Filling
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20 years of stretch-blowing and filler technology in PETplanet Insider
Dear friends of PETplanet,
I would like to give you my subjective summary of the last 20 years of two-stage SBM and filling. I’ve been working on this for a long time because my thoughts have digressed so many times. The many people we have got to know throughout our 20-year journey, the interviews, the site visits, the travelling. For me, it’s been 20 years full of emotions. In this overview, I have tried to sketch out the history of the main protagonists, the companies and the technology. Corpoplast has always been a tower of strength. Sold many times (Krupp, SIG, KHS) and even more frequently trying to integrate, the company has continually developed and under today’s KHS umbrella, it is enjoying what may be its golden era. Which brings us to the just as chequered history of KHS. A continually changing CEO - I won’t bore you with all their names - bankruptcy of the parent company WCM and now finally, structured expansion under Salzgitter. Things were not always so changeable at KHS and this was shown in our interview in 2010 with Maternus Gemmel, who retired as CSO after 48 years in the company.
Two further old hands that must get a mention here are Gianfranco Zoppas, owner of Sipa and, of course, Volker Kronseder of Krones. Both have promoted and supported the development of PET drinks technology with clear vision. Over 20 years ago, Volker Kronseder recognised that stretch blowing belonged in filling and he has continually driven forward his own Contiform development. The first facilities may have raised a smile but today they are among the market leaders. Gianfranco Zoppas is a technological visionary. Regardless of what had gone before, he has always addressed the question of what the market needs.
In Top Talk Filling Special 2005, he was still convinced that single-stage was the right way to go but in a 2018 interview, he reinforced the 2- stage procedure. But what does he have in mind? The blocked Xtreme from granulate to finished bottle all at one heat. But isn’t that the signature feature of the 1-stage process? So Zoppas statement in 2005 has proven to be well-founded, although in quite a different way than first thought.
Enjoy the overview. Perhaps you’ll be mentioned somewhere too.
Yours
Alexander Büchler
| Year | Acquisitions | Market and technical data | Sipa | SIG Corpoplast from 2008 KHS Corpoplast | Krones | Sidel | Tech-Long Packaging Machinery |
|---|---|---|---|---|---|---|---|
| 1999 | Introduction of rotary SBM | ||||||
| 2000 | SIG takes over Krupp Kunststofftechnik and therefore also Corpoplast | SIG Plastics reports that the world market for 2-stage stretchblowing facilities is 1,590 units, for single-stage facilities 1,355 units and 1,150 preform facilities. In their view, in 2005, 17% of investment was in other drinks, 9% in oil and soya, 7% each in water and hotfill, and 4.4% in CSD. | Introduction of the SBM Series III | ||||
| 2001 | SFR rotary SBM, up to 1,750 b/h per cavity | Top Talk with Roman Boutellier, CEO SIG: He reports on the purchasing of various elements from Germany, Italy and Switzerland. Corpoplast (stretch-blowing, Germany) and SASIB (filler, Italy) should free SIG from dependence on drinks cartons | Top Talk with Volker Kronseder, CEO of Krones. Presentation of Contiform S 2nd generation with suspended preform heating. 1,600 b/h per cavity. Presentation of Contiform Bloc SBM filler block | Top Talk: Francis Olivier, CEO Sidel. At that time, Sidel had 2,800 machines on the market | |||
| 2002 | Packaging strategies reports over 2,125 million barrier bottles in 2001. Of these, 60% multilayer and 40% coated | The first electronic filler Unitronic | Introduction of Plasmax interior coating | Top Talk with Gerard Stricher, new CEO of Sidel. Sidel is taken over by Tetrapack | |||
| 2003 | The EU Commission approves the purchase of Sidel by Tetra Laval Group. KHS takes over All-Fill | Canadean reports that the market share of PET in water packaging has risen from just over 40% in 1997 to 70% that year. The loser is the PVC bottle, which has fallen from 15% to 0% | Contiform H: first heat-set SBM | ||||
| 2004 | SIG Blowtec launched 2nd generation ISBMs, in the same breath, SIG announces sale of Blowtec | Top Talk Fabio Firmani, CEO Sipa: “We are the only provider that delivers the entire process chain from preform to pallet”. Triple cavity blow moulder SFR 9/27 | Top Talk: Rolf-Dieter Rademacher, CEO SIG Holding reinforces the concept with acquisition subsidiaries Corpoplast and Simonazzi as the direction for SIG in the PET world. SBM Blomax 24 Series III C with up to 1,800 b/h per cavity; KHS: launched third generation aseptic cold filling; cleanroom shrinks by 80% | Top Talk Christoph Klenk, Krones. “We need facilities for the high-end market and also for the low-spec market.” Contiform S increases to 1,800 b/h per cavity | |||
| 2005 | SIG sells Simonazzi to Tetra Laval. KHS takes over majority at India production site | Canadean reports that 40% of packaged drinks globally are in PET | Top Talk Gianfranco Zoppas, Owner Sipa:" I believe the best solution is single stage". SFL linear SBM were redesigned (SFL 4 and 6) | TopTalk Olaf Weiland, CEO SIG Corpoplast: he reports on the 1,000th SBM, SIG Corpoplast appears independently for the first time at Interpack, Top Talk Ralf Bajorat, Head of SIG Beverage; KHS presents plastics-only filler | SBM Contiform creates OPP bottles at the same speed as PET bottles; Krones F1 filler table-free filler only for PET | SBO Universal. 3rd generation SBM 1,800 b/h per cavity. SBO first linear blower | |
| 2006 | WCM as owner of the Klöckner factories is insolvent. KHS is later taken over by Salzgitter | SIG reports that 60% of bottle costs are raw materials, 13% preform production and only 7% investment in SBM | The first volumetric isobaric filler | Top Talk: Rolf-Dieter Rademacher, CEO SIG: Sales increase, erosion of margins stops. KHS Till and Carlsberg launch the PET keg | Krones reports a rapid rise in orders for blocked facilities | Top Talk with Gerard Stricher, CEO of Sidel, about merger of Simonazzi and Sidel. Sale of 100th SBO Universal: Publisher Alexander Büchler, together with Subba Bangera, plants his second tree in India on the Sidel factory site | |
| 2007 | GEA takes over Procomac. Simonazzi fillers are now only sold under the name Sidel | Canadean reports that almost 60% of all packaged water globally is in PET | Redesign of the SFR EVO, now up to 2,000 b/h per cavity | Introduction of InnoPET BloFill, the first SBM filler block | Sidel sells 20 water lines at 36,000 b/h to Ting Hsin, China | ||
| 2008 | Salzgitter takes over KHS and SIG Beverages with Corpoplast. Brings everything together under the KHS umbrella. So KHS becomes a complete facility provider | The lightweight 0.5 l bottle is here: Krones 8.85 g, Sipa 10.9 g, Sidel 9.9 g | The first Sincro Bloc | KHS expands capacities for Corpoplast in Hamburg. So Anker goes to India, Allfill to Bad Kreuznach | Top Talk Marcel Krauth, "Mr. Beer" by Sidel: “Beer is the largest packaging market worldwide after water; PET has a good starting point to gain a significant market share there.” | ||
| 2009 | Kosme, provider of facilities in the low-spec range, is taken over 100% by Krones | Sincro Tribloc: SBM filler and labelling | Introduction of InnoPET Blomax Series IV | Contiform S with 2,000 b/h per cavity. Sale of 1,000th Contiform. Presentation of ErgoBloc L SBM with filler and labeller | Sale of 500th SBM | ||
| 2010 | Departure of Maternus Gemmel, CSO KHS, after 48 years in the company: “The takeover by Salzgitter was a sign for us” | SBO Universal 2 2,000 b/h per cavity | |||||
| 2011 | For 2015, Pira International envisages 7.7 billion PET beer bottles, of which around 50% without barriers, 1/4 multilayer, 10% coated, the rest with monolayer blends | Sale of 100th InnoPET Blomax Series IV. Presentation of the dual concept aseptic filler Innosept Asbofill | Contiform 3. Third generation, now with 2,250 b/h per cavity. Introduction of PET-Asept D Compact for low output range | ||||
| 2012 | |||||||
| 2013 | Launch of Flexotronic: new filler platform with high flexibility | ||||||
| 2014 | Awarding of the PETplanet After Sales Award Developing Countries for the categories "They know me" and "pricing and volume discount on aftermarket" | Awarding of the PETplanet After Sales Award Developing Countries for the categories "Supplier addresses me", "friendliness", "effective training", "Competence" and "Responsiveness" | Awarding of the PETplanet After Sales Award Developing Countries for the categories “Technician close to my plant" and "Reachability". LiquiForm, a JV between Amcor and Sidel to develop bottle forming and filling. Introduction of Sidel Matrix Hotfill filler from 200 ml to 2 l | ||||
| 2015 | Sipa takes over Automa | SBM and preform compression moulding Xtreme as a block in a facility. From granulate to finished bottle all at one heat | Corpoplast celebrates 40 years of existence | Contiform 3 Pro with 2,300 b/h per cavity. Volker Kronseder hands over operations to Christoph Klenk | LiquiForm, the JV between Amcor and Sidel, is launched in USA | Tech-Long presents 5th generation SBM. 2,400 b/h per cavity | |
| 2016 | LiquiForm partners with Krones as development partner. LiquiForm also cooperates with KHS | Sidel reports on the reduction of the 0.5 l water bottle from 28 g in 1985 to 7.95 g in 2015 | Introduction of the Triblock FreshSafe | ||||
| 2017 | Launch of Xtra rotary SBM with 2,550 b/h per cavity | FormFill SBM and filling in one process | Contiform 3 Pro now with 2,500 b/h per cavity | 3G technology (laser heating of preforms) gives previously unheard of freedom in bottle design | |||
| 2018 | Sidel takes over PET Engineering GEA takes over Vipoll | Gianfranco Zoppas, Owner, presents the Xtreme with blocked SBM and filler in Vittorio Veneto. "In the past single stage plants were required. Today, it has become a two-stage technology" | Kai Acker as new CEO makes it his primary goal to bring more structure and order to the KHS Group. InnoPET Blomax V with 2,500 b/h per cavity |
Filling
Companies
All-Fill | Alfieri | AMS Ferrari | Amsler Equipment | AVE Technologies | Bardi | CHP | Claranor | Comac | ENOBERG | Fogg Filler | GEA Group AG | GEA Procomac | HEUFT | Index-6 | Induflex Sondermaschinenbau GmbH | Jiangsu Huihe Packaging | KEENPRO | KHS | Kosme | Krones | LiquiForm | Melegari | M/S Mechanical Systems | Newamstar Packaging Machinery | Ocme | PET Machinery | PET Technologies | Pressco | PROMEC | Sacmi | Sidel | Sipa | SMF Maschinenfabrik GmbH | SMI | Tech-Long Packaging Machinery | Thermo-Pack | Vaccum Barrier | Vanta | Vipoll | ... |
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