No.10 2025 www.petpla.net D 51178; ISSN: 1438-9452 PETplanet is read in 162 countries Compressors 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 13 . 10 . 25 MATERIALS Page 28 EDITOUR Page 18 Page 10
GULFOOD MANUFACTURING NOV. 4 - 6 DUBA I DRINKTEC INDIA NOV. 1 3 - 1 5 MUMBA I PACK EXPO LAS VEGAS SEPT. 29 - OCT.1 LAS VEGAS MEET US AF COMPRESSORS ENERGY SOBRIETY The world leader of PET oil free piston compressors WWW.AFCOMPRESSORS .COM SALES@AFCOMPRESSORS .COM
No.10 2025 www.petpla.net D 51178; ISSN: 1438-9452 PETplanet is read in 162 countries Compressors 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 13 . 10 . 25 MATERIALS Page 28 EDITOUR Page 18 Page 10
edvanced.erema.com New product contains up to 100 % rPET. Turn your PET flakes into recycled pellets or turn them directly into preforms: EREMA bottle-to-bottle systems stand for uncompromising food contact compliance with all the advantages of unique SafeFlake technology. Rely on highly effective decontamination, high-performance filtration, safe handling and the highest energy efficiency. For the best quality end product. Consistent quality even if the input material changes. It’s how you keep driving the bottle cycle forward sustainably. Cost effective, safe and environmentally friendly. Edvanced Recycling – EREMA prime solutions for advanced recycling Experience our innovations and technologies live at the K trade fair Hall 9 | C09 + Outdoor Area FGCE 03
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. 10/25 www.petpla.net Drinktec has regained its position as the leading trade fair for the beverage industry. After a rather weak start following Covid in 2022, around 10% more exhibitors showed visitors their innovations. The number of visitors rose by 20% to just under 60,000. The raw material situation in the PET market was a key topic. The high price of recycled PET (rPET) compared to virgin PET is causing considerable uncertainty. Many bottlers now only use the prescribed minimum amount of rPET, as a voluntarily higher proportion make little commercial sense. It has also been reported that rPET plants have already been partially shut down. This development is seen as a backward step for the circular economy and raises questions about investment security in the recycling sector. The trade disputes and high tariffs imposed by the USA are also weighing on the industry. In particular, the punitive tariffs under the Trump administration are leading to noticeable uncertainty and a shift in the markets, as international supply chains and sales markets are losing stability. China appears to be benefiting from the uncertainty. This applies both to Chinese suppliers of machinery and systems, who are looking for replacement markets for the USA, and to Western system manufacturers, who see great potential in China. On our 2026 Editour through China, we will take a look at the market on site. Yours, Alexander Büchler Dear readers, Snapshots from drinktec 2025 - the PETplanet booth in action
PETcontents 4 PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 10/2025 EDITOUR CIRCULAR ECONOMY 10 Saving material on the floor is sustainable 12 Producing your own rPET is sustainable 14 Material savings from neck to base 16 Avient plans for sustainability MATERIALS / RECYCLING 18 Scientists transform plastic waste into efficient CO2 capture materials 20 Glass-like compact - Toly and Eastman introduce a cosmetics compact made from modified PET 21 Performance upgrade via magnesium - Additives for recycled plastics target consistency and quality improvements 22 PET recycling in India: Trends, challenges and opportunities - Technologies for B-to-B resin including chemical recycling & bio- chemical recycling PACKAGING / PALLETISING 26 Banderole instead of shrink film - Reduced engineering effort in PET packaging lines PREFORM PRODUCTION 27 Smart and flexible PET packaging systems - SIPA’s new XFORM 160 preform system & SFL Flex SBM machinery MARKET SURVEY 28 Suppliers of compressors MOULD MAKING 30 Preparation for 2030 PPWR regulation with rPET project - Plastisud develops thin-wall yogurt cup in bottle-grade rPET BOTTLE MAKING 31 Air recovery system supports sustainable process - SIAPI launches ARS 5.0 to halve air consumption in blow moulding EVENT REVIEW 32 drinktec 2025 review 33 Efficiency in plastic processing - Moretto processing solutions for both recycled and virgin materials 34 Compact, connected and automated - Krones launches Ingeniq complete line concept for PET bottling 36 Driving sustainability without compromising performance - Husky features 200 cavity HyPET 6e, PET caps and other new solutions 38 Lighter but stronger packaging via laser heating 40 More efficient material production - Piovan and Thermal Care present new solutions for high quality PET and rPET manufacturing 42 Advances in PET packaging promise lighter bottles and lower costs OUTER PLANET 54 Nordic Co-operation programme - Environment and climate evolving 2025–2030 BUYER’S GUIDE 48 Get listed! INSIDE TRACK 3 Editorial 4 Contents 6 News 44 Bottles for Home + Personal Care 45 Bottles for Beverage + Liquid Food 47 Patents MATERIALS Editour Page 10 Page 36 Page 42
L i ght revea l s t radi t i ona l Swi ss per fect i on. 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 yellow.agency O F P R E C I S I O N 70 YEARS
PETnews 6 NEWS PETplanet Insider Vol. 26 No. 10/25 www.petpla.net Natural Mineral Waters Europe and UNESDA launch DRS Playbook Natural Mineral Waters Europe (NMWE) and UNESDA Soft Drinks Europe launch the ‘DRS Playbook: Everything you need to know about developing, financing and operating Deposit Return Schemes’. This guide, commissioned by OLHC Consultants, is designed to support the implementation of effective Deposit Return Schemes (DRS) across Europe. With the Packaging and Packaging Waste Regulation (PPWR) recently approved and with more EU Member States in the process of considering, implementing or redesigning DRS, the Playbook is intended to provide a practical, experience-based guide to creating effective collection systems for the environment, consumers and the beverage industry. When designed and implemented well, DRS can significantly improve the quality and quantity of beverage packaging recycling. “There can be no one-size-fits-all for DRS. Every system will need to take into account the country’s specific context. But with this Playbook, we hope to provide the essential ingredients to build effective schemes. By working together and sharing key learnings and best practices, we can build solutions which will deliver circularity for beverage packaging across Europe”, said Patricia Fosselard, Secretary General of NMWE. Drawing on industry knowledge, real-world case studies and policy analysis, the DRS Playbook reflects years of engagement with DRS across Europe. Aligning closely with the PPWR, it provides detailed guidance on: How to design an efficient and consumer-friendly system. How to finance and ensure long-term sustainability. How to operate systems that guarantee high return rates and clean, closed-loop recycling. www.unesda.eu www.naturalmineralwaterseurope.org LNJ GreenPET and Sumitomo Corporation sign MoU for strategic collaboration in rPET sector LNJ GreenPET, a part of the LNJ Bhilwara Group, announced the signing of a Memorandum of Understanding (MoU) with Japan-based Sumitomo Corporation to establish a strategic collaboration in the rapidly growing rPET sector in India. The agreement outlines a multi-pronged framework for cooperation, encompassing commercial development, raw material procurement, marketing, and potential investment opportunities for the company’s upcoming rPET project in India. As part of the partnership, both companies intend to jointly conduct a comprehensive market study on the rPET landscape in India. The study will include market sizing, customer segmentation, technical assessments, supply chain benchmarking, and regulatory feasibility. These insights will serve as the foundation until LNJ GreenPET begins commercial production in 2026. To support the project during its pre-production phase, Sumitomo Corporation will facilitate interim sourcing of rPET flakes from Southeast Asia and other global regions. Additionally, the two companies will collaborate on pre-marketing activities, customer engagement, and the development of sales channels in both domestic and international markets. LNJ GreenPET, part of the LNJ Bhilwara Group, works in the plastics recycling sector with a focus on producing food-grade rPET. The company applies recycling technologies to support efforts in reducing plastic pollution and advancing circular economy practices in India. www.lnjbhilwara.com www.sumitomocorp.com TOMRA launches new eBook examining AI’s role in material recovery and sorting systems TOMRA Recycling has published its latest eBook, ‘AI in Recycling: Unlocking New Possibilities’. This comprehensive guide explores the rapidly evolving role of Artificial Intelligence (AI), particularly deep learning (DL), in revolutionising the global recycling industry and driving material circularity. The free-to-download eBook aims to demystify deep learning, explaining its mechanisms and showcasing its practical applications in overcoming complex sorting challenges, such as enabling the separation of previously hard-to-classify materials through the training of vast datasets. The eBook details how the synergy achieved by combining deep learning with traditional sensors in optical sorters is unlocking new opportunities for the recovery of valuable resources, enhancing material purity and creating new revenue streams. Readers will gain insights into the tangible benefits of DL-based solutions, including enhanced flexibility, the creation of new high-value material streams, superior sorting accuracy, advanced plant automation and optimised processes. Furthermore, it examines the crucial role of AI in meeting the demands of evolving regulations like the Packaging and Packaging Waste Regulation (PPWR). Looking ahead, the eBook presents a vision for the future where AI could drive fully transparent and self-optimised recycling plants. www.tomra.com
7 NEWS PETplanet Insider Vol. 26 No. 10/25 rPlanet Earth shutdown – a wake-up call for US recycling policy, APR states The US Association of Plastics Recyclers (APR) published a statement on the recent shutdown of Vernon-based PET recycler rPlanet Earth according to which the closure should serve as a wake-up call to policymakers in California and across the country. The organisation notes that rPlanet Earth represented around 4% of the nation’s rPET capacity, and that its vertically integrated operations supplied key product streams – including thermoform trays and PET bottle material – that are now under pressure. APR points out that, like many U.S. recyclers, rPlanet Earth faced weak demand for its products while competing with a surge of low-cost imported material and cheap, oversupplied vi rgin plast ic. According to the association, these market dynamics are driven by two factors: brands scaling back recycled content commitments in favour of virgin plastic, and brands sourcing imported rPET to meet U.S. recycled content requirements rather than purchasing from domestic recyclers. The association warns that this is pushing U.S. recyclers out of the market at a time when the country urgently needs more – not less – domestic capacity to support a circular economy. The Association of Plastic Recyclers warns that the recent closure reflects the broader chal lenges of plast ics recycling, drawing a comparison to Europe, where multiple plants have already shut down under similar conditions. The group cautions that without stronger policy measures, the U.S. risks facing the same trend, with consequences for jobs, investment, and recycling infrastructure. APR calls on policymakers to take decisive measures, including creating incentives for brands to use domestically sourced recycled content and requiring country-of-origin labelling. The Vernon, California, site of rPlanet Earth covered 300,000 square feet and included SQF-certified, food-grade packaging manufacturing as well as the company’s corporate headquarters. Conceived as the first fully integrated recycling and packaging operation of its kind, it was intended to close the loop for domestic recycling programs and streamline processing. www.plasticsrecycling.org 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. 10/25 www.petpla.net Growing beverage packaging market to hit $221.5 billion by 2032, report finds Global market research company Meticulous Research published a research report titled, ‘Beverage Packaging Market by Material Type (Plastic, Glass, Carton & Paperboard), Packaging Type (Bottles & Jars, Cans, Tetra Packs), Beverage Formulation, Beverage Type (Alcoholic Beverages and Non-alcoholic Beverages), and Geography – Global Forecast to 2032.’ According to this latest publication, the beverage packaging market is expected to reach $221.5 billion by 2032, at a CAGR of 4.9% from 2025-2032. The growth momentum in beverage packaging is primarily propelled by the increasing consumption of ready-to-drink (RTD) beverages, the study finds, including alcoholic and non-alcoholic variants. These products cater to fast-paced lifestyles favouring convenience, portability, and singleserve formats such as cans, PET bottles, tetra packs, and pouches. The growth of diverse retail channels, rising demand for health-focused beverages, and advances in fill-finish processes are driving demand for customised, efficient packaging, supporting a projected CAGR of 4.9 % through 2032, according to the market research company. Sustainability is driving beverage packaging innovation, with companies shifting from conventional plastics to biodegradable alternatives; recycling and circular economy principles are reshaping design through monomaterials or refillable containers, and wider use of aluminium, paper, and recycled plastics. Regional leaders in the market through 2032 Asia-Pacific stands out as the dominant region in the beverage packaging market over the next decade, expected to capture more than 39% market share in 2025. This dominance is largely due to rapid urbanisation, populat ion growth, and evolving consumer lifestyles that prioritise convenience and premium beverage options. North America and Europe continue to be significant markets, driven by mature retail infrastructures and strong commitments to sustainability regulations. www.meticulousresearch.com Plastics Recyclers Europe warns of recycling plant shutdown The European plastics recycling industry is “facing imminent collapse” due to a surge in cheap imports, shrinking demand for EU-made recyclates, rising economic pressures, and excessive red tape, according to industry organisation Plastics Recyclers Europe (PRE). In a recent warning, PRE said that by the end of 2025, Europe is expected to have lost nearly one million tonnes of recycling capacity compared with 2023. Between January and July 2025 alone, almost as much capacity disappeared as during the whole of 2024 – three times the level seen in 2023. The Netherlands, Germany, and the United Kingdom have been among the hardest-hit markets. The organisation described the trend as “proof of the damaging effects of the recession” on the sector, noting that for the first time in years, forecasts point to zero net growth. PRE warned this signals a critical slowdown in Europe’s transition toward a circular economy. To avoid further closures, the group is urging policymakers to act quickly by introducing trade and market defence mechanisms, ensuring consistent extended producer responsibility (EPR) rules across member states, and strictly enforcing certification and penalties for non-compliant materials. PRE also called for cheaper access to clean energy, streamlined permitting procedures, stronger customs controls, and investment incentives to restore competitiveness. According to PRE, without decisive action, Europe risks undoing a decade of environmental progress and jeopardising its climate targets. “The collapse of the European plastics recycling sector would cause irreversible damage to the environmental progress and innovation achieved over the past decade, jeopardising the achievement of the EU’s climate goals and its long-term competitiveness,” states the organisation. www.plasticsrecyclers.eu New IMARC report: Australia’s PET bottle market to reach USD487.8m by 2033 The Australian PET bottle market, valued at USD380 million in 2024, is projected to reach USD487.8 million by 2033, according to a new report from IMARC Group, ‘Australia PET Bottle Market Size, Share, Trends and Forecast by Capacity, Colour, Technology, Distribution Channel, End Use, and Region, 2025-2033’. This represents a compound annual growth rate of 2.8% between 2025 and 2033. The report identifies rising demand for bottled water and functional beverages, supported by health-conscious consumers and tourism, as a major driver of PET bottle consumption. Sustainability is another central theme, with regulatory initiatives such as Australia’s Packaging Covenant and container deposit schemes pushing beverage and FMCG companies toward recyclable and recycled PET. Technological advances in lightweighting, barrier properties and bio-based PET are also contributing to market growth, as are investments in smart packaging features such as QR-coded bottles for traceability and consumer engagement. The study provides forecasts by capacity, colour, technology, distribution channel, and end use, and highlights regional trends across the country. www.imarcgroup.com
9 NEWS PETplanet Insider Vol. 26 No. 10/25 www.petpla.net
EDITOUR PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 10 Saving material on the floor is sustainable Customer satisfaction is always the top priority for François Desfretier, Managing Director of PDG Plastiques. His customers don’t just come to PDG with standard enquiries - they also approach him with projects that other converters don’t really dare to tackle. PDG has built up a highly specialised machine park for this purpose. In addition to the 20 Netstal systems, there will also be one of the first Otto Systems units for preforms of large-volume containers with 16 cavities, a small 1Blow machine with two cavities for small batches with a new technology for moulding deep recessed grips in the containers. Also in use is a SIPA system for sparkling wine and wine bottles - to name just a few examples. But first things first: Editour Interview with PDG Plastiques // April 8, 2025 We met: François Desfretier, CEO PDG, Philippe Blonda, Business Development Material supply: complexity from the first step This is where the complexity of the process begins. Many preforms and bottles contain different proportions of rPET. This is mixed with new material in a mixing station (see image above) according to the desired proportion and then passed on to the dryer. François Desfretier, CEO of PDG, would like the industry to agree on fixed rPET percentages - for example 25%, 50% and 100% - and for the material to be supplied ready-mixed by the raw material manufacturer. In the long term, he sees chemical recycling as the solution, as it ensures less contamination and guarantees consistently high material quality. State-of-the-art logistics: round the clock versatility of AGVs Five AGVs (Automated Guided Vehicles) have been handling inhouse logistics since 2024. They move along fixed routes or with the help of modern navigation technologies such as laser scanners or SLAM (Simultaneous Localisation and Mapping). The AGVs can change their batteries independently and are therefore ready for use around the clock. Weight saving with large containers For the large 20 L containers, PDG is now reducing the material thickness in the base area. The new preform weighs just 372 g instead of the previous 485 g, i.e. almost 25% less. This technology takes material out of the base of the preform. The idea comes from ReduPET and CPS (Creative Packaging Solution): with the help of mint technology, after the preform has left the mould, the injection point is reshaped again in the post-cooling station using a deep-drawing process (see image below). Sponsors to date The classic preform cavity can be clearly seen in the open mould as well as the lighter head area - on the mandrels of the post-cooling - which is formed by minting thermoforming. F.l.t.r.: François Desfretier, CEO PDG, next to Philippe Blonda, Business Development in front of the mixing plant for virgin and rPET material by Alexander Büchler
PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 11 EDITOUR Sparkling wine and wine bottles made of PET: almost standard Compared to the innovations mentioned above, stretch blow moulding of champagne and wine bottles is almost standard. The PET bottle impresses with its stable shape and is equipped with barrier blockers to keep CO2 inside and oxygen out. A PET bottle weighs 560 g less than a glass bottle. The CO2 footprint has fallen by more than half to just under 1 kg of CO2 per bottle. In addition, lorries can now make full use of all pallet spaces with filled bottles - previously this was only possible for two thirds of the space due to the high weight of the glass. As many factual advantages as the PET bottle offers, the end consumer has so far been slow to accept it. “So far, the industry has been trying to convince traditional sparkling wine and wine buyers to switch to PET bottles,” says François Desfretier. “I think producers need to appeal to environmentally conscious target groups - with innovative marketing and perhaps also new products such as non-alcoholic variants or mixed drinks.” Innovation also outside the beverage sector It is not only in the beverage segment that PDG is showering the industry with material- and CO2-saving technologies. A new PET ketchup bottle will soon be launched on the market. It is 20% lighter than conventional polyolefin bottles and offers a 40 times better oxygen barrier. As a special highlight: the end consumer can see the product. www.pdg-plastiques.com For large containers, PDG is reducing the material thickness in the base area via MINT-TEC technology.
EDITOUR PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 12 Producing your own rPET is sustainable SGT is one of the few preform manufacturers that produce their own rPET. Around 1 billion bottles produce 30,000 t of rPET. Over 40% of all preforms at SGT leave the factory with rPET content. The in-house production of rPET means that transport routes are very short. Lorries are not required. Interview with SGT // April 10, 2025 We met: Romain Claerebout, Plant Manager SGT Group, manufacturer of PET preforms and food-grade rPET based in Rezé, Loire-Atlantique, France, initially started in 1981 with PVC packaging. Today, SGT France operates with modern laboratories and 27 injection moulding presses at the 27,000m² plant in Rezé as well as an additional 29 injection moulding machines at four locations in Algeria. The company produces around 7 billion PET preforms in France and Algeria every year, as well as caps in Algeria. Turnover in 2024 was 400 million euros. The SGT Group acquired Axium Packaging at the beginning of this year. Axium produces injection- and blow moulding bottles, jars, and caps. With six entities and 385 employees, the company achieved a turnover of €76 million in 2024. Axium serves primarily cosmetics, health and wellness markets. The recycling division is called SGR (Société Générale de Recyclage). 30,000t of recycled PET (rPET) are produced under the SGR umbrella, 14,000t of which at a plant in Chalonsur-Saône, France, in 2018 and 16,000t at the headquarters since last year. In Chalon-sur-Saône, an SSP decontamination line from Bühler Polymetrix is used for food-grade rPET with underwater machining. For the new plant in Rezé, SGT did not opt for the solid (SSP) process, but ventured in the direction of the liquid process (LSP). (Fig. 2) In SSP - Solid State Polycondensation - the PET is treated after melt polymerisation as pellets under vacuum or inert gas (nitrogen) at high temperatures (180-220 °C). This increases the IV (intrinsic viscosity). Very high IV values can be achieved with this process and you have good control over the final viscosity. In LSP - Liquid State Polycondensation - polycondensation takes place directly in the melt (before granulation), often inline in the reactor stream. The process achieves target IV without a separate solid phase process. The process is more energy-efficient as no second heating step is necessary, production times are significantly shorter and it has a smaller footprint. On the other hand, the IV can only be increased to a limited extent and the process control requirements are higher. NGR’s LSP plant in Rezé started production in 2024. To guarantee the high quality of the rPET, all flakes Sponsors to date Plant Manager Romain Claerebout shows us the clean rPET granulate Editour
PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 13 Editour first go through a sieving process in which large flakes and fine particles are sorted out. This is followed by metal detection for ferrous and non-ferrous metals. It follows in the third quarter. The second step is the removal of coloured and opaque flakes. In the final step, Unisensor uses laser spectroscopy to remove PVC, PC and other non-PET elements. The PET flakes are then thermally melted and pumped through a special vacuum process with continuous deep condensation. This significantly increases the intrinsic viscosity (IV) - around 0.01 dl/g per minute - which enables continuous process control. During this melting process, impurities (including NIAS, bisphenol A, and spin oils) are efficiently removed - at a level that complies with the strict EFSA and FDA approvals. This is followed by pellet crystallisation and final cleaning (acetaldehyde removal). The material is then stored and, if necessary, mixed with new material in a mixing plant. (Fig. 3) www.sgt-pet.com Fig.2: View into the material cooler of the new LSP system for rPET Fig. 3: The mixing system for vPET and rPET is at least as complex as the LSP system
EDITOUR PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 14 Material savings from neck to base by Alexander Büchler The injection moulding process requires a hot/liquid core as the plastic part cools in the mould until it solidifies completely. Otherwise, the material that has already been injected would shrink due to cooling and sink marks would be visible. The preform developer must therefore ensure that - starting from the injection point to the last point at the top of the neck - the flow paths become continuously thinner so that the preform can solidify backwards from the neck and the shrinkage is compensated via the hot core. Editour Interview with ReduPET // June 16, 2025 We met: Stefan Bock, CEO In the stretch blow moulding process, however, one doesn’t need this kind of material distribution, here an optimum (weight-saving) material distribution would be as follows: a stable neck area, thin walls and an even thinner preform base. If you were to inject the preform the other way round (from the neck area to the base), the material distribution in the preform would come pretty close to the requirements of stretch blow moulding. I have not yet seen a corresponding mould. With its preform compression moulding XTREME, SIPA is the only company to optimise material distribution in the preform for the stretch blow moulding process. This is not possible in conventional injection moulding due to the hot core required by the system as described above. ReduPET has taken up the challenge and continues to mould the floor area in the aftercooling station to the outside. This distributes the material better and makes the floor area much thinner. As the process takes place outside the mould, the technology has no influence on the cycle time. This is of course particularly impressive with 20L canisters (see PDG article on page 10) where 25% material could be saved from 485g to 370g. The owners of the patents ReduPET and CPS (Creative Packaging Solution) intervenes more in the preform geometry with their Neck-Lite technology. The initial consideration is the same: the preform needs its hot core right up to the tip. In addition to the unnecessary accumulation of material in the floor area, there is also an unnecessary accumulation of material on the neck between the shoulder and the neck ring. The wall thickness there is necessary to completely fill out the neck finish. The idea now is that the necessary wall thickness is only at least minimum five positions around the neck, sufficiently to have the hot core up to the tip and to remove material in between. Visually, the neck now looks as if it has bars. The stretch blow-moulding machine manufacturers have reservations as to whether the “bars” - which now lie exactly in the preform and bottle holders - will not interfere with the high-speed systems. Mohamad Rias from Oman is using the new geometry from SIPA and Krones systems for the first time. The new neck geometry could be driven at the same speed without changing the holders. The water preform’s weight could be reduced by 0.15 g per preform using Neck-Lite. That results in a savings of 75 t/a of PET for 500 million preforms. www.redupet.swiss Sponsors to date The picture clearly shows the bars in the Neck-Lite geometry on the preform neck. Neck and base of most bottles on supermarket shelves are still showing an obvious optimisation potential of up to 8%. Neck-Lite acts directly in the mould and has no influence on the system. An especially developed geometry below the transport ring allows thinnest wall sections while the thread is fully formed.
PETplanet Insider Vol. 26 No. 06/25 www.petpla.net 15 EDITOUR vbr-voѲࢼomvĸ1ol SFL v_b[v |_; 0om7-ub;v bm |_; ;oѲࢼom o= Ѳbm;-u 0ѲoloѲ7bm]Ķ o@;ubm] l-bll Y;b0bѲb| 1ol0bm;7 b|_ bm1u;-v;7 o|r|. 1omvoѲb7-|;7 |;1_moѲo] b|_ |_; Ѳo;v| |o|-Ѳ 1ov| o= om;uv_br Ŏ$ ŏ om |_; l-uh;|Ķ 7;vb]m;7 |o or;u-|; b|_ Ǝ |o Ѵ 0Ѳobm] 1-bࢼ;v -m7 |o u;-1_ - l-bll ruo71ࢼb| o= ƏĶƍƍƍ 0oѲ;vń_ouń1-b|Ķ b|_ |_; Ѳo;v| ;;u ;m;u] 1omvlrࢼomĸ $_; u;=;u;m1; =ou |_; $ r-1h-]bm] l-uh;|Ķ ml-|1_;7 bm |_; bm7v|uĶ v_ov ml;uov |;1_moѲo]b1-Ѳ 7;;Ѳorl;m|v bm |;ulv o= vr;;7Ķ t-Ѳb|Ķ ;uv-ࢼѲb|Ķ 1-r-1b|Ķ ;m;u] ;L1b;m1 -m7 o;u-ѲѲ vv|-bm-0bѲb|ĸ | bm1ourou-|;v _b]_Ѳ bmmo-ࢼ; 7b]b|-Ѳ voѲࢼomv |o C| bm |_; lov| bvbom-u "l-u| -1|ouĸ ѲѲ |_;v; mbt; =;-|u;vĶ |o];|_;u b|_ |_; Ѳo l-bm|;m-m1; 1ov|vĶ l-h; " |uѲ - ļ0;v| bm 1Ѳ-vvĽ -lom] Ѳbm;-u vv|;lv. FLEXIBLE packaging and extreme stretching capabilities SUPERIOR productivity & performance EASY to use and to maintain ECO energy saving & sustainability focused TCO SAFE & CLEAN no hydraulics, operator and food safety LINEAR BLOWMOULDER: SIMPLY THE BEST IN CLASS.
EDITOUR PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 16 Avient plans for sustainability Our Editor-at-Large, Ruari McCallion, visited Avient’s facility in Knowsley, Liverpool, England, where he met with Marco Schaefer, Senior Marketing Manager; Adam Parsons, Site Manager; and Adrian Carmichael, R&D Director, and had a tour of the site. Editour Interview with Avient // June 11, 2025 We met: Marco Schaefer, Senior Marketing Manager; Adam Parsons, Site Manager; and Adrian Carmichael, R&D Director Avient Corporation, based in Avon Lake, Ohio, USA, operates over 100 production sites across 35 countries and employs approximately 9,400 people. The company provides advanced material solutions to a wide range of industries, including packaging, healthcare, transportation, construction, consumer goods, and telecommunications. One of Avient’s key facilities is located in Knowsley, near Liverpool, England. This site serves as the company’s primary production hub for colour and additive solutions tailored to the PET bottle industry and also houses Avient’s global R&D centre for PET packaging. The facility spans four buildings within an industrial estate, strategically positioned near major transport routes and Liverpool docks. “Avient has over 35,000 solutions in its portfolio, due to a high number of custom colour formulations but it also includes a wide variety of additives for various industries. These products could be based on a liquid or a solid carrier system. Plastic packaging is one of the most important markets for us,” said Marco Schaefer, Senior Marketing Manager. As a supplier to the packaging industry, Avient is also an enabler of recycling and circularity “Avient’s solutions aim to contribute to sustainability through lightweighting, reducing energy consumption and cutting VOCs (volatile organic compounds). We offer solutions for virgin plastics as well as post-consumer recyclate (PCR).” State of the art production facility for liquid masterbatches Adam Parsons, Site Manager, took the lead for a tour of the production lines. “The mixing process is a lot like making a cake. You have your wet ingredients and your dry ingredients and the trick is to blend them properly,” Adam Parsons said. “Maintaining a vortex during mixing is very important. We fill units in volumes from 15 to 1,100 kilograms.” “The base production line handles small batch production, of up to 250 kilos. Small batches are mixed in a way quite like a paint mixing machine,” he said. Inspection is ongoing. “Any deviation from customer specifications is fixed, in-house, before despatch to customers. We retain small samples for three years.” Filled drums are handled by machinery designed to reduce the need for manual handling, which pretty much eliminates strain-related workplace injuries. Sustainability After the tour of the production floor, the group reconvened in the conference room and covered Avient’s drive to deliver sustainability. Avient is rated with a Silver Medal by EcoVadis, a score that puts it in the top 15% of companies, and has a CDP Climate Score of A minus. Its annual Sustainability Report, which runs to 67 pages and reports via the GRI, TCFD and SASB frameworks, goes into detail about the action it is taking across all its operations. “We are committed to reduce our greenhouse gases (GHG) by 55% by 2030; and we reached a 52% reduction in scope 1 and 2 emissions in 2024 already,” said Mr Schaefer. “We are permanently working on internal sustainability projects, focused on waste reduction and energy efficiency and include energy-efficient motors, air compressors, forklifts and lighting.” On-site solar power and/or wind installations; purchasing sustainable energy; and investing in virtual power agreements have increased renewable electricity levels to over 50%. It is committed to reduce waste to landfill by three per cent a year, which may not sound much but is a tough target, as Avient doesn’t send much to landfill in the first place. Its efforts extend to the supply chain, also. “We assess our suppliers using the EcoVadis platform. Our goal is to assess 90% of our suppliers by 2030; we reached 75% in 2024,” he continued. Avient recovers heat from its closed-loop water cooling for reuse used in building heating. New extrusion lines are equipped with nextgeneration motors and heating lines optimised to reduce energy use. Manufacturing software dynamically measures process data, which is used to improve efficiencies. Avient is also an active member of PETCORE, RecyClass, and APR and is driving circularity by improving the mechanical recycling process through additive and colour innovation. Regulatory challenges “EU regulations impose an extra burden on companies doing business in Europe but, if the rules are applied equally to companies producing in Europe and those importing into Europe, it would create a level playing field,” Mr Schaefer said. “Stricter regulations, such as PPWR, including limitations on using non-PFAS chem- Sponsors to date by Ruari McCallion
PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 17 EDITOUR istry, will require innovation and also opens opportunities to grow with more sustainable solutions.” However, Europe’s recycling capabilities are a concern especially when it comes to the availability of food grade PCR outside of PET. Food grade PCR’s based on polyolefins and polystyrene are not widely available yet and it will mean a big effort for the industry in the next years to reach the mandatory PCR addition rates in 2030. “Complying with EU 2050 net-zero targets would mean switching significant volumes from virgin to recycled or bio-based plastics, which could increase costs and it also requires a transformation of the industry.” R&D to drive better products Adrian Carmichael, R&D Director, led the tour of the PET R&D Centre, which is engaged in several projects covering material efficiency and improved sustainability. “We are working on gas barrier performance, to improve content protection and reduce food spoilage, e.g. with our Avient Amosorb oxygen scavenging portfolio for PET packaging,” he said. Light barrier products include the familiar ColorMatrix Lactra and Ultimate which provide visible and UV light protection. “The aims include using less colour to achieve the desired effect and, in the case of multilayer PET bottles, delivering higher performance with less and making more use of recyclable materials.” Multilayer packaging is often difficult to deal with in the recycling stream, as it is often composed of different polymers and materials. The effort going into this research was evident in a lot of new equipment, including a multilayer PET preform production pilot line, as well as a range of analytical equipment that allows detailed analysis of rPET and new products coming from Avient’s innovation pipeline. This is especially of interest in order to identify nonintentionally added substances (NIAS) that are part of the current recycling streams or might be also created during further processing of PET along with different additives. With the tour concluded, we reconvened for an informal closing discussion and confirmation of technical matters, prior to going our separate ways – Mr Schaefer to Frankfurt, Germany, and our Editor-at-Large to Salisbury, England. www.avient.com abc-compressors.com Mixing vats on the production floor
MATERIALS / RECYCLING PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 18 Scientists transform plastic waste into efficient CO2 capture materials The researcher team at the University of Copenhagen has developed a method in which decomposed PET plastic becomes the main ingredient in efficient and sustainable CO2 capture. It turns “one man’s trash into another man’s treasure”, they say, and go on to claim that their solution simultaneously addresses two of the world’s biggest challenges – plastic pollution and the climate crisis. These key global problems are often interconnected and, typically, the solution to one problem creates another one while the clock keeps ticking. PET plastic is one of the most widely used types of plastic in the world but, when it has served its purpose, it becomes a pressing global environmental issue. In many parts of the world it ends up in landfills, where it breaks down into polluting microplastics that spread to the air, soil and groundwater and a large proportion also end up in the oceans. “By turning waste into a raw material that can actively reduce greenhouse gases, we make an environmental issue part of the solution to the climate crisis,” says Margarita Poderyte from the Department of Chemistry at the University of Copenhagen, lead author of the research paper disclosing the invention. The solution is a potential winwin on a global scale, where plastic waste not only does not end up in nature but also becomes an active player in climate mitigation. BAETA: development and deployment The new chemical technology enables PET plastic waste to be transformed into a primary resource, a new form of CO2 sorbent they have developed. The process ‘upcycles’ the waste to a new material named BAETA, which can absorb CO2 out of the atmosphere so efficiently that it easily compares with existing carbon capture technologies. Over 60 per cent of PET (by weight) is carbon, which has an inherent chemical and physical ability to maintain the structure. This ability is enhanced by transforming the plastic by adding a quantity of ethylenediamine, a compound known for its ability to bind CO2. The newly-developed Copenhagen University process breaks down the plastic from polymer to a monomer, giving the material, which the team has named BAETA, a chemical composition that is claimed to be effective in pulling CO2 out of the air and binding it. The BAETA material has a powdery structure that can be pelletised, and a chemically ‘upgraded’ surface, which enables it to effectively bind and chemically capture CO2. Once saturated, CO2 can be released through a heating process allowing the CO2 to be concentrated, collected and stored or converted into a sustainable resource. Sustainable, flexible and scalable In industrial plants, exhaust gases can be transmitted through BAETA units, which will cleanse them of CO2. When the BAETA material is saturated, its efficiency decreases; however, CO2 can be released from the plastic through a heating process, restoring its efficiency. MATERIALS Fig. 1: Margarita Poderyte Margarita Poderyte, lead author of the research paper (photo: Max Emil Madsen)
MATERIALS / RECYCLING PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 19 The carbon released can then be stored underground or used in, for example, Power2X plants, which convert electrons into another product of value. “The main ingredient is plastic waste that would otherwise have an unsustainable afterlife, and the synthesis we use, where the chemical transformation takes place, is gentler than other materials for CO2 capture because we can make the synthesis in ambient temperatures. It also has the advantage that the technology can be scaled up more easily,” Margarita Poderyte says. No conflict with recycling During the development process, the researchers encountered concerns that their technology could undermine efforts to recycle plastic, which has been heavily invested in. That is not the case: it is complementary to recycling, not a competitor. “In principle, we could use new plastic for our method, but our target is PET plastic that is difficult to recycle because of low quality, colouration or mixed sources – or that has decomposed to such a degree that it’s no longer suitable for recycling,” Margarita Poderyte says. Co-author and Associate Professor at the Department of Chemistry, Jiwoong Lee, highlights the material’s flexibility. “One of the impressive things about this material is that it stays effective for a long time. And flexible. It works efficiently from normal room temperature up to about 150 degrees Celsius. With this kind of tolerance to high temperatures, the material can be used at the end of industrial plants where the exhausts are typically hot,” Jiwoong Lee says. From laboratory to innovation at the end of the chimney With a potentially revolutionary idea, a proven method and an effective finished product, the researchers are now ready for the next step. “We see great potential for this material, not just in the lab, but in reallife industrial carbon capture plants. The next big step is scaling up to produce the material in tonnes, and we’re already working to attract investments and make our invention a financially sustainable business venture,” Margarita Poderyte says. The technical challenges do not worry the researchers. Instead, the decisive challenge, they say, is to persuade decision-makers to make the necessary investments. If they succeed in that, the invention could ultimately lead to significant changes. Economic incentive to cleanse the oceans The PET plastic that has been accumulating in the oceans, damaging ecosystems and breaking down into microplastics, is very well suited for the technology. “If we can get our hands on the highly decomposed PET plastic floating in the world’s oceans, it will be a valuable resource for us as it’s so well suited for upcycling with our method,” Margarita Poderyte says. “We’re not talking about stand-alone issues, nor will the solutions be. Our material can create a very concrete economic incentive to cleanse the oceans of plastic,” Jiwoong Lee says. The research paper is published in Science Advances journal, which describes the chemical process behind the invention. The process is claimed to be gentle compared to existing technologies and, at the same time, well-suited for industrial scaling. https://chem.ku.dk/news/2025/ scientists-transform-plastic-wasteinto-effi cient-co2-capture-materials/ DNC boosters Turnkey all-in-one system • Compact powerhouse with a footprint of only 2.35 m² ,QLWLDO SUHVVXUH XS WR EDU ² ÀQDO SUHVVXUH XS WR EDU • Plug and play: ready for immediate operation 3UHPLXP HˣFLHQF\ ,( PRWRU GHOLYHUV LPSUHVVLYH SHUIRUPDQFH DQG HQHUJ\ VDYLQJV • Sigma Control 2 controller: RSWLPXP HˣFLHQF\ DQG QHWZRUN FDSDELOLW\ ,QGXVWULH www.kaeser.com
MATERIALS / RECYCLING PETplanet Insider Vol. 26 No. 10/25 www.petpla.net 20 Toly and Eastman introduce a cosmetics compact made from modifi ed PET Glass-like compact Toly and Eastman have developed Gemini, a cosmetics compact produced with a new co-polyester from Eastman. The material combines recycled content with compatibility in existing PET recycling streams, offering a sustainable option for thick-wall compact packaging. Gemini is the first compact to be manufactured with the co-polyester Cristal One Renew IM812. The resin is claimed to provide the transparency and gloss required for premium designs while incorporating certified recycled content through molecular recycling. According to Toly, the use of Eastman’s new material enables brands to meet increasingly strict sustainability requirements while maintaining the aesthetics and tactile qualities expected in the cosmetics sector. Olaf Zahra, chief technical and sustainability officer at Toly, described the project as part of a broader effort to reconcile design and environmental responsibility. “Our partnership with Eastman on the Gemini compact represents a shared vision for the future of beauty packaging, one that balances luxury with responsibility,” he said. “By utilising Cristal One Renew IM812, we are able to offer our clients packaging solutions that empower brands to meet stringent sustainability goals while delivering the high-end aesthetics and tactile experience consumers expect.” Cristal One Renew IM812 has been developed to offer glass-like clarity for thick-wall PET cases, allowing for transparent and glossy surfaces without the need for alternative plastics. The resin can contain up to 100 per cent certified recycled content, allocated through the ISCC mass balance system, and is claimed to be fully compatible with established PET recycling streams. Certifications from EPBP, APR and RecyClass confirm its recyclability within existing infrastructures. For Eastman, the collaboration with Toly represents the first application of Cristal One Renew IM812 in compact packaging. Tara Cary, global cosmetics market manager at Eastman, said the development illustrates how materials innovation can support regulatory preparedness in the industry. “This innovative solution ensures that packaging not only meets today’s standards but is also ready for the legislative demands of tomorrow,” she noted. The Gemini compact was presented by Toly and Eastman at the Luxe Pack Monaco trade show. www.toly.com www.eastman.com MATERIALS
MATERIALS / RECYCLING PETplanet Insider Vol. 25 No. 10/24 www.petpla.net 21 product development caps & closures design high cavitation moulds multi-component moulds closure production systems after sales service +43 5572 7272-0 | [email protected] | www.z-moulds.com z NEXT SHOWS K-SHOW Dusseldorf Oct 8-15 | Booth H10-G32 GULFOOD MANUFACT. Dubai Nov 4-6 | Booth S2-A10 INSPIRING PARTNER FIND OUT MORE ABOUT THE PET CAP REVOLUTION DURING THE UPCOMING SHOWS Additives for recycled plastics target consistency and quality improvements Performance upgrade via magnesium Kisuma Chemicals, a supplier of magnesium-based additives, has introduced a range of solutions for compounders and converters of recycled plastics. These include individual additives and synergistic blends designed to enhance product performance and consistency. Reported benefits include odour reduction, melt flow index retention, colour and yellowing index retention, and gel reduction. “As part of a major initiative to expand our portfolio, we are working closely with our customers to help them unlock the full potential of recycled plastics,” says Zachary Hoffman, Business Development Lead Europe, Middle East & Africa for Kisuma. “Beyond a diversified suite of magnesium-based additives already available for this market, we are actively developing the next generation of these unique products, including tailor made solutions with functionalities engineered to boost the performance, efficiency and sustainability of recycled plastics or retain virgin-like properties. By enhancing colour, reducing odour, improving melt flow and minimising gels, we can achieve consistent, high-quality outcomes together and accelerate the shift towards a more sustainable plastics value chain.” Kisuma’s magnesium-based additives for recycled plastics are designed to align with the European Union’s ambitious directives for increasing the recycled content in many industries, such as packaging (PPWR), automotive (ELV), and building & construction. With a focus on carbon neutrality and supported by the non-toxic HSE profile of these products, the company aims to help customers reduce their carbon footprint and phase out additives that risk future regulation worldwide. Visitors to K show 2025 can explore Kisuma’s magnesium-based additive solutions at the company’s booth H31 in Hall 8B. www.kisuma.com MATERIALS Kisuma Chemicals presents a suite of magnesium-based additive solutions for compounders and converters of recycled plastics. The products are aimed at improving colour stability, reducing odour, maintaining melt flow, and minimising gels. (Photo: Kisuma Chemicals)
RkJQdWJsaXNoZXIy NTY0MjI=