pet bottle - G R Pet Preforms · Title: pet bottle.cdr Author: Pc2 Created Date: 6/23/2018 2:51:41 PM
PET Preforms & PET Multi-Layer Co-Injection Technology
Transcript of PET Preforms & PET Multi-Layer Co-Injection Technology
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PET Preforms &PET Multi-Layer Co-Injection Technology
Fabrice BECKER at Safripol Conference 2019 - Johannesburg
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World-Leading Supplier of Manufacturing Solutions, including Tooling, Hot Runners, Machines and Services
Beverage Manufacturing
• Canada • Luxembourg • China • USA
MSP Tooling Manufacturing
• Austria • Czech Rep. • Switzerland • USA
AM AP
EMEA
Team Members | 4500+ Husky Employees
Division of Team
Members GloballyClosures
Specialty
Packaging
PET
Emerging
Mature
Customer Support | 500+ Dedicated Husky Sales and Service
Revenue
by Market
Revenue
by Region
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Mega Trends – Continuing to Shape Packaging
Millennials and
Ageing Generations Digital Shoppers Health Conscious Environmental
Friendly
Premiumisation Personalization
Smaller &
On-the-Go
Package
Smart
PackageSustainability
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PET Forecast for Non-Alcoholic Beverages
Source : Global Data
PET Bottle Consumption is forecast to outpace other materials and formats for
beverage packaging.
PET 3.1% CAGR 2019 - 2023
Non-PET 2.3% CAGR 2019 - 2023
Global Non-Alcoholic Beverages Package Consumption
(M of Units)
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Consumption by Segment in PET
CSD Growth 1.3% CAGR 2019 - 2023
JSDT Growth 2.5% CAGR 2019 - 2023
Source : Global Data
Water Growth 4.1% CAGR 2019 - 2023
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Answer to the needs of the differentiated products that proliferate in new white spaces
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Growth by Category in PET
All water categories are showing strong growth, as are RTD coffee
drinks and nectars.
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Marketing Strategy – Consumer Needs
Premium
Convenience
Health LifestyleNon Sustainable
Sustainable
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Marketing Strategy – Consumer Needs
Premium
Convenience
Health LifestyleNon Sustainable
Sustainable
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Technology
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Introducing HyPET HPP5e
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HyPET Product Line Consolidation
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Sustainability
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Trends towards Circular Economy Package Design
100% reusable, recyclable or compostable plastic packaging by 2025
Follow their lead
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European Single Use Plastics Directive Proposal
• SUP Ban approved by European Parliament in December 2018
• Recycled PET in beverage bottles : at least 25% in 2025 and 30% in 2030
• Separate collection targets for PET beverage bottles: 77% in 2025, 90% in 2029
• Tethered closures:
Still and carbonated products in May 2024
AB-2779 (California Bill) currently inactive, expected renewed push.
• 2019 SUP steering committee formation within CETIE
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Husky – Sustainability Today
Bottle
Light-weighting
Thread & Closure
Light-weighting
Tethered Cap
Recyclable barrier
Multi-layer
Recycled Flake
Processing
Non-food rPET
Multi-layer
Industry
Associations
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Husky – Sustainability Today
Bottle
Light-weighting
Thread & Closure
Light-weighting
Tethered Cap
Recyclable barrier
Multi-layer
Recycled Flake
Processing
Non-food rPET
Multi-layer
Industry
Associations
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Best-in-class injection capability enables innovative package designs -Integrated Systems Approach
Recycling
Process
Cooling
Resin
Handling
Preform / Closure
Handling
Hot
Runner
Machine Mold
Mold
Dehumidification
+Factor 100TM
500ml water,
5g preform,
0.7g closure
1.5 mmbody wall thickness*
0.8 mmneck wall thickness*
Up to 55length/thickness ratio*
* Many factors affect the minimum achievable dimensions, such as resin, bottle
design performance, TSS lip diameter, application, and cavitation are just some
of the examples. These dimensions may not all be simultaneously achievable.
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PET Bottle Weight Evolution
Time
6
8
10
12
14
16
18
20
22
24
26
500ml Water
2014
29/2530/25H 25/22
Preform
Weight (g)
2000 Today20112008
Improved
Injection Capability
Improved
Blowing Process
Neck Finish Evolution
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Husky – Sustainability Today
Bottle
Light-weighting
Thread & Closure
Light-weighting
Tethered Cap
Recyclable barrier
Multi-layer
Recycled Flake
Processing
Non-food rPET
Multi-layer
Industry
Associations
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Enabling Package Optimization with HUSKY
Safripol 2019 Under Neck OptimizationHPP Capability – Thickness & Design
Body OptimizationStretch Ratios
Intelligent Preforms
Base DesignOptimized Performance
Right Weighting
Closure PortfolioProven Off-the-Shelf Designs
License-free
Neck Finish PortfolioStandard Necks
Light Weight Options
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Enabling Package Optimization with HUSKY
Under Neck OptimizationHPP Capability – Thickness & Design
Body OptimizationStretch Ratios
Intelligent Preforms
Base DesignOptimized Performance
Right Weighting
Neck Finish PortfolioStandard Necks
Light Weight Options
Closure PortfolioProven Off-the-Shelf Designs
License-free
Dispensing
Systems
Safripol 2019
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26/22 High Carbonation - CSD Dispensing System Evolution
~8g ~6g- 2 g
Less than 10 years ago started the conversion from PCO1810 to PCO1881.
- Reduction of ~2g on the
complete dispensing system
- Same Inner Bore Diameter
- Height reduced by 4mmWeights may vary depending on closure
design and neck customization.
~4g- 2 g
- Reduction of ~2g on the
complete dispensing system
- Same Inner Bore Diameter
- Height reduced by 4.1mm
PCO1810PCO1881
26mm CSD
Similar modifications and ROI expected from PCO1881 to 26mm CSD
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Water Dispensing System Evolution
~5.6g~3.6g
- 2 g
- Reduction of ~2g on the
complete dispensing system
- Same Inner Bore Diameter
- Height reduced by 5.9mm
Weights may vary depending on closure design and neck customization.
~1.7g- 2 g
- Reduction of ~2g on the complete
dispensing system
- Inner Bore Diameter reduced by 3.27mm
- Height reduced by 3.6mm
30/25H 29/25 25/22
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Tethered Closures – Case Study Conversion from 29/25
Snap-On 25Leash Snap-On 21 Flip Lid
29/25
Neck Finish 29/25 or
29/25 LW
26/21
(21mm Opening)
New Neck Finish
(25mm Opening)
29/25 or 29/25LW or 29/25MOD
Neck weight 2.1g-2.41g 1.25g 1.6g 2.1g-2.41g
Neck Impact NONE NEW NEW NONE
Closure Impact Slides + Outer Cores NEW NEW NEW
Line Impact NONE Capper retrofit, Chucks, Pick and Place, Cap feeder, Cap
chute, neck finish personalization parts
Capper retrofit, Chucks, Pick and
Place, Cap feeder, Cap chute
Target Market Still & Sparkling
Beverages
Still Beverages Still Beverages
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Husky Multilayer Solutions
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Why Multi-Layer Barrier?
Coffee/Tea Meat Seafood/Tuna Vegetable/Fruit
O2
Light
Moisture
PP/EVOH/PP
PET/Barrier/PET
Small
format CSD
Sensitive
beverages
Milk and milk
alternativesBeer
CO2
O2
Light
Plastics are more or less permeable depending on:
• Material structure and properties
• Container wall thickness
• Type of gas, liquid or light exposure
Extend the shelf life of sensitive food and beverages
Oxygen
Odors
Water
Light
Aromas
Gas
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Multi-Layer Technology Runway
Engineered
Packages
Gas barrier
Aesthetics
Light Barrier
CO2
O2
H2O
Haptics
Smart Packaging
Post-Consumer Recycled,
Circular Economy
Package Design
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Engineered packages with Multi-Layer enable next level of performance
Complete package
protection enabled by a
fully encapsulated dome
Layer bias control
allows barrier layer to
be positioned away
from the surface to
the core for improved
bottle appearance
Accurate barrier
position enables
excellent leading
edge position
control
Middle layer materials:
MXD6 (Nylon)
Plemat (Coke)
Verian (PGA)
PET w carbon black
Oxygen scavengers
EVOH (passive)
PET w colorant additives
Recycled PET
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HPP5 Multilayer Evolution – Ease of use and capability
New HR nozzle
design to reduce
degradation and
reduce clogging
issues
Front mounted
HR nozzle to
reduce
maintenance
effort and
improve uptime
Melt distribution
redesigned to
allow low barrier
dosage and low
shot to shot
variation
Servo driven
valve stem
for accuracy,
speed, and
barrier layer
adjustment
flexibility
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HPP5 Multilayer Evolution – Application Range
Encapsulate or
open dome
without hardware
changes
Center or Bias
Hthe B layer by
processing
changes only
Leading and
trailing edge
variation
capability enables
positioning the B
layer right where
you need it
Precise
dosing at
lowest % to
enable a
wide range of
application
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Latest Multi-Layer Technology
CSD
Juice
Dairy
Beer
Tea
Food
Personal Care
Systems sold around
the world since 201541 Applications8Winner of the Ringier Technology
Innovation Award 2018
Industrial Pails
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“The much better balance helps to make the economics work”
Frederic Mignot - SGTPresident and CEO
24t less barrier per yearmaterial, assuming 1.5% lower content,
16g bottle, 100M bottles per year
3.5%5%
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Multi-Layer packages offer superior barrier performance AND reduced material costs
30%-60% More effective
additives and clear bottles
More light protection
with less additives for
UHT milks
Unique aesthetics at
reduced cost
Monolayer
blends
Multilayer
Monolayer blends
VS Multilayer
barrier
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Success of HyPET® HPP5 with high capability multilayer, drop-in solution for PET lines
41 machines
in 13 countries
5 billion preforms
≈ total installedproduction capacity
8 applications types
Source: HUSKY. Image credit: Sidel
Pepsi
345ml
Pakistan, UAE
Coke 250-350ml
USA, Egypt, Algeria
Loic Raison
250ml
France
Adelholzener
750ml
Germany
Perrier
500ml
France
San Pellegrino
500ml
Italy
Hamoud
350ml
Algeria
Abatilles
500ml
France
50% less
barrier material
CO2
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Superior performance of Multi-Layer offers opportunities to further improve shelf life and/or reduce costs vs mono-layer and blends
Su
rface/ vo
lum
e
Small containers
Have a challenging surface
to volume ratio leading to
higher CO2 loss
Shelf life
[days]
17.5 g
Total material cost
PET & barrier [normalized]
11095 100 120
50
45
40
35
130
Monolayer
Source: M-RULE
15 g
Multi-Layer
2.5%
Verian™High Barrier Polyester
17.5 gBlend
7%
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“Higher performing packages that also look better”
35% less CO2 barrierwith multi-layer barrier vs. blend,
better CO2 protection and bottle
clarity.
Rizwan Seth - NOVATEXPresident and CEO
3.5%5.5%
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Success of HyPET® HPP5 with high capability multilayer, drop-in solution for PET lines
41 machines
in 13 countries
5 billion preforms
≈ total installedproduction capacity
8 applications types
Source: HUSKY. Image credit: Sidel
ECKES
Granini,
Hohes C
Germany
TSK, Tea
400ml
Japan
O2
scavenger
50% less
barrier material
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Multi-Layer packages offer superior barrier performance AND reduced material costs
Monolayer
blends
Multilayer
Monolayer blends
VS Multilayer
barrier
30%-60% More effective
additives and clear bottles
More light protection
with less additives for
UHT milks
Unique aesthetics at
reduced cost
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Husky’s HyPET HPP5 with Barrier module can run all LDP applications at the lowest cost to produce
COLD CHAIN AMBIENT TEMPERATURE
≈ 10 days ≈ 5 weeks
WhiteWhite Flavored
3 – 6 months 6 – 9 months
UHT - White
99.95%< 99%95%10% Barrier to light
To
tal c
os
t to
pro
du
ce
Multi-layer
White/Black/White
Husky
Solution
0-20% BARRIER
PET ~ 8% TiO2
PET ~ 5% TiO2
PET
>10% TiO2
Illustration only
White pigment - High costBlack pigment - Medium cost
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Success of HyPET® HPP5 with high capability multilayer, drop-in solution for PET lines
41 machines
in 13 countries
5 billion preforms
≈ total installedproduction capacity
8 applications types
Source: HUSKY. Image credit: Sidel
black PET core
2x white PET skin
Light
core bias encapsulated
dome
Parmalat, Elegé,
1L UHT Milk,
Brazil
Ifap,
1L UHT Milk,
Italy
Light
O2O2
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“The best solution for our dairy project.Second to none!”
Up to x2 more bottlescompared to alternative usinginject-over-inject technology, comparable cavitation, same barrier to light – 6 month shelf life
Data from 32 cavities Inject-Over-Inject system, annual output normalized for 72 cavities for comparison purposes
Filipe de Botton - LogoplasteChairman
Source: Quote from HUSKY customer. Data from HUSKY internal competitive intelligence
200 Mgood quality
bottles per year
100 Mgood quality
bottles per year
Data for 72 cavitiesHUSKY Multi-Layer
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Success of HyPET® HPP5 with high capability multilayer, drop-in solution for PET lines
41 machines
in 13 countries
5 billion preforms
≈ total installedproduction capacity
8 applications types
Source: HUSKY. Image credit: Sidel
LightO2
CO2
Frankfurter Pils,
Viaplast,
500ml Beer,
Germany
OMB,
Plastipak,
12oz Beer,
US
O2
O2
O2
O2CO2 CO2
CO2
CO2
UV
core:
O2 scavenger +
nylon
skin: PET + amber
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Husky – Sustainability Today
Bottle
Light-weighting
Thread & Closure
Light-weighting
Tethered Cap
Recyclable barrier
Multi-layer
Recycled Flake
Processing
Non-food rPET
Multi-layer
Industry
Associations
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Any dissemination to anyone other than the recipient is unauthorized and strictly prohibited.48
The Multi-Layer PET package offers solutions using up to 40% recycled PET
rPET pellets + black
additive
washed opaque
rPET flakes
Up to 40%
mid-layer
40%
*transversal bottle thickness view
25%35%
biasedposition of the layer
in*
out*
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The industry is getting organized to establish dedicated streams for opaque PET
Dedicated stream with
secondary level of sorting
washing, pelletizing
Preform injection
Retailer
Deckel
Group
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Multi-Layer packages offer superior barrier performance AND reduced material costs
Monolayer
blends
Multilayer
Monolayer blends
VS Multilayer
barrier
30%-60% More effective
additives and clear bottles
More light protection
with less additives for
UHT milks
Unique aesthetics at
reduced cost
Husky controlled. Husky information is only intended for the recipient.
Any dissemination to anyone other than the recipient is unauthorized and strictly prohibited.51
Success of HyPET® HPP5 with high capability multilayer, drop-in solution for PET lines
41 machines
in 13 countries
5 billion preforms
≈ total installedproduction capacity
8 applications types
Source: HUSKY. Image credit: Sidel
P&G,
Logoplaste,
Alpla
200ml Shampoo,
China
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Premiumisation – Multilayer - Color Gradient
Ability to:
– Create completely opaque containers
– Color only the outside (less colorant)
– Color only the inside (less colorant)
– Adjust inside layer (colored) positions
– Color superpositions within A&B layers
P&G, Logoplaste,
Alpla
200ml Shampoo,
China
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Smart Packaging - Activated Technology
Glow-in-the-dark Sleeve,
White Water, England.
• Glow-in-the-Dark Sleeve, UV light exposition
allows sleeve to glow electric blue in the dark.
• Photochromic, (Sun Activated) to change
color pigment from white to final required color.
• Thermochromic, colors change according to
temperature.
• Intelligent Labels, to provide customers with
interactive, personalized brand experiences.
• Intelligent Polymers, colors change according
to product shelf life.
Intelligent Label, Heinz.
Nestlè, Aqua Vera Kids,
Happy Sleep, Italy.
Thermochromic Printing
Coors Light Beer Cans, USA
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Multilayer Innovation – Smart Packaging
Phospho/fluorescent
12oz CSD bottle
Color Gradient
12oz CSD bottle
Thermochromic
12oz CSD bottle
• Phosphorescent and fluorescent effect
(Glow-in-the-dark)
• 26/22 CSD high carbonation neck finish
• Husky closure
• Thermochromic effect
• 26/22 CSD high carbonation neck finish
• Husky closure
• Top-Down Bottle with Color gradient effect
• 1881 neck finish, Husky closure
• Base overcap
• Spherical bottle base