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MAGAZ INE FOR BOTT L E RS AND BOTT L E -MAKERS IN THE AMERICAS, ASIA, EUROPE AND ALL AROUND THE PLANET

01 .02 .08

PETplanet is read in 136 countries

Suppliers of caps and

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MARKETsurvey

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Regional market repor ts

Czech RepublicPart 2

Page10

KHS fi lling technology at Coca-Cola in Chongqing, China

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EDIT

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3PETplanet insider Vol. 9 No. 01+02/08 www.petpla.net

PUBLISHERAlexander Bchler, Managing Director

HEAD OFFICEStefanie Saueressig, Head Offi ce Managerheidelberg business media GmbHLandhausstr. 469115 Heidelberg, Germanyphone: +49(0)6221-65108-0fax: +49(0)[email protected]

EDITORIALDoris Fischer, Content ManagerTony ONeill, Senior EditorWolfgang von Schroeter, Consultant EditorIlona Trotter, Editorial CorrespondentGabriele Kosmehl, Editorial Correspondent

MEDIA CONSULTANTSUte Andrphone: +49(0)6221-65108-0fax: +49(0)[email protected]

France, Italy, Spain, UKElisabeth Maria Kpkephone: +49(0)6201-878925fax: +49(0)[email protected]

America:Ottmar Brandau434 Oakland Road Mahone Bay NS BOJ-2EO - Canadaphone: +1-902-531-2028fax: [email protected]

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PETplanet insider ISSN 1438-9459 is published 10 times a year. This publication is sent to qualifi ed subscribers (1-year subscription 149 EUR, 2-year subscription 289 EUR, Young professionals subscription 99 EUR. Magazines will be dispatched to you by airmail). Not to be reproduced in any form without permission from the publisher.Note: The fact that product names may not be identifi ed as trade marks is not an indication that such names are not registered trademarks.

EDITORIALdear readers,

KHS and Corpoplast now under one roof

For a long time the future of KHS, with its parent company Klck-ner-Werke, was kicked back and forth like a football between its now insolvent owner WCM and the previous managing director Roland Flach and this cronies (see Editorial PETplanet Insider 11+12, 2006). Finally, in 2007, Salzgitter AG, taking over 86 percent of the shares, brought some stability and direction to the KHS business. With signifi -cant investment in the infrastructure by the new owners KHS suc-ceeded, in 2007, in growing a lot faster than their eternal rivals Krones (see PETplant Insider 10/2007, page 50ff).

Another milestone in the Salzgitter strategy is now the acquisi-tion of SIG Beverages as confi rmed by Bernd Gersdorff, spokesman for Salzgitter AG, in an interview with PETplanet Insider. In addition to our three major commercial interests - trading, pipelines and steel - we are now deliberately building an important new area of interest in what for us is a relatively young sector, namely beverage technology. The take-over of Klckner-Werke was the fi rst step. SIG Beverges is now a further step. In our conversation Gersdorff also did not rule out the possibility of more take-overs in this sector.

A key element in the SIG Beverages business is the SIG Cor-poplast range of stretch blow moulding machines. KHS will now be able to offer clients a full PET beverage line from a single source. In fact SIG Corpoplast was at one time already part of a single-source supplier. Under the SIG umbrella Corpoplast and Simonazzi were supposed to constitute full-line supplier, but it was a marriage that was accepted by the market only hesitantly. The cultures within the two companies, in Germany and Italy, were just too different.

KHS can now join the exclusive club of full-line suppliers, i.e. Krones, Sidel (with the former Simonazzi), and Gea with Procomac. Other big companies that work closely together are Sipa (PET SBM machines) and Berchi (fi lling machines).

KHS had already adopted the idea of offering SBM machines to their clients, and the company had in particular been down the road of developing such equipment in house. Volker Till, R&D director at KHS, has submitted several patent applications in this regard, some of which have already been published. I feel sure we will soon see his mark on the Corpoplast machines.

Yours,

Alexander Bchler

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4 PETplanet insider Vol. 9 No. 01+02/08 www.petpla.net

PETcontents 1+2/08INSIDE TRACK

3 Editorial 4 Contents 6 News 31 Products 32 Bottles 38 Patents

REGIONAL MARKET REPORT 10 Czech Republic Part 2

MATERIAL / RECYCLING 16 Coca-Cola aims for

100 percent recycling in USA

BOTTLE MAKING 18 PET container air conveyors

MARKET SURVEY 19 Suppliers of caps and

closures for PET bottles

BOTTLING / FILLING 24 China - a Coca-Cola

success story

TRADESHOW SPECIAL 28 Successful premiere for

drink technology + PET India

CAPPING /CLOSURES 30 Sacmi continues to develop

compression technology

BUYERS GUIDE 34 Get listed!

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Page30

Page32

Page18


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PETnewsSidel names new presidentMart Tiismann succeeded Grard Stricher as president and CEO of Sidel on January 1st, 2008. Swedish-American Mart Tiismann (51) joined Sidel in 2005 as executive vice president. He took over industrial operations and product R&D activities at Sidel after holding a variety of posts with Scania, Eaton, Ingersoll-Rand, and Esab in Europe and the United States. Stricher, who has worked alongside Tiisman for two years, joined Sidel in 2001 and has led the Group since 2002. He has been the catalyst for Sidels trans-formation into a full line supplier of bottling equipment, including the suc-cessful merger between Sidel and Simonazzi that began in 2005.Stricher is retiring in April 2008 at the age of 60. Until then, he will con-tinue to assist Sidels new president as he assumes his duties.

ColorMatrix opens China offi ceIn January the ColorMatrix Group Inc. celebrated the opening of Color-Matrix Plastic Colorant (Suzhou) Co. Ltd., a manufacturing and offi ce facility in Suzhou, Jiangsu Province, China. The event was celebrated in true Chinese style with a lion dance and the traditional ribbon cutting ceremony. The occasion was attended by Suzhou Government offi cials, ColorMatrix customers and the management and employees of The ColorMatrix Group.William Ravenna, Managing Director of ColorMatrix Europe and Asia, said: Our Asian customers have benefi ted from the companys know-how and service, managed from our commercial offi ce in Hong Kong, since 1995. They will now further profi t from the advantages the vicinity of the ColorMatrix manufacturing plant will grant: local production and speed of delivery.The new facility occupies more than two thousands square metres and hosts, alongside the production plant itself, a colour-matching laboratory and offi ces.

Eastman to sell PET and PTA assets in EuropeEastman Chemical Company has announced that it has entered into defi nitive agreements with Indorama to sell its PET facility and related businesses in the United Kingdom, and its PET and PTA facilities and related businesses in the Netherlands. The total cash proceeds of the transaction are expected to be US $330 million. The Eastman site at San Roque, Spain, was divested in April 2007.This transaction will complete the plan we announced one year ago to address our non-strategic PET assets outside the U.S., said Gregory O. Nelson, Eastman executive vice president and polymers business group head.

Senior management changes at LurgiLurgi AG, who recently acquired the business of Zimmer (Frankfurt based suppliers of polyester production technology and plant), have announced the departure of CFO Klaus Buchborn-Klos. Meanwhile Klaus Moll is to resign his position as CEO of Lurgi and join the companys supervisory board on behalf of Air Liquide. Lurgi is a member of the Air Liquide Group.

Salzgitter/KHS acquires SIG BeveragesIt has been announced that Salzgitter AG, the parent company of KHS, has acquired SIG Beverages, and with it the Corpo-plast range of blow-moulding machines. The acquisition will allow Salzgitters KHS subsidiary to supply complete PET bottle blowing, fi lling and packaging lines from a single source. SIG Beverages has 480 employees, mainly in Germany, and as well as SIG Corpoplast includes SIG Asbofi ll and SIG Plasmax. SIG Com-bibloock is not part of SIG BeveragesWhen Salzgitter acquired Klckner-Werke AG, and the KHS packaging machinery line, in 2007 the company made it clear that there was a policy of strategic and operative expansion. The acquisition of SIG Beverages is described as an ini-tial, and highly relevant step in further developing Kloeckner-Werke. The parties have agreed to keep the value of the sale confi dential.

Rexam trading statementIn a pre-close trading statement Rexam have announced that underlying trading for the second half of 2007 is anticipated to be broadly in line with managements expectations, excluding the impacts of foreign exchange and a one-off fair value inventory adjustment arising on the acqui-sition of O-I Plastics.Beverage Cans is performing well, driven by strong volume growth in Europe and South America. Plastic Packaging is seeing a continuation of the trends expe-rienced in the fi rst half. At that time sales were up 3% on the equivalent period in 2006 benefi ting from organic growth of 4% and acquisitions of 5%, offset by a 6% negative currency effect.The integration of O-I Plastics is proceed-ing well and is set to deliver the expected synergies from 2008 onwards. However, the 2007 operating profi t for O-I Plastics will be affected by an estimated addi-tional 5m fair value inventory accounting charge arising on acquisition.Rexam will announce its preliminary results for the year ending 31 December 2007 on 20 February 2008.


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Packaging design by tecPETThe German company tecPET, based in Regensburg, offers a complete bottle design service that boasts an inte-grated concept of technical know-how and visual design resulting in a very short time to market.The advantage becomes obvious during the client brief-ing when at this early stage not only design aspects but also technical and technological requirements can be discussed. Bottle development and label design go hand in hand and it is tecPETs mission to accentuate the unique-ness of the product and to include label requirements in the development process from the start. Small, or even trial quantities can be supplied as the company operates a Husky HyPET and a Nissei ASB machine. Small PET bot-tles are entering the fi eld of cosmetics and personal care, and milk in PET is enjoying a high level of interest - both are areas of special focus at tecPET.

New web site for Engel Since mid-November information about the broad range of Engel products is provided quickly, clearly and extensively on a new web site. www.engelglobal.com contains not only current product and application details, but also the latest information about Engels target markets, current press releases and event information, and an online registration form for seminars.

Krones in joint project to cut heating oil consumption Following the completion of protracted planning permis-sion procedures the Krones concept for using solar-gen-erated process heat in a brewery is now scheduled for prompt implementation. The announcement was made by Krones and the privately owned Hofmhl Brewery in Eich-sttt during the BRAU exhibition in Nuremberg. In the fi rst stage the project partners are installing a solar thermics system with a collector area of 1,000 m2, scheduled to go into operation early this year, with plans for subsequent upsizing to 3,000 m2. In all, the solar-thermic energy is set to replace about 60 per cent of the heating oil hitherto required by the brewery. Krones contribution covers the entire engineering work, the process control system and supplying the collectors. The project is being subsidised by the German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety. The 1,000-m2 collector fi eld at Eichsttt is able to produce around 500,000 kWh of heat a year and will create annual savings equivalent to more than 55,000 litres of heating oil. Simultaneously, CO2 emissions at the Hofmhl Brewery will be reduced by around 150 t/a compared to oil-fi red heating, even in the fi rst phase of the project.

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International beer strategy conferenceCanadean, the global beverage research company, has announced the 6th International Beer Strategy Confer-ence which will take place in Madrid on the 24th and 25th of April 2008. The title of this years conference is Delivering Value Profi table Growth in a Challeng-ing World.There have been many dramatic changes in the global beer industry since Canadeans fi rst international beer conference in 1998. Leading companies, such as InBev and SABMiller were yet to be created. The ranking of the worlds leading brewing groups, once dominated by brewers from Western Europe and the Americas, now includes Chinese companies such as China Resources, Yanjing and Tsingtao. China overtook the USA as the worlds largest beer market in 2002 and growth of the Rus-sian market has also been dramatic, with consumption having trebled since 1998. Against this background, Canadeans 6th International Beer Conference offers delegates the ideal opportunity to learn more about current issues and trends and the chance to debate these issues with other industry leaders and experts. The keynote speech will be given by Jorgen Buhl Rasmussen, the new CEO of Carlsberg.For further details on Canadeans Inter-national Beer Conference please con-tact Canadeans Corporate Marketing Department on tel: +44 (0) 1256 394210 or visit www.canadean.com.

Fourteen Amcor plants awarded AIB Gold Standard Fourteen Amcor PET Packaging plants have been awarded AIB Internationals rigorous Gold Standard certifi cation, more than any other packaging supplier in the world. AIB International is a corporation founded by the North American baking industry in 1919. The Gold Standard programme is the most thorough, integrated food safety and quality system a com-pany can adopt for its manufacturing organization. On a facility by facility basis, it ensures that the highest levels of food safety and quality management have been achieved and will be maintained, in order to meet and exceed the most demanding customer and regu-latory requirements. The successful completion of four audits is required for Gold Standard certifi cation during the 12 months prior to application. These include two unannounced Good Manufac-turing Practices (GMP) audits, a Hazard Analysis Critical Control Point (HACCP) accreditation, and a Quality Systems Evaluation (QSE) audit. Once the application is accepted, the facility submits random production samples for compliance validation.

Onex completes acquisition of HuskyOnex has now formally completed its 960 million Canadian Dollar acquisition of Husky Injection Molding Systems. I am pleased that shareholders over-whelmingly approved the arrangement for Onex to acquire Husky, said John Galt, Huskys President and CEO. I would like to thank them for their sup-port over the years and now look for-ward to partnering with Onex to execute our strategic plan and continue to grow the business.

8% growth for ResiluxThe sales of both preforms and bottles at Resilux grew in 2007 by more than 8% compared to 2006, despite a weak summer period.This growth can be ascribed to the continuous growth in the market for PET packaging. It is also the result of the implemen-tation of the new Resilux sales strategy whereby the geographi-cal spread within Europe is a major asset, allowing Resilux to make optimum use of the logistic advantages. The combination of growth, favourable product mix and cost control resulted in a strong increase in EBITDA. After some diffi cult years a turnaround has been realised and Resilux expects to return to a profi t position when the 2007 fi gures are released.

Record PET year for HuskyHusky Injection Molding Systems have announced that orders for preform moulds and systems increased more than 13% in fi scal 2007 and that was the highest PET order intake in the companys history. This is the second consecutive year in which Husky has achieved a record-breaking number of orders for the PET market. All segments of the market performed strongly. Bottled water, aseptic juices, hot-fi lled teas and sports drinks all grew at double-digit rates and all of our geographic markets grew beyond expec-tations, said Jeffrey MacDonald, Huskys Vice President of Bever-age Packaging.Husky attributes the strong order levels to a robust market, but also to improvements in HyPET performance, which included cool-ing improvements, dry-cycle reduction times and hot runner refi ne-ments that have allowed an overall cycle time reduction of more than 25% compared to 2003 when HyPET was launched.PET still accounts for only one-third of all beverage packaging, so there is room for more growth, said MacDonald. Were working to make PET the preferred choice for beverage packaging by provid-ing lightweighting solutions, barrier technologies, and improving the economics of PET manufacturing.

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Alliance for Krones in IndiaThe Indian beer market is in a very promising growth phase. Krones regards the Indian subcontinent as one of the key markets of the future and has accord-ingly agreed a long-term alliance with the Indian Dairy Machinery Company (IDMC). Informal collabo-ration and joint sales approaches with quotations for numerous brewery projects have been practised since 2001. The high import duties often render it imperative for European vendors to manufacture some brewery equipment locally. IDMC stood out as an optimum solution for Krones. This company, headquartered at

Annand in the state of Gujarat, manufactures lines for both the brewery sector and the dairy and pharmaceu-tical industries, which means it covers the majority of Krones potential client sectors. Encouraged by the successful collaboration in two major brewery projects Krones has decided to work more closely with IDMC. The alliance involves exclu-sive manufacture for Krones on the brewery technology sector. Krones will in return be intensifying its proactive sales and marketing activities on Indias future-friendly beer market and will consequently strengthen the sales force at Krones India in Bangalore.

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Having taken a close look at the Czech beverage industry in our last issue we now,

in line with the usual format, bring you the reports on our visits to the major players.

The comments and views of the machinery manufacturers were already included in

Part 1, so that here we carry the reports on our visits to the two big beverage fi llers Mat-

toni and Korunni, and an interesting report on a different aspect - recycling. We visited

PTP, a company that has developed a novel recycling method and equipment, and with

their pilot plant have become a key player in the Czech Republic.

The Czech Republicby Alexander B. Bchler

KorunniThe Czech mineral water fi ller Korunni is one of the

key players on the Czech market. With 20% value share* on non-fl avoured mineral water Korunni is not the market leader, but surely is the trend setter. It was this brand that introduced the concept of non carbonated mineral water to the Czech market. The market leader tried to follow Korun-nis steps but even three years later Korunni still accounts for 40% of sales in this segment. Several years ago there was only carbonated mineral water in Czech Republic. To-day carbonated variants account for 50%, mid-carbonated for 30% and non-carbonated for 20% of total value sales in the category. The market in this sector of the beverage industry is growing by 5% per annum, although Korunni has only a low double-fi gure market share. In the Czech Republic the changeover from glass to PET was started as early as 1997 and within two years glass became a niche packaging option. Today 90% of the fi llings are in 1.5 litre bottles. In impulse-purchase packaging a shift from 0.5 li-tre PET to 0.75 litre PET is being seen. Korunni again was the fi rst mineral water fi ller to introduce the 0.75 litre PET format to the Czech market.

Since 2005 plastic labels have also been used in Ko-runni and an eye is being kept on the development of PLA materials.


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Korunni see themselves as leading the way in the min-eral water business and have set new standards with their products. When developing the product a great deal of at-tention was also paid to the packaging, which is one of its distinguishing features. In Czech korunni is the equivalent of crown prince or crown princess and the bottle design took the name into consideration. It is intended to look rather like the queen in a chess set.

The closures are attractive, crown-like and at 3.8 grams are considerably heavier than the general average of 2 grams. For the coming season a sports cap from Seaquist will be used for non-carbonated Korunni in a 0.75 litre PET bottle.

The slogan used to promote Korunni products is A drop Better Life. A recent Korunni product, launched in Oc-tober of 2007, is Silueta. It differs from the companys other products in many respects and is the fi rst bottled water in the Czech Republic sweetened with sucralose (Splenda) - the zero calorie sweetener - and using nutritional labelling by GDA. Unlike the companys other products the colour pink has been chosen for the Silueta bottle - with the aim of conveying the idea of lightness and to show clearly that

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the product is primarily targeted at women. Other non-fl a-voured and fl avoured mineral waters are fi lled in turquoise bottles.

The business of the market leader Mattoni is volume driven. This means that its premium products were exten-sively promoted by extremely low prices, and is claimed to be ruining the business with the bottled water in the Czech market. Again it had to be Korunni to take the fi rst step and increase prices, becoming the most expensive local brand in the market. Once the consumers accepted the prices, the market leader followed. The strong competition in this sector has led certain competitors such as Bonaqua (a Coca-Cola product) to cut their prices for a 1.5 litre bottle from 15 Crowns to 5.5 Crowns during its re-launch period when the packaging and pricing policy was changed.

Korunni sees the major driver of future growth of bottled water in the Czech Republic in the segment of functional water. Would Korunni enter that segment? It surely would not be surprising.

*Year 2007, source: MEMRB/IRI)

In Czech ko-runni is the equivalent of crown prince or crown princess and the bottle design took the name into con-sideration. It is intended to look rather like the queen in a chess set.

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From prototype to a fully

commercial process

Plastic Technologies & Products, part of PTP Group, is a bottle-to-bottle recycler in the Czech Republic. How-ever, the company does not use the traditional method of increasing I.V. in a vacuum environment (SSP method). The company has developed its own technology, which is based on mixing cleaned fl akes with a modifi er, which reacts in a special reactor and during the extrusion stage to convert the PET once more into bottle grade material.

Plastic Technologies and Products (PTP), headquar-tered in Prague, was founded in 2001 and today employs some 80 people. In addition PTP has offi ces in Europe and the USA. It was in 2002 that PTP successfully developed its new concept for recycling technology. After its initial use the polymer material (be it PP, PE, HDPE, PET or PC) is sub-jected to a chemical modifi cation process for recycling. In the case of PET this material is known as PET-M. The recycled granulate PET-MTM produced by PTP from post use PET bottles was approved in 2005 by the Czech ministry of health (SZU) and the American FDA for food contact use.

When realising these new recycling concepts PTP puts special emphasis on the cleaning process to minimize dis-coloration (known as yellowing). In addition to continuous quality control the simplicity of the process is a prime con-sideration. Energy consumption has to be as low as pos-sible and the different process steps should be particularly environmentally-friendly. Development and innovation in re-cycling technology and processing of packaging materials are the principal activities of PTP. The recycling plant in the Czech Republic is to demonstrate that producing recycled granulate that is no different in quality from virgin material, is a realistic concept.

The total usage of bottles in the Czech Republic ac-counts for 65 kilo-tonnes of material per annum. Of this, 32 kilo-tonnes are collected and 10 kilo-tonnes are recycled at the PTP plant in the Czech Republic. In the fi rst stage of the process PET bottles are ground, washed and impuri-ties are separated to supply clean PET fl akes to the PET-M process. The main characteristic of the PET-M process is the addition of a mixture of modifi ers. In the process these modifi ers are mixed with PET fl akes, heated and dispersed over the PET fl akes surface, where the reaction starts partly. The coated fl akes are transferred to the extruder where a full reaction is realized in the melt phase of PET. For optimal processing the Crystal Cut Technology, devel-oped by BKG is applied in this technology, under license of PTP Group.

After developing the process in 2002 and installing a Husky G Line preform system in 2003 PTP has been able to successfully work on optimization of the process. Today the preform system, can make 4 different preforms (between 35 and 47 grams), containing up to 70% PET-M. PTP produces 50 million preforms a month.

The recently installed state-of-the-art equipment allows continuous material recycling and allows PTP to produce economically recycled PET that is as good as virgin in terms of quality. This means that PTP can supply PET-M to converters at a price level of about 85% of the price of virgin material.

PET-M is going to be produced at several locations across Europe.


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MattoniThe company was originally founded in 1873 by Mr.

Heinrich Mattoni. At that time what is today the Czech Re-public was still a part of the Austro-Hungarian Empire and the family of Heinrich Mattoni was originally from the south part of the Empire, from Italy. He established his mineral water business in the north of the Empire, in Carlsbad. The name Mattoni remains the same, although the ownership has changed several times. After the 1989 Velvet revolution Italian infl uence appeared once again in the form of Mr. Antonio Pasquale, who in 1991 entered enterprise through a joint venture, bringing with him many years experience in the operation of fi lling lines in Italy. He quickly focused his attention on Mattoni enterprise and sold his Italian busi-ness in 1995. Then the rapid development of Mattoni, part of Ronaldsay group, began, and today it belongs 100% to the Pasquale family.

The family expanded the business signifi cantly, buy-ing up mineral water operations in the Czech Republic, Ukraine, and most recently in Austria. The company now has several lines and fi lls 1 billion litres of water, ice tea and fl avoured water annually. In the Czech Republic, the Ronaldsay group satisfi es one quarter of soft drinks market (including the bottled water, CSD, juices, ice teas, energy and sport drinks). When we consider that the group does not produce juices and CSDs, the market share of the sec-tors where they compete is really much higher. But this strong brand positioning did not simply fall into Mattonis lap. Top quality and cost-effi cient production methods are the secrets of a strong business. And right from the beginning, in 1991, Pasquale saw the importance of good marketing, which at the time was almost unknown in the country. Thus he was able to rapidly increase his output and his market share.

The importance of marketing is still acknowledged today. The Mattoni core product in a 1.5 litre bottle has just been relaunched. It has been given a new shape by creative designers and the eagle, the company logo, has been given pride of place, moulded into the bottle during the blow-moulding process. The label has been made more optically lighter and partially transparent. The ergonomic shape of the new bottle with slimmer waist area better fi ts even the ladies hand. In the view of Alessandro Pasquale, son of Antonio Pasquale, another big step was the colour change - from dark green to a very light green. Here in the Czech Republic it is as if Coca-Cola changed their red to a light pink colour, he said. We will be interested to see how well the new bottle is accepted by the consumer.

But it isnt only in quality and marketing that Mattoni leads the way. They have adopted some ideas in their



The Mattoni core product in a 1.5 litre bottle has just been relaunched. It has been given a new shape by creative designers and the eagle, the company logo, has been given pride of place, moulded into the bottle.


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manufacturing plants that can only be explained by spe-cial local conditions. For example the warehouse is on the second fl oor; blowing machines and fi lling lines are on the fi rst fl oor. It was of course necessary to erect some heavy load-bearing supports to carry the weight of the ware-house. The reason for doing this is the enclosed hillside location, which would allow only this type of logistically optimised material fl ow. The trucks drive directly to the second fl oor along the hillside. A pallet lift moves the full pallets from the fi rst fl oor to the second fl oor. When buying the business Pasquale acquired not only the brand and the mineral springs, but also an adjoining 18 km railway track and a bridge over the river. The bridge, more than 100 years old, is still full of life. On one side of the river is bottle production and fi lling, and on the other side pre-forms have been produced since 2001.

Mattoni produce own preforms, weighing 30 grams or more, for the 1.5 litre bottles. Three Husky Index ma-chines, running 60 cavity tools, turn out preforms for fi lling directly in the factory. No preforms are supplied to the groups other plants. These are all purchased from pre-form manufacturers. For the Mattoni plant in Carlsbad only preforms for 0.5 litre bottles are purchased. Furthermore, Pasquale doesnt want to start any new preform produc-tion in his other factories and because the transport costs from Mattoni plant to other factories of the group would be far too high, he prefers to outsource it and use external suppliers. And perhaps even more important, if the pre-forms are not to specifi cation we can send back them to the supplier. If we mould them ourselves we are saddled with defective preform.

With the new 1.5 litre bottle design Pasquale is now looking to reduce the preform weight. He is of course considering the idea of a new, weight-saving, neck fi nish. But the Index machines always need two or four neck-ring sets. For Pasquale the service availability of the equip-ment is very important. And that is excellent, he con-fi rms.

Mattoni chooeses the Original

Mattoni, the Italian owned, bottled water company, and the biggest in the Czech Republic, has opted for the Seaquist 28mm Original bi-colour sports cap with Sim-pliSqueeze valve for its 0.75 litre range of fl avoured and functional waters. The transparent contours of the clo-sure complement the elegant lines of the bottle, while the brightly coloured spouts matching the labels indicate the fl avours or product lines.

Mattoni has opted for the Seaquist 28mm Original bi-colour sports cap with SimpliSqueeze valve for its 0.75 litre range of fl avoured and functional waters.

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In September Coca-Cola announced its intention to recycle or reuse all of the PET bottles that the company uses in the U.S. market. Coke is investing more than 60 million Dollars to build the worlds largest bottle-to-bottle recycling plant, and to support recycling in the U.S.

Coca-Cola aims for 100 percent recycling in USA

We have set an ambitious goal, said Sandy Douglas, president Coca-Cola North America. Our investments in recycling infrastructure, coupled with our work on sustainable package design, will help us reach this target.

The Coca-Cola Company and United Resource Recovery Corpora-tion (URRC - see inset) will build the worlds largest plastic bottle-to-bottle recycling plant in Spartanburg, S.C. The plant will produce approximately 100 million pounds (about 45,000 tonnes) of food-grade recycled PET each year the equivalent of produc-ing nearly two billion 20-ounce Coca-Cola bottles.

The new 30-acre Spartanburg plant will open in 2008 and will be fully operational in 2009. It is part of a con-tinuing effort by Coca-Cola to support recycling in key markets. Coca-Cola has also invested in recycling facilities in Switzerland, Mexico, Austria and the Philippines. Today the Coca-Cola Company uses recycled content in more than 17 countries, including the United States.

Over the next ten years the Spar-tanburg plant is expected to eliminate the production of one million metric tons of carbon dioxide emissions the equivalent of removing 21,500 cars from the roads.

Coca-Cola recycling

While PET has a high value as a recyclable in the marketplace, not enough material is recovered to meet the increasing demand for recycled con-tent. To help bridge this gap and ensure ready access to recycled material, Coca-Cola Enterprises, Inc., the largest Coca-Cola bottler in North America, and the Coca-Cola Company formed Coca-Cola Recycling LLC (CCR) in Novem-ber 2006.

CCR is dedicated to recovering and recycling Coca-Cola packaging materi-als used within the Coca-Cola system in the U.S. including PET, aluminium, cardboard and plastic fi lm.

Expanded partnership with RecycleBank

Coca-Cola also continues to expand its relationship with curbside collection organisations. The company will be expanding its partnership in Recycle-Bank (see inset), an organisation that currently operates post-consumer col-lection services in six US states. The additional investment will support a national rollout of the RecycleBank pro-gram by 2009.

RecycleBank makes recycling easier and more convenient for con-sumers, said Scott Vitters, director of sustainable packaging at the Coca-Cola

Company. While consumers reap the rewards of recycling through Recycle-Bank incentives, businesses also ben-efi t through the increased collection of valuable, reusable materials like PET.

Recycled PET merchandise programme

Coca-Cola also has introduced a line of merchandise made out of recycled PET bottles. The products feature playful, pithy slogans such as Im wearing post-consumer waste, and My white T-shirt is green, and are designed to inspire action by making every bottle count. Coca-Cola apparel and consumer products made with recycled PET are available online at www.cokestore.com and at the New World of Coca-Cola in Atlanta. The line will shortly be available in retail loca-tions across the United States.

Sustainable package design

Coca-Cola introduced the fi rst food-grade plastic bottle made with recycled material in 1991. Since then the company has continued to improve the resource effi ciency of its packages by lightweighting. Lightweighting and bottle closure design efforts across all Coca-Cola products in PET packages will save 100 million pounds (46,000 tonnes) of plastic this year in the U.S.

The Coca-Cola Company and URRC will build the worlds largest plastic bottle-to bottle recycling plant in USA.

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URRC United Resource Recovery Corporation

(URRC), headquartered in Spartanburg, S.C., is a leader in PET recycling technology. In 1994 URRC completely revolutionised the PET recycling industry by developing and patent-ing the world renowned Hybrid UnPET process for chemically super-cleaning PET fl ake for cost effi cient food grade packaging. In 1996, the com-pany entered into a 5-year development program with the Coca-Cola Company to commercialise the process by producing food-grade quality PET chips for bottle-to-bottle recycling. URRC provides manufacturing in the United States and offers licensing opportunities and engineering services for clients world wide.

RecycleBank RecycleBank is a rewards program that moti-

vates people to recycle. It does this by quickly and easily measuring the amount of material each home recycles and then converting that activity into RecycleBank reward dollars that can be used at hundreds of local and national rewards partners. RecycleBank is simple to implement, is market-driven and proven to work.

The plant will produce about 45,000 tonnes of food-grade PET each year.

Norgren has over 15 years experience as full-line supplier of pneumatic equipment for Stretch Blow Moulding (SBM) machines.

Norgren SBM product range: Blowing valve blocks Actuators Compensation valves Cooling valves Air recovery valves Silencers

Cooling ValveOptimisation of your heat set process

NORGRENSSTRETCH BLOW MOULDING

TECHNOLOGY CAN MAKEALL THE DIFFERENCE

For more details visit www.norgren.com/sbm or e-mail to [email protected]

Oxygen Ingress Measurements

Non-invasive

Non-destructive

Under real conditions

In liquid and gas phase

Shelf life determination

Quality inspection

Phone +49 941 942 72 160Web www.PreSens.de

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PET containerair conveyors*

In addition to offering a blocked blower/fi ller/capper installation Krones portfolio also includes the AirCo range of air conveyors. Air transport now operates quietly and energy-effi ciently, requiring only minimised change-over times when switching to a different product. Operator control is simple, maintenance requirement is minimal, and commis-sioning is quickly completed.

Newly developed triangular ducting

The AirCo system is continually being enhanced and the most recent innovation is the new AirCo triangular ducting, which has been designed to prevent bottles jamming due to climbing in the plenum. The ducting can be adapted to suit different hygienic requirements. The standard version can be upgraded to feature enhanced hygienic design, incorpo-rating various fi lters and the transportation path is enclosed with transparent plastic panels to exclude the ambient air. It can all be easily opened for inspection and cleaning.

Neck-ring guide system

The design of the plastic neck-ring guides in air con-veyors is a crucial factor in the performance of the system. The plastic guides are now secured using a slip-on or clip system. The extremely smooth, PE-based material ensures trouble-free operation even for low preform quali-ties and complex container shapes. An optimum neck-ring

There is currently a clear trend toward producing PET containers on site in the bottling facility. The two-stage production process for PET beverage containers has been widely adopted, but presents the question of how to move the blow-moulded containers from the blow-moulder to the fi ller as smoothly as possible? Block synchronisation of the blow-moulder and the fi ller, or a conventional link with appropriate buffering capacity between the blow-moulder and the fi ller using an air conveyor?

guide geometry is provided for each container range. In the event of wear and tear the guides can be quickly and easily replaced, with no subsequent adjustment necessary. The more conventional U-rail method of securing the neck-ring guides necessitates time-consuming replacement and adjustment. An option of automatic width adjustment of the neck-ring guides is offered by means of two-position pneu-matic cylinders and permitting two different neck-ring guide settings. Using part-curve segments also enables them to be automatically adjusted in curves.

Guide rails and diverter gates

Multi-position cylinders enable the bottle guide rails to be adjusted with maximised precision to set up to twelve posi-tions. If additions are made to the container range retrofi ts can be incorporated at any time without major modifi cations. The rails are fi tted with ultra-wear-resistant, bottle-friendly profi les. PET containers are distributed and combined using pneumatically operated diverter units. Krones offers many different distribution gate variants, so a solution can always be found for any conveyor layout.

Machine infeed and discharge with neck-handling

Dependable container guidance from the air conveyor into the fi lling machine is assured by a neck-handling infeed.


Suppliers of caps and closures for PET bottlesAt the start of another year we turn our attention, as usual, to the question of caps and closures for PET containers. Just one year ago, when we published our survey of cap manufacturers, we mentioned the emergence of new lightweight 28mm caps and neck fi nishes. In the last 12 months we have carried several reports in the pages of PETplanet Insider on new neck fi nishes and correspondingly lightweight caps. It is a trend which is gaining momentum, driven not only by environmental considerations but the price of crude oil and hence the price of plastics. Several of the manufacturers listed have developed alternative lightweight fi nishes, or produce caps for the new PCO 1881 neck fi nish.Product differentiation is a critical factor in a highly competitive beverage industry and it is noticeable how many cap suppliers are striving to offer something unique. The standard 28mm beverage cap is a commodity item, with profi t margins governed by the cost of resin and the speed/effi ciency of the moulding machine - with injection moulding competing hard today with compression moulding.Around the world there must be dozens suppliers producing beverage caps. In our survey we have listed 16 of the most high profile suppliers in our sector of the industry (but of course only those who replied to our questionnaire). We do however believe that we have gathered a fairly representative cross-section, including this year, we are pleased to say, Blackhawk Moulding of Addison Illinois, to enable us to include an American supplier in the listing.For every type of beverage there is a cap to suit, and although we can display only a limited number of the worlds cap manufacturers we believe that we have most types of cap well covered.A point which we continue to make when discussing caps is well worth repeating. The cap seals on the bottle and the bottle seals on the cap. When there is a leakage problem there is a tendency to blame the cap. But maybe there is something wrong with the bottle neck! The cap and the bottle have to work as a team!

Although the publishers have made every effort to ensure that the information in this survey is up to date no claims are made regarding completeness or accuracy

01+02/08MARKETsurvey

Suppliers of caps and closures

Single stage machinery manufacturers

2-stage SBM machinery manufacturers

Manufacturers of preform systems

Producers of pellets and additives

Preform manufacturers

Manufacturers of preform moulds and stretch bloe moulds

Barrier technology

Producers of fi lling equipment

Compressor manufacturers

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Company name Bericap GmbH & Co. Silgan White Cap Seaquist Closures (Seaquist Lffl er )

Postal address

Telephone numberWeb site addressContact nameFunctionDirect telephone numberFaxE-mail

Kirchstrasse 5, 55257 Budenheim, Germany0049 6120 290 2 - 0www.bericap.comThomas HenkelSales Director0049 6120 290 2 - 00049 (6139) [email protected]

Fabriekstraat 25, 2547 Lint, Belgium0032 475 81 64 85www.silganwhitecap.comHans van BaekelBusiness Development - Plastic Closures0032 475 81 64 85

[email protected]

94076 Freyung, Germany0049 (0) 8551 9750www.seaquistclosures.comFlorent GrasMarketing Manager Europe0033 6 78 86 35 910033 1 60 41 12 01fl [email protected]

Product range

One-piece closures Yes. HDPE Yes. PP and PE Yes. PP

Two-piece closures (with liner) PP with EVA Yes. Polypropylene with thermoplastic elastomer liner

PET applications All beverage sectors Hotfi ll, coldfi ll and cold aseptic beverages and foodstuff

Water, near water, sports & health drinks, sauces & condiments

Neck fi nishes available as standard

All corresponding neck fi nishes Various neck fi nishes incl. 38mm 28 pco/bpf, 30-25 high & low, 38mm 31-400, 35-400

Printed caps Yes. 1-3 colour top prints Yes On request

Colour matching service Yes Yes Yes

Child-proof closures Yes. 28/26, 38/30, 24/415 CR PE No No

Push-Pull / sports caps Push + Pull and Thumb Up for wide range of neck fi nishes; both versions suitable for aseptic fi lling.

No All beverage closures are fl ip-top sports closures

Special comments/special closures

Range of non-food caps 63, 70, 82 mm Flip-tops, pourspouts, large footprint closures for inverted packaging

Special patented closures or marketing features

SuperShorty suitable for PCO 1881 in CSD and beer design.HexaLite screw plastic closures for still beverages for new 26/21 and 29/25 neck fi nishes.

SimpliSqueeze closures (silicone valve system) for non-drip dispensing

Company name Georg Menshen GmbH & Co. KG Finn-Korkki Oy Has Plastik A.S. (Hascap Closures Co.)

Postal address

Telephone numberWeb site addressContact nameFunctionDirect telephone numberFaxE-mail

Industriestrasse 26, 57413 Finnentrop, Germany0049 2721 518-0www.menshen.comAlexander KnippSales Manager0049 2721 518-00049 2721 518-115 [email protected]

Konepajantie 10, 13300 Hmeenlinna, Finland00 358 (0)3 628 641www.fi nn-korkki.comRobert JeynesExport Marketing00 358 (0)3 628 642800 358 (0)3 619 7294robert.jeynes@fi nn-korkki.com

Esenyurt Yolu No. 74, Avcilar 34320, Istanbul, Turkey 0090 21269 55 000www.hasplastik.com and www.hascap.com.tr Unal HaspaylanManagement Representative0090 21269 55 0000090 [email protected]

Product range

One-piece closures Yes. PE, PP No Yes. HDPE. Triple seal

Two-piece closures (with liner) Yes, PP, PE Yes. Tinplate crown type with standard, O2 scavenger or PVC free liner

Not for CSD

PET applications CSD, water, juice, isotonics, sports and functional drinks, dairy, beer, wine, spirits

Beer, juice, water, energy drinks, CSD and RTD bever-ages

All kinds of beverages (pressurized and non-pressurized)

Neck fi nishes available as standard

PCO 28 / 38, 28/410, and many more Standard Crown cap neck fi nish and 42mm RipCap neck fi nish

28 PCO/BPF, 30/25mm, 32mm fl ip-top38mm, 48/41mm , 55mm (snap-on)

Printed caps Yes Yes Yes (incl UV ink)

Colour matching service Yes Yes Yes

Child-proof closures Yes Not applicable Yes

Push-Pull / sports caps Yes, including the Cool Cap for CSD No Yes

Special comments/special closures

Sports closure / drinking cap for carbonated beverages. Single handed operation

Ring pull closures for PET bottles with a crown cap fi nish.Designed to be opened by hand (without using a bottle opener)

55mm(snap on) , 32mm fl ip-top , 38mm(oval fl ip top)

Special patented closures or marketing features

See above The wide mouth RipCap 42mm ring pull closure offering tamper evidence for PET bottles with a RipCap fi nish

Patented design for 30/25, 28mm, 55mmwith improved tamper evidence etc.

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Massmould Ltd. Idee+Form Sagl Corvaglia Ltd Gulf Packaging System Co. Heinlein Plastik-Technik GmbH

Massmould 3/4, Maulden Road, Flitwick,UK, MK45 5BZ0044 (0)1525 718718www.gcs.comRichard BarcockProduct Designer0044 (0)1525 7187180044 (0)1525 [email protected]

Via Leoncavallo 18, CH-6614 Brissago, Switzerland0041 91 780 96 48www.sportverschluesse.comGerhard PrieweDirector0041 91 780 96 480041 91 780 96 [email protected]

Hrnlistrasse 14, 8360 Eschlikon,Switzerland0041 71 973 77 00www.corvaglia.chTheo PoyyayilHead of customer relations0041 71 973 77 130041 71 973 77 [email protected]

Post Box No. 20266, Jeddah 21455, Saudi Arabia 00966 2 6360099www.gulf-pack.com Mohammed Najmuddin / Mohd. Fyasuddin DulviOperations Manager00966 50467863000966 2 [email protected].

Industriestr. 7, D-91522 Ansbach, Germany0049 (0) 981-9502-0www.heinlein-plastik.deGerhard SchragnerSales Manager - Beverage Sector0049 (0) 981-9502-120049 (0) [email protected]

Yes. PP and PE (see below) Yes. HDPE Yes. HDPE Yes. HDPE

Yes (see below) No Yes, PP for shell + liner from non-PVC material Yes. PP (One look closure - see below)

s Food, beverage (non CSD soft drinks and water) and healthcare.

Water, juice, carbonated drinks, functional drinks

All beverage sectors CSD, water, juice, milk, oil, pharmaceuticals and toiletries, mayonnaise.

CSD, water, juice, near water

Various, including 38mm UCS neck and a 30/25 neck. GF316 modifi ed for PET jars

28 mm, 38 mm All types of neck fi nish for the sector 28 mm PCO / BPF, 30/25 HNF, 38 mm 3 start, 45 mm 3 start HNF

PCO / BPF 28 / Pharma 15mm up to 31.5 mm

No Yes Yes Yes Yes.

Yes Yes Yes Yes Yes

No No No Yes Yes.

No Yes Yes, and SmartSeal Flex active closures

Yes No

kaging M-Cap style closures (tear membrane caps used on, e.g. spice or vitamin bottles)MTE push-on, screw-off closures (widely used in the dilute and soft drinks market)

Twist for carbonated drinks up to 12 bars. Cold-aseptic

29mm for edible oilSenso Cap foil seal cutting closuresSmartSeal Flex active closureAseptic sports cap. 5 gallon cap

Flip top cap for mayonnaise PET Squeezy bottle

3 and 5 Litre Carry Handle designed for use on large PET bottles.

Winning caps 38 mm Juice Corvaglia Patent30/25 HN water - Corvaglia Patent28 mm PCO CSD HL33 cap PCC Patent

One look - New ringless tamper evidence

Bjco A/S / Scandinavian Closures ApS Blackhawk Molding Co., Inc. Viscose Closures Ltd CCT - Creative Closure Tech-nology GmbH

.tr

56, Baekgaardsvej, DK-4140 Borup, Denmark0045 57 56 18 00www.bojco.dk / www.closures.dkDorte Krger MolinSales Manager0045 57 56 18 000045 57 56 18 [email protected]

120 Interstate Road, Addison, Illinois 60101, USA001 630-543-3900www.Blackhawkmolding.comDale BergGeneral Manager 001 630-458-2026001 [email protected]

Fleming Way, Crawley, UK0044 (0)1293 519251www.viscose.co.ukIan CosterTechnical Services Manager0044 (0)1295 5968150044 (0)1293 [email protected]

Idsteiner Strasse 74, 65527 Niedernhausen, Germany0049 (0) 6127 8954 / or 8957www.cct-gmbh.comAlexander SchmitzManager0049 (0) 6127 89540049 (0) 6127 [email protected]

Yes Yes. LDPE, HDPE Yes. HDPE Yes. HDPE

Yes Yes. Foil liner, Foil liner with lift tab, various foam liners Yes. HDPE with polythene resin liner

n- Juice, milk, water, sauces Water, milk, juice and other food products. CSD, water, juice, sauces CSD, water, juice

Up to to 80mm Super Quad (four thread neck fi nsih for HDPE bottles and PET (12 OZ to 16 OZ). Single thread and press-on necks

BPF/PCO PCO 28, PCO 1881, 30/25, 27, 38

Yes Yes Yes Yes, 3 colours

Yes Yes Yes Yes

Yes Yes No No

Yes Yes. Exclsive US sales of Seaquist Original Yes, in 28, 30 and 38mm No

al Flip-top closures

Super Quad cap is patented for tamper evident characteristicsBlackhawk also offers patented Clear Cap that has visible tamper evidence andnew space for advertising message and color coding

Various patented closures

Vol.

5

PETplanet print

Polyester Bottle Resins

Production, Processing, Propertie

s

and Recycling Dr. Ulrich K. Thiele

PET - from the basic raw materials to the production of preforms and bottlesIn this book Polyester bottle resins - production, processing, properties and recycling the author looks in detail at the raw materials used and the different processes for the production of PET. He examines the effects on PET product quality of variations in processing parameters and the likely causes of processing problems. The packaging requirements of different beverages are reviewed, and practical guidelines are offered for the quality analysis, storage and handling of PET resin.

This publication is a highly instructive textbook on the whole subject of PET as well as a handy reference work for those involved in the day-to-day handling and processing of PET resins.

Table of Contents

A. Preface

B. PET Production

C. Resin types and related polymer compositions

D. Resin quality parameters impact on bottle processing and bottle quality

E. Polyester chemical and physical analysis

F. Resin handling, preparation and processing

G. Additives

H. Polyester bottle recycling

I. Alternative bottle and packaging polymers

J. Register

Polyester Bottle ResinsPETplanet print

* prices in EUR + VAT.

149.*

ISBN: 978-3-9807497-4-9

Vol.5

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heidelberg business media GmbH | Landhausstrae 4 | 69115 Heidelberg | Germany | phone +49 6221 651080 | fax +49 6221 6510828 | [email protected]

ORDER your copy

ORDERfax: +49 (0) [email protected]

PETplanet print Vol. 5:

Polyester Bottle ResinsProduction, Processing, Properties and Recycling

Dr. Ulrich K. Thiele

Over 300 pages, with colour illustrations

149.*

www.hbmedia.netwww.dpet.com

http://www.hbmedia.net

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Infl ow and outfl ow conveyor sections enable the containers to be transferred from the air conveyor to a conventional conveyor and vice versa. These sections can be manually height-adjusted and are thus suitable for a container range featuring different heights.

Filter technology

A variety of air fi ltration systems with different ratings are available. For use in production facilities with ultra-stringent requirements for sub-micron particle count the conveyors will be fi tted with HEPA fi lters.

Electrical equipment

All drives are frequency-controlled and all messages, with comprehensive diagnostics, are displayed on the touch-screen (iPanel). A retrievable alarm history enables past messages to be accessed. In contrast to photo-cells the ultra-sonic sensors used by Krones require no regu-lar cleaning intervals. Incorrect information of the kind caused by soiled photo-cells is eliminated.

Pressure control regulation

A constant transport speed of the containers is condi-tional on a constant overall overpressure in the plenum. The optional pressure-controlled regulation feature com-pensates for any pressure drop caused by soiled fi lters. If the pressure drops the frequency of the radial fan will be automatically increased, so there is no need for manual adjustment. A display on the touch-screen reminds staff to replace the fi lter in good time.

Drive technology

All drives have been designed for low noise emission. The radial fan is accommodated in a stainless steel hous-ing. All the fans components are made of stainless steel, which ensures a long effective lifetime and maintenance-free operation. Thanks to the new drives, designed spe-cifi cally for air conveyors, energy consumption has been reduced by about 30 per cent.

Adapted from an article by Kyoung-Won Lee, Krones AG, Neutraubling, Germany

The new triangular ducting has been designed to ensure that the bottles do not jam.

BMPSNEW, USED, REBUILD MOLDING MACHINES, PARTS, SERVICE AND AUXILIARY EQUIPMENT

Contact: Peter Tordy1260 Creditstone Road.

Concord, OntarioL4K 1K5

PH: 905/738-5540 Fax: 905/738-2098

e-mail: [email protected]: www.bmps.ca

We Want Your Used Equipment

93&95 Husky SX 600 systemwith 24.5 gm PCO 96 cavity (2) 93 Husky XL 500 robot, dryer 91&94 Husky XL 300 robot anddryer (4) machines 85 Husky XL 300 robot and dryer.Moulds 20,24,37,47,54 gm 89 Husky XL 225 robot, dryer.

Ultra Modern Preform, blow mould-ing + Filling plant 2000 and newer, Netstal, SIG, Blowmax, Sidel

80s Cincinnati Milacron 250 with16,21,28 gm moulds 80s Cincinnati Milacron 375 ton 97 Krupp/SIG/Engel Permax 48with robot and dryer Rebuilt Van Dorn 250 ton co-exlab machine low hours with dryer

We have in stock perform moulds 24 to 55 gram and 25 high heat dryer systems for PET.

Autotek/EFI 98 RSB 2,000, 2,000 Bohn 04 BE 2 - 1500, 2,000 bph B & G 90s RHB W & RHB XT Cincinnati Milacron RHB 5, 4,000bph, RHB 2,000, 91 2,000 bph Krones 01 Contiform 10,12,000bph low hours. Krupp 95 B 66, 6,000 bph, 90 B80, 10,000 bph, 90s B 177, Mag 96 SSB 20, MAG SSB 20+40 Side 01, 2 cavity, 2,200 bph and2 4 cavity machines 4,400 bph,low hours. SIG/Krupp 01 Blowmax 1 cavitylab machine low hours, Blowmax10/14 99, 12,000 bph, Blow-max 16H 99, 20,000 bph Sidel SBO 2/3 95 2,000 bph,SBO 4/6 01 4,400 bph for 5 liter,low hours: SBO 4/6 97 4,400bph, SBO 6/10 98, 6,600 bph,94 SBO 10/12, 10,000 bph. 93SBO 16, 16,000 bph, 92 SBO24/24, 18,000 to 24 bph (4) SIPA 98 SF 4000, 4000 bph

mailto:[email protected]://www.bmps.cahttp://www.petpla.net

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Coca-Cola has been produced in China since 1981, although bottling began in Shanghai for the fi rst time in 1927. In 1948 Shanghai was the fi rst city outside the USA where Coca-Cola exceeded a sales volume of more than a million unit cases equalling about 5.6 million litres. In view of Coca-Colas success today it seems that all of China was waiting for their re-entry into the market.

China - a Coca-Cola success story*

In China today 35 production facilities bottle the full Coca-Cola soft drinks range. This is done by three separate bottling groups and very much with the help of KHS systems. In all there are 40 KHS fi lling and packaging systems in operation at the moment and the fi rst investments in KHS technology were almost simulta-neous with the brands re-entry to the market. Since then Coca-Cola sales growth and new investment in KHS technology have gone virtually hand in hand. Plans for the near future include the commissioning of yet another KHS PET system for the Coca-Cola facility in Kunming.

3.5 litres per annum per-capita

The market share of Coca-Cola brands in the area of CSDs is a solid 55 percent. Chinese per capita consumption of CSDs has currently reached 6.4 litres/person and a per capita consumption of carbonated Coca-Cola products of 3.5 litres. Based on the population of 1.3 billion it can be seen that there are about 45 billion litres of Coca-Cola drinks con-sumed each year. Besides Coca-Cola itself, as the biggest brand in Coca-

Colas range of CSDs, it is primarily Sprite and Fanta that contribute to the companys success. In all CSDs comprise almost 75 percent of Coca-Colas total sales in China.

However the company also plays a signifi cant role in the non-carbonated beverage sector. Minute Maid contrib-utes a good 12 percent to Coca-Colas overall success. Good results are also recorded for Qoo, a non-carbonated fruit beverage developed especially for children. Added to this are a few well-established local water brands as well as Nestea and Bonaqa.

Market to treble in ten years

In ten years it is expected that the Chinese market for soft drinks will have trebled. The main reason for this posi-

tive estimate is the anticipated increase in income of the Chinese population. Although the purchase of CSDs, espe-cially among the Chinese rural popula-tion, is often considered a luxury, over the next 10 years it could become daily routine.

However, the Chinese market is not a uniform one. In many rural areas the average consumption of carbon-ated soft drinks is still in single fi gures. In comparison, in large cities such as Beijing and Shanghai it has already climbed to more than 23 litres per capita.

Based on these facts, its no wonder that the Coca-Cola Company defi nes China as one of the biggest markets in the world from a global standpoint. Martin Jansen, CEO of Coca-Cola China Industries Limited, says, If we didnt have a presence here, in 20 years we would certainly no longer be the world leader in carbonated soft drinks. So far Coca-Cola has invested a good 1.25 billion U.S. dollars in the Chi-nese market and the system currently employs more than 30,000 people. For this year, according to Jansen, Coca-Cola China Industries Limited expects double-fi gure sales growth.

Attention-grabbing posters illustrate Coca-Colas sponsoring of the 2008 Beijing Olympics.

Imposing design the entrance to the Coca-Cola plant in Chongqing, built in 2005. Currently, 35 production facilities

around the entire country bottle Coca-Colas range of brands.


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PET the packaging of choice

In China non-alcoholic beverages are bottled primarily in PET, which is why 80% of Coca-Cola products are fi lled in PET bottles, 15 percent in cans, and 5 percent in glass. Thus, the latest investment in fi lling and packaging technology for Coca-Cola Chongqing (billed as the worlds largest city) in 2005 had to be a PET line, just as the newly ordered system for the Kunming plant.

The KHS system in Chongqing is designed for an output of 18,000 (0.6 litre) PET bottles. In Kunming the order is for a 40,000 bph KHS line. Both lines have one thing in common: they process the entire Coca-Cola range of CSDs, fi lling all PET bottle sizes in the range, from 0.6 litres through 1.25 litres and 2.0 litres, up to the 2.5 litre variant.

By air conveyor to the rinser-fi ller-capper block

On both lines pre-labelled bottles are carried by an air conveyor directly to the rinser-fi ller-capper block. The rinsing system is a mechanically con-trolled, single-channel Inno-clean FR-EM rinser. Bottles can be rinsed out with both cold as well as hot water.

The Innoclean FR-EM is blocked with the fi lling system. The familiar KHS Innofi ll DRV fi lling system is installed in the line at Chongqing while the Kunming plant has installed the new version of this fi lling system, recently launched on the market and which is being used for the fi rst time in China.

Jansen says, When KHS has something new to offer, well be happy to profi t from it.

Freshly shrink-wrapped in 6-packs - as usual for large size PET bottle formats at Coca-Cola.

PET bottles are preferred by soft drinks consumers in China primarily for reasons of convenience.

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A particular feature of the newly designed, computer-controlled volumetric single-chamber Innofi ll DRV fi ller is that it operates with only two pneumatically actuated mem-brane cylinders for the entire fi lling process. The cylinders lift the bottles and press and seal the bottle mouths against the fi lling valves. For pressure fi lling the gas used for PET bottle pressurisation comes from the ring vessel. The force created by the pressurisation is transmitted by a mem-brane plunger directly to the neck ring holder. This force alone lifts bottles, and seals the bottle mouths against the fi lling valves. No additional lifting elements are necessary. The force is regulated fully automatically. (This method of pressing the bottle is also adapted for the CIP plates during sanitising).

The fi lling process itself is identical in the conventional and the newly designed Innofi ll DRV. Once the bottle is pressurised the fi lling valve opens electropneumatically. A swirler conducts the product to the inside walls of the bottle and the fi lling speed is reduced in the bottle neck after the fast fi lling phase. The fi lling valve is closed electropneumat-ically as soon as the pre-specifi ed fi lling volume is reached.

Capping system

The capping system in Chongqing is the classic Innofi ll SV screw capper. The Innofi ll SV-ACF, designed to aseptic criteria, is the capper of choice for Kunming. The SV-ACF is also a new KHS development, characterised by its simple, open, hygienic design as well as the constant capping force which provides increased bottle opening con-venience for consumers. Each capping spindle, operating

Pre-labelled PET bottles are carried by air conveyor to the rinser-fi ller-capper block.

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To avoid condensation on the PET bottles they pass through an Innopas heater before the packing process.

completely independently of the machine speed, is equipped with a servo drive tailored to the particular style of cap.

Planned for Kunming is the Innocheck Promecon 4000 camera inspection system which automatically checks fi ll levels and caps, with information on different measuring points to neutralise the effects of splashing.

End-of-line packing

To avoid condensation the PET bottles pass through a heater at the Chongqing and Kunming plants before pack-ing. While Chongqing can choose between shrink packs or pad shrink packs, Kunming has decided to pack exclusively in shrink packs.

At Chongqing PET bottles are conveyed over a buffer segment to the Innopack Kisters PSP, which arranges and packs 4 x 6 or 4 x 3 0.6 litre bottles in 24-bottle or 12-bottle pad shrink packs. The 6-pack is the choice for large bottles. Alternatively, the PSP can pack in shrink packs without a pad, and in alternative formations.

In Chongqing, the pad shrink packs are palletised manu-ally, but for Kunming a high-performance Innopack PB 1 HS palletiser is planned, with inline robot grouping directly upstream.

Quality, quality, quality Coca-Colas recipe for success

Martin Jansen says, KHS system concepts like those for Chongqing and Kunming are thought out to the last detail something we value highly. And for us that means that we get quality we can rely on.

In view of the continuously increasing demand for Coca-Cola products this is not a factor to be underestimated. Huaiyu Ren, Managing Engineer of the Coca-Cola plant in Chongqing, says, Our new system runs and runs. We now run three shifts with an even better line effi ciency than KHS promised us. The potential market in Chongqing is made clear by the fact, according to Jansen, that the annual per capita consumption of Coca-Cola brand products is only 1.4 liters. Jansen says, As in many regions of China, we here in Chongqing are just at the beginning of a success story. In my opinion China is the land of a thousand opportunities. Coca-Cola has set its sights on taking advantage of those thousand opportunities and to their full extent, by providing quality, quality, and more quality. With KHS as a partner we can trust.

* Adapted from an article by Werner Gessner, Director Business Area China , KHS AG

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After a very successful two-day confer-ence, participants and organizers all

agreed: drink technology + PET India immediately made a name for itself in the

beverage industry. 539 visitors took part in the conference and associated exhibition, which made its premiere in Mumbai, India

from November 29th 30th, 2007.

Successful premiere for In the presentation area and the lecture halls, the picture

at the Grand Hyatt Hotel, where the conference was held, was one of bustling activity and a positive atmosphere. The presentation area in particular, where 42 renowned compa-nies from 11 countries made presentations, was a forum for discussions and the exchange of information. While partici-pants were busy networking at the exhibition area in the hotel lobby, trade visitors in the two lecture halls gathered informa-tion about the latest market developments and current trends in beverage and liquid-food technology. The speakers at the workshops and symposia included high-calibre specialists from around the world.

539 industry experts from 15 countries, including bever-age distributors and manufacturers, traveled to Mumbai to experience the fi rst drink technology + PET India. Besides conference delegates from India, who made up the major-ity, there were also visitors from Bahrain, Germany, France, Great Britain, Israel, Italy, Austria, Nepal, Poland, Saudi Arabia, Slovakia, South Africa, the United States and Viet-nam. Visitors also included 30 media representatives from India and other countries.

The prospect of holding discussions with decision-makers from India and neighboring countries generated a strong response before the fair began, especially among European specialists. Even the presentation area, which had 276 m of space, was quickly booked to capacity. Companies from 11 countries took advantage of the opportunity to book the small presentation space in the hotel lobby. The event was sponsored by four companies Reliance, KHS, Krones and Ziemann.

Given the large number of visitors from India, Europe and Asia, exhibitors were defi nitely satisfi ed with the outcome of the event. Positive, good, very satisfi ed the response

Menno M. Holterman, Chief Gr

owth Offi cer Norit NV:

drink technology + PET India 2

007 offered a more

than satisfactory outcome to th

e newly opened Norit Of-

fi ce in India. In addition to servin

g as the perfect forum

in the commercial capital of Ind

ia (Mumbai) to announce

recent successes and Norits am

bitious plans for India,

it was a perfect opportunity to d

isplay the strength of our

current presence and future inte

nt to Norits global and

regional key-accounts. The inte

rest for our Norit Sdmo

valves, Norit Haffmans Total CO2

& O2 Management and

Norits Brewery of the Future b

ased on Norits Beer Mem-

brane Filtration and Membrane

BioReactor - lowering the

water consumption to 2 hl of wa

ter for 1 hl of beer - was

overwhelming. The event offer

ed a chance to understand

fi rst hand the readiness of the v

ibrant Indian Brewing,

Beverage and Food Processing

industries to invest in

technology and quality in order

to meet tomorrows sus-

tainable requirements and reas

sured the soundness of

Norits growth strategy for the c

ountry.

Yatindra R Sharma, Executive Director, KHS India: Drink Technology+PET Inidia event has attracted all decision makers of beverage world of India. We have found interactions with foreign and Indian visitors very useful. This prestigeous event full exhibition should come to India very soon.

Hermann Graf Castell, Head of Group Communica-tions, Krones AG: By holding drink technology + PET India 07, or-ganizers succeeded in establishing an effective and successful trade show and exhibition program for the

Indian market. Its proximity to users on the Indian mar-ket allowed us to hold several discussions on specifi c topics. Topics related to aseptic bottling in particular are very important to the development of the Indian beverage industry. Presenting our expertise on location in India allowed us to address potential customers and users who want simple and uncomplicated information on a broad basis.

Norbert Bargmann, Managing Director

at Munich International Trade Fairs: We were always convinced that this

event would be a success. Still, this kind

of positive response and a premiere that

is practically perfect is not something one

takes for granted. Apparently, our concept,

i.e. the combination of specialty lectures,

an accompanying exhibition and time for

networking, worked completely. Everyone

involved appreciated the short distances

and having all the information available

under a single roof.


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drink technology + PET Indiato the new conference was almost unanimously positive. Exhibitors were particularly praiseworthy when it came to the organization and the quality of the visitors. Valuable market information, exceptional contact quality, good location, very well organized was the tenor of most comments.

The organizers Munich International Trade Fairs, VDMA Association for Food Processing and Packaging Machinery in Frankfurt and the publisher hbmedia in Heidelberg were extremely positive as they assessed the results. According to Norbert Bargmann, the responsible Managing Director at Munich International Trade Fairs, We were always convinced that this event would be a success. Still, this kind of posi-tive response and a premiere that is practically perfect is not something one takes for granted. Apparently, our concept, i.e. the combination of specialty lectures, an accompanying exhi-bition, plus time for networking, worked completely. Everyone involved appreciated the short distances and having all the information available under a single roof. Richard Clemens, Managing Director of VDMA Association for Food Process-ing and Packaging Machinery, also felt that the exhibition reached its objective of bringing together the supply and demand sides of the market: We are pleased at the positive response among visitors from India and neighboring coun-tries. As far as German participants are concerned, the dis-cussions they held were very productive and helped them to better identify market needs. Our feeling that there is a great deal of interest in modern beverage technology, especially from Germany, proved to be correct. That was clear in all of the discussions that we held with participants between con-ference events. This event helped participants to make new contacts, and we hope that everyone manages to strengthen those contacts perhaps when the conference is held again next year.

The next drink technology + PET India is scheduled to take place in late November or early December 2008.

Reiner Gaub, Pall GmbH:

At drink Technology + PET India Pal

l was presenting

the world of Filtration for the Food & B

everage Industry with

a stand and a lecture given at the wor

kshop to the audi-

ence. For Pall the participation at the

convention was a

great success, due to fostering well es

tablished business

relations most of the top customer P

all could welcome

on the stand but also new contacts

where made with

representatives from different Food &

Beverage Industries.

For Pall many project specifi c subjec

ts have been a topic

for various discussions, in addition ne

w capital investment

projects but also new business for se

rvices and consuma-

bles have been initiated.

Vezio Bernardi, Sacmi, Italy:

First of all I would like to congratulate all the people

involved in the organization for the useful and focused

convention. The arguments and the companies were

absolutely the best available in the beverage market

and all the Indian customers involved in the beverage

had the chance to have a visit. I hope it will be repeated

again next year. Thanks again for the nice job.

Rdiger Selig, marketing & com-

munication food, beverage and

tobacco, Siemens: As a supplier of automation an

d

drive technology for the beverage

industry, we monitor global trends

among plant operators that pertain

to total cost of ownership, increased

fl exibility and tracking & tracing. That

also applies to the Indian market,

where we see a great deal of po-

tential. So we took advantage of the

opportunity to actively participate in

the fi rst drink technology + PET India

07 in Mumbai. The response at the

Siemens stand confi rmed our view

of the trends and was quantitatively

and qualitatively so positive that we

will probably return for the next drink

technology + PET India.

Sipa Plastic Packaging Systems, Italy: Congratulations to the organizers of drink technology + PET India 07. Being the fi rst edition we did not know what to expect. It turned to be an excellent opportunity to meet top-ranking customers from many parts of India, to talk about specifi c projects and to attend to an interesting symposium and a workshop. Timeframe and location were perfect. We came back with a very positive experience and we look forward to drink technology + PET India 08.

Richard Clemens, Managing Director of VDMA Association for Food Process-ing and Packaging Machinery: We are pleased at the positive re-

sponse among visitors from India and neighboring countries. As far as German participants are concerned, the discus-sions they held were very productive and helped them to better identify the markets needs. Our feeling that there is a great deal of interest in modern beverage tech-nology, especially from Germany, proved to be correct. That was clear in all of the discussions that we held with participants between conference events. This event helped participants to make new contacts, and we hope that everyone manages to strengthen those contacts perhaps when the conference is held again next year.

Joachim Gunkel, Managing Director Sales and Marketing, Z

iemann Group:

The positive results of drink technology + PET India confi rme

d our decision

to invest in turnkey brewery projects on the Indian market. The

success of this

conference and exhibition is not least of all due to outstanding

organizational

work on the part of Munich International Trade Fairs.

Stefan M. Behnke, General Manager OHL Engi-neering GmbH, Germany.This platform offered OHL Engineering a welcome opportunity to present itself, in particular thanks to the combination of exhibition (trade fair booth) and convention (symposium and work-shop). We were able to discuss the topics we had presented in the workshop in more depth during in-dividual discussions at our stand. At that occasion, we noted the high quality of visitors and conversa-tions. We therefore see the internationalization / decentralization of drinktec as a good thing.


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Sacmi continues to develop compression technology

In addition to new solutions designed to render cap-

making machines even more competitive, Sacmi has

also produced applications for different products such as preforms, fl ip-top, sport caps, toothpaste shoulder and dispenser. The com-

pany has also developed a new process for the produc-tion of containers: compres-

sion blow forming.

CapsSacmis new CCM64M can produce around 600 plastic caps a minute with

just 64 compression mould cavities. The cycle time is less than 2.4 seconds. The machine can be incorporated into a line to demonstrate how, on a sur-prisingly limited amount of fl oor space, raw materials can be transformed into fi nished, boxed caps. Considerable advantages are derived from lower energy consumption, faster speed, the absence of an injection gate, oriented outfeed, quick colour change, on-line video-based quality control, height and dimensional consistency.

Preforms

PAM technology (PAM stands for Preform Advanced Moulding) is the latest system to be developed by Sacmi in the compression moulding fi eld. This 48-cavity machine will be able to produce different kinds of preforms. At the moment the machine is set to produce 23 gram, 28mm PCO preforms for car-bonated drinks (CSDs) at guaranteed output rates of 27,0

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