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No. 10 2009 MAGAZ INE FOR BOTT L E RS AND BOTT L E -MAKERS

IN THE AMERICAS, ASIA, EUROPE AND ALL AROUND THE PLANET19 .10 .09

PETplanet is read in 137 countries

Labels for PET bottles

MARKETsurveyPage21Regional market r

epor ts

Germany Part 1

Page10

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The color of success for thinking caps

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EDIT

OR

IAL

3PETplanet insider Vol. 10 No. 10/09 www.petpla.net

PUBLISHERAlexander Bchler, Managing Director

HEAD OFFICEheidelberg business media GmbHLandhausstr. 469115 Heidelberg, Germanyphone: +49(0)6221-65108-0fax: +49(0)[email protected]

EDITORIALDoris Fischer fi [email protected] von SchroeterRuari McCallionTony ONeillIlona TrotterGabriele Kosmehl

MEDIA CONSULTANTSUte [email protected] [email protected]: +49(0)6221-65108-0fax: +49(0)6221-65108-28

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

LAYOUT AND PREPRESSEXPRIM Kommunikationsdesignwww.exprim.de

PRINTWDW Druck GmbHGustav-Throm-Strae 169181 Leimen-St.IlgenGermany

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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 sub-scription 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,dear readers,drinktec/PETpoint - a great success

What else would he say? I can hear you asking. After all he was one of the organisers! But they are not my words. Our exhibitors were more than satisfi ed, as is clear from, for example, the words of Matthias Jablonski, Manager Marketing of Husky: Our booth was extremely busy with not only local visitors, but guests from all around the world. Having given us the opportunity to meet with existing beverage packaging cus-tomers, as well as build new relationships, this was a successful show for Husky.

Or in the words of one of Huskys major competitors, Waldemar Schmitke of Netstal-Maschinen AG in Switzerland, who also comes to a similar conclusion: For us drinktec/PETpoint is a real barometer. We came to Munich with high expectations and these have almost been exceeded. The visitors came from all over the world, in particular there were many from the Middle East and the Far East, among them several delegations from China.

And even the seemingly hard-pressed full line suppliers can now see light at the end of the tunnel, as Volker Kronseder, Chairman of Krones AG, said: Virtually all the CEOs and Presidents from companies around the world turned out here, even though the climate as regards investment is still cautious, drinktec 2009 has marked a turnaround in decision-making. It is the world summit for the beverage and liquid food industry - in this, too, exhibitors and visitors alike were agreed.

But it wasnt only the gut feeling of the exhibitors that support this view, the hard facts also point the way to the same conclusion: 33,000 trade visitors travelled to Munich from abroad; they came from a total of 170 countries. There were particularly strong increases in visitor num-bers from China, India, the USA, South Africa, Mexico and the United Arab Emirates, as well as from South America and Africa. Overall the trade fair attracted around 60,000 visitors. And the two-day PET World Congress, held for the third time and once again tackling all the relevant issues in technology and marketing, held the attention of 250 partici-pants.

The visitors to drinktec/PETpoint 2009 came from all parts of the beverage and liquid food industry. For the fi rst time soft drinks profes-sionals made up the largest group, at 40%, followed by visitors from the brewing industry, with 37%. A clear rise was noted in the number of visi-tors from the fruit juice sector (16% of the visitors), milk (10%) and liquid foods (8%).

For all of our readers who want to follow up on their visit to drinktec, or who didnt manage to get to Munich, we recommend the PETpoint/drinktec review that starts on page 32.

Yours,

Alexander Bchler

http://www.petpla.netmailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.exprim.dehttp://www.petpla.nethttp://www.pet-point.net

4 PETplanet insider Vol. 10 No. 10/09 www.petpla.net

PETcontents 10/09Page28

Page21

INSIDE TRACK3 Editorial4 Contents6 News43 Patents

REGIONAL MARKET REPORT

10 Germany Part 118 Interview with

Volker Kronseder

BUYERS GUIDE38 Get listed!

MARKET SURVEY22 Suppliers of labels

for PET bottles

TRADESHOW REVIEW

32 drinktec PETpoint, Munich, September 14 - 19, 2009

35 beverage innovation award

Page35

Page26

PREFORM PRODUCTION

21 Moldmasters and Abba form iPET

22 Recycling, energy savings and livetime support

BOTTLE MAKING26 More eco-effi ciency,

increased R+D investment

BOTTLING /FILLING28 Comprehensive solutions30 Niagara Bottling - the story continues

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PETnewsNestl launches fi rst rPET bottled water

Nestl is to launch its fi rst range of mineral water in the US packaged in bottles containing 25% recycled PET and is supporting the launch with a recycling scheme.

The company has teamed up with Whole Foods Market to sell the new Re-Source brand natural spring water at outlets throughout the US. Consumers will be encouraged to recycle the bottles at collection points in Whole Foods Market stores. This is the fi rst time the company has introduced a product that incorporates rPET in its packaging.

The launch and recycling initiative, in collaboration with Whole Foods Market and Waste Management, is designed to engage consumers in the importance of recycling and the programme will start at 26 stores in California and Arizona with plans to reach 200 stores nationwide by the autumn. Nestl has pledged to donate 5 cents to the anti-litter charity Keep America Beautiful for every plastic beverage container that is recycled at participating stores.

PWP plans second PET recycling plant

A projected surge in demand for recycled PET in food and beverage packing has led a US company to announce plans for a second recycling plant, just a month after open-ing their fi rst plant in West Virginia.

California-based PWP have unveiled proposals for a new plant to be based in the fi rms home state and to become operational in the second quarter of 2010. The company will use the reprocessed resins to manufacture its own thermoformed food packaging products.

For the second planned centre, PWP said it would once again be working with Coca-Cola among others to convert post consumer PET bottles into FDA compliant resin for food-grade material. Expectations of the US demand for rPET foresee an increase over the next fi ve years to even-tually double the current demand.

drink technology India and International PackTech India to merge

The two exhibitions drink technology India and Inter-national PackTech India will in future take place under one roof. The fi rst joint event will be from November 18th to 20th, 2010 at the Bombay Exhibition Center in Mumbai. Previously these two events were organised separately by the Messe Mnchen GmbH and the Messe Dsseldorf GmbH who will now collaborate in this venture and both benefi t from a much larger event for the promotion of pack-aging materials and equipment. The overall aim is to estab-lish a commercial platform for India and the neighbouring countries covering packaging and also the beverage and liquid food industries.

VLB PET bottling symposium in BerlinThe VLB, the German brewery industry training and

research institute in Berlin, is running a 2-day seminar in November devoted to the subject of PET bottling.

The event takes place on November 9th and 10th 2009 at the Novotel Berlin am Tiergarten. The symposium will be entirely in English and is aimed at technicians from the areas of production, fi lling, quality assurance and prod-uct development in breweries and the beverage industry in general. On day one the programme includes new PET and barrier materials, aseptic fi lling and the single-trip keg, and ending with a dinner in central Berlin. The second day will cover, among other things, environmental aspects, container design and analytical questions. The event is sponsored by PolyOne, who will also be staging a small exhibition.

For further details please go to https://www.vlb-berlin.org/ (which is available in English) and click on News/Events schedule

Polyester & PET Chain 2009 The 14th Polyester & PET Chain congress takes place in

Zurich from December 14th to 17th 2009.For three days 36 international presenters and several

hundred delegates will be discussing how to emerge from the global economic crisis, and how to cope with the uncertain market conditions in the entire polyester business chain.

Major concern will focus on the worldwide polyester over-capacity, which is currently around 58 million tons (60% for fi bre, 40 % for packaging). Consumption for all polyester applications is around 46 million, indicating the massive prob-lems that this industry is facing, resulting in several global and local companies closing individual plants or totally ceas-ing production. This, however, has not hindered other global players in the chain adding further production plants.

Several attempts by PP (52 million tons global capacity) to challenge PET in various applications has not happened. On the contrary, thanks to its unique properties, PET has continued to replace PP, styrenics and other major thermo-plastics.

The congress provides a comprehensive overview with presenters from all continents and all sectors of the business: MEG, PX, PTA, PET, PETG, PBT, R-PET, PLA, catalysts, additives, modifi ers, stabilisers, nano technology, process technologies, production improvements, capacity and product developments, material savings, cost reduction programmes, regulations, trade patterns, energy effi ciency and carbon footprint analysis. BO-PET fi lms, the use of PET laminates, in-line PET sheet co-extrusion and thermoforming, plus high barrier CPET trays for autoclave sterilizable foods will be major topics of a packaging session with global brand owners presenting their views and requirements. Other topics will cover the sustainability of packaging with PET materials, the use of bio-based MEG, B-to-B recycling, residuals testing and LCA / carbon footprint themes.

For further details please visit: www.mbspolymer.com

https://www.vlb-berlinhttp://www.mbspolymer.comhttp://www.petpla.net

NEW

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Global bottled water sales driven by developing marketsGlobal bottled water consumption grew by 4.5% to 218 billion litres in 2008, according to the new 2009 Global Bottled Water

report from drinks consultancy Zenith International. Growth in less developed markets, where per capita consumption is low, helped to counteract the combined pressures of the economic downturn and public concerns over the environment.

Asia/Australasia reinforced its position as the biggest regional market by volume, achieving a 28% share of the global busi-ness. Africa and the Middle East also recorded gains of 14% and 6% respectively. Consumption increased in all other regions except Western Europe and North America. In North America sales fell by 0.7% in 2008. Despite the decline the USA is still the largest national market in the world in both volume and value terms.

Providing detailed forecasts by country for the next fi ve years, Zenith predicts that bottled water consumption will rise a further 18% to 259 billion litres in 2013. The 2009 Zenith Report provides 2003-13 fi gures across 75 key countries plus smaller country groupings and includes a 12 month subscription to the bottled water database at www.globaldrinks.com. Contact Zenith International on tel +44 (0)1225 327900 or e-mail [email protected].

Change of name for Zenith

At the recent drinktec exhibition in Munich Zenith International Publishing is announce that the company is changing its name to Food-Bev Media. The main reasons for the change are that the name corresponds with the groups online presence at www.foodbev.com, that the group recently purchased and integrated Food & Bever-age International magazine, and that it further asserts the groups intention to expand across more food and bever-age sectors.

All other company details remain unchanged other than a switch from zipublishing.com to foodbev.com for email addresses.

Engel new dealership in former Yugoslavia

In a move to strengthen its coverage in Eastern Europe Engel have established a new distributor for Serbia and Croatia. The agreement is with the Serbian company Neofy-ton. Engel is currently market leader in the former Yugosla-via with an almost 40%, which they hope to increase with the help of Neofyton. The company has been representing Engel since July 1st.

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NEW

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Plastic materials and articles intended EU recycling regulations into contact with foods

The European Plastics Recyclers professional body (EuPR) draws atten-tion of the plastics recycling and con-verting industries to the rules applica-ble during the transition period for the Regulation 2008/282 (EC) on recycled plastic materials and articles intended to come into contact with food.

On 28th March 2008, the regulation was published in the Offi cial Journal of the European Union and entered into force on the 20th day following. The regulation covers a transition period during which applications to operate a recycling process shall be submitted to and evaluated by the European Food Safety Authority (EFSA). Only when all the recycling processes for which an application has been submitted during the 18 months following the publication of the EFSA guideline on the 21st May 2008 have been evaluated by the EFSA, the Commission shall, within six months, draft the decisions granting or refusing authorisation of the recycling process.

Article 16 2 of the regulation clearly states that until the adoption of these decisions, national provisions in force concerning recycled materials and articles and recycled plastics shall continue to apply in the Member States. Therefore, before that date the manu-facture and trade of plastics recyclate for food contact articles must follow those National rules and restrictions. Exist-ing recycling processes can only sell to markets where their process has been approved, where they have received a letter of no objection or where the national legislation allows it. If a new process is started during the transition period, then the existing National legal requirements should be respected. This could entail asking for a national authori-sation covering the transition period.

For more information please contact Antonino Furfari:

[email protected]

P E T C O R E

C O L U M NPPPPPPPCCCCCCCC

European PET recycling successAt the time of writing Petcore is waiting for the fi nal statistics on PET collection

in Europe for 20081. Provisional data show that 1.26 million tonnes of PET bottles were collected in 2008. This is an increase of 11.3% over 2007 and represents 41.6% of all PET bottles put into the market. 20% of the resulting RPET was used to make new containers. The amount of RPET used to make fi bres remained static at 47%. A great proportion of this will be made into fi lling fi bres and non-wovens but the outdoor industry in Europe makes great use of recycled PET fi bres. According to ForumPET more and more manufacturers of outdoor clothing and equipment rely on recycled plastic materials. Many manufacturers of premium brands offer fl eece jackets and trekking shirts made from recycled PET bottles. Many more individual bottles were collected in 2008 than the above increase sug-gests. In the mid 1990s a 500ml bottle to package water weighed 22 grams but by 2006 the lightest 500ml bottle weighed 12.5g. It is now possible to package 500ml of liquid in a bottle weighing only 6.6g. However, this saving of material means that for the PET recycler every bale he purchases will contain a greater ratio of contamination (caps, labels, residual contents etc) than bales bought even 2 years ago. Separation into purer streams will therefore cost more.

Plastics are too valuable to throw away.

The EUs Waste Framework Directive (WFD) is a piece of EU legislation dating back to 1976 which sets the legal framework for waste management in the EU. It is periodically revised, and the latest revision was concluded in late 2008 (2008/98/EC).

The WFD is a hugely important piece of legislation for the plastics industry which sets European requirements in crucial areas such as:

End-of-waste criteria for certain waste streams Recycling targets for municipal solid waste and construction and demolition wasteIntroduction of extended producer responsibility Implementation of the Waste Hierarchy in the Member States.

The 5-step waste hierarchy is intended to improve resource effi ciency by set-ting out a priority order of waste management techniques: Prevention Re-use Recycling Recovery (including energy recovery) Disposal.

The rationale for this hierarchy is that a higher amount of resources are saved by preventing waste, followed by reuse, recycling and recovery, going down through the hierarchy to disposal, which should be avoided as far as possible due to a growing shortage of landfi ll sites and in some countries, the imposition of landfi ll taxes.

This Directive must be transposed into law by each member state by Decem-ber 2010. The EU agreement also allows for the hierarchy to be applied with fl exibility when justifi ed by lifecycle thinking. As the domestic packaging plastic most frequently collected, PET will continue to make a large contribution to each member states fulfi lment of its plastics recycling target. In order to meet the new targets investment will have to be made in new recovery technology. It is possible to break down PET chemically into its original raw materials that can be purifi ed and used to make new PET. Also the inclusion of energy recovery in the waste hierarchy means that every PET bottle sent for disposal will be recovered either as raw material or to replace fossil fuel in energy production.

Finally, we have some good news from the UK. Following hot on the heels of cooperation with the UK retail trade came the successful launch of the Plastic-sEurope initiative, Plastics 2020 Challenge2. This will aim to divert plastics from landfi ll and to encourage reduction, reuse, recycling, and recovery. PlasticsEu-rope will provide signifi cant scientifi c support and waste management expertise and additionally, facilitate development of energy from waste. Petcore is fully behind the Plastics 2020 Challenge which will depend on the successful continu-ation of growth in PET recycling across Europe.

1 Available from [email protected] http://www.plastics2020challenge.com/

mailto:[email protected]:[email protected]://www.plastics2020challenge.com/http://www.petpla.net

http://www.chinaplasonline.com

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Part 1Germany

After 10 years of PETplanet Insider we at last have summoned up the courage to publish a report on our own home market - Germany. The PET market is still running on an economic basis almost everywhere in the world. Large and small fi lling companies supply what the consumer wants - and of course pays for. The preform and cap manu-facturers adapt themselves to the needs of these fi llers. But this is not the case in Ger-many. Here the government is trying to steer the consumers in a particular direction. And the legislators are themselves driven by var-ious interest groups. The fi lling companies react to this and the consumers are trying to side-step the problem. In other words, to

understand the PET business in Germany we have to dig deep. A simple presentation of the numbers involved is not enough. In our researches we have come across some amazing and unique things unparalleled in the rest of the world: take for instance an eight sided neck-ring, a manufacturer of PET packaging that has been in the hands of the same family for more than 500 years, the discount retailer that has taken vertical integration so far that they now make their own preforms and caps, the specialist drinks retailers as a central pillar of the distribution system, a large percentage of beer bottled in PET, and to crown it all a legal statute grandly entitled the Packaging Ordinance.

Discounters drive PET single-trip bottle business

by Alexander

Bchler

Regional market repor ts

Germany Part 1


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bottles. And as Coke was one of the first to introduce a PET bottle the distribution network adopted refillable PET bottles in crates. In the juice and milk industries the carton pack had become established and sales are mainly via the usual grocery outlets.

Then the discounter storm burst. The very first to make things difficult for the classic distribution chain was Aldi. Soon Lidl and other discounters joined in. The discounters had no interest in taking back empty bot-tles and so took the logical step of introducing single-trip containers, mainly cans and PET.

The long-established distribution channels found the going tough, and ostensibly the 1991 packaging ordinance was introduced to curtail the use of single-trip containers. However, for those involved at the time it was more a question of protecting the small-scale manufacturers and distribution system from the up-and-coming discounters and not so much a move based on ecological considerations. The refillable quota of 72% laid down in the ordinance for the various types of bev-erage frequently failed to be met and so, from 2003 we saw the introduction of an obligatory deposit on mineral water, beer or soft drinks such as Coca-Cola or lemon-ade, in single-trip bottles. The reaction of the discount-ers was swift. They did not revert to refillable bottles, but installed single-trip bottle return systems in their stores. However, since drinks cans could not be resealed ready for returning, and they started to smell when left in the returns container, the discounters removed cans totally from their shelves and listed only resealable PET bottles. Overnight Germany became the leader with regard to beer in PET.

Fig. 3: Development of the packaging structure in the non-alcoholic sector 1999 to 2007. The drop in PET single-trip sales can clearly be seen in 2003, the year when the deposit law was introduced, but also that the Packaging Ordinance could only hold back the growth of single-trip PET for about one year. (Source: wafg)

Lets start with the interest groups: for centuries Ger-many has been split into small regions - and so are the beer and mineral water industries. 25 years ago there were 393 mineral water companies in Germany - today we have just 134 (Fig. 1).

400

300

200

100

1992 1997 2002 2007

0

0

0

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313

370

134

Fig. 1: Development in the number of companies and small businesses in the soft drinks and mineral water market 1992 - 2007 (Source: German Federal Offi ce of Statistics and wafg)

A large number of these companies supplied their local area only. The mineral water companies then formed themselves into a joint buying organisation called the Genossenschaft Deutscher Brunnen eG (GDB). The companies retained their independence but joined the refillable glass bottle pool of the GBD. Peace reigned for many years in the market. The crates were handled through another typical German institution - the special-ist beverage retailer. Here the consumer can drive up in his car and buy his drinks in returnable packaging (bot-tles and crates)(Fig. 2).

Fig. 2: A typical specialist drinks retailer. Consumers here will find mainly drinks in returnable crates and refillable bottles, other than PETcycle there are almost no single-trip bottles. (Source: PETplanet Insider)

The situation was similar for the brewers. Here too there was a refillable bottle pool and here too were the small brewers supplying the local market, and here too bottled beer was sold mainly through the specialist bev-erage retailers. The big brands, like Coke and Pepsi, initially joined the existing system with refillable glass


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Hence the packaging ordinance helped the single-trip PET bottle to reach unexpected new heights. It only took one year for single-trip PET to further increase its success in the soft drinks market (Fig. 3). And looking at the break-down by beverage type it can be seen that there has been a signifi cant fall in refi llable beer bottles (Fig. 4).

Fig. 4: Development of the refi llable market quota for bever-ages from 1970 to 2006 (Source wafg)

The medium-sized beverage fi llers who were most affected by this development decided to make the best of it. The GDB added refi llable PET bottles to their bottle pool. A refi llable bottle is good for an average of 14 or 15 cycles, and could not stop the triumphant march of the single-trip bottle. The so-called PETcycle was set up as an alliance of well-known producers of beverages, machinery and packaging to handle single-trip bottles. For the medium-sized fi llers in particular PETcycle developed a closed loop for such bottles. The bottles are sold in returnable crates through the traditional beverage retailers and the empty bottles are returned in crates to the beverage producer who sends them for recycling.

Fig. 5: An 8-sided neck ring makes the PETcycle system bot-tles easy to recognise. (Source: PETplanet Insider)

To meet the highest ecological standards the bottles are made of 50% recyclate. And to make PETcycle bottles easy to recognise they have an eight-sided neck ring (Fig. 5). In 2007 1,450 million PETcycle bottles were sold across Ger-many using 50,300 tonnes of PET at 34.5g per bottle.

Despite all of the efforts the share of the market taken by the discounters grew. Today more than 50 percent of all non-alcoholic drinks are sold through discounters (Fig. 6).

The discounters went looking for a totally different sort of bottling company - a contract fi ller - and hence Mit-teldeutsche Erfrischungsgetrnke, Altmller Mineralb-runnen and Hansa Heeman grew to become the three biggest bottling companies with more or less 2 billion litres per annum each.

Fig. 6: There seems no stopping the growth in the market share achieved by discounters, which is getting bigger and bigger and hit more than 53% in 2007. (Source: wafg)


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These three companies do not have any serious brands of their own but simply fi ll own-label drinks for the big discounters. With an annual requirement of about 2 billion preforms for each company all three have established their own in-house preform production facility. Hansa Heeman have a through-the-wall operation run by Alpla whilst the other two make their own preforms. At a time when Mit-teldeutsche Erfrischungsgetrnke had some cash-fl ow problems the discount chain Lidl stepped in and bought the business, including the preform and cap production. This means that Lidl now own and operate injection moulding machines, and Lidl was the fastest growing of the discount-ers whilst Aldi still has the biggest turnover.

Fig. 7: The share of the alcohol-free drinks market taken by own-label brands and selected discounters (Source: wafg)

By setting up their own preform production the fi llers working for the discounters eliminated a signifi cant part of the market for the converters. It is estimated that within Germany there is an overcapcity of 2 to 4 billion preforms.

It can be foreseen that there will be more consolidation amongst brewers and fi lling companies and that the clas-sic, traditional German drinks distribution network will lose more ground to the discounters (Fig. 7).

Macroeconomic Macroeconomic DataDataPopulation ..................................................... 82.0 million

Average age .................................................. 43.8 years

Gross National Product ............................3.7 trillion US$

Growth rate of GNP ................................................... 1%

Unemployment ........................................................ 7.8%

General infl ation ...................................................... 2.7%

Total imports ............................................. 814.2 billion

Total exports ............................................. 992.9 billion

All fi gures 2008


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The economic crisis has not had any noticeable impact on the per capita consumption. The weather in Germany has a greater impact on beverage consumption than does the level of disposable income. If the temperature goes above 30 C almost only water is sold and CSDs and beer fall signifi cantly.

Fig. 10 The value of the total German market for the packaged drinks industry is about 20 billion Euros. More than 8.6 billion Euros was spent on alcohol-free drinks in 2007. Beer sales were 7.5 billion Euros. (Source wafg)

MilkAt 92l per capita the market in Germany is a signifi cant

one. Here well known dairy companies have tried to intro-duce milk bottled in PET. However their efforts have still not succeeded as in Germany milk is in part seen as being a cheaper commodity than water and so only really low cost packaging is successful. It is only with higher priced yoghurt and dairy drinks that the PET bottle is making inroads (Fig. 11). Beverages with at least 50% dairy con-tent are exempt from the obligatory deposit system.

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14.3

20.9

29.5

37.938.9

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Fig. 11: The share of PET in the dairy drinks market has risen to 42% in recent years (Source: Forum PET)

Beverage facts and fi guresPer capita consumption:

With just about 540l of packaged drinks (soft drinks, alcoholic drink,s, milk) per capita Germany is one of the biggest markets in Europe (Fig. 8 and 9). Total turnover is around 20 billion Euros (Fig. 10).

Fig. 8: Per capita consumption of beverages in Germany - 2007 (Source: wafg)

Fig. 9: With just about 300l per capita Germany is a leader in alcohol-free beverages. (Source wafg)


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Edible oil

Because Germany is not a traditional market for oils the consumption of edible oil per capita is low in compari-son with the Far East. The high priced sector still uses glass or metal cans.

Wines and spirits

This drinks sector, with just about 30l per capita, is still dominated by glass. As there are no cheap spirits, as in India for example, PET bottles are seen exclusively in air-craft catering and duty free shops etc. Wines and spirits are also exempt from the deposit system.

Beer

With a per capita consumption of 112l beer is one of the strongest beverage sectors. As described above the classic distribution channel for beer is the traditional drinks retailer. The preferred packaging format here is the refi llable bottle. Nevertheless the discounters have successfully tackled the deposit problem and offer low-end beers in single-trip PET, and only in 0.5l bottles. The three big breweries that have taken advantage of this business are:

Martens Feldschlsschen Frankfurter Brauhaus.

Martens in Belgium produce beer bottles with a Sidel Actis coating. Felschlsschen is the second biggest, and fi lls in multilayer bottles. The Frankfurter Brauhaus at Frankfurt an der Oder also uses bottles with an internal coating. In total beer in PET accounts for 11 percent of the German market (Fig. 12).

12

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2003 2004 2005 2006 2007 0.0

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8.9 9.1

11.0 Beer in PET

Fig. 12: Following the deposit law beer cans disappeared and beer appeared in PET bottles (Source: Forum PET)

http://www.petpla.nethttp://www.plama.de

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Water

At 138 litres per capita water in Germany is the strong-est category. Single-trip bottles are subject to the deposit law. The share held by PET at the moment is 77.1 percent. The glass refi llable bottles from the GDB a have a strong foothold here (Fig. 13).

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29.9

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Fig. 13: Even the strong share of PET among water bottlers has room for considerable expansion (Source: Forum PET)

Juice

The juice sector, at 38 litres per capita, is once again exempt from the deposit law so that we have here a rela-tively undistorted packaging market structure. When Eckes Granini switched from glass to PET the PET bottle began its triumphant march into the juice market. Unlike in the beer sector, it is the premium juice brands that are fi lled in multilayer PET. Lower-end products are sold in cartons. Nevertheless the share of the market held by cartons is reducing. PET now enjoys a market share of 30% (Fig. 14).

60

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Fig. 14: Fruit drinks in PET. The share held by cartons and glass fell by 20% in only 3 years. The driving force here was Eckes Granini who switched to premium PET bottles (Source: Tetra Pak)

Soft drinks

By soft drinks we mean principally CSDs. In total German consumers drink 115l per capita each year. The strongest categories are colas and cola mixed drinks at something over 40l per capita. Lemondes and simi-lar drinks are a close second with just about 35 litres per capita. At 91% the share taken by PET is very high. Almost the whole of this beverage sector is subject to the deposit law for single-trip bottles (Fig. 15).

100

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70

60

50

40

30

20

10

0

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2001 2002 2003 2004 2005 2006 2007

66.5

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Fig. 15: PET share (%) of the sweetened drinks market (Source: Forum PET)

Regional market report

Germany Part II with:

An analysis of the PET bottles and

caps currently used in the m

arket

A look at the taste preferences of the

German consumer and some

back-

ground on the German Packaging

Ordinance

Regional market report

Germany Part III featuring

interviews with:

Alpla PET-Verpackungen Uniplast Bericap Coca-Cola and Eckes Granini


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Interview with Mr. Volker KronsederKrones, as the indisputable world leader in the production of beverage fi lling machines, has its roots in Germany. At Krones Made in Germany is still a proud boast. We wanted to know from CEO Volker Kronseder what the importance of Germany is for him and how he sees the German market.

PETplanet: Mr. Kronseder, could the success story of Krones have happened in any other country? Volker Kronseder: We still do 15 % of our turnover in Germany. From a historical point of view we have benefi ted from the fact that several hundred brewers and bottlers in and around our location in the Oberpfalz have placed rigourous demands on us and we have supplied them with quality products right from the start. Important for us is the dual training system here in Germany, which means that we can fi nd top-class design engineers as well as excel-lent machine fi tters. Without these people we would not be where we are today.

PETplanet: If we look back at this years drinktec/PETpoint we see almost exclusively equipment for big fi lling compa-nies. Have you forgotten about the small brewers and min-eral water bottlers that helped you to grow so successfully? Volker Kronseder: You are right. Walking around the exhibition you could reach that conclusion. We are trying, together with our new subsidiary Kosme, to offer economi-

cally-priced equipment for companies with lower outputs. In Germany in particular we have the two-class system of big fi llers for discount retailers and the still very active guilds of small to medium sized fi llers. Both of these are important to us.

PETplanet: That brings us nicely on to discounters. They are driven by the word cheap. Does that apply to PET bottles too? Volker Kronseder: I dont believe so. Even those fi ll-ers with a high degree of vertical integration dont work cheap. They are very cost conscious and are always interested in anything new. I dare to say that because of this situation we always offer the latest technology to the market and that worldwide our fi llers keep costs under control!

PETplanet: Nevertheless the PET bottle is getting a cheap image in Germany Volker Kronseder: Here too we have to differentiate

F.l.t.r.: Volker Kronseder, CEO Kr

ones AG, and

Wolfgang von Schroeter and Alex

ander Bchler

for PETplanet Insider


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between different market sectors. In the water and CSD markets PET is incredibly strong. The refi llable glass bottle doesnt carry a premium image in the mind of the con-sumer. However, in the juice market the PET bottle has become established as a premium packaging format. Its only in the beer market that PET is seen as cheap.

PETplanet: PET has replaced the metal can in the beer sector and the can previously had the cheap beer image.Volker Kronseder: Today the beer can is a no go. I think that beer in PET still has potential. I am still waiting for somebody in Germany to take the step of launching a 1 litre or even 2 litre PET beer bottle. Why would the con-sumer not want this size of pack for home consumption? Consumers have accepted this type of pack with open arms in the water and soft drinks sectors.

PETplanet: No interview is complete these days without a word on the economic crisis. For ten years Krones has grown steadily quarter by quarter at a rate of two or three fi gure millions. And now suddenly it has stopped. How are you dealing with that?Volker Kronseder: Firstly it is a principle of mine, and of Krones, always to keep my feet on the ground in the face of facts, and to handle things in a prudent and modest way. The continuous growth was for us always tempered with a high degree of realism, with our feet on the ground. To that extent we have been able to handle the situation well. We havent had to let any of our employees go and it looks as if the light which has been on the horizon for a few weeks now is not getting any smaller. We are more than satisfi ed in particular with our sales in Germany. It seems to me that the businesses which have been running with the hand-brake on are slowly returning to normal operations.

PETplanet: When your share price fell through the fl oor you announced a large-scale share buy-back scheme.Volker Kronseder: Thats right. For a time our share value fell below our capital, which from a company management point of view makes no sense. So we bought back 4,51% of our shares. In better times we can sell these again at a profi t or use them in payment for any acquisition we may make, or just cancel them and so make the reaming shares stronger.

PETplanet: One last question What are you next objec-tives?Volker Kronseder: In 2010 I plan to visit the highest bot-tling plant in the world. Its in the Himalayas and stands at 5.,000 metres. Im looking forward to it.

PETplanet: But this is an interview about Germany - not Himalayas.Volker Kronseder: Ok. Ill start my trip from Germany.

PETplanet: Thanks very much Mr Kronseder - and bon voyage!.

M A G A Z I N E F O R B O T T L E R S A N D B O T T L E - M A K E R S IN THE AMERICAS, ASIA, EUROPE AND ALL AROUND THE PLANET

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Manufacturers of stretch blow moulding machines

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http://www.petpla.nethttp://www.petpla.nethttp://www.petpla.netmailto:[email protected]://www.petpla.nethttp://www.petpla.netmailto:[email protected]://www.petpla.nethttp://www.petpla.nethttp://www.petpla.nethttp://www.petpla.nethttp://www.petpla.nethttp://www.petpla.nethttp://www.petpla.nethttp://www.petpla.nethttp://www.petpla.nethttp://www.petpla.nethttp://www.petpla.net

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Mold-Masters and Abba form iPETMold-Masters and Abba have been well known for some time in the preform industry: Mold-Masters with their hot runners and Abba as a long-established manufacturer of stacks (cores, cavities, neck rings, etc.). They have now come together to form a new alliance and, as the second biggest player in pre-form tools, to capture a greater slice of the market.

In particular thanks to the global presence of Mold-Masters with fi ve manufacturing centres in America, Europe and the Far East, the iPET alliance should soon enjoy a high level of market penetration. As a techni-cal refi nement the tool designers at iPET have developped a system for installing the cooling channels as near as possible to the preform walls. The system is as ingenious as it is simple: long cooling water channels are milled into the cavity exactly following the contours of the preform walls and sealed by a metal sleeve containing the moulding surfaces. The classic cooling concepts that are by cur-rent manufacturers will always be a compromise as the drilled cooling in a straight line provides only point cool-ing, explains Manfred Lausenhammer.

Bruce Catoen, Vice President of Mold-Masters, expressly points out that the fi nished tool as well as all of the modular components ( like stacks and hot runners) can be directly integrated into existing equipment supplied by other manufacturers. In doing this the preform manufacturer

can acquire new tooling step by step. iPET can supply tools of between 2 and 192 cavities. Tools with 32 to 96 cavities have already been undergo-ing fi eld trials for more than a year. Thanks to the combination of hot runner and cooling technology it has been possible to reduce the average cycle time by up to 10% while increas-ing annualized uptimes.

An iPET 72 cavity tool

Sprint 72 Cavity - hot half


Labels for PET bottles For the fi rst time since we began publication of PETplanet Insider we have carried out a market survey of suppliers of labels suitable for use on PET bottles. At the recent drinktec exhibition there was a specifi c area devoted to the World of Labels, which was previewed in our article in PETplanet Insider issue 9/2009, and now, in our survey, we include further details of label and label material suppliers and their products.

Almost everything has a label, so there are literally thousands of print-ing companies, large and small, producing labels of one kind or another. However, we of course are clearly focussed on labels and appropriate materials for use on PET bottles, which itself encompasses numerous options - self-adhesive labels, paper labels, foil labels, shrink fi lm and stretch fi lm labels etc etc.

Labels play a key role in building a brand image, they carry important consumer information, they attract the eye at the point of sale and of course they have to perform well on the automated line - in short they are a very important feature of a beverage package. As with all aspects of packaging, labels also have their role to play in the recycling chain. Con-sumers are increasingly looking for ecologically acceptable packaging - including labels - and companies who offer paper labels have made it a speciality to produce labels that are made of post-consumer or renew-able material or is particularly suitable for recycling.

Whilst PETplanet Insider has have made every effort to ensure that the information in this new survey is up to date no claims are made regarding completeness or accuracy. All data is as supplied by the manufacturers.

10/09MARKETsurvey Producers of caps and closures

Producers of pellets and additives

Single stage machinery manufacturers

2-stage SBM machinery manufacturers

Suppliers of preform moulds and SBM moulds

Preform manufacturers

Suppliers of preform systems

Filling equipment

Suppliers of labels

Compressor manufacturers

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MARKETsurvey 10/09Company name Stora Enso Packaging Papers Brigl & Bergmeister GmbH Etapak Bask Ambalaj A.. CPostal address

Telephone numberWeb site addressContact nameFunctionDirect telephone numberFaxE-mail

Pinnauallee 3 25436 UetersenGermany+49 4122 719 685www.storaenso.com/packagingpapersJeannette KuhanenMarketing Manager+49 4122 719 685+49 4122 719 [email protected]

Proleber Strae 108712 Niklasdorf Austria+43 3842 800-0www.brigl-bergmeister.comFriedrich TschogglMarketing Director+43 3842 800-216+43 3842 [email protected]

A.O.S.B. 10034 Sk. No:835620 Cigli - IzmirTurkey+902323283345www.etapak.comN. Hande UsluerSales&Marketing [email protected]

KaD G+4wwKaKe ++ Ka

Printing technologyFlexoprinting, Offset, Rotogravure, others label papers for all printing technologies x rotogravure, offset, fl exoprinting ro

Paper labels Yes xwhite paper/metallized white paper & base paper for metallisation x wet strength paper, wet strength metallized paper Yeadhesive (wet glue/self-adhesive) Yes x Yes / Yes Yreel-fed/pre-cut Yes x Yes / Yes Yefor single serve/returnables Yes x Yes / Yes YeWrap around labels xmaterial (OPP...) Paper paper OPP, paper O

Oadhesive (hotmelt/wet-glue/self-adhesive) Yes x Yes / Yes / Yes Yewhite/transparent/metallized white paper & base paper for metallisation x Yes / Yes / Yes, Perlized Metallized Yreel-fed/pre-cut Yes x Yes / Yes Yefor single serve/returnables Yes x Yes / Yes YPSLmaterial paper OPP, Paper, Wash Offwhite/transparent/metallized white paper & base paper for metallisation Yes / Yes / Yes Yfor single serve/returnables Yes Yes / Yes YeShrink Sleevesmaterial (OPS, PLA, PET, PET-G, PVC, PS, others) No x Oreel fed/pre-cut x Yefor single serve/returnables x YStretch Sleevesmaterial (HDPE...) No x Nfi lm: white/transparent xfor single serve/returnables xRecycling considerations

label papers are produced from renewable raw materialslabel papers are biodegrable and compostable (DIN EN 13432)product NeoSet contains post-consumter-waste fi bres

x

Special technologies/promotion technologiespaper with different surface structures avail-able (plain and embossed).reverse side printing possiblemultitude of fi nishing possibilities (hot-foil embossing, varnishing, etc.)

CfroholalummpeQccthunUVvaw

http://www.storaenso.com/packagingpapersmailto:[email protected]://www.brigl-bergmeister.commailto:[email protected]://www.etapak.commailto:[email protected]

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Constantia Haendler & Natermann Polysack Plastic Industries Ltd. Sleever International F.P. Sleeve srlKasseler Str. 2D 34346 Hann. Muenden Germany+49 5541 704 0www.constantia-hn.comKai SparbierKey Account Manager +49 5541 704 417 + 49 5541 704 239 [email protected]

Nir YitzhakD.N. Negev, 85455Israel+972-8-9989796www.polyphane.comMr. Ronny Ben-ShushanProduct Engineer - R&D [email protected]

5 avenue Arago, ZI Le Val, BP 27F-91421 Morangis cedex France+33 (0) 1 69 74 75 76www.sleever.comEric MassonEuropean Sales Director+33 (0) 1 69 74 75 76+33 (0) 1 69 74 75 [email protected]

Via CareNo 821040 VedaNo Olona (VA) Italy+39-0332-402317www.fpsleeve.comAntonio FrattiniOwner

[email protected]

rotogravure / fl exo / offfset perfect match for fl exographic, rotogravure, offset and digital printers

rotogravure, fl exo, heliofl ex rotogravure

Yes / Yes Yes / YesYes / Yes Yes / Yes

OPP white / OPP transparent / OPP metallized / OPP holographic surface

Polyphane FIT shrink label

Yes / Yes / Yes Yes / Yes / YesYes / Yes Yes / (Yes)

Yes / Yes / YesYes / Yes

OPS / PLA / PVC / PET PET, OPS, TPE OPS, PLA; PET, PET-G, PVCYes / Yes OPP Yes / No single serve

No

Excellent recyclability - clean separation of fi lms from containers

PETsleeve, a sleeve based on a low density fi lm, which allows PET packagings recycling.

Ccate labelling (Non-permanent)frontal- and reverse side printing holographic surface technologylaser coding inks and lacquersluminescent coloursmetal-effect-inksmartial de-embossingpeel-off technologyQR codesccratch-off-applicationthermo sensitive inksunique coding technologyUV Eye spot technologyvarious embossingswindow-effect , magic window

Skinsleever (3D relief)Biosleeve (Biodegradable shrink sleeve)Sleever Braille (the response to new UE Directive)Holosleeve 3D (Protecting up-market brands)PETSleeve (recycling PET Packaging)

http://www.constantia-hn.commailto:[email protected]://www.polyphane.commailto:[email protected]://www.sleever.commailto:[email protected]://www.fpsleeve.commailto:[email protected]

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John Galt, president and CEO of Husky Injection Molding Systems Ltd., opened his companys press confer-ence at drinktec 2009 by reminding everyone that he has not always been a corporate executive. He began his career as a mould designer and he has a philosophy that design follows function.

We think about the end-product fi rst and then design for the applica-tion, he said. We are constantly striving for better performance, lower cost and higher quality. We have progressed from simply being a PET equipment manufacturer to a bever-age packaging solutions provider. One of the systems that Husky showed at drinktec followed the line of optimising use of raw materials, through recycling. HyPET is claimed to be the fi rst system in the world that is specifi cally optimized for manufac-turing preforms with a high percent-age of food-grade recycled PET fl ake.

Husky used drinktec 2009 to expand on its three-pronged approach to its business going forward. It sees the key areas for focus as recycling of PET material, reduction in energy costs and support for its equipment throughout its lifecycle, not just at the initial sales point.

Recycling, energy saving and lifetime support

Recycled PET with no time penalty

The business environment has, for a long time, been focused on virgin material. Not much value was placed on scrap, John Galt said. What we have done is to fi nd ways through technol-ogy to reintegrate scrapped material, which has helped to raise the value of waste material. HyPET currently runs at 50/50 virgin/recycled material and we hope to raise that proportion to the point where food grade product can be man-ufactured from even low grade recov-ered, washed fl ake. This will help to address concerns about plastics being discarded and will further help to reduce the industrys carbon footprint. The system produced 33.6g EcoBase pre-forms at 10.5s cycles - the same time as would be expected from 100% virgin PET, and with additional resin savings of 2.5%. Specifi c system enhancements incorporated for recycled PET include in-line melt fi ltration, to eliminate black

specks and other contaminants, and a new extruder design for improved processing of pellet and fl ake blends.

One way of reducing concerns about waste is to cut the amount produced in the fi rst place and this is something the company claims to achieve with its HyCap system, which was unveiled at NPE 2009 and demon-strated at drinktec. A 72-cavity HyCap 300 produced PCO1881 closures for carbonated soft drinks that weighed in at just 2.3g, at sub-four-second cycles a signifi cant step up from the industry standard of 2.8-3.0g, produced at 4.8-6.0s cycles.

HyCap is an optimised, one-piece closure system with fast cycle time and represents a solution geared to improved plastic packaging, said Galt. It can also use 50% recycled material. Opportunities to improve energy con-sumption, reduce weight and cut cycle times have to be measured against fi rst

HyPET is optimized for manufacturing preforms with a high percentage of food-grade recycled PET fl ake


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principles and systematically eliminate sources of waste.

HyCap is based on Huskys Hylectric injection machine platform and is the result of refi nements to the entire system, aimed at maximising speed, reliability and effi ciency. As closure resins are often viscous and, therefore, more diffi cult to mould, modifi cations incorporated in the new system have been aimed specifi -cally at those challenges. They are intended to help closure manufactur-ers achieve higher productivity levels, with tighter tolerances and offering the opportunity to incorporate more technical designs. The HyCap system is designed to integrate all aspects of the workcell, from resin handling, through tooling to optimised melt stream control and full inspection. One-piece closures should be inher-ently more cost-effective, as they use less raw material and should, there-fore, require less energy to process.

The HyCap system for one-piece closures can also use 50% recycled material

Lifecycle Services lifetime support

We are designing entire manu-facturing solutions around eliminat-ing waste and we believe that, in fi ve to 10 years time, we will see some very different moulding solutions, said Galt. In the meantime, Husky is devoting more energy and investment to helping its customers get more out of their equipment, through Lifecycle Services, a new support and service programme.

Lifecycle Services is aimed at helping manufacturers to get peak effi ciency from their equipment over its entire life, he explained. It isnt just about total costs but about sustainability of solutions, also. All solutions typically show deterioration in performance over their lives. That deterioration will occur even if service and maintenance schedules have been rigidly adhered to. Machines

begin to wear out; with Lifecycle Services, Husky will baseline equip-ment on delivery and then provide services that will maintain perform-ance, from both servicing and main-tenance and from new developments during the equipments life. Users will benefi t from front-line technol-ogy, with upgrades and retrofi ts. We believe this is a rich pipeline of opportunity for us to go down.

Over the longer term, Husky is committed to offering 6%/a produc-tivity improvement. Shotscope NX is an expansion and extension to the companys existing Shotscope con-trol system. It is web-based, which enables users to access it remotely, can connect with PDA and webcam services and features more data collection points. By making more information more readily available, the intention is to help customers improve operational effi ciency and part quality.

33.6g Eco-Base preforms (50/50 virgin/recycling material) pro-duced on a HyPET 300 system


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More eco-effi ciency, increased R&D investment

Under the optimistic banner

of Responsive Solutions for

a Changing World, French

company Sidel explained its

response to the economic

downturn and its priorities

going forward.

Sidel maintains that current market circumstances are making beverage companies rethink their products, sys-tems and processes. It has committed itself to a big increase in research and development (R&D) investment around 65% in 2009, compared with 2007. The focus of its efforts is three-fold: reinvent the package; revitalise the equipment; and re-energise the lines.

At drinktec 2009, the company reminded its audience that each gram trimmed off a bottles raw materials and weight leads to millions of euros in savings each year. The challenge lies in making sure that the package remains attractive for consumers, retaining both attractive designs and functional qualities, while retaining and guaranteeing industrial feasibil-ity through the adaptation of pack-aging machines. Existing (installed) equipment still offers opportunities for improvement in both productiv-ity and production costs; however, additional options and upgrades have to show very fast ROI (return on investment), in order to maintain high levels of performance while, at the same time, reducing energy and fl uid consumption. Re-energising involves line audits that will lead to performance improvement solutions across the board in economic, industrial and technical terms, and including integration skills, especially in relocation projects and in the incorporation of previously-used equipment.

More with less

The short-term answer is to produce better and con-

sume less, the company said at its press conference. Sidels

Eco-Booster programme, presented at drinktec, includes standard OEE (operating equipment effectiveness) audits, covering leaks and other areas of waste. The objective is to achieve machine optimisation that is validated by an energy consumption approach. Its Eco-EIT (effi ciency improvement tool) uses measurement equipment 24/7 to record data about energy con-sumption (air, water, electricity, gas, etc.) for a machine, a zone, a line or a complete plant. It facilitates cor-relation between consumption levels and the different steps of production (start-up, effective production, product changeover, cleaning, shutdown, and so on) generates detailed consump-tion reports that can be exported to other systems such as ERPs. The information can be used to detect vari-ations or peak consumption and pro-vides support for users who are look-ing to reduce consumption levels and to optimise production energy costs. The companys presentation on rein-venting the package examined new, lighter weight PET bottle designs; RPET (recycled PET) and focused on the huge opportunities for energy, raw material and weight savings available by moving wine from glass to PET.

Ecological and dry sterilisa-tion developments

Sidels stand at drinktec had 20 new innovations on display. Its Eco Booster for SBO Series1, SBO Series 2 and SBO Universal blow moulders is used to measure and reduce machine energy consump-tion. The Predis system, which was previously sold with SBO Universal blow moulders and Combis, is now available for adaptation to already installed equipment and is compatible with output rates up to 36,000bph per

Sidel launched its SBO Universal 2 range, which accelerates indus-trial blow moulder outputs by 10, achieving 2,000bph per mould.


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hour for mineral water, fruit juice and dairy products. It sterilises PET pre-forms, rather than bottles, by deposit-ing hydrogen peroxide (H2O2) vapour on the inner walls of the preforms as condensate. The process uses no water, very little chemicals, no rinser and produces no liquid effl uents. The technology has been adopted by French company LSDH for bottling UHT milk (whole, skimmed and semi-skimmed) in 1.0 and 1.5-litre bottles. It is reported to have enabled LSDH to reduce bottle weight by 20% and to achieve large savings in chemicals and water. The same dry decontami-nation principle is also used for caps with Sidels Capdis system.

Sidel launched its SBO Universal 2 range, which accelerates industrial blow moulder outputs by 10, achiev-ing 2,000 bottles per hour per mould. Energy consumption is, at the same time, cut by 10%. The process has already been tested and validated at several customer facilities and opens up the opportunity of blowing bottles from recycled PET. The 1.5l mineral

Polyester and PET Chain 2009 Global Business Developments, Technology and Applications

14th Annual World Congress December (14)151617, Swisstel Zrich, Switzerland

Tuesday, 15th December Wednesday, 16th December Thursday, 17th December1. Global Business Scenario 5. Pkg. Products / Future Materials / Environment OPEN HOUSE at EMPA St. GALLEN

Maack (CH): Global ActivitiesSRIC (USA): MEG / PX / PTA MarketsSamsung* (KR): PTA Next Generation TechnologySinopec (PRC): Technologies PX, PTA, PETSRIC (USA): LCA/Carbon Footprint Polyesters/PET

Futura (India): PET Barrier Development / Retail Pckg.Cytec (USA): UV Absorbers / Global MarketsHolland Colours* (NL): Light Barrier Technology / Dairy Pckg.BASF (DE): Bio-degradable Packaging SolutionsStarlinger (AT): Bottle-to-Bottle High Output Recycling

Swiss Materials Science & Technology Institute

9.00 h Departure by bus from Swisstel, Zrich 9.45 h Arrival at EMPA, St. Gallen

2. Process Technology & Speciality Products 6. PET End-Uses / Brand-Owners / R-PET / Testing Demonstrations in EMPA Laboratory:

Lurgi* GmbH (DE): Altern. Rawmatls, Tech. / EconomicsUhde Inventa-Fischer* (DE): Melt-to-Resin TechnologyAdvansa (TR): Speciality Resins / MarketsDuPont P&IP (CH/USA): Modifi ers for PET / PBTClariant (CH): Polyester Additives / Performance

Unilever (DE): PET in Food Packaging ApplicationsHJ Heinz (USA): Sustain. & Diversity of PET & New PkgCoca Cola (USA): Novel PET PlantBottle Sustain. Pkg.Fraunhofer (DE): Residuals / Testing PET, other Packaging Group Panel Experts Discussion, incl. Procter & Gamble (BE)

Key-note IntroductionProduction of Bio-Polymers in HP ReactorsBi-component Spinning PlantElectro-Spinning for Medical ApplicationsHigh Tech Analysis of Fibers (Nano Technology)Laboratory VisitsDiscussions of Specifi c Topics

15.00 h Departure to Airport Zrich or Swisstel

3. Process / Manufacturing Technology 7. Technologies / Additives / R-PET / Fiber / Tape

Invista (UK): Polyester Sustainability ImprovementsAquafi l (DE): Direct PET Process TechnologiesBKG - UOP (DE/IT): High Quality PET Production Kreyenborg (DE): Filtration R-PET Packaging/Strapping

Zhejiang Hengyi Group (CN): The Paradigm Shift of Asian PET ChainErema (AT): R-PET for Strapping / Tape ApplicationsEMPA (CH): Bi- & Tri-Comp. / Nano Tech PET Fib.Group Panel Experts Discussion

4. Packaging Film, Sheet, Lamination 8. Global Fiber, Yarn, Textile Production & Reviews

Gneuss (DE): Melt Filtration Extruder SystemWelex (USA): In-line PET Sheet Coex / FormingFaerch (DK): High Barrier CPET TraysPolyplex (IN): BO-PET Film ApplicationsGroup Panel Experts Discussion

SRIC (USA/CH): Global Overv. Fibers / Cap. RationalizationCCFA (PRC): Chinese PET / R-PET Fiber IndustryThiele (DE): Future Pester Fiber & Filament Prod.Textile Support Org. (PK): Polyester Fiber / Yarn Report Group Panel Experts Discussion

Hospitality FunctionsSamsung Petrochemical

Lurgi / Air LiquideOthers tba

Hospitality FunctionsMaack Business Services

SRI Consulting Chemical Week

MAACK BUSINESS SERVICESMAACK & SCHEIDL PARTNERSHIP PLASTICS TECHNOLOGY AND MARKETING CH-8804 Au/near Zrich, Switzerland Tel: +41-44-781 30 40, Fax: +41-44-781 15 69

E-mail: [email protected] www.MBSpolymer.com

2009Dec. 14, 2009, 1821.30 h

Early-Bird Reception

Supported by:

GLOBAL CONFERENCES,STUDIES, PROJECTS

GLOBAL CONFERENCES,STUDIES, PROJECTS

*Full page advertisements in printed program

water bottle produced at the Sidel stand with an SBO 14 has all the attributes of a traditional PET bottle crystallinity, resistance and elegance and contains 50% recycled materi-als. This bottle is the result of a joint development with Husky.

Sidel also demonstrated its latest beer line, including fi ller, crown feeder, crowner, labeller, pasteuriser, accu-mulation tables and end of line; its AQ-HC (high capacity) accumulation table; and a multi-form palletiser.

The Sidel Predis system is now available for already installed equipment.

http://www.petpla.netmailto:[email protected]://www.MBSpolymer.comhttp://www.mbspolymer.com

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The only end-to-end

vision inspection system in the

world.

29200 Aurora RoadCleveland, Ohio 44139 USA

If you need a fully-integrated

PET container vision inspection

system, able to cover your whole

process from start to finish,

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ideal for inspection at various

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KHS Life Cycle Solutions advises and supports the beverage, food, and nonfood industries throughout the entire service life of KHS machinery and is divided into four areas: idea fi nding, investment, operation phase, and divestment, including repurchase and possible relocation of machin-ery and equipment. It starts with line design and includes advice on, among others, the subject of separate stretch blow moulders, air conveyors and sep-arate fi ller/capper systems or mono-blocked stretch blow moulder/fi ller/capper systems. It will also help with the design of suitable PET packaging systems using the companys Bottles & Shapes program, assists with installa-tion and commissioning, and provides service, support, operational optimisa-tion and conversions throughout the entire life cycle of the lines.

KHS Corpoplast, KHS Plasmax and KHS Moldtec have been fully

integrated into the KHS Group since August 2008. With these companies and with KHS Asbofi ll KHS AG is now active in PET solutions across the board. The brewing industry continues to be the companys most important segment, representing 48% of total sales.

New and upgraded products

The company exhibited, for the fi rst time, its InnoPET BloFill system, a monoblocked stretch blow moulder/fi ller/capper system. It says that the system involves costs for investment and production that are lower than traditional PET bottle manufacturing and processing equipment and that it also offers increased line effi ciency, minimized space requirements, and lower operator involvement.

The upgraded HotFill+ system can now cope with fi lling capacities up to

ComprehensivesolutionsKHS exhibited at drinktec 2009 under the slogan Compe-tence in Solutions, which refl ects its emphasis on whole-of-life service and support to its customers, from initial sale to divestment and dismantling.

The KHS monoblocked stretch blow moulder/fi ller capper system: the InnoPET BloFill

mailto:[email protected]://www.pressco.comhttp://www.petpla.nethttp://www.pressco.com

A new generation of stretch blow moulders: the innoPET Blomax Series IV

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43,000bph. A new development is the incorporation a system that compen-sates for shrinkage of PET bottles after hot fi lling by adding a measured amount of nitrogen to the headspace immediately before capping. KHS says that its system reduces production costs by enabling reduction of bottle weights, among other features.

With the InnoPET Blomax Series IV, KHS Corpoplast was present-ing a new generation of stretch blow moulders. We are going to publish an extended article in the next issue of PETplanet isider.

The company presented an enhanced 3D line design system, which allows customers to see a com-plete 3D computer visualisation and simulation of their line design before ordering. It enables a realistic impres-sion of the machinery and how it fi ts in with other operations in customers factories to be given, and for amend-ments to be made immediately, before installation.

KHS Innopack WSP wrap-around shrink packer is part of the new Advanced series. It features exchange-able functional modules for fl exibility and uses servo motors that are identi-cal for all functional modules. The machine body has a cubic design and, with its new protective hood, offers the operating crew a better view into the inner workings of the machine. The Innopack WSP on display at drinktec featured a downstream eco shrink tunnel, which operates with a gas heater that can cut energy costs by up to 50%, compared with a conventional electric heater.

The Innoket 360 roll-fed label-ler on the stand demonstrated the

machines new self-sharpening cutter, a segmented vacuum drum, and an induction-based gluing tem-perature control system. Other recent developments from KHS include its SPF (6.4g) 0.5l PET bottle; the Inno-fi ll DRV fi lling system, which provides volumetric metering for beverages with low or no conductivity and can measure a range of plastic bottles with two neck sizes; Innopro Paramix C dosing and blending system; and the Innocheck centralised inspection technology.

KHS presented a sober assess-ment of the impact of the economic downturn at its press conference and indicated commercial, fi nancial and technical measures it is undertaking to ensure future prosperity. Studies undertaken by KHS found that the beverage industry accounts for 23% of the total world market for fi lling sys-tems and packaging machines, with food and non-food sectors accounting for 77%. On that basis, the company believes that signifi cant growth oppor-tunities remain in its chosen markets.

http://www.petpla.nethttp://www.petkamold.com

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PETplanet insider Vol. 10 No. 10/09 www.petpla.net30

Niagara Bottling the story continuesThey fi rst appeared on the front cover of PETplanet Insider, issue 4/2009, later this year they won the Beverage Innova-tion Award in the best PET technology innovation category, sponsored by Plastic Technologies Inc. (the award was in recognition of the 9.9 gram Eco-Air bottle), and recently, at drinktec/PETpoint 2009, we found the father and son team Andy Peykoff I and II in great form.

annum, given a PET price per ton of eight hundred US dollars.

With the conclusion of the Eco-Air bottle lightweighting project, Niagara, in the summer of 2007, almost simultaneously placed orders with Krones for five high-speed PET lines, each with a maximum output of 72,000 containers an hour and mainly in the twin-line layout. In this layout three Con-tiform S24 blow-moulders (each rated at 43,200 containers an hour) supply two labeller/filler blocs, each in their turn producing between 64,800 and 72,000bph. In addi-tion, another 43,200 containers an hour are fed into the line from an unscrambler silo (installed by the client), so that the two lines can be run at their maximum hourly output of 144,000 containers. Two intelli-gent air-conveyor servo distribution gates installed one behind the other provide line control. All five new lines were acceptance-tested with optimum line efficiencies, some-

No wonder that with an annual growth rate of 40 % over the last 10 years the company is now selling around fi ve billion (5,000,000,000) containers a year. There is currently installed capacity for 8 billion bot-tles per annum, which we believe will soon be at full stretch - based on the fact that Andy Peykoff II ordered the companys 11th line from Krones at drinktec/PETpoint.

Reduced carbon footprint

Four billion fills times a weight saving of 2.6 grams per bottle means around 10,000 tons of PET saved in a year - which significantly reduces the carbon footprint of our products whilst also allowing us to offer lower prices to our custom-ers, said Andy Pekoff II. This cor-responds to eight million dollars per

F.l.t.r.: Andy Peykoff II, Frank E. Semersky (PTI), Claire Phoenix (foodbev) and Andy Peykoff I at the presentation of the Beverage Innovation Award in the best PET tech-nology innovation category, sponsored by Plastic Technologies Inc. The award was in recognition of the 9.9g Eco-Air bottle.

Three Contiform S24 blow-moulders (each rated at 43,200 containers/h) supply two labeller/fi ller blocs, each in their turn producing between 64,800 and 72,000bph.

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PETplanet insider Vol. 10 No. 10/09 www.petpla.net 31

Doing moreFor Krones, the theme of its presence at drinktec was We Do More; a clutch of announcements and new developments were evidence in support of that assertion.

One of the key announcements from Krones was its new enviro concept. The programme focuses on ecology, economy and ergonomics in machine design and technology in a continuous process of optimisation that is intended to demonstrate quan-tifi able value.

Examples already in place:bloc-synchronisation of blow- moulder and fi ller that renders an air conveyor superfl uous, reducing energy requirement the Air Wizard optimisation package that cuts compressed-air con-sumption in the Contiform stretch blow-moulding machine.

times running at far more than 90%. They are operated in four shifts, twice twelve hours a day, around the clock, seven days a week. We try to change over to different container sizes as little as possible, or not at all, explains the companys direc-

Lifetime supportIn common with other companies,

Krones placed a lot of emphasis on its ongoing support programme, LifeCy-cle Service (LCS). The LCS product portfolio includes services, spares and handling parts and software pack-ages, all of which can be combined with each other, from a simple support contract to a full-service agreement. It is intended to provide budgetary and planning stability, high levels of line availability, effi cient spare parts management and specialised service personnel.

At the stand

On the stand, Krones unveiled and demonstrated ErgoBloc L (for liquid), a complete wet-end monobloc com-prising a Contiform S16 blow-mould-ing machine, Multimodule labeller and a Volumetic VODM-PET fi ller, for producing and fi lling PET containers. The system is designed for an output of 28,800 containers an hour, and can

be used for both still and carbonated beverages. ErgoBloc D (for dry) is a bloc-synchronised solution for the dry end that combines standard machines into a synchronised system for end-of-line packaging and palletising. It is made up of a Variopac Pro packer with a downstream shrink tunnel, a short pack conveyor and a Robobox pack grouping system with a Modulpal 1 ADR palletiser.

Also new at the show was the companys Varioline packaging system, which is capable of handling a multi-stage packaging process for primary, secondary or tertiary pack-ages, depending on confi guration and in a space-saving footprint. The design allows a number of different end-of-line packages to be created on a single packaging system.

In addition to its hardware, Krones discussed and described a number of IT products, including its MES (manu-facturing execution system) packages and line analysis tools.

tor of engineering. The twin-line concept has now been adopted in every plant.

The Eco-Air lightweight bottle, which we designed in close collabo-ration with Krones, was launched

on the market in April 2008 and has been very well received by our customers. At some point there are diminishing returns with lightweight-ing, and we may already be at the limit. That being said, there are still quite a few options for becoming more efficient in other areas of our business and our packaging.

In the future we have to take a long, hard look at areas such as freight costs, maintenance costs, payroll, vertical integration and so on. The current recessionary phase that were going through is admit-tedly less than encouraging, but it has its advantages: the lower oil prices result in lower transportation costs as well as lower raw mate-rial costs for our bottles. Im still very confident as far as the water and drinks market is concerned. In the future well intensify the diver-sification process for our beverage portfolio and offer the entire range of drinks, also including sports drinks, for example, is how Andy Peykoff maps out his firms corporate future.

Weve now adopted the twin-line concept in every plant.

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Beverage packaging monitoring technology suite

American company Mocon, Inc, a provider of instrumentation and consulting and laboratory services to medical, pharmaceutical, food and other industries worldwide, unveiled its suite of products for beverage instrumentation. The lead offer is OpTech O2 Plati-num, an oxygen analyser that uses a fl uorescence-based system for measuring total package integrity for both rigid and fl exible beverage packages. The fl uorescence can then be read optically, which makes it suitable for non-destructive permeation analysis, headspace and dissolved oxygen analysis and leak determination. The technology can be used to measure and report O2 stability at various points in the distribution channel.

Mocon had a number of technologies on display for measuring CO2 and O2 transmission and permeation, torque testing of closure application and removal, leak and seal and other monitoring and quality control solutions.

Quality and quiet satisfactionThere was a trend of restrained optimism at drinktec 2009 the biggest-ever edition of the beverage industrys leading exhibition.

Even before the doors to drinktec 2009 opened, the organisers Messe Munchen were confi dent that the event would be a success and so it proved to be. Around 60,000 trade delegates from 170 countries attended; nearly half 42% of the exhibitors took orders at the fair and around three-quarters were successful in preparing for follow-on business. A similar proportion said that they had paved the way for new commercial rela-tionships. 78% drinktec 2009 as good to excel-lent; and the international scope and quality of the visitors were given top marks 33,000 (55%) travelled from outside Germany. The breadth and depth of the range of exhibitors, the products on display and the quality of exhibitor services were all very well received. With such a positive response, it is not surprising that the overwhelm-ing majority said that they want to take part in the next drinktec.

The quality of the visitors was very good as more than 80% were decision makers - Virtu-ally all the CEOs and Presidents from compa-

nies around the world turned out here, exhibitors observed. The average length of visitor stay two days represented a serious commitment of time and money. Professionals from the drink sector made up the largest single group, just ahead of colleagues from the brewing industry. Fruit juice, milk and wine were also well represented and, for the fi rst time ever, drinktec 2009 attracted del-egates from liquid food producers.

This issue of PETplanet Insider includes tes-timonials from PET people in our drinktec cover-age. You will also be able to read about the PET-relevant items we found some expected, others a bit of a surprise. The focus of PETpoint in Hall B3 enabled PET people to meet and exchange ideas and views easily.

In case anyone forgot, the PET World Con-gress was held at the same time as drinktec 2009! There was a lot of ground covered over the two days and we will present a full report in issue 11+12.

Waldemar Schmitke, Gen-eral Manager PET Systems, Netstal-Maschinen AG, Switzerland: For us drinktec is a real barom-

eter. We came to Munich with

high expectations and these

have almost been exceeded.

The quality of the visitors was extremely high

people who want to do business and have a

real interest. We were also happy with the visitor

frequency at our stand. The visitors came from all

over the world, in particular there were many from

the Middle East and the Far East, among them

several delegations from China. We were also

able to sign deals during the fair, and expect for

the future a moderate growth in the PET area.


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Wide mouths, handles, global expansion, new investment

Siapi displayed its new corporate image, announced the opening of two new subsidiaries and unveiled several updates and innovations.

In 2008 Siapi developed a three-year, 1 million business plan that included a new building for R&D with three laboratory machines and increased staffi ng and a renewed commitment to expansion of its sales and marketing operations. Its new corporate style and logo is intended t

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