to introduce automation, AI and IoT technologies require specialists for data analysis and IT security. This staff and skills shortage occasionally slows down implementation even though technical solutions already exist. AR (Augmented Reality) goggles can provide relief here by displaying maintenance instructions or training content right in the staff’s field of vision. This accelerates maintenance and onboarding processes without always having external experts on site. Summary & outlook Digitalisation proves to be a catalyst for a more sustainable and efficient plastics industry. Connected production systems make for real-time optimisation thereby reducing rejects rates and buffering market fluctuations more confidently. At the same time, new business models can be developed – in the form of digital platforms and maintenance services. www.k-online.com www.sacmi.com Product design Product development Product validation Industrial production plant Process & quality control On-site and start-up assistance After-sales and Customer service SACMI 4.0 THE COMPLETE CLOSURE, PREFORM AND CONTAINER SOLUTION FOR YOUR SMART FACTORY 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

ARTIFICIAL INTELLIGENCE 18 PETplanet Insider Vol. 26 No. 05/25 www.petpla.net How digitisation is driving sustainable packaging innovation Measure the shift based on an article by Reece Armstrong, CAE Graduate Engineer and Ross Blair, Head of Simulation at BMT As global sustainability goals accelerate the shift from virgin PET to 100% recycled content (rPET), companies in the packaging sector face increasing pressure to adapt - or risk severe consequences, from supply chain vulnerabilities to regulatory penalties and market irrelevance. In response, Blow Moulding Technologies (BMT) is adopting science-based strategies to navigate these demands. By combining advanced material modelling, digital simulations, and physical testing, the company helps businesses create packaging that is high-performing and more sustainable. This data-driven approach aims to reduce waste, lower carbon footprints, and minimise risk by empowering companies to make smart decisions before moving to production. BMT has implemented the ‘Measure, Digitise, Execute’ methodology. Where outdated trial-and-error methods once dominated, the company now integrates advanced finite element analysis (FEA) simulations with precise physical data to drive informed, confident decision-making. Rather than eliminating prototyping, BMT aims to enhance it by using smart, targeted validation to strengthen simulations. This is claimed to result in faster innovation cycles, reduced material waste, and designs that perform as intended the first time. The process begins with ‘Measure’, conducting rigorous physical testing to capture how processing history influences material behaviour. Next, BMT ‘Digitise’ this data, transforming physical test results into precise material models. The digitisation phase is where the gap between laboratory data and industrial application is bridged. Finally, ‘Execute’ - deploying these validated digital models to optimise designs through risk-free virtual prototyping before any physical production begins. This workflow delivers transformative results, says BMT. Development cycles are accelerated, material usage optimised to the gram, and waste reduction measured in tonnes. BMT begin by measuring what matters most - how materials behave under production-replicated conditions. Using advanced techniques like Digital Image Correlation (DIC) during Free Stretch Blow (FSB) testing and biaxial tensile methods, data is captured on how materials deform, how processing history impacts performance, and how variables such as temperature and strain rate influence behaviour. This extensive data set is then used to calibrate user-defined material models in the Abaqus simulation and analysis programme to bridge the gap between physical tests and virtual simulations. The result is a simulation that mirrors real-world material behaviour with up to 95% accuracy - a solid foundation for advanced forming and performance simulations that match reality. Simulation meets reality After gathering critical data to inform material models, the next step is validating that the simulations accurately predict the performance of the final product. This involves comparing the results of the forming and performance simulations against experimental data, ensuring that key attributes like mass distribution and structural integrity align with real-world conditions. For example, when evaluating a 500ml carbonated soft drinks (CSD) bottle (Figure 2), SBM simulations - based on the calibrated material models - have been compared with experimental data collected in BMT’s laboratory. Here, BMT performs bottle in-service test- (a) Strain evolution free stretch blow testing (FSB), obtained from digital image correlation (DIC) Figure 1: Calibration of a temperature and rate-dependent constitutive model for the stretch blow moulding (SBM) process AI (b) Calibration of a representative constituive model of rPET against FSB data

ARTIFICIAL INTELLIGENCE 19 PETplanet Insider Vol. 26 ing and rapid prototyping using 3D-printed moulds. Results show simulation results closely align with the experimental data, with deviations under 5%. This validation process also extends to key metrics like thickness distribution and top load performance, confirming that the simulations accurately represent the final product’s mass distribution and strength characteristics. A well-validated simulation boosts predictive accuracy, enabling lightweighting and optimised performance, says BMT. It reduces material waste, shortens development cycles, and delivers both environmental and commercial benefits, proving that sustainability and performance go hand in hand. Driving the future of sustainable packaging The adoption of digital simulations and data-driven methodologies is helping the packaging industry enhance efficiency and support sustainability goals. The shift from trial-and-error testing reduces material waste, streamlines production, and minimises carbon emissions, all while maintaining product performance. BMT’s ‘Measure, Digitise, Execute’ approach supports companies to make confident, data-backed transitions to rPET and other sustainable materials, reflecting a broader industry trend toward more environmentally conscious and technically robust packaging solutions. www.bmt-ni.com Experiment Simulation Top 7.3 g 7.2 g Panel 3.9 g 4.2 g Grip 5.1 g 5.1 g Base 4.4 g 4.3 g Total 20.7 g 20.8 g Top load 162 N 159 N Figure 2: Simulation vs. experimental data comparison

ARTIFICIAL INTELLIGENCE 20 PETplanet Insider Vol. 26 No. 05/25 www.petpla.net Sipa’s AI systems for PET packaging machinery The digital twin: a virtual reality In the dynamic landscape of PET packaging solutions efficiency, speed and precision are paramount. Sipa integrates artificial intelligence into its machines to improve overall performance, as well as connectivity technologies to build a robust and secure communication infrastructure. The digital twin project Another distinctive factor is the adoption of innovative design systems, including the use of the digital twin. There lies an immense potential of digital replication. Sipa has been using the digital twin process since 2018. Initially implemented for the design of the new SFL series of linear blow moulding machines, this virtual counterpart has evolved into an indispensable asset. The core task of Sipa’s digital twin is the ability to design and debug machine software even before the physical machine takes shape. This technology is claimed to allow moving beyond traditional sequential development, enabling parallel workflows to reduce lead times and accelerate the innovation cycle. The digital twin acts as a virtual laboratory, accurately predicting the behaviour of all machine mechanisms during the project phase. Its special software synchronises every digital component, mirroring the intricate interactions of a real machine. Design of a machine with the digital twin The physical machine and the control software are developed simultaneously. The digital twin is connected to the project software via the PLC for early troubleshooting. The complete machine movements are simulated and checked. This allows potential design and software errors to be recognised and rectified before the first physical part is manufactured. The realistic simulation environment allows for comprehensive testing and validation of machine functionalities under various operating conditions. The Automation Division The driving force behind Sipa’s digital twin technology and automation advancements is Sipa’s Automation Division. The company says that this diverse and specialised team is implementing the digital twin and spearheading numerous other new AI related projects, many of which have resulted in patent applications. These AI projects enhance both internal operations and customer support. Sipa is actively integrating AI-driven solutions to streamline processes and provide support. One example is EVA, an intelligent chatbot which empowers Sipa personnel and customers to effortlessly access critical information, including details on clients, articles, orders, offers, contracts, machine specifications, mould information, related documentation, and easily navigate IoT data. In addition to EVA, there is MAIA, an AI assistant for maintenance. MAIA is designed to provide quick and intuitive access to the comprehensive information contained in the machines’ user and maintenance manuals, simplifying troubleshooting and maintenance procedures. As a supplement Sipa introduced ARES, an AI resolution expert system which assists in the analysis and resolution of technical issues, providing efficient and effective support. The company’s approach to security has been recognised by an independent external rating agency, awarding an optimal status that ensures the performance and security of its networked solutions. Shaping the future of PET packaging with digital solutions The new Sipa machine generation, designed and tested with the power of the digital twin, will be showcased at this year’s drinktec trade fair in Munich and at the K’ Show in Düsseldorf, Germany. www.sipasolutions.com Sipa is actively integrating AI-driven solutions to streamline processes and provide support. AI

RkJQdWJsaXNoZXIy NTY0MjI=