Next steps in PET bottle
lightweighting
Tuesday 26th June 2007
Phillip Ward
Director for Waste Implementation
Programmes: WRAP
WRAP: Waste & Resources Action Programme
Private company, funded by DEFRA and the
devolved administrations
Set up in 2001 from Waste Strategy 2000
200 staff, 7 programmes
“Helping businesses and the public to reduce
waste, to use more recycled material, and
recycle more things more often”
The role of WRAP
“to minimise the production of waste by consumers
and maximise the recycling of materials.”
Minimising household waste
Creating markets for recyclate
Increasing recycling infrastructure
Training & increasing collections
Promotion of consumer recycling
Waste minimisation, recycling, composting
The scale of the challenge
European perspective
Waste Strategy for England 2007
• Published by Defra on 24 May 2007
• Much stronger focus on waste minimisation
• Retail and food manufacturing are both seen as
priority sectors
• Reducing food waste an urgent issue for
government
• Focus on alternative technology investment
– Anaerobic digestion and composting favoured
• Consultation on incentive charging scheme
The changing retail
environment
Grocery retailers: ‘Green Wars’
Strategic targets on:
– Reduction in waste and packaging
– Specifying recycled content / biodegradable packaging
– Recyclability / access to recycling facilities
– Sustainable materials
– Carbon foot-printing
Courtauld Commitment: Phase 1 Retailers
The signatories commit to supporting WRAP in the achievement of its
objectives, as follows:
To design out packaging waste growth by 2008
To deliver absolute reductions in packaging waste by 2010
To identify ways to tackle the problem of food waste
Signatories represent over 90% of the UK grocery market
Courtauld Commitment: Phase 2 Brands
Expansion of Courtauld Commitment to include top UK selling
brands and suppliers;
Influence the brand sector
Influence own brand
Influence consumers
Partnership working with retailers / WRAP
Focus on suppliers to household grocery sector
Brand signatories now in double figures
Consumers: seeking engagement
Recycling
Incentive charges
Kerbside collection
On-pack messages
Media
Lightweighting PET
Why a conference on lightweighting
PET?
Lightweighting has been happening for a long
time BUT a new step-change is needed
Commercial, consumer and environmental
opportunities
Understanding the challenges
Bringing together technical & commercial
expertise
Future plans
WRAP’s PET lightweighting project
overview
Three projects involved:
Esterform Packaging:500ml and 2 litre bottles
Coca-Cola Enterprises
Amcor PET Packaging
Where we want to get to
Shared understanding
Clarity on potential benefits
Awareness of barriers to and challenges in
adoption
Identify areas for collaboration
Thank you
Next steps in PET
bottle light weighting
PET bottle manufacturing and
light weighting- an overview
Professor Edward Kosior
Managing Director
Nextek Limited
Overview
• The Light Weighting Issue
• The UK PET bottle market
• Light weighting design principles
• Limitations to Light weighting
• Review of current best practice
• Potential for future light weighting
The Light Weighting
issue
Light weighting of PET bottles
•Light weighting has been occurring since PET bottles
were produced in the beverage market
•The target has always been to reduce cost without
reduction in bottle performance and consumer appeal
Savings delivered by light weighting PET
Each one gram saved on a preform used for a
market of 100 million bottles saves
•100 tonnes of PET
•£80,000 of costs for PET resin at £ 800/tonne
•80,000 kWhr of energy for preform moulding
•2670 kWhr of energy for preform heating for
blow moulding
•36 tonnes of CO2 being generated
•27.2 tonnes of Carbon being used
The UK PET
bottle market
UK Soft Drinks Market
Growth from 2000 to 2005 has been at
approx 4% p.a.
Year Litres (million) index % annual change
2000 9,248 100 NA
2001 9,740 105 +5.3
2002 10,239 111 +5.1
2003 11,128 120 +8.7
2004 10,991 119 -1.2
2005 11,123 120 +1.2
Market Sectors
•Carbonated Soft Drinks 55% of the market
•Juice 20% and Water 19%
•PET bottles are the major form of packaging
(66%)
Estimated % Share of the UK Drinks Industry Market
2005
0%
3%
3% Carbonates
19%
Juice/juice drinks
Bottled water
Sports drinks
55%
Energy & stimulant drinks
20% Smoothies
Share of the CSD market by brand owners
% Share of the UK Carbonated drinks market by
brand, 2004 M ltrs
The top three Brand
owners for carbonated
drinks are
Coca-cola
4% 3% 4% 5%
Enterprises
Diet Coke
Britvic soft Coca-cola
5%
•Coca Cola
Fanta
7%
14% Schweppes
3%
•Britvic
Pepsi
4% Diet Pepsi/Pepsi Max
drinks
•AG Barr (Irn-Bru)
Tango
10% R Whites
They account for nearly
Virgin Cola
26% Irn-Bru
15% Other brands
Own-label
60% of the CSD volume
PET packaging is used for
66% of the total market
Share of the Water market by brand owners
% share by brand of the bottled mineral water
•Own Label water
market 2005 M ltrs dominates the
market at 47%
Danone
Volvic
Evian
•Nestle, Danone
Highland Spring
and Highland
Nestle
Buxton
Vittel
Aqua Pura
spring are the
Own labels other major
Others
players
•81% of the
packaging is in
PET bottles
Share of the Juice market by brand owners
•Own label account for
% share of the UK fruit juice/juice drinks market 41% of the market
by brand 2004, M ltrs
Ocean Spray The top four brands
Robinsons
Ribena
are
Capri-sun
Sunny D
•Gerber
Other brands
Own-label
•Britvic
•Glaxo Smith Kline
•Coca Cola Enterprises
PET bottles are used
for 25% of the market
Summary of the PET Packaging market
Segment Total volume %PET share Estimated number of
PET bottles
Carbonated S.D. 6,057 m litres 66% 3,100 million
Bottled water 2,158 m litres 81% 1,500 million*
Fruit juice/drinks 2,202 m litres 25% 1,055 million
Others 820 million
TOTAL: 6,475 million
Light Weighting Design Principles
PET Bottle design
Key issues for bottle design:
•Manufacturing process
single stage or two stage
– (economics, material efficiency)
•Size and shape of bottle
– (stretch ratio, barrier and rigidity)
•CSD, juice or water market
– (Resin IV, base design)
•Neck and Closure design
– (Major weight and waste factor)
•Shelf life and oxygen barrier
– Wall thickness and construction
•Production stability
– Available BM machines
Light Weight Bottle Design Principles
•The latest advice on bottle and preform re-design is obtained from leaders
in the technology- preform manufacture, moulds, resins blow moulding
machines.
•The new, lighter design is created on a 3-D CAD System
•Surface stress and deformation test is carried using Finite Element Method
(FEM) analysis to check the bottle performance
•The new CAD design is optimised to meet customer specifications.
•Manufacture of prototype tooling to make sample bottles on production
equipment.
•Testing of prototypes for an additional analysis of all important parameters.
•The filling volume and material distribution is checked.
•The designs may require further refinement and the moulds adjusted.
• Bottles are again moulded and tested.
•Bottles are tested at the customer on the filling lines at full production
speed and tested with real products.
Issues that often arise in Light Weighting
•Wall thickness can get too low and product rigidity is
lost- poor feel, low top load resistance
•Nesting of preforms (body of preform is less than
opening of the neck) leads to preform unscrambling
problems in the blow stage
•Very light bottles are difficult to handle and fill at high
speed
•Barrier properties and creep of CSD bottles can cause
shelf life and label stability issues.
•Stability of base and Stress Cracking of base may
become a problem
Review of current Best
Practice
Best in Class survey –Wrap/ Exel 2005
Data for CSD based on 2003 data
Product Size Position in class Weight of plastic Estimated weight of
packaging (grams) PET (gms) (assuming 3gm
closure weight)
330ml PET Best 18.8 15.8
Worse 19.09 16.09
500ml PET Best 24.5 21.5
Worse 42.2 39.2
l ltr PET Best 31.7 28.7
Worse 52.91 49.91
1.5lt PET Best 47.81 44.81
Worse 50 47
2 ltr PET Best 44 41
Worse 58 55
Most common CSD bottle weights
Volume: Weight(s):
330ml 17.4gms
500ml 28.1gms
1 litre 31.9gms, 39.5gms
1.5 litre 44.8gms
2 litre 44.2gms, 46gm, 50gms,
51.7gms
Best in Class survey –Wrap/ Exel 2005
Data for Water based on 2004 data
Product size Position in Weight of PET packaging Estimated weight of PET
class (grams) (gms)assuming 2.5gm closure
330ml PET Best 17 14.5
Worse 28.24 25.74
500ml PET Best 20 17.5
Worse 45.8 43.3
750ml Best 28.79 26.29
PET Worse 40.8 38.3
1 ltrs PET Best 29.58 27.08
Worse 40 37.5
l.5 ltrs PET Best 38 35.5
Worse 58 55.5
2ltr PET Best 46 43.5
Worse 66.5 64
5ltr PET Best 103 98.0*
Worse 147.85 142.85*
Most common Water bottle weights
Volume: Weight(s):
330ml 25.74gms
500ml 17.5gms, 23.5gms
750ml 26.29gms
1 litre 36.4gms
1.5 litres 39.3gms, 43.8gms, 54.5gms
2 litres 44.7gms, 46.5gms, 47.1gms
Best in Class survey –Wrap/ Exel
Data for Juice based on 2006 data
Product size Position in Weight of plastic packaging Weight of PET (gms) assuming
class (grams) 3.5gm closure
250ml PET Best 19.5 16
Worse 24 20.5
500ml PET Best 23.9 20.4
Worse 41.2 37.7
1 ltrs PET Best 32.8 29.3
Worse 52.3 48.8
l.5 ltrs PET Best 45.6 52.1
Worse 60.6 57.1
Most common Juice bottle weights
Volume: Weight(s):
250ml 16.4gms
500ml 21.8gms, 27.4gms
1 litre 40.1gms, 46.4gms
1.5 litre 58gms
Potential for future light
weighting
What is being achieved.
• Esterform reduced 500ml CSD preform from 25g to 20g
• Esterform reduced 2000ml CSD preform from 42g to 40g
• CCE reduced 500ml CSD preform from 26g to 24g
WRAP sponsored projects in 2005 and 2006
What could be achieved in UK
A reduction of 10 % of bottle weight for the whole
range of UK PET bottles would :
•Reduce UK PET usage by 20,000 tonnes ( based on
200,000 tonnes for the bottle market)
•This equivalent to 570 million 30g bottles being
removed from the waste stream
•Reduce resin costs by £16 million ( based on PET
•Reduce power demands for process by 16.5 million
kWhrs
•Reduce CO2 production by 7200 tonnes
•Reduce carbon use by 5,500 tonnes
Advancements in
Preform Lightweighting
Sylvain Talarico
June 26th 2007
Preform Lightweighting
• Overview of today’s PET market
• Why lightweight?
• How to lightweight?
• Thread Lightweighting Trends
• Husky support
Husky Injection Molding Systems
• World's largest brand name supplier of injection
molding equipment and services to the plastics
industry
• Manufacturing facilities in Canada, the United
States, China and Luxembourg
• Over 40 offices in over 100
countries
Beverage Packaging
Preform Products
A Solution For Every Application
More than 3.200 Husky PET M/C
• Production at 750 Customers
in
Global PET Support
§
Europe – 72% converters / 77 Billion Preforms
Preform Production in Western Europe
N° Installed Cavities
Converters In-House Fillers Total
France 3,388 4,404 7,792
Italy 6,876 2,040 8,916
Spain 4,488 1,968 6,456
Germany 4,368 1,696 6,064
Benelux 3,760 680 4,440
UK 5,264 304 5,568
Western Europe 28,144 11,092 39,236
Technology Improvements
1980 – 17 Systems Today – 1 System
(96 cavities)
Technology Improvements
Output (pph)
0 20000 40000 60000 80000 100000 120000
216 cavity – HyPET650
2005 144 cavity – HyPET500 Speed up
144 cavity – HyPET500
2001 144 cavity – G600
96 cavity – Index 400
72 cavity – Index
96 cavity – G600 phase 2
1997
96 cavity – G600 phase 1 w/ Servo Robot
96 cavity – SX600 w/ Servo Robot, 3
1993 96 cavity – XL600 w/ Servo Robot, 3
96 cavity – XL600 w/ Servo Robot, 3 Position
72 cavity – XL500 w/ Servo Robot, 3 Position
1989
72 cavity – XL500 w/ Air Robot
1985 48 cavity – XL300 w/ Air Robot
2.0L CSD
32 cavity – XL225 w/ Air Robot
1981 20oz CSD
16 cavity – H388 w/ TE Robot
12 cavity – H388 free drop 0.5L Water
1977
Technology Improvements
Weight Cavitation Cycle Output Output /
(g) (s) (parts/hr) Capital
1998 21.0 96 11.0 31400 19.6
1999 21.0 96 11.0 31400 19.6
2000 20.0 96 10.0 34500 21.6
2001 17.5 144 10.0 51800 25.9
2002 16.0 144 9.5 54500 27.3
2003 14.5 144 9.0 57600 28.8
2004 14.5 144 8.5 60900 30.5
2005 13.5 144 8.0 64800 32.4
2006 13.0 144 7.0 69100 34.4
500ml PET Water Bottle Output Evolution
PET Price Trend (US$)
100
90
Cents / Pound
80
70
60
50
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
2003 2004 2005 2006
Average PET Prices Trend (Average PET Prices)
Source: PCI 2006
Resin Prices Continue to Increase
Trends in Preform Lightweighting
60
50
2L CSD
40
Weight (g)
30 1.5L Water
600ml CSD
20
500ml Water
10
0
1996 1998 2000 2002 2004 2006 2008
• Significant ongoing weight reduction for most beverage containers
– 15% – 50% over past 10 years
– Combination of shorter and thinner preforms and lighter threads
Market Trends
CSD Applications Mineral Water Applications
Milk / Juice Applications Oil Applications
The above tables are summaries and do NOT include all possible specifications.
Lightweighting Advantages
• Reduce resin consumption
• Increase productivity & performance
• Maximize cycle benefit (thinner means faster)
• Satisfy end consumer demand for sustainable
development
Sustainable Development
“…because it is made with less plastic”
PET Market Trends
• Lighter necks
• New bottle base and body concepts
5 liters / 38 mm Neck 28 mm CSD 30/25 low, PCF26
500 ml Lightweighted MW Packaging
Bottle: 13.80 g Bottle: 12.30 g
Closure: 1.73 g Closure: 1.58 g
Volume: 500 ml Volume: 500 ml
Height: 196 mm Height: 205.8 mm
Max Dia: 65.9 mm Max Dia: 66.3 mm
Thread: PCF-26P-1 Thread: PCF-26P-1
Small Size Containers
Options in Preform Lightweighting
• Preform change only
– Thread conversion
– Body conversion (from 0.1g to several grams)
Neck Body
Thread Core
side side
Cavity side
• Bottle change including a preform change
• Resin change including bottle & preform changes
Thread Lightweighting Projects
Blowing
Husky
partner
Customer
Closure
partner
Case Study ($US)
Assumptions
Bottles or preforms per year 240 Million
PET resin cost 1.4 $/kg
HDPE cost 1.15 $/kg
Resin Savings Opportunity Resin (g) $US
Thread 1.3 $ 436,800
Body 1.2 $ 403,200
Preform total 2.5 $ 840,000
Closure 0.6 $ 165,600
Sub-total Savings $ 1,005,600
Investment cost $US
Injection molding machine and tooling $ 250,000
Blowing molding investment $ 250,000
Capping investment $ 250,000
Sub-total $ 1,550,000
Additional profit per year $ 1,005,600
Return on investment (years) 1.5
Additional Profit Every Year $ 1,005,600
Thread Lightweighting
• Focus on:
– Carbonated Soft Drinks
– Mineral Water
CSD Thread Evolution – 28 mm
Alcoa
Common in
PCO 1810 / 1816
Americas
~ 5.9 g
BPF‐C ~ 5.1 g
Global Usage
Common in
Europe
~ 5.7‐6 g
PCO is the most widely accepted CSD thread finish
CSD Thread Evolution - What’s Next?
CSD Thread Lightweighting
* Non-exhaustive list
500ml Lightweighted Beer Packaging
Volume: 500 ml
Height: ~235 mm
Max Dia: ~65 mm
Thread: Bericap
MW Thread Evolution
PCF26
Common in
Alaska 267
Americas
~ 3.9 g
30/25 ~ 3.7 g
Global Usage
Common in
Europe
~ 3.9 g
MW Thread Evolution - What’s Next?
30/25 High
3.9g weight
- 36% Target weight
below 2.5g
Mineral Water Thread Lightweighting
* Non-exhaustive list
500 ml Lightweighted MW Packaging
• 9.9 g with Snap on Closure 13g today
•10.6 g with 3 start threaded closure
Prototyping with Husky
• Preform / mold optimization
– performance at production system level
• Latest system / mold technology used
• Project confidentiality preserved
• Design validation
• Competitive leadtimes
Get your product to market faster and safer
Preform Development Center
• Show Room integrating
2 new HyPET 90 systems
• Optimized output with 4 cavity modular mold
• Various mold tool options available
Moving Forward
• High amount of development activity
• Lightweighting demand for all applications
• Success of new threads depends on closure
standardization and availability
• Need to evaluate overall cost along the supply
chain
Global Impact to the PET Market
• ~35% of the PET global beverage market
affected
• Beverage retailers looking for ~5% weight
savings
• Brand owners looking for sustainable packaging
and cost savings
• Converters taking proactive measures to meet
market expectations
Husky Initiatives
• Add global manufacturing capacity
• Add global refurbishing cells
• Support new thread development
• Work closely with down stream equipment
providers
• Introduce new programs for mold conversions to:
– Preform prototyping
– Include body lightweighting
– Minimize customer downtime
– Incorporate technical upgrades to improve cycle and/or
preform quality
Advancements in
Preform Lightweighting
PET bottles at lighter weight
An integrated approach
Birmingham, June 26th, for WRAP
SIG Corpoplast Frank Haesendonckx Date
SIG Beverages history shows a pioneering role in PET,
barrier development and dry aseptic filling
SIG Corpoplast partners with Schott to RANK acquires SIG
Corpoplast develops And announces to
Heidenreich & Harbeck develop the PLASMAX barrier coating first plasma coating
system for plastics applications keep the structure
establishes SBM machine for bottles including Beverages
division
as is
SIG acquires Corpoplast: PLASMAX
revenue €80m / 270 12D;
employees (excl. Moldtec) industrializatio
n and pilot
launch
1968 1974 1997 2000 2002 2003 2004 2005 2006 2007
ASBOFILL 610
World’s first PET with integrated
Stretch Blow Moulding SIG acquires Asbofill capper launched at
Machine produced in filling assets from Drinktec 2005
ASBOFILL (GEA) Techne
cooperation with develops first purpose
DuPont SIG acquires Schott
built Linear Aseptic equity in Technology
(8,000 bph 16 cavity) Bottle Filler JV for Plasmax
development
SIG Corpoplast Frank Haesendonckx Date
SIG Beverages - offering comprehensive PET solutions
along the value chain for low speed aseptic filling
Customer Design and Stretch Blow Barrier Aseptic Bottle
Request processing Moulding Coating Filling
Bottles &
Shapes™
Packaging and Bottle Barrier Product
Briefing
Process Design Manufacture Coating Filling
SIG Corpoplast Frank Haesendonckx Date
SIG Corpoplast
… focusing on “value added bottling” for high volume and
non aseptic filling lines
Value added bottling: „high quality bottle at lowest cost of ownership”
Customer Bottles & Stretch Blow High Speed Bottle
Request Shapes Moulding Filling via partner
Bottles &
Shapes™
Packaging and Bottle Product
Briefing Filling
Process Design Manufacture
SIG Corpoplast Frank Haesendonckx Date
Content
• The playground
• Material influence
• Design influence
• Processing influence and incorporation into machine technology
• Examples
SIG Corpoplast Frank Haesendonckx Date
Content
• The playground
• Material influence
• Design influence
• Processing influence and incorporation into machine technology
• Examples
SIG Corpoplast Frank Haesendonckx Date
The playground of lightweighing PET containers
… combining all elements of the value chain
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Preform design Weight reduction
Environment/ specification
Or
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SIG Corpoplast Frank Haesendonckx Date
Content
• The playground
• Material influence
• Design influence
• Processing influence and incorporation into machine technology
• Examples
SIG Corpoplast Frank Haesendonckx Date
Material
… Influences on bottle performance and process design
• The basics: Strain hardening
• Influences on material use
– Reaching above the point of natural strain hardening
– Re.heat capacity influences freedom in preform design
SIG Corpoplast Frank Haesendonckx Date
Strain Hardening
… through material characteristics and design
Stress Whitening
Influence of IV on SHP
60
Typical Design Range
50 CP 559
(IV: 0.808)
40
1101
Force [N]
(IV: 0.770)
30
Thicker Preform
CP 552
20 Higher Orientation
(IV: 0.719)
10
0
1 1.5 2 2.5 3 3.5 4
stretching at 110°C
ratio
Thinner Preform
Lower orientation
SIG Corpoplast Frank Haesendonckx Date
Stretch ratio inside/outside of the preform wall
… Consequences on preform re-heat
• Preform inside is more stretched
than outside
• The thicker the preform wall, the
more important to obtain heat
penetration
• Importance of good re-heat resins is
increasing
SIG Corpoplast Frank Haesendonckx Date
Content
• The playground
• Material influence
• Design influence
• Processing influence and incorporation into machine technology
• Examples
SIG Corpoplast Frank Haesendonckx Date
Preform and bottle design
… starting point for good process design
• Factors
– Stretch Ratio
– Wall thickness
• Reflects on
– Process stability
– Re-heat capacity
– Container performance
• Bottle design
– Between technical and marketing optimization
– Imperative to respect relation to preform
SIG Corpoplast Frank Haesendonckx Date
Preform design
SIG Corpoplast Frank Haesendonckx Date
Preform – functional sections
Body
Part below support ring Diameter, length and
wallthickness defined by bottle
Diameter and shape/dimensions, application
wallthickness defined by and weight
neck finish
Neck
Defined by bottle
Taper Base
Length defined by length Diameter and wallthickness defined
of bottle shoulder by prefomr body and application
SIG Corpoplast Frank Haesendonckx Date
Preform design
… incorporating stiffness by orientation
7
6
5
λ4
Q
3
2
λ
1
1 2 3 4 5
L
Minimize cost („design to cost“)
• Minimize amount of material employed
• Optimize material distribution
• Optimize stretching ratio
• Optimize grip resistance
SIG Corpoplast Frank Haesendonckx Date
Bottle design
… performance at low weight lays in the details
SIG Corpoplast Frank Haesendonckx Date
Content
• The playground
• Material influence
• Design influence
• Processing influence and incorporation into machine technology
• Examples
SIG Corpoplast Frank Haesendonckx Date
The process of bottle blowing
… and the required machine characteristics
• Aim • What is required
– Obtain a uniform material – Stable re-heat
distribution » Small pitch between preforms
» Material pull
– Above NSR, to obtain strenght » Repeatable profile
by orientation, not wall
thickness
– Stable material distribution
» Repeatable stretching
» Repeatable bubble development
SIG Corpoplast Frank Haesendonckx Date
Wall thickness distribution
... Depends on preform re-heat characterisitcs
SIG Corpoplast Frank Haesendonckx Date
Preform re-heat profile evolution when traveling in IR oven
• Obtaining a perfect heat distribution
with inside temperature > outside
temperature
Stress / Elongation vs.Temperature
700
600
• At minimum required stretch
Stress ( PSI )
500
400
90 C temperature to have highest stifness
95 C
300 at equal material thickness
100 C
200
100
0
0 100 200 300 400
Elongation ( % )
SIG Corpoplast Frank Haesendonckx Date
Reheat optimization
… machine technology to obtain stable heat penetration
• Smallest pitch possible: 38 mm • Re-heat profiling
– Limit is support ring – Neck shielding is more simple
» Natural heat convection
• 25% less re-heat energy » No air suction required
» Sharp transition under support ring
possible
• Allows for „smooth“ heating » Top lamp possible
where required
» No water condensation from cooling
shield on preform
SIG Corpoplast Frank Haesendonckx Date
Optimize material use
… only there where required, at minimal variance
Pneumatic Stretching Mechanical Stretching = Δ1 – Δ2
PFM weight PFM weight
Δ2
Δ1
MIN limit for bottle property such as TOP
LOAD
SIG Corpoplast Frank Haesendonckx Date
The machine: design to cost
…high precision and repeatability
• Precise oven control, double Segment weight variation with high precision process
guided mechanical stretching
system, precise valves, short 10,20
cycle time: 9,80
9,40
1 g saving:
Highest process preciseness 9,00
216 T€ /Year
and repeatability, thus light 8,60
weighting 8,20
Average max min
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Mould
Segment weight variation with low precision process
10,20
9,80
9,40
9,00
8,60
Average max min
8,20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Mould
•180 mil bottles/ year (BLOMAX 20 * 5000 h * 95%) , 1l
SIG Corpoplast Frank Haesendonckx bottle Date
•With energy cost of 12 €c/ kwh, 0,19 kw/qm
•Pet resin cost of 1,2 €/ kg
Content
• The playground
• Material influence
• Design influence
• Processing influence and incorporation into machine technology
• Examples
SIG Corpoplast Frank Haesendonckx Date
Lightweighting in Water/ CSD
• Brandenburger Urstromquelle, 1.5 l and 0.5 l CSD, 8 gr CO2/l
• 0.5 l weight reduction
from 23 g down to 19.5 g
• 1.5 l weight reduction
from 38 g down to 35.5 g
• Pressure reduction from
35 bar down to 21 bar at
speed of 1800 bphm
SIG Corpoplast Frank Haesendonckx Date
Lightweighting in dairy
• 0,119 l Yoghurt bottle
Weight reduction from
7.5 down to 7 g
•speed of 1700 bphm
SIG Corpoplast Frank Haesendonckx Date
Example for a sophisticate bottle development
• Japanese field 2.0 l rectangular Aseptic bottle
Weight reduction from 47
g down to 41,9 g
• Wide range of
specification items
• Corpoplast task:
• bottle shape
• Preform design
• process design
SIG Corpoplast Frank Haesendonckx Date
The Bottles & Shapes concept links material, processes,
machines and requirements
… to deliver a customized bottle at the best performance / price
Bottle Concept
Product to be filled Bottle Design
Differentiated
–Aseptic integrity
shape
–Heat resistance
Corporate identity
Required shelf life and barrier Product suitability
Bottle
– CO2 / O2 transmission Bottle Coat-ability
Differentiation Concept Design Filling
Pressure
Process / Operations resistance
Material costs (resin / cap / Process/ Stability of
Thank you
sleeve) contours
PaT parts/ change over Industrial Preform Handling
Preform Design stability
Blowing costs Design
solution Design to give best material
Barrier costs
very much
distribution
Filling costs
Minimum heat for maximum
Design shape
Mold
Design Validation validation
Design
3D mock-up
Pilot molds Mold Manufacturing
Pilot bottles / Performance Design optimized for preform
tests Bottle finish
Consumer focus groups
SIG Corpoplast Frank Haesendonckx Date
Seminary
"Next Steps in PET Bottle Lightweighting"
Solihull, West Midlands – June 26, 2007
PET Resins
Enabling
Lightweighting
Roland Leimbacher
Market Manager – Polymers EMEA
Eastman Chemical Company
Content of Presentation
• Introduction to Eastman
• Market Trends & Requirements on PET
• Light-Weighting of PET bottles
• Vorcalor & Aqualor PET - Eastman's New PET Resins
• Reheat Process & Performance of PET
• Outlook for PET Resins & Technology
Eastman – At A Glance
• A global manufacturer of
chemicals, plastics and fibers
• World's largest manufacturer of
PET polymers for packaging
• 2006 sales revenue of $7.5B
• 11'000 employees
• Headquarters in Kingsport,
Tennessee
Eastman - History
• Began in 1920 when George Eastman acquired
wood distillation plant in Kingsport, TN
• Expanded manufacturing production to
include new products such as:
– Acetate yarn and acetate tow
– Acetic anhydride
– Cellulosic plastics
– Polyethylene terephthalate (PET) polymers
• Became first to operate a commercial coal
gasification facility in U.S. in 1983
• Won Malcolm Baldrige National Quality
Award in 1993
• Spun from Kodak in 1994; became independent,
publicly traded company on the NYSE
Eastman - Markets
2006 Sales Revenue by Markets 2006 Sales Revenue by Region
20%
57%
13%
9%
Eastman - Products
• Coatings, Adhesives, Specialty
Polymers and Inks
• Fibers
• Performance Chemicals and
Intermediates
• Performance Polymers
– PET: Poly-(ethylene terephthalate)
• Specialty Plastics
– copolyesters (PETG)
– cellulosic plastics
Performance Polymers
• One principal product line:
– Polyester (PET)
• Eastman is the leader in PET for
packaging; used in packaging of:
– Carbonated soft drinks
– Water
– Juice
– Personal care item
• 2006 sales revenue of $2.6B
Specialty Plastics
• Highly specialized copolyesters and
cellulosic plastics valued for their
unique characteristics
– Strength
– Durability
– Heat and chemical resistance
• Used in a variety of
value-added end uses:
– Shrink labels
– Food and beverage packaging
– Store fixtures and displays
– Personal care and cosmetic packaging
– Medical devices and packaging
• 2006 sales revenue of $818M
Eastman's Polyester History
1975 First PET packaging resin from converted fiber plant (SC)
1978 Eastman begins manufacturing PET resin for containers
1988 First PET plant in Europe (Workington / GB)
1994 Eastman Chemical Company is spun off from Eastman Kodak
1996 PET plant start-up in Cosoleacaque - Mexico
1997 PET plant start-up in San Roque - Spain
1998 PET plant start-up in Rotterdam, Netherlands
PET plant start-up in Zárate -Argentina
2006 First world-scale PET plant based on IntegRex Technology
Parastar Resins - commercial since 1Q – 2007
450'000 MT PET as of 2008
2007 PET plant in San Roque - Spain sold to La Seda de B.
PET Manufacturing in Europe
2007 PET Capacity in Europe: 340'000 MT
2007 PET Capacity in Europe: 340'000 MT
Workington - UK Rotterdam - NL
1988 built 1998 built
190 KMT PET
150 KMT PET 315 KMT PTA
PET Portfolio in Europe
Produced in Europe
•• Eastman PET CB11E (0.82 IV)
Eastman PET CB11E (0.82 IV)
•• Eastman PET 9921W (0.80 IV)
Eastman PET 9921W (0.80 IV)
•• Eastman Aqua PET 18696 (0.71 IV)
Eastman Aqua PET 18696 (0.71 IV)
•• Eastman PET 9921P (0.80 IV)
Eastman PET 9921P (0.80 IV)
•• Eastman PET PJ003 (0.80 IV – glass like)
Imported
Eastman PET PJ003 (0.80 IV – glass like)
•• Eastman PET 5214A Amber (0.74 IV – pharma)
Eastman PET 5214A Amber (0.74 IV – pharma)
Trends in European
Packaging Market (1)
• Pressure on overall Cost Effectiveness
• Differentiated packaging with standard resins
• PET packaging the choice over glass, aluminium, carton
• Trend towards smaller packaging size
• Sustainability PET the best overall choice
PET has established recycling infrastructure
PET is a light and durable packaging without compromise
• CSD Market is mature
• Water continues to grow but less in Western Europe
• Growth in juices, sports & functional drinks, dairy, beer
• In film & sheet PS is being substituted by PET, PP, PLA
Prices of Plastics in Europe
PET is a very competitive commodity plastic for packaging
PET has had relatively stable, predictable prices since 2004
Source: PIE
www.pieweb.com
LDPE
PP
PS
PVC
PET
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
Trends in European
Packaging Market (2)
Market Drivers - Specific for PET Packaging
• Bottle fillers increasingly blowing their own bottles
• More efficient operations, less manpower needed
• Less experience/knowledge
• Low inventories
• Weight reduction in finished articles
• Changes in preform design
• Use of PCR polymer even in food contact applications
(bottle to bottle recycling)
• Emphasis on cost savings
• Energy savings
• More creative use of standard resins
Requirements on PET
rating from Eastman
market study in 2005
Improved blow moulding consistency 9
Energy and cost reduction 8
Increased barrier (CO2) 8
Control over AA 6
Balance between reheat and color 6
Cycle time reduction (injection moulding) 4
Ability to light-weight 4
Same IV for carbonated and still water 2
Light-Weighting PET Bottles
Technologies Enabling Light-Weighting
• Design of Bottle / Preform
• Blow Molding Machine
• Process /Technology Improvement
• PET Resin
Light-Weighting PET Bottles
PET Resin Parameters Enabling Light-Weighting
For blowing at maximum stretch ratio, following
PET properties need to be optimized:
• Viscosity
• Reheat Performance
• Consistent Reheat
• Consistent Viscosity (IV)
• Resin Formulation, e.g. Modifications
• Barrier properties
Eastman's Solution
Eastman PET CB11E (0.82 IV)
Eastman PET CB11E (0.82 IV)
Eastman PET 9921W (0.80 IV)
Eastman PET 9921W (0.80 IV)
Eastman Aqua PET 18696 (0.71 IV)
Eastman Aqua PET 18696 (0.71 IV)
enabling light-weighting by improved processing,
reheat, and barrier performance
Vorcalor PET CB11E (0.82)
Vorcalor PET CB11E (0.82)
Vorcalor PET 9921W (0.80)
Vorcalor PET 9921W (0.80)
Aqualor PET 18696 (0.72)
Aqualor PET 18696 (0.72)
Review of New PET Resins
Vorcalor PET CB11E
The Premier Reheat PET Resin
• 0.82 IV PET resin
• up to 60% energy savings
• Highest reheat without compromise
on clarity
• The best choice for:
- carbonated soft drink (CSD)
- beer applications
- ideal for blends with lower IV (PCR)
Clarity of Vorcalor CB11E
Vorcalor
CB11E
Current
CB11E
Old
Vorcalor CB11E - Benefits
• Better reheat & colour consistency than current
CB11E
allows blowing of more complicated shapes
allows efficient blowing of light-weighted
preform/bottle designs
• Haze free appearance, glass-like colour Wider
range of use, less resins in stock needed
• Drop-in replacement of current CB11E
• Needs up to 60% less energy for reheating preforms
• Very compatible with recycling of PET
Vorcalor PET 9921W
Versatile, General Purpose PET
• 0.80 IV PET resins
• up to 30% energy savings
• maximum light weighting
• perfect PET for complicated bottle shapes
• The best choice for:
- carbonated soft drink (CSD)
- carbonated and still water
- juices
- dairy
- personal care & household
- pharmaceutical
- high quality film & sheet
Vorcalor 9921W - Benefits
• Even with its reheat performance, Vorcalor 9921W
looks like a non-reheated PET wide use of
applications
• Needs up to 30% less energy in reheating preforms
• Better reheat consistency than PET without reheat
allows blowing of more complicated shapes
allows efficient blowing of latest, light-weighted preform/bottle
designs
• Wider processing window in injection moulding
• Improved CO2 barrier 5 to 10% longer shelf life
• Improved AA suitable to replace PET of 0.76 IV
Aqualor PET 18696
Best PET Resin for Still Water
• 0.72 IV PET resins
• up to 30% energy savings
• fastest for moulding preforms
• maximum light-weighting
• superb clarity & sparkle of bottles
• The best choice for:
- still water
- non-carbonated containers
- small, difficult to mould - containers
Aqualor 18696 - Benefits
• Moderate level of reheat without compromise on
bottle appearance
• Needs up to 30% less energy in reheating preforms
• Fast injection speed, potential for reduced preform
cycle time
• Low energy consumption in injection moulding of
preforms
• Low injection pressure long lifetime of moulds
• High definition of bottle imprints (embossing &
engraving)
Reheat Performance of PET
Reheat performance …
is a key element enabling light-
weighting of PET bottles
… but what does "reheat" mean ?
graphics provided by
What is Fast Reheat? (Blow Stage)
• Quartz-infrared lamps are used
to heat preforms to about 100 -
110 °C for blowing bottles.
• Maximum power output from
lamp at these temperatures
occurs at about 1100 -1200 nm
• PET absorbs poorly in this range
• Infrared absorbing compounds
are added to the PET to
- increase productivity or
- reduce energy consumption
graphics provided by
Reheat Process
stabilisation
distribution oven
stabilisation
penetration oven
distribution oven
stabilisation
penetration oven
graphics provided by
Reheat Comparison
of 6 PET Resins
Comparing:
• Eastman PET 9921W
• Vorcalor PET 9921W
• Vorcalor PET CB11E
• Resin A - no reheat
• Resin B - moderate reheat
• Resin C - "high reheat"
Measurements:
• Preform outside temperature
• Preform inside temperature
• Energy consumption of the
blowing machine
Results from trials with
Preform Temperature
Preform Surface Temperature at 80% power setting
140
128
Preform Surface Temperature
130
120 114
112
Outside [ °C]
110
110 104 104
100
90
80
9921W Vorcalor™ Vorcalor™ PET A - PET B - PET C -
9921W CB11E No reheat Moderate "High
reheat reheat"
Preform Surface Temperature
to Avoid Pearl-Whitening
106
104 Preform Surface
Preform Temperature (°C)
Tem perature Outs ide
102
Preform Surface
100 Tem perature Inside
98
96
94
92
90
88
0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 1.80
Reheat Level (indexed)
Energy Savings
70.00 Benchmarking with Competitive Resins
Benchmarking with Competitive Resins
60.00
50.00
Energy Savings (%)
40.00
30.00
20.00
10.00
0.00
PET A Eastman™ PET B Vorcalor™ PET C Vorcalor™
no reheat PET 9921W moderate PET 9921W "high PET CB11E
(reference) reheat reheat"
But … Reheat is More
Than Energy Saving
The lower outside preform temperatures results in
following benefits:
– Less risk of (local) overheating
– Less crystalline outside layer / gate
– Positive effect on all properties that have to do with
avoiding crystallinity
The faster heat absorption of the inside layer leads to:
– Less risk on overstretching / white feet
– Less critical process, wider processing window
But … Reheat is More
Than Energy Saving
"Fast Reheat" PET results in additional benefits:
• More consistent blowing operation
– Reheat functions as processing aid
– Less scrap
• Faster heat absorption
– Higher output on heat limited machines
• Allows blowing of light-weighted and more
complicated bottle shapes
• Very suitable for heat-set process
Outlook for
PET Resins & Technology
Polyester Value Chain
PTA
PTA
23'000 KMT
fibre
fibre 70% of polyester stream
1-3% growth
p-xylene OR
p-xylene Integ
Integated
rr
atedProc
Proce s "
es
PX
ss "P to
X toPET" solid
melt PE T"
melt solid
DMT phase state preforms bottles bottlers retailers
DMT phase state preforms bottles bottlers retailers
PET PET
PET PET
ethane
ethane 11'000 KMT
27% of polyester stream
film &
film & 7-10% growth
sheet
ethylene EO EG sheet
ethylene EO EG
1'400 KMT
propane 3.5% of polyester stream
propane or 12% of PET bottle stream
10-15% growth
Eastman’s position shown in green
IntegRex PET Technology
• New Plant in South Carolina - 350 KMT per annum;
2008 – debottleneck to 450 KMT per annum
• marketed as ParaStar™ for the American Market
Next Generation PET
• "Next Generation PET" with new product attributes and
benefits
• IntegRex Plant #2 – Study Phase
– New, World-Class North America Site
– Full IntegRex Technology (PX PET)
– Logistics Optimization
• Potential Future Developments: large scale,
fully-integrated, new technology sites
IntegRex PET plant in South
Carolina producing ParaStar™
Next Generation PET
Twice the capacity
Half the footprint
PET Barrier Technology
• To improve the CO2, O2, and Light barrier of PET
• Numerous technologies & solutions available:
– coatings (internal & external)
– mono-layer blends
– multilayer
– special polyesters
– labels (for light barrier)
• No "single best" solution … depends on total system
cost, application, volume, logistics, design, recycling ...
• Total cost of many solutions are becoming more
acceptable for end-users
Sustainability of PET
• attractive PET recycling system – unique amongst plastics !
– an effective bottle collection systems is in place
– economically attractive outlets are available for PET
• All outlets/reuse of RPET have a similar, positive influence on
the environmental profile of PET containers
• In collection system, like the German DSD, the environmental
effects of one-way PET are similar to those of refillable glass
• Negligible effect on fossil resources of "one-way PET" versus
refillable glass: similar to an average German citizen driving
40 km extra per year in a standard car
• PET containers use less than 0.1% of global oil production
• PET packaging is proven to be the best material for beverage
containers best overall performance regarding properties,
life-cycle, cost a true sustainable solution.
Use of Oil for Plastic
Transport
87% 45%
burnt
Energy & Heating 5% Other
42%
Chemistry 8%
> Plastics 4%
• Plastics (all) use 4% of global oil consumption
• PET for fibers and packaging uses 0.3% of oil consumption
• PET for packaging uses less than 0.1%
• Plastics protect food and other goods most efficiently
Source: Plastics Europe
Recycling – where to go ?
Oil / Gas
EG + PTA 1
Incineration (burn)
PET
PET or landfill
Preform Bottle In Use
Collection Recycling
RPET
Chem. Sheet Strapping Fibre Bottle
Recycling
Conclusion
Only the right PET resins allows maximum light-
weighting! Therefore, Eastman launches this year
three new resins in Europe:
Vorcalor PET CB11E (0.82)
Vorcalor PET CB11E (0.82)
Vorcalor PET 9921W (0.80)
Vorcalor PET 9921W (0.80)
Aqualor PET 18696 (0.72)
Aqualor PET 18696 (0.72)
Vorcalor & Aqualor PET resins are the best resins
for making PET containers
PET Containers are proven to be the most
sustainable solution for beverage packaging
Contact to Eastman
For more information on the new resins, please
consult your Eastman sales representative or the
following websites:
www.VorcalorPET.com
www.AqualorPET.com
Eastman Chemical International AG
Hertizentrum 6
6300 Zug, Switzerland
Phone: +41 41 727 58 70
Fax +41 41 727 58 50
E-mail: emeapet@eastman.com www.eastman.com
Eastman, Vorcalor, Aqualor, IntegRex, ParaStar and the Eastman logo are trademarks of Eastman Chemical Company
DISCLAIMER: Eastman Chemical Company and its marketing affiliates shall not be responsible for the use of this information, or of any
product, method, or apparatus mentioned, and you must make your own determination of its suitability and completeness for your own
use, for the protection of the environment, and for the health and safety of your employees and purchasers of your products. No warranty
is made of the merchantability of fitness of any product, and nothing herein waives any of the Seller's conditions of sale.
Roland Leimbacher – June 22, 2007
Reducing PET bottle weight
with new low profile necks
and lighter closures
Speaker: Alexander Krautkrämer,
Bericap Holding GmbH
Position: Director Marketing & Sales
What is the Bericap Group
sales 435 million € in 2006
44 billion plastic closures
per year
18 closure manufacturing
sites in 17 countries in the world,
2 mould factories (Hungary
and Poland
4 R&D centres
(France, Germany, Spain,
Turkey)
Strategic allies in Australia
and South Africa
sales offices, and agents in
70 countries
Bericap Package
Some of the significant contributions of BERICAP to the
packaging industry of the last 30 years
BO2S®
1975 Push & Pull passive &
1995
sports cap active barrier
Pull-up Tear off
SuperShorty® telescopic membrane
spout 1998
2007
light
weighting
DoubleSealTM
28 / 38mm
GALILEO® and O2S®
2005
2000
THUMB’UP® Light weight
Bi-injected 2003
sports cap HEXACAP®
closures for
hinge cap and TERXOCUT®
VALVELOCK® self piercing
TAPSEAL® carton fitment
tap closure
Presentation structure
Reducing PETbottle weight for
carbonated soft drinks and water
still water
milk and juices
edible oil and vinegar
Short Neck Standard CSD
PCO 1881 carb water
Neck PCO 1881
- Technical committee „bottle and closure“ as currently under evaluation by ISBT
within ISBT selects in November 2006
PET short neck standard PCO 1881
- currently under evaluation -
- ISBT = International Society of Beverage
Technologists (www.bevtech.org)
- approval of PCO 1881 as voluntary standard
foreseen for Oct 2007
- members of ISBT are brand owners (Coca-Cola,
Pepsi-Cola etc.), preform manufacturers (Amcor,
Plastipack etc.), closure manufacturers (GCS,
Alcoa, Bericap, OI etc.) and machine manu- 1-start thread neck
facturers (Sacmi, Husky, Sidel etc.) Pitch: 2,7mm
- CETIE (European standardization body) will adopt Thread length: 650°
PCO 1881 for Europe Neck weight: 3,74gram
PCO 1881 is the target neck for the industry
all closure technologies work on PCO 1881 weight saving to
PCO 1810 (PCO 28):
1,31 gram
Short Neck Standard PCO 1881 CSD
- technical details - carb water
Neck PCO 1881 Neck PCO 1810
as currently under called PCO 28
evaluation by ISBT
40° angle for easy application
21,0 mm
17,0 mm
Centering ring Drop height sufficient Thread length 650° Usable thread length:
for TEband for all TE band offers extension to 680° feasible 650°
pitch 2,7mm
PCO 1881 is the target neck for the industry.
All closure technologies work on PCO 1881
Short Neck Standard CSD
carb water
PCO 1881
PCO 1881 neck drawing
as pdf-file or 3D-edrawing
available in the Internet with following link:
button on www.bevtech.org at
Technical comittee Packaging Technology
www.profileservices.ca/files/tidbits/tidbits_missc.html
(profile services is member of ISBT)
or try
Google: „PCO1881“ or „PCO 1881“
The lighter option CSD
carb water
- a proposal from Bericap -
Short neck standard
PCO 1881 Lighter Short neck proposal
under evaluation by ISBT but off-standard Bericap – ENG-00-014132
- weight saving through:
+ reduced angle at PP ring
+ deletion of centering ring
below PP ring
+ light weighted support ring
Neck weight: 3,74gr Neck weight: 3,45gr
PCO 1881 is the target neck for Limitations of neck 14132:
the industry - all closure Neck 14132 is a off-standard neck
technologies work on PCO 1881 only SuperShorty® works properly
on neck 14132
SuperShorty® CSD
carb water
from Bericap
History of SuperShorty® from Bericap
- Bericap has started SuperShorty®
development in 2004
- development project triggered by emerging
market of beer in PET in Germany
market introduction:
- production start end of Feb 2007 in
Germany. Initial capacity 300mln
- capacity to be extended in the course of
2007 to 2.000 mln for beer and CSD
SuperShorty® provides safe
bottle Performance for up to
2ltr bottles and 8gr CO2/ltr
In the market since March 2007
SuperShorty® CSD
- closure design - carb water
Product program
SuperShorty® CSD look SuperShorty® crown look SuperShorty® still
weight 2,40 gram weight 2,60 gram weight 1,70 gram
Product features
Double Seal
- outer seal
- inner seal
Tamper evidence band
- slitted Option for inshell-
- with flexible wings for moulded oxygen
easy application scavenger liner
SuperShorty® + PCO 1881 CSD
economics carb water
reference volume 1.000 mln units
closure SuperShorty® systems PCO system
CSD CSD crown 1-pc closure
closure weight gramm 2,40 2,40 2,60 3,00
resin weight for 1.000 mln units to 2.400 2.400 2.600 3.000
weight saving from closure to -600 -600 -400
neck neck 14132 PCO 1881 PCO 1810
only SuperShorty® (under evaluation) (PCO 28)
neck weight gramm 3,45 3,74 5,05
PET resin weight for 1.000 mln necks to 3.450 3.740 5.050
weight saving from neck to -1.600 -1.310
total resin weight saving off-standard
compared to PCO 1810 (PCO 28) to -2.200 -1.910 -1.710
valued at 1.300 EUR/to EUR -2.860.000 -2.483.000 -2.223.000
Saving = 1,7 to 2,2gr/bottle
2,20 to 2,80 EUR/1000
Figures acc. best knowledge
SuperShorty® and PCO 1881 CSD
carb water
- step blow off -
F-2-01-01 BC_Step Blow off Beverage F 02-05-1122-02
Procedure:
Closure: DS28/16 FB 7077 O2S filling date: number of heads: revolutions p. min.
- closure applied on preform work procedure: AA 02-05-1028
ENG - PRO # :
Prod. Info:
00-012100 b
Comparison CSD
test start:
test end:
25.10.2006
27.10.2006
kind of head:
line speed:
adjustment:
topload:
- 1 bar applied over 1 minute order no.:
Customer:
06G181
BC Germany kind of neck:
tested by: E. Bergmann
material
core no.:
kind of closing:
closing torque:
CO2 formula:
16 inchlbs
- pressure increased over 1 minute bottler:
filling:
NR
PCO
REF
MCA1
screw cap automatic Torque Tester
Line Trail
1
2
CC - F
CC - N
Preforms Eltex 1331
to 2 bars bottle size:
bottle manufacturer: Amcor
PCO HC
BPF
MCA2
7,5R
Capper
mechanical Torque Tester X
3
4
GDB short
PCz
other X ENG #.: OPT and by hand 5 manual
- 2 bar pressure hold over 1 minute
- cycle repeated with pressure leakproofness (Process)
device
increases of 1 bar until closure leaks explanation
[101.5psi]
[130.5psi]
no.
[14.5psi]
[43.5psi]
[72.5psi]
[174 psi]
[116psi]
[145psi]
[160psi]
[29psi]
[58psi]
[87psi]
10 bar
11 bar
12 bar
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
sawed off
1 bar
2 bar
3 bar
4 bar
5 bar
6 bar
7 bar
8 bar
9 bar
preform
1 X x x x x x x x x x x x x
2 X x x x x x x x x x x x O direkt X pass
Temp. 23°C
3 X x x x x x x x x x x x O direkt O fail / leak
4 X x x x x x x x x x x x x 3 Blow off
Result: 5 X x x x x x x x x x x x x
6 X x x x x x x x x x x x x
7 X x x x x x x x x x x x O direkt
X x x x x x x x x x x x X
SuperShorty® holds pressure at 8
9 X x x x x x x x x x x x O @ 40s
X x x x x x x x x x x x x
ambient temperature (23°C) 10
11 X x x x x x x x x x x x x
X x x x x x x x x x x x O @ 40s
till 11 bar 12
device leakproofness (Process)
no. explanation
] 1 min.
] 1 min.
[101.5psi
[130.5psi
SuperShorty® holds pressure at
[174 psi]
[14.5psi]
[43.5psi]
[72.5psi]
[116psi]
[145psi]
[160psi]
[29psi]
[58psi]
[87psi]
10 bar
11 bar
12 bar
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
sawed off
1 bar
2 bar
3 bar
4 bar
5 bar
6 bar
7 bar
8 bar
9 bar
preform
elevated temperature (38°C) 1 X x x x x x x x 0 @ 20s
2 X x x x x x x x x x 0 direkt X pass
till 7 bar
Temp. 38°C
3 X x x x x x x x x x 0 direkt O fail / leak
4 X x x x x x x x x 0 direkt 3 Blow off
5 X x x x x x x x x x 0 direkt
6 X x x x x x x x 0 direkt
7 X x x x x x x x 0 @ 35s
8 X x x x x x x x x x 0 direkt
9 X x x x x x x x x x x 0 direkt
10 X x x x x x x x 0 @ 10s
11 X x x x x x x x 0 @ 20s
12 X x x x x x x x x x 0 direkt
SuperShorty® and PCO 1881 CSD
- opening performance test - carb water
SuperShorty® and PCO 1881 CSD
carb water
- blow-off performance on 2l bottle -
Opening Perform ance after
OPT test for SuperShorty® torque dependent clos ing 19 lb.in. /
2 litre - 1 litre gas - abs.4,0 bar Pres s ure
shows safe venting
5,0 absolute pressure
on 2l bottle
abs.Pressure [bar]
4,5 #1 Sk28/16 7077 FB (Eltex 1331)
4,0 #2 Sk28/16 7077 FB (Eltex 1331)
3,5
Measurements taken by the Opening ope n s e al ~ 201°
3,0
Performance Tester (OPT). The OPT 2,5
measures gas venting. 2,0
1,5
Pressure 1,0
Tests have shown that a half-full 0,5
2 litre bottle (meaning 1l gas volume) 0,0
0 100 200 300 400 500 600 700
filled with CSD can build up a maximum
Ope ning Angle [°]
inside pressure of 2,7 bar.
-> therefore opening performance Technical informations:
measured on 4 bar total pressure or Simulated bottle: 2,0 litre
3 bar overpressure Rest volumne/liquid: 1,0 litre
Opening speed Gasvolumne: 1,0 litre
100rpm means almost 2 turns per second Opening torque speed: 100 rpm.
Abs. pressure: 4,0 bar
overpressure: 3,0 bar
Technical performance of CSD
SuperShorty® on PCO 1881 carb water
• Total weight saving of 1,9 gram realisable with PCO 1881
• Weights saving can be increased up to 2,20 gram with off-
standard neck
• No blow-off risk also for large size bottles
• Secure seal up to 11bar at ambient temperature and up to 7bar at
38°C realisable
• PCO 1881 has satifactory performance under hot climate conditions
SuperShorty® with DoubleSeal shows superior performance
• CO2 retention comparable with current PCO 1810 / PCO28
solutions
CSD
Line adjustment carb water
The following bottling line elements need adjustment:
- preform infeed
- neck rings of blow molds and transfer pins in blowing machine
- bottle conveying
- bottle grippers in rinser/filler/capper
- capper sorter and feeding equipment
- capping heads to be equipped with new springs to counterbalance
reduced pitch
- new CAM for cappers which cannot adjust to lower bottle height
- adaptation of down-the-line equipment to reduced bottle height
total cost of adaptation 50.000 to 150.000 EUR/line
total saving appr. 300.000 EUR/line/year (150mln fillings p.a. per line)
payback in less than 6 months!
SuperShorty® CSD
- good look on all bottle sizes - carb water
Lightweight options for still water
still water
HEXACAP® 30/25 HEXACAP® 30/25 HEXACAP® 26,7
ultralight ultralight
at 1.90 g at 1.50 g at 1.20 g
on 3.91 g on 2.90 g on 2.50 g
neck finish neck finish neck finish
total weight: total weight: total weight:
5,81 g 4,40 g 3,70 g
Savings -2,11g or -36,3%
compared to
standard 30/25 necks and closures
Galileo I for juices
milk
juices and milk
38mm 2-piece
Galileo I
screw cap Sportscap
Traditional neck: 38mm 3-start
(in use since 12 years)
Proposal from Bericap:
Galileo I
- press-on light-weight neck
- 1-piece hinge cap made from
HDPE, completely closed from
outside before first opening
- no market application yet weight
-2,9 gr
weight saving: 2,9gr/bottle
40 % light weighting juices
milk
for juices and milk
Ref. 3419
Current 38 mm 3.3 g
neck finish
and closure - 25 %
2.5 g
GALILEO® I 38
neck finish
4.5 g and closure
- 46 %
2.4 g
7.8 g
- 37 %
Total saving 4.9 g
Neck 26/21 for edible oil
vinegar
edible oil and vinegar
Traditional neck: PET 29/21
(in use since 20 years)
Proposal from Bericap:
neck PET 26/21
- same inner diameter as PET29/21
less changes on blow moulding
equipment
- first introduction with Castelo, Brazil
others follow
- 1-piece and 2-piece closure
available from Bericap
weight saving: 3,7gr/bottle
45 % light weighting for edible oil
edible oil and vinegar vinegar
5.6 g / 6.6 g
- 43 % / 51 %
current neck
PET 29/21 3.2 g
and 2-piece
closure
2.7 g
- 49 % neck finish
PET 26/21 and
1.4 g 2-piece closure
GALILEO® II 26/21
8.3 g / 9.3 g
- 45 % / - 51 %
4.6 g
Total saving
There is a lot of plastic to be saved.
Thank you!
Presentation on Bottle & Cap Lightweighting using
induction cap sealing.
Stopping Leakers is only the beginning
Presented by: Mr Simon. S. Measures
The Point is…..
The reduction of food packaging materials and the
recycling of them, is currently one of the top priorities for
the Planet/governments/large supermarkets/food
companies/bottle manufacturers/cap
manufacturers/packaging line machinery
manufacturers/contract packers and the end user – us
How does Induction Sealing Work ?
For many years now, in fact over
30, we at Enercon Industries Ltd,
have been successfully sealing
foils onto containers to aid
packaging weight reduction.
How does Induction Sealing Work ?
The cap sealer mounts over the
conveyor and from the induction
coil emits a controlled
electromagnetic field through which
the containers complete with the foil
normally placed in the cap are
passed.
How does Induction Sealing Work ?
The electromagnetic current
induced into the foil layer of
the inner seal creates a
circulating current within the
foil, causing it to heat up due
to its internal resistance
How does Induction Sealing Work ?
• The heated foil then ‘makes active’ the
polymer coating on the heat seal face,
bonding the foil
to the neck of the container and creating a
hermetic seal.
What to do….
I will now give an example of how we have helped in a real
world application
Within the Milk Industry in the UK some 15 years ago
Enercon Industries worked very closely with a large Super-
Market to solve an issue
What to do….
The bottle manufacturer and cap manufacturer were at the time
listening to the Milk Industry, who wanted a lower priced
container and cap for their customer – the Super Market.
As a by-product of this exercise they received a light weight
bottle and cap which was also recyclable and
crushable….Unfortunately it leaked due to the many stresses the
container under went in transit from the filling line to the home
What to do….
After many new cap designs with a varying lack of success, the
dairies came up with a credit system for leaking bottles.
This however created a lot of waste not only in production but
also in the whole supply chain network
The issue of transit, storage & leakers was eventually
solved by sealing the plastic milk bottle
hermetically with foil, coated with polymer –
Issue Resolved!
What to do….
The Super Market ended up with the
product they required. Which SAVED
MONEY, helped the planet by using less
plastic, and it was RECYCLABLE.
The bottle and cap suppliers pulled back
their investment with the higher volumes
of product they sold and we all WON.
But; Stopping Leaker’s is only the beginning!
Induction cap sealing creates an hermetic foil seal. It’s Air Tight.
It also reduces:-
Bacterial Contamination and Product Oxidation
Improves Storage and Transit Conditions
Reduces rejects and Scrap in Packaging and Filling Lines
Induction Sealing also seals in freshness and can extend
shelf life (ESL)
But stopping leaker’s is only the beginning!
But a MAJOR benefit often missed by the industry especially Large
Outlets and the Prime Food Suppliers is the proven fact that
Induction Cap Sealing allows the cap and bottle to be;
Reduced in Thickness
Reduced in Weight
But stopping leaker’s is only the beginning!
The foil seal will not stop or hinder the RECYCLABLE nature of the
bottle
The strength and flexibility of the seal means that the cap or
closure will NOT require a tear band
The foil seal also means that a Bore Seal is not required
Which will reduce cap weight
But stopping leaker’s is only the beginning!
The bottle can be reduced in it’s thickness at the neck and shoulder
because ;
It no longer has to withstand high application torques for cap or
closure transit requirements
Air carriage rings on and around the neck can be reduced in
thickness and weight as they are no longer need to give additional
support to the neck
But stopping leaker’s is only the beginning!
Add to this an increase in size of the market the packing company
can attack means
Every one benefits.
And the cost for all this?
Machinery Less than £20,000 per
Production line
Packaging modification costs & addition of foil – normally paid back
by material savings in a short period
Last Thoughts to Take Away with you….
With a Foil Seal you can
Remove the Tamper Evident Band on the cap – Saving Weight
Remove the Inner Bore Seal in the cap – Saving Weight
Remove the knurling on the neck for the TE Band – Saving Weight
Reduce the neck thickness and weight as it does not need to be so
strong – Saving Weight
Move from Screw Caps to light flexible clip on covers – Saving Weight
For Single Dose applications the cap can be removed altogether
Last Thoughts to Take Away with you….
Target Industries;
Dairy
PE, PP, PET
Food and beverage (Non-Carbonated)
PE, PP, PET, Glass, CO-EX & Barrier Materials
Pharmaceutical
PE, PP, Glass
Agrochemical
PE, PP, PET, CO-EX, Fluorinated & Barrier Materials
And on & on & on…..
Any Questions?
Optimising Packaging and
Engaging Consumers
Peter Skelton
WRAP: Retail Team
Challenging time for plastic packaging …..
Recycled (PCR)
Biodegradable
content
Recyclable
Low carbon
Compostable
Innovation Weight reduction
Biodegradable Material switch
15g 49g
PET packaging
PET is growing in popularity:
– Performance
– Weight
– Recycability
– Recycled content
Polymer switch & material switch
Thermoformed sheet: move from PVC, PS to PET
Bottle: move from PVC, glass to PET
Still has opportunities for lightweighting but
increasingly challenging ……
‘Best in Class’ benchmarking …..
Sector and product level pack weight data
Enables benchmarking for optimum pack weights.
Data covers all pack inc cap/label.
Moving to ‘best in class’
Product
Packaging weight in 2003
(Tonnes )
Packaging weight reduction if all moved to the
BIC (Tonnes)
1 Wine bottles 274,817 107,000
2 Beer bottles 51,608 19,641
3 Ketchup table sauce 21,632 13,666
4 Frozen ready meals 18,100 11,601
5 Whisky and vodka 49,129 10,546
6 Carbonates (cans) 28,158 9,972
7 Beer cans 27,602 9,171
8 Carbonates (PET) 74,218 8,833
9 Frozen pizza 12,003 8,005
10 Cooking sauce jars 62,984 7,170
11 Fruit juice cartons 30,175 5,595
12 Pet food (cans) 47,773 5,435
13 Cows milk (cartons) 7,597 4,419
14 Water bottles (PET) 25,371 3,468
15 Cows milk (plastic) 62,570 3,076
Estimated total 756,472 222,375
WRAP Innovation fund:
PET Bottle Lightweighting projects
and their relevant supply chains & customers
…… but why the need for trials
Challenges
Lowest practical ‘best in class’ weights
Branded: shape retention
Design options
Processing options
‘Step change’ opportunities
Esterform project
2L CSD bottle, 500ml water bottle
Reduction:
2L: 42g to 40g : 4.8%
500ml: 25g to 20g: 20%
Both new ‘best in class’ for category.
2L: Own brand CSD
500ml: carbonated Radnor Hills water
Focus on lightweighting through design of
body/base.
500ml CSD bottle
Retained std neck
Body and base design changes
25-20g incremental steps using
different preforms
Different preforms designs
4 & 5 foot bases trialled
Overcome nesting challenge
500ml CSD bottle
Findings:
5 foot base provides better material distribution, strength
and stability. Less distortion by carbonation.
4 foot base is standard and accepted design.
Shorter preform with wider diameter performed best.
20g bottles with 4/5 feet were trialled successfully for
production, filling, capping and labelling.
Esterform
Energy saving due to resin reduction
Esterform total = 200MWhr
Coca-Cola Enterprises Ltd
CCE's 500ml light weighting progress
40
38
36
Bottle Weight (g)
34
32
30
28
26
24
22
20
94
95
96
97
98
99
00
01
02
03
04
05
06
07
19
19
19
19
19
19
20
20
20
20
20
20
20
20
Coca Cola Enterprises
Challenge:
To move evaluate feasibility of moving all UK production
from 26g to 24g 500ml bottle for all 500ml CSD bottles -
c7.5% reduction
Retain iconic bottle designs
Stringent internal testing procedures
4 UK production sites
Varying blow mould equipment
Trials
Developed a new innovative preform design to allow
material distribution and retain wall strength.
Shorter preform pilot tooling trials
Stepped trials on all 4 CCE sites
Culminating in 4m bottles being produced for market
trials from 2 sites
Outcomes
24g Bottle successfully produced and approved for
use.
CCE committed to move to 24g in Sidcup (Sept 2007)
and Wakefield (part production start 2008).
Bottle blowing equipment at some sites less capable
of blowing 24g bottle efficiently
Investment needed to allow roll out to all production
- pending.
Reports, case studies etc ….
Reports or case studies available for
projects that have completed.
www.wrap.org.uk/retail
Future picture for PET packaging……..
PET recycling
Consumers increasingly engaged with recycling
Plastic collection will grow
UK reprocessing capacity is increasing
Post consumer plastic collection
• Mixed bottles collected c45% is PET, 45% PE, 10% other/caps
• c132,000t of post-use mixed plastic collected (annualised Q4 2006)
• 50% of homes have plastic collection
Material cost …..
Oil prices?
As a general rule, less packaging = less cost …..and less carbon
Consumer behaviour
• Willwant convenience, Value, Choice
• But is going to be more demanding:
– ‘Green’ shopper
– Carbon
– Recycability
– ‘Excess’ packaging
• Greater need for education
904g
486g Glass to PET
Filled weights
Carbon
Carbon foot printing/labelling is likely to be more
understood and important
Greater need to look at carbon not just recycability,
weight etc – more complex.
What we do know:
– less material = less carbon
– lightweight packaging = less carbon
– recycled content = less carbon
WRAP LCA on 500ml non-carbonated drinks bottles:
– PET, PE, PLA, Cartons, Glass
– Recycling, composting, landfill, incineration
considered.
– Due to be published in August
Summary
It’s a changing world!
PET lightweighting needs to continue:
– Incrementally
– Step change
Carbon debate will require a more radical approach.
PET has a great opportunity in retail packaging.
Thank you
peter.skelton@wrap.org.uk
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
WRAP Conference
Next Steps in Bottle Lightweighting 26th June 2007
Where is the Market Going?
Robin Young
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
1981-2007
Gradual weight reductions
1981 1997 2007 Saving Average
2.0 litre Carbonates 60g 44-42g 26% 1%/yr
500ml Carbonates 34g 26-24g 23% 2.3%/yr
500ml still 28g 18g 36% 3.6%/yr
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Historical Barriers to Lightweighting
TECHNOLOGY
CONSUMER RESISTANCE
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Historical Barriers to Lightweighting
TECHNOLOGY
CONSUMER RESISTANCE
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Historical Barriers to Lightweighting
Technological Improvements
Improved Oven, stretching and air control with closed loop monitoring
Improved PET material grades and improved temperature uptake.
Improved preform and bottle design technology
Introduction of FORM/FILL/SEAL technology for PET bottles.
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Historical Barriers to Lightweighting
FORM/FILL/SEAL
Form/fill seal is a lightweighting tool
The bottle is handled by the neck as it is blown, filled and capped.
Removes the need to handle flimsy empty bottles allowing thinner wall
sections
Permits ULTRA LIGHTWEIGHTING
Conclusion: The technological barrier to ULTRA lightweighting has been
removed
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Historical Barriers to Lightweighting
TECHNOLOGY
CONSUMER RESISTANCE
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Historical Barriers to Lightweighting
Consumer Resistance
POLITICAL and CULTURAL CHANGE OF
CLIMATE
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
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. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Historical Barriers to Lightweighting
Consumer Resistance
POLITICAL and CULTURAL CHANGE OF CLIMATE
The constant barrage of media publicity/propaganda which will only increase
as it is at the top of the political agenda, has already affected our
consciousness and lifestyle.
We are already aware of our carbon footprint and we have already adapted
our habits by sacrificing convenience for “the greater good of the planet” –
some examples:
Re-useable shopping bags – a return to the shopping baskets of old?
Fortnightly bin collections
Separating household waste
Switching off computers and their transformers
Eco friendly light bulbs
Road miles
Congestion charges
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Historical Barriers to Lightweighting
Consumer Resistance
POLITICAL and CULTURAL CHANGE OF CLIMATE
Conclusion
The consumer is aware that plastic packaging uses non renewable resources
and contributes to landfill
The consumer will accept some inconvenience as his or her contribution to a
reduction of their carbon footprint
Has this removed the Consumer Resistance barrier to Ultra Lightweight
bottles?
There is already a challenge to the PET bottle from the flexible Pouch
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
On The Market Today in PET
Ultra Standard Saving
330ml Still Water 4.5g 18g 75%
1.0 litre Edible Oil 15g 24g 37%
1.5 litre Still Water 20g 30g 33%
100ml Probiotic 5g 7g 28.5%
100ml drinking Yogurt 2.4g -- --
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Historical Barriers to Lightweighting
Conclusion
TECHNOLOGY – Barrier Removed
CONSUMER RESISTANCE – Barrier
Removed
Fit for Purpose
When considering any level of
lightweighting, the consumer should be
made aware of the carbon footprint benefits
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Thank You
Next steps in PET
bottle light weighting
Triple Bottom Line Savings-
Waste, Carbon and Costs
Professor Edward Kosior
Managing Director
Nextek Limited
Overview
• The Light Weighting of existing
bottles
• Target weights for PET bottles
• Savings in materials, carbon and costs
250 ml Bottles
Estimated weights of 250mL bottles in the UK marketplace
30
25
Weight (gm)
20
15
10
5
0
0 2 4 6 8 10 12
Millions of Bottles Produced
330 ml Bottles
Estimated weights of 330ml bottles in the UK marketplace
25
20
Weight (gm)
15
10
Recommended Target Weight: 16gm Key Targets
5
0
0 20 40 60 80 100 120
Millions of Bottles Produced
500ml CSD Bottles
Estimated weights of 500ml csd bottles in the UK marketplace
30
25
Weight (gm)
20
15
Recommended Target Weight: 20gm Key Targets
10
5
0
0 100 200 300 400 500 600
Millions of Bottles
1000 ml CSD Bottles
Estimated weights of 1L csd bottles in the UK marketplace
50
40
Weight (gm)
30
20
Recommended Target Weight: 30gm Key Targets
10
0
0 5 10 15 20 25 30 35
Millions of Bottles
1000 ml Water Bottles
Estimated weights of 1L still water bottles in the UK
marketplace
60
50
Weight (gm)
40
30
20
Recommended Target Weight: 25gm
10
0
0 5 10 15 20 25 30
Millions of Bottles
2000 ml Bottles
Estimated weights of 2L bottles in the UK marketplace
48
47
46
Weight (gm)
45
44
43
42
Key Targets
41
40
39
0 100 200 300 400 500 600
Recommended Target Weight: 39gm Millions of Bottles
The Savings
Savings delivered by light weighting PET
Each one gram saved on a preform used for a
market of 100 million bottles saves
•100 tonnes of PET
•£80,000 of costs for PET resin at £ 800/tonne
•80,000 kWhr of energy for preform moulding
•2670 kWhr of energy for preform heating for
blow moulding
•36 tonnes of CO2 being generated
•27.2 tonnes of Carbon being used
Assumptions for savings calculations
•The best in class weights or feasible targets were used
to model savings
•Tonnage savings greater than 90 tonnes /year were
considered financial viable
•This is equivalent to savings in resin of more than
£200,000/yr
•The ratio of data submitted by fillers was used to model
the UK industry
Data submitted to the seminar
Fillers Volume Tonnes Ave bottle Annual % Weight Ave % Light Cost
millions pa used weight weight saving weighting savings
saving
tonnes
PET
Fillers total 3648 109148 28 12425 11% 14% £9,940,351
Moulders total 953 24103 26 3166 13% 24% £2,532,400
Potential weight saving projects
Bottle Type Fluid Quantity Current Light saving Annual tonnes % weight Cost savings
(carbonated, Capacity produced Bottle weight grams per weight used saving
water, or juice) (ml) per annum weight (g) target preform saving
(millions) tonnes
PET
Juice 200 22,087 17.5 14.5 3 66 387 17% £53,009
Juice 200 26,099 17.5 14.5 3 78 457 17% £62,638
juice 250 5.5 20 14.5 5.5 30.25 110 28% £24,200
Juice 1000 4,280 39 25 14 60 167 36% £47,936
Juice 200 28,197 17.5 14.5 3 85 493 17% £67,673
Juice 200 41,984 17.5 14.5 3 126 735 17% £100,762
Juice 200 47,182 17.5 14.5 3 142 826 17% £113,237
Juice 200 67,559 17.5 14.5 3 203 1182 17% £162,142
Juice 200 107,272 17.5 14.5 3 322 1877 17% £257,453
Juice 300 25,571 20.5 16 4.5 115 524 22% £92,056
Juice 300 30,043 20.5 16 4.5 135 616 22% £108,155
Juice 330 60 21 16 5.0 300 1260 24% £240,000
Juice 440 12,147 31 20 11 134 377 35% £106,894
Carbonated 500 13,679 26 20 6 82 356 23% £65,659
Carbonated 500 23,526 28 20 8 188 659 29% £150,566
Still 500 60 25.5 20 5.5 330 1530 22% £264,000
Carbonated 500 88,016 26 20 6 528 2288 23% £422,477
CSD 500 800 26 24 2.0 1600 20800 8% £1,280,000
Juice 1000 5,609 40 25 15 84 224 38% £67,308
Juice 1000 5,600 43 25 18 101 241 42% £80,640
juice 1000 7.9 40 25 15.0 118.5 316 38% £94,800
Juice 1000 13,187 38 25 13 171 501 34% £137,145
Juice 1000 13,191 40 25 15 198 528 38% £158,292
Juice 1000 16,242 40 25 15 244 650 38% £194,904
CSD 1000 80 36.5 30 6.5 520 2920 18% £416,000
Carbonated 1000 118,044 36 30 6 708 4250 17% £566,611
still water 2000 70 43 40 3.0 210 3010 7% £168,000
Juice 2000 156,084 43 40 3 468 6712 7% £374,602
CSD 2000 500 42 40 2.0 1000 21000 5% £800,000
Total 8346 74994 11% £6,677,156
Summary of savings that could be achieved
by companies at this conference
•Based on 74,994 tonnes of current PET useage
•Average weight saving is 11%
•Tonnage saved is 8346 tonnes of PET
•Cost savings of £6,677,156
•Ratio of “viable projects” was 69%
Projections for the UK PET market
•PET resin savings of 15,300 tonnes per annum
•Equivalent to 510 million bottles diverted from waste
•Energy savings 12.6 million kWhrs
•CO2 emission savings of 5500 tonnes
•Carbon savings of 4160 tonnes
•Cost savings of £12.2 million
Tonnes saved Bottles Energy CO2 Carbon Resin Cost Power cost
equivalent Saving Saving Saving saving saving
Tonnes pa Millions at kWhr tonnes tonnes 0.05£/kWhr
30 gm/bottle
15294 510 12,643,420 5506 4160 £12,235,074 £632,171