PET Preforms & PET Multi-Layer Co-Injection Technology

Husky controlled. Husky information is only intended for the recipient. Any dissemination to anyone other than the recipient is unauthorized and strictly prohibited.

PET Preforms &PET Multi-Layer Co-Injection Technology

Fabrice BECKER at Safripol Conference 2019 - Johannesburg

Husky controlled. Husky information is only intended for the recipient.

Any dissemination to anyone other than the recipient is unauthorized and strictly prohibited.3

World-Leading Supplier of Manufacturing Solutions, including Tooling, Hot Runners, Machines and Services

Beverage Manufacturing

• Canada • Luxembourg • China • USA

MSP Tooling Manufacturing

• Austria • Czech Rep. • Switzerland • USA

AM AP

EMEA

Team Members | 4500+ Husky Employees

Division of Team

Members GloballyClosures

Specialty

Packaging

PET

Emerging

Mature

Customer Support | 500+ Dedicated Husky Sales and Service

Revenue

by Market

Revenue

by Region



Mega Trends – Continuing to Shape Packaging

Millennials and

Ageing Generations Digital Shoppers Health Conscious Environmental

Friendly

Premiumisation Personalization

Smaller &

On-the-Go

Package

Smart

PackageSustainability



PET Forecast for Non-Alcoholic Beverages

Source : Global Data

PET Bottle Consumption is forecast to outpace other materials and formats for

beverage packaging.

PET 3.1% CAGR 2019 - 2023

Non-PET 2.3% CAGR 2019 - 2023

Global Non-Alcoholic Beverages Package Consumption

(M of Units)



Consumption by Segment in PET

CSD Growth 1.3% CAGR 2019 - 2023

JSDT Growth 2.5% CAGR 2019 - 2023

Source : Global Data

Water Growth 4.1% CAGR 2019 - 2023



Answer to the needs of the differentiated products that proliferate in new white spaces



Growth by Category in PET

All water categories are showing strong growth, as are RTD coffee

drinks and nectars.



Marketing Strategy – Consumer Needs

Premium

Convenience

Health LifestyleNon Sustainable

Sustainable



Technology



Introducing HyPET HPP5e



HyPET Product Line Consolidation



Sustainability



Trends towards Circular Economy Package Design

100% reusable, recyclable or compostable plastic packaging by 2025

Follow their lead



European Single Use Plastics Directive Proposal

• SUP Ban approved by European Parliament in December 2018

• Recycled PET in beverage bottles : at least 25% in 2025 and 30% in 2030

• Separate collection targets for PET beverage bottles: 77% in 2025, 90% in 2029

• Tethered closures:

Still and carbonated products in May 2024

AB-2779 (California Bill) currently inactive, expected renewed push.

• 2019 SUP steering committee formation within CETIE

https://ec.europa.eu/commission/news/single-use-plastics-2018-may-28_en

https://leginfo.legislature.ca.gov/faces/billTextClient.xhtml?bill_id=201720180AB2779



Husky – Sustainability Today

Bottle

Light-weighting

Thread & Closure

Light-weighting

Tethered Cap

Recyclable barrier

Multi-layer

Recycled Flake

Processing

Non-food rPET

Multi-layer

Industry

Associations




Bottle

Light-weighting

Thread & Closure

Light-weighting

Tethered Cap

Recyclable barrier

Multi-layer

Recycled Flake

Processing

Non-food rPET

Multi-layer

Industry

Associations



Best-in-class injection capability enables innovative package designs -Integrated Systems Approach

Recycling

Process

Cooling

Resin

Handling

Preform / Closure

Handling

Hot

Runner

Machine Mold

Mold

Dehumidification

+Factor 100TM

500ml water,

5g preform,

0.7g closure

1.5 mmbody wall thickness*

0.8 mmneck wall thickness*

Up to 55length/thickness ratio*

* Many factors affect the minimum achievable dimensions, such as resin, bottle

design performance, TSS lip diameter, application, and cavitation are just some

of the examples. These dimensions may not all be simultaneously achievable.



PET Bottle Weight Evolution

Time

6

8

10

12

14

16

18

20

22

24

26

500ml Water

2014

29/2530/25H 25/22

Preform

Weight (g)

2000 Today20112008

Improved

Injection Capability

Improved

Blowing Process

Neck Finish Evolution




Bottle

Light-weighting

Thread & Closure

Light-weighting

Tethered Cap

Recyclable barrier

Multi-layer

Recycled Flake

Processing

Non-food rPET

Multi-layer

Industry

Associations



Enabling Package Optimization with HUSKY

Safripol 2019 Under Neck OptimizationHPP Capability – Thickness & Design

Body OptimizationStretch Ratios

Intelligent Preforms

Base DesignOptimized Performance

Right Weighting

Closure PortfolioProven Off-the-Shelf Designs

License-free

Neck Finish PortfolioStandard Necks

Light Weight Options



Enabling Package Optimization with HUSKY

Under Neck OptimizationHPP Capability – Thickness & Design

Body OptimizationStretch Ratios

Intelligent Preforms

Base DesignOptimized Performance

Right Weighting

Neck Finish PortfolioStandard Necks

Light Weight Options

Closure PortfolioProven Off-the-Shelf Designs

License-free

Dispensing

Systems

Safripol 2019



26/22 High Carbonation - CSD Dispensing System Evolution

~8g ~6g- 2 g

Less than 10 years ago started the conversion from PCO1810 to PCO1881.

- Reduction of ~2g on the

complete dispensing system

- Same Inner Bore Diameter

- Height reduced by 4mmWeights may vary depending on closure

design and neck customization.

~4g- 2 g




- Height reduced by 4.1mm

PCO1810PCO1881

26mm CSD

Similar modifications and ROI expected from PCO1881 to 26mm CSD



Water Dispensing System Evolution

~5.6g~3.6g

- 2 g





Weights may vary depending on closure design and neck customization.

~1.7g- 2 g

- Reduction of ~2g on the complete

dispensing system

- Inner Bore Diameter reduced by 3.27mm


30/25H 29/25 25/22



Tethered Closures – Case Study Conversion from 29/25

Snap-On 25Leash Snap-On 21 Flip Lid

29/25

Neck Finish 29/25 or

29/25 LW

26/21

(21mm Opening)

New Neck Finish

(25mm Opening)

29/25 or 29/25LW or 29/25MOD

Neck weight 2.1g-2.41g 1.25g 1.6g 2.1g-2.41g

Neck Impact NONE NEW NEW NONE

Closure Impact Slides + Outer Cores NEW NEW NEW

Line Impact NONE Capper retrofit, Chucks, Pick and Place, Cap feeder, Cap

chute, neck finish personalization parts

Capper retrofit, Chucks, Pick and

Place, Cap feeder, Cap chute

Target Market Still & Sparkling

Beverages

Still Beverages Still Beverages



Husky Multilayer Solutions



Why Multi-Layer Barrier?

Coffee/Tea Meat Seafood/Tuna Vegetable/Fruit

O2

Light

Moisture

PP/EVOH/PP

PET/Barrier/PET

Small

format CSD

Sensitive

beverages

Milk and milk

alternativesBeer

CO2

O2

Light

Plastics are more or less permeable depending on:

• Material structure and properties

• Container wall thickness

• Type of gas, liquid or light exposure

Extend the shelf life of sensitive food and beverages

Oxygen

Odors

Water

Light

Aromas

Gas



Multi-Layer Technology Runway

Engineered

Packages

Gas barrier

Aesthetics

Light Barrier

CO2

O2

H2O

Haptics

Smart Packaging

Post-Consumer Recycled,

Circular Economy

Package Design



Engineered packages with Multi-Layer enable next level of performance

Complete package

protection enabled by a

fully encapsulated dome

Layer bias control

allows barrier layer to

be positioned away

from the surface to

the core for improved

bottle appearance

Accurate barrier

position enables

excellent leading

edge position

control

Middle layer materials:

MXD6 (Nylon)

Plemat (Coke)

Verian (PGA)

PET w carbon black

Oxygen scavengers

EVOH (passive)

PET w colorant additives

Recycled PET



HPP5 Multilayer Evolution – Ease of use and capability

New HR nozzle

design to reduce

degradation and

reduce clogging

issues

Front mounted

HR nozzle to

reduce

maintenance

effort and

improve uptime

Melt distribution

redesigned to

allow low barrier

dosage and low

shot to shot

variation

Servo driven

valve stem

for accuracy,

speed, and

barrier layer

adjustment

flexibility



HPP5 Multilayer Evolution – Application Range

Encapsulate or

open dome

without hardware

changes

Center or Bias

Hthe B layer by

processing

changes only

Leading and

trailing edge

variation

capability enables

positioning the B

layer right where

you need it

Precise

dosing at

lowest % to

enable a

wide range of

application



Latest Multi-Layer Technology

CSD

Juice

Dairy

Beer

Tea

Food

Personal Care

Systems sold around

the world since 201541 Applications8Winner of the Ringier Technology

Innovation Award 2018

Industrial Pails



“The much better balance helps to make the economics work”

Frederic Mignot - SGTPresident and CEO

24t less barrier per yearmaterial, assuming 1.5% lower content,

16g bottle, 100M bottles per year

3.5%5%



Multi-Layer packages offer superior barrier performance AND reduced material costs

30%-60% More effective

additives and clear bottles

More light protection

with less additives for

UHT milks

Unique aesthetics at

reduced cost

Monolayer

blends

Multilayer

Monolayer blends

VS Multilayer

barrier



Success of HyPET® HPP5 with high capability multilayer, drop-in solution for PET lines

41 machines

in 13 countries

5 billion preforms

≈ total installedproduction capacity

8 applications types

Source: HUSKY. Image credit: Sidel

Pepsi

345ml

Pakistan, UAE

Coke 250-350ml

USA, Egypt, Algeria

Loic Raison

250ml

France

Adelholzener

750ml

Germany

Perrier

500ml

France

San Pellegrino

500ml

Italy

Hamoud

350ml

Algeria

Abatilles

500ml

France

50% less

barrier material

CO2



Superior performance of Multi-Layer offers opportunities to further improve shelf life and/or reduce costs vs mono-layer and blends

Su

rface/ vo

lum

e

Small containers

Have a challenging surface

to volume ratio leading to

higher CO2 loss

Shelf life

[days]

17.5 g

Total material cost

PET & barrier [normalized]

11095 100 120

50

45

40

35

130

Monolayer

Source: M-RULE

15 g

Multi-Layer

2.5%

Verian™High Barrier Polyester

17.5 gBlend

7%



“Higher performing packages that also look better”

35% less CO2 barrierwith multi-layer barrier vs. blend,

better CO2 protection and bottle

clarity.

Rizwan Seth - NOVATEXPresident and CEO

3.5%5.5%




41 machines

in 13 countries

5 billion preforms




ECKES

Granini,

Hohes C

Germany

TSK, Tea

400ml

Japan

O2

scavenger

50% less

barrier material




Monolayer

blends

Multilayer

Monolayer blends

VS Multilayer

barrier





UHT milks


reduced cost



Husky’s HyPET HPP5 with Barrier module can run all LDP applications at the lowest cost to produce

COLD CHAIN AMBIENT TEMPERATURE

≈ 10 days ≈ 5 weeks

WhiteWhite Flavored

3 – 6 months 6 – 9 months

UHT - White

99.95%< 99%95%10% Barrier to light

To

tal c

os

t to

pro

du

ce

Multi-layer

White/Black/White

Husky

Solution

0-20% BARRIER

PET ~ 8% TiO2

PET ~ 5% TiO2

PET

>10% TiO2

Illustration only

White pigment - High costBlack pigment - Medium cost




41 machines

in 13 countries

5 billion preforms




black PET core

2x white PET skin

Light

core bias encapsulated

dome

Parmalat, Elegé,

1L UHT Milk,

Brazil

Ifap,

1L UHT Milk,

Italy

Light

O2O2



“The best solution for our dairy project.Second to none!”

Up to x2 more bottlescompared to alternative usinginject-over-inject technology, comparable cavitation, same barrier to light – 6 month shelf life

Data from 32 cavities Inject-Over-Inject system, annual output normalized for 72 cavities for comparison purposes

Filipe de Botton - LogoplasteChairman

Source: Quote from HUSKY customer. Data from HUSKY internal competitive intelligence

200 Mgood quality

bottles per year

100 Mgood quality

bottles per year

Data for 72 cavitiesHUSKY Multi-Layer




41 machines

in 13 countries

5 billion preforms




LightO2

CO2

Frankfurter Pils,

Viaplast,

500ml Beer,

Germany

OMB,

Plastipak,

12oz Beer,

US

O2

O2

O2

O2CO2 CO2

CO2

CO2

UV

core:

O2 scavenger +

nylon

skin: PET + amber




Bottle

Light-weighting

Thread & Closure

Light-weighting

Tethered Cap

Recyclable barrier

Multi-layer

Recycled Flake

Processing

Non-food rPET

Multi-layer

Industry

Associations



The Multi-Layer PET package offers solutions using up to 40% recycled PET

rPET pellets + black

additive

washed opaque

rPET flakes

Up to 40%

mid-layer

40%

*transversal bottle thickness view

25%35%

biasedposition of the layer

in*

out*



The industry is getting organized to establish dedicated streams for opaque PET

Dedicated stream with

secondary level of sorting

washing, pelletizing

Preform injection

Retailer

Deckel

Group




Monolayer

blends

Multilayer

Monolayer blends

VS Multilayer

barrier





UHT milks


reduced cost




41 machines

in 13 countries

5 billion preforms




P&G,

Logoplaste,

Alpla

200ml Shampoo,

China



Premiumisation – Multilayer - Color Gradient

Ability to:

– Create completely opaque containers

– Color only the outside (less colorant)

– Color only the inside (less colorant)

– Adjust inside layer (colored) positions

– Color superpositions within A&B layers

P&G, Logoplaste,

Alpla

200ml Shampoo,

China



Smart Packaging - Activated Technology

Glow-in-the-dark Sleeve,

White Water, England.

• Glow-in-the-Dark Sleeve, UV light exposition

allows sleeve to glow electric blue in the dark.

• Photochromic, (Sun Activated) to change

color pigment from white to final required color.

• Thermochromic, colors change according to

temperature.

• Intelligent Labels, to provide customers with

interactive, personalized brand experiences.

• Intelligent Polymers, colors change according

to product shelf life.

Intelligent Label, Heinz.

Nestlè, Aqua Vera Kids,

Happy Sleep, Italy.

Thermochromic Printing

Coors Light Beer Cans, USA



Multilayer Innovation – Smart Packaging

Phospho/fluorescent

12oz CSD bottle

Color Gradient

12oz CSD bottle

Thermochromic

12oz CSD bottle

• Phosphorescent and fluorescent effect

(Glow-in-the-dark)

• 26/22 CSD high carbonation neck finish

• Husky closure

• Thermochromic effect

• 26/22 CSD high carbonation neck finish

• Husky closure

• Top-Down Bottle with Color gradient effect

• 1881 neck finish, Husky closure

• Base overcap

• Spherical bottle base

Husky controlled. Husky information is only intended for the recipient. Any dissemination to anyone other than the recipient is unauthorized and strictly prohibited.

Closures & Multi-Layer Co-Injection Technologywith Single-Serve Capsules

Fabrice BECKER at Safripol Conference 2019 - Johannesburg

PET Preforms & PET Multi-Layer Co-Injection Technology

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Transcript of PET Preforms & PET Multi-Layer Co-Injection Technology