Aluminum Bottles - Asia CanTech Mall//Herlan in a nutshell Manufacturing lines for the aerosol,...
Transcript of Aluminum Bottles - Asia CanTech Mall//Herlan in a nutshell Manufacturing lines for the aerosol,...
wifag//polytype Metal Packaging
Aluminum Bottles Dr. Bernd Ullmann
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Mall//Herlan in a nutshell
Manufacturing lines for the aerosol, Al-bottle and tube industry
Turn-key supply from A to Z
Container Development
Installation and ramp-up
Ca. 250 employees
Part of Wifag Polytype Group (1500 employees)
MH acquired the market leader in machines for shaping metal containers (Frattini) in 2009
MH introduced DWI technology in 2010
DWI lines sold and in operation for aerosols and for bottles
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Mall//Herlan CH Mall//Herlan DE
A multi-national company
Mall//Herlan IT Wifag-Polytype
German engineering meets Swiss precision and Italian Genius
Mall//Herlan MB
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Market : Bottles
The bottle market is dominated by glass
• Regarded as premium
• Unique shapes
• Strong on on-trade sales
• Specific filling equipment
• Strong in Crown closure (beer)
• Scew caps for CSD
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Market : Metal
Metal beverage packaging today means beverage cans
• Gas tight
• Optimum recycling
• Fast filling
• 250+ bn cans per year
• Safe
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Market : Take the best of two worlds
Combine the premium from the glass bottle with convenience of the bev can
Bottle Can Alu
bottle
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• 4 out of 8 refillable containers are made of glass
• 1 out of 18 containers are made of metal
• 14 out of 18 containers are reclosable
• 7 out of 18 containers have (more or less) straight walls
Reclosability required
Shaping required
Soft drinks tend to shaped bottles
A closer look to a CSD brand
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• 3 out of 18 containers are made of metal
• Plastic basically not present
• 0 out of 18 containers are reclosable
• 17 out of 18 containers have (more or less) straight walls
Reclosability maybe not required
Shaping obviously not yet used widely as a marketing instrument for beer
Beer tend to straight wall bottles
A closer look to a beer brand
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Mall Herlan helped to make several Alu bottles
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Two types of Alu bottles
Impact Extrusion
DWI
Impact Extrusion (IE) and Draw and Wall Ironing (DWI) are two ways to make bottles
Yes, but what is a large number
???
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Alu bottle market : Perspective 1
Extrapolate from existing markets to 2013 + 5 years
Conservative Optimistic (Japan extrapolation)
No of bottles related to bev cans (Assumption of the scenario)
2% 7%
No of bottle per year in 5 years 5 bn 18 bn
Current No of bottles 3 bn 3 bn
Increase 2 bn 15 bn
Increase per year 400 mio 3 bn
= No of new 200 cpm lines p.a. 6 45
= No of new 500 cpm lines p.a. 2 20
= No of new 2000 cpm lines p.a. n/a 3
There will be 200 cpm and 500 cpm lines, 2000 cpm lines is unlikely
Alu bottle market : Perspective 2
250+ bn beverage cans are made with lines making ca. 1bn cans per year
This is ca. 0.4% of the world market on one line
If we transfer this number to our two scenarios, we get:
5 bn * 0.4% = 20 mio bottles per line and year
18 bn * 0.4% = 71 mio bottles per line and year (This is about a 200 cpm line)
If we like to maintain risk minimizing, competition, flexibility, logistics cost, then a 500 cpm bottle line is already fast and seems to be more than appropriate for the market in the coming years
Two perspectives indicate that bottles will be made with 200 to 500 cpm lines
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Learn from beverage cans to understand the supply chain
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Necker
Standard line layout, most machines well known, smart innovations where needed
Coater, Decorator, O/V and ovens
Cupper
Bodymaker Accumulator Accumulator Accumulator
Pre- Washer
Inside spray
IBO
MH Hi-Flex™ 200 DWI
Washer
Accumulator
Trim/Brush
Post Washer
DWIFront-End Standard line
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Use one uncoiler/cupper and two identical lines to get 400 cpm total
MH Twinline 400
400 cpm is just the expansion of a 200 cpm line grow with demand, expand whenever you want
Fully utilize the uncoiler and cupper
Less labor
Efficient coil supply, less logistics
Two decos two lithos at the same time
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A dedicated 500 cpm bottle line
MH Hi-Flex™ 500 DWI line
500 bottles per minute
Fully integrated line, turn-key from A to Z
New deco area with continuous printing machines
New buffer system – MH Flexstore™
The Bottlemaker for finishing cylinders incl. necker and postwasher
It all starts with the container
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Together we will get Alu bottles easier in the market than we have thought so far
Work on container and machines in parallel to save time to market
Mall Herlan can help to design the bottle straight from the beginning
The bottle can be tested and approved even before the line is installed and start operation
Mall Herlan can manage the total project incl. container design
Mall Herlan can help to assess cost of container
Define bottle Define
manufacturing process
Make samples Test samples
Define machines
Make machines
Install machines
Ramp-up
Mall Herlan Container Development
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It’s not only design – it’s passion, team work and a lot of sweat
Definition of the bottle starts with cost
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Mall Herlan helps to find the technology that solves the task
Clear statement on capex incl. auxiliaries
Help on plant layout
Metal cost calculation
Labor, Energy, etc
Material choice and cost
Total cost of container
0
20
40
60
80
100
120
IE DWI 200
DWI 500
Co
st in
% c
om
par
ed
to
IE
Summary
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Aluminum bottles are closer than you may think
You can get proven machines for making bottles
You can decide on today’s volume – risk free and perfectly utilized lines
You can expand in the future – grow with demand
You can use existing Mall Herlan experience in container design
You can ask us to develop bottles and get your special samples made by us
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Thank you.