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No. 03/201128 .03 .11
PETplanet is read in 136 countries
Page25
MARKETsurveySuppliers of conveyors
for preforms and empty
bottles
MAGAZ INE FOR BOTT L ERS AND BOTT L E -MAKERS IN THE AMERICAS, ASIA, EUROPE AND ALL AROUND THE PLANET
Page12-31
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EDIT
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PUBLISHERAlexander Büchler, Managing Director
HEAD OFFICEheidelberg business media GmbHLandhausstr. 469115 Heidelberg, Germanyphone: +49(0)6221-65108-0fax: +49(0)[email protected]
EDITORIALDoris Fischer fi [email protected] MaruschkeRuari McCallionIlona TrotterWolfgang von SchroeterAnthony Withers
MEDIA CONSULTANTSUte Andrä[email protected] [email protected]: +49(0)6221-65108-0fax: +49(0)6221-65108-28
France, Italy, Spain, UKElisabeth Maria Köpkephone: +49(0)6201-878925fax: +49(0)[email protected]
LAYOUT AND PREPRESSExprim KommunikationsdesignMatthias Gaumann | www.exprim.de
READER SERVICESKay Krü[email protected]
WWWwww.petpla.net | india.petpla.net
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.
3PETplanet insider Vol. 12 No. 03/11 www.petpla.net
EDITORIALdear readers,EDITORIALdear readers,,,
The recycling of plastics is a matter of increasing and justifi ed concern amongst the general public, involving as it does the use of fi nite resources and the burden it places on the environment. Undoubtedly PET recycling in particular is high on the list of priorities for the beverage and packaging industry. Producers of bottled water – using thousands of tons of PET - see recycling as a major element in the sustainability of their business and their long-term survival.
This concern is shared by PETplanet Insider and our commitment to the subject will be extensively demonstrated during 2011 in a series of articles examining in detail the subject of recycling – we will be looking at the pro-cess itself, the equipment involved from a number of very different angles and of course to some rPET applications. Approximately 12 million t/a of virgin PET was globally produced in 2009 by chemical industries for use in the packaging sector. Approximately 4 million t/a (bottles) were collected for re-use – mainly in markets of developed countries.
Only 20% of the recycled material are used for bottle-to-bottle due to the high quality requirements, 22% for sheets, 45% for fi bre, 11% for strap-ping, 2% for miscellaneous – in 2009*. Data and fi gures must be taken with a little pinch of salt, since markets in the emerging world like Brazil, India and China are statistically unknown quantities.
Some conclusions, however, are beyond doubt: The collection of post- consumer bottles needs to be improved. This is an obligation for everone – the general public, politicians and communities. One further, important point to be mentioned is that engineers and industries must face up to the challenge of improving the processing of PET waste to produce high quality food-approved RPET .
Well established companies are focusing on PET bottle collection and waste separation, and in the production of fl ake and pellets, as well as the conversion of RPET fl akes and pellets into fi nal products. Big name sup-pliers have developed and produced machines to convert so-called “bad” PET waste to food grade RPET for re-use. But since the incoming “bad” PET often turns out to be a “bad” surprise for the recycler, the quality of the RPET that is produced is more a result of trial and error than expected.
Thus the challenge remains for all parties concerned and involved to reduce the dependence of the good quality of PET intake as well as the unpredictable quality of outgoing RPET. In this edition of PETplanet we are looking at innovative equipment to do just that.
Wolfgang von Schroeter
* Recycling fi gures taken from PCI PET Packaging
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INSIDE TRACK3 Editorial4 Contents6 News38 Products40 Bottles42 Personal care35 Patents
BUYER’S GUIDE29 Get listed!
MARKET SURVEY22 Suppliers of conveyors for
preforms and empty bottles
PREFORM PRODUCTION32 Milky preforms The rapid guide to perfect preforms, part 17
BOTTLE MAKING34 Automatic handle for edible oil Automated solution from Sipa at JRD, Dubai
RECYCLING SPECIALMATERIAL / RECYCLING
12 The power of sorting An innovative approach from Unisensor, Germany16 A conference selection 6th China International Recycled Polyester Forum
Hangzhou 201018 Forum PET Europe launched PETplanet speaks to Jean-Marc Rostagno, First President of Forum PET Europe20 Maximising use Recycling technology responding to regulatory
and market demands22 Bangladesh recycles First Krones bottle-to-bottle recycling line at Akij30 From bottles to bags Outdoor specialist Vaude uses rPET for
production of bags
PREFORM PRODUCTION31 Raising recyclate in preforms Handling high levels of recyclate
in preform machines
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Our injection moulds are used to produce suitable PET preforms for any design and shape. www.otto-hofstetter.com/pet
PET FOR MEN AND WOMEN .
PETnews
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PlastID to develop detection and separation in recycle stream
An industry group comprising Petcore, ColorMatrix, Pellenc, EPRO, EuPR, PlasticsEurope, UNESDA and EFBW has applied for a European R&D grant to fund the full scale-up of PlastID, a Petcore project intended to develop methods to detect and separate specifi c containers from the plastics recycle stream. The multi-million Euro project will focus on approved food-stand-ard packaging polymers and it is envisaged that the technology developed through the PET recycle experience will be transfer-rable to HDPE, PP and PS.
The use of novel materials in PET bottles can cause discol-oration during the recycle process. One aim of the project is to facilitate the recovery of bottles containing novel materials from the clear bottle stream and divert them to higher value outlets. The PlastID project will develop an LCA (lifecycle assessment) on the collection, sorting and recycle processes and provide training in new technologies. The consortium is awaiting the outcome of its application and intends to present the project in greater detail in future editions of PETPlanet.
www.petcore.org
More exhibitors and services at 25th Chinaplas, May 2011
The 25th edition of Chinaplas, the International Exhi-bition on Plastics and Rubber Industries, will be held at China Import and Export Fair Pazhou Complex, Guang-zhou, PR China, from May 17 to May 20, 2011. The confi r-mation of the India Pavilion brings the total of country and regional pavilions at the event to 11. Chinaplas will now be arranged under 12 themed zones, with the addition of the Rubber Machinery & Equipment; Industrial Services; and Bio-Plastics and Degradable Plastics zones. Over 20 enterprises have already reserved space in the Rubber Machinery & Equipment zone, in Hall 3.1.
ChinaplasOnline.com, the offi cial website, has been revamped and improved, with a search engine func-tion that allows keyword searches in the website content and exhibitor’s data. The ‘Download Centre’ holds show-related information, such as the visitor brochure, eNews-letter, etc. available for visitors to download. Japanese, Korean, Spanish, Italian, Russian and Arabic versions are now available. Latest show updates, transport and hotel information, and seminar details are available through WAP Chinaplas.
www.chinaplasonline.com
Mould Technologies Group acquires Magor Mold Inc.
Mould Technologies Group (MTG) of Diessenhofen, Switzerland, which incorporates Schöttli AG, has acquired all of the issued shares in Magor Mold, Inc., of San Dimas, Ca, USA, as of January 2011. MTG also owns s-mouldtech, of Suzhou, China. Schöttli and Magor both specialise in the development and production of extremely high-output injection moulds. Schottli develops and produces injection moulds for the production of medical parts, caps and closures and thin-wall packaging and caters to medical disposables manufacturers and packaging and plastic cap producers. Magor injection moulds are mainly used for the production of transfusion systems, dialysis units, respirators and anaes-thetic systems, drug applicators and hygiene products made from standard polymers and engineering thermoplastics. It predominantly supplies manufacturers of medical parts and disposables. Service and maintenance across MTG’s range of products will now be carried out by the local companies. Wolfgang Bühler and Martin Schöttli will both remain manag-ing directors of Magor and Schöttli.
www.schoettli.comwww.magormold.com
www.s-mouldtech.com
Clear Path Recycling PET recycling facility operational
Clear Path Recycling, LLC, the PET recycling joint venture company established by Shaw Industries Group, Inc., and DAK Americas LLC, in April 2009, has completed the fi rst phase of its PET recycling facility in Fayetteville, NC and the plant is now operational. The facility produces recycled PET (RPET) fl ake from post-consumer PET bottles and now has the capacity to recycle up to 160 million pounds of PET bottles per year. This is estimated to save over 550,000 cubic yards of landfi ll space each year and over 1.9 trillion BTUs of energy annually, equal to the power needed for over 20,000 U.S. homes per year, according to Energy Information Administration data. Shaw and DAK will be the primary users of the RPET Flake (Recycled PET bottles) in their respective polyester based products including carpets, fi bres and resins. The remaining product will be sold for merchant use. Plans for the facility include increasing throughput to 280 million pounds (127 million kg), about 5 billion bottles per year, which will make it the largest recycling facility in North America.
www.clearpathrecycling.com
New closures factory in South East AsiaBericap has recently opened a production facility in Singapore, which will be providing direct service to customers in the
ASEAN zone. It is intended to be the nucleus for future expansion of sales and production facilities in South East Asia. The facility will initially manufacture closures for the non-food and non-beverage market, with beverage closures to follow in the near future, as well as a hinge closure for bottlers of soya sauce who require anti-drip features, tamper-evidence and a clo-sure design allowing capping of hot-fi lled glass bottles. Bericap Singapore is preparing to introduce the DoubleSeal one-piece closure technology for carbonated beverages or hot-fi lling. A screw-cap with folded tamper evidence band for the agrochemi-cal industry is also to be produced. The manufacturing process and other additional safety features make the closure diffi cult to copy and support anti-counterfeiting measures. and Bericap says that the new factory has space and capacity to enlarge the product range and increase output.
www.bericap.com
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Husky to acquire KTW Husky Injection Molding Systems has announced its intention to acquire
closure mould maker KTW of Waidhofen, Austria. The sale is expected to complete in May 2011. The two companies have been working together for the past 14 years. From the completion of the acquisition, Husky will offer KTW-branded closure moulds as part of its fully-integrated turnkey systems, which include mould, machine, hot runner, temperature controller, and con-sulting and after-sales services. The current KTW leadership team, including Managing Directors Anja and Claus Ziegler, will continue to be involved in the business. KTW’s operations in Austria, the Czech Republic and Ger-many, will become Husky’s closure mould development and manufacturing centres. Husky plans to initiate a strategic review process of Injectoplast, KTW’s custom injection moulding division, in order to avoid any potential confl ict of interest with Husky’s customers.
www.husky.ca
MachinePoint group launches MachinePoint Food Technologies
MachinePoint Group has announced the launch of a new subsidiary company, MachinePoint Food Technologies. The new company is dedicated to offering complete turnkey projects and plant and process installation to processors in the agro food, beverage and dairy industries. The company intends to include the inte-gration of used machinery into new pro-jects in its offer. MachinePoint Food Tech-nologies´ sister company, Machine- Point Used Machinery, controls 80% of the used equipment currently for sale in Europe; and has extensive logistics and engineering experience in transporting and integrat-ing used equipment into new plant layouts.
Machine Point Food Tech-nologies has been created by a partnership between Machine Point Group and Gemina, a highly special-ised process integrator that manufactures customised equipment for the agro food, beverage and dairy indus-tries. Gemina is located in Murcia, southern Spain. It has been designing and building plants and process lines in its domestic markets and in Africa and Asia for liquid processing industries for 25 years. MachinePoint Food Technologies’ engineer-ing centre, in Murcia, has more than 5000m2 of space for engineering, automa-tion, manufacturing, fi nish-ing, assembling, testing and quality control of equipment to be installed at customers’ facilities.
www.machinepoint.com
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Indorama acquires Chinese assets, Investa N America businesses, looking at India expansion
Indorama Ventures PCL, the Indonesian company that is the world’s largest producer of polyester and PET, has signed a defi nitive agreement to acquire PET polymer and resins manufacturing facilities located in Spartan-burg, S.C. and Querétaro, Mexico from certain sub-sidiaries of Invista B.V., for US$420 million less certain assumed liabilities. The price includes $229 million for the net fi xed assets and equity interests and $174 million for the net working capital of the business. The acquisition is expected to be fi nanced from a combination of cash, existing credit facilities and additional debt, with comple-tion in Q1 2011, subject to necessary regulatory approv-als. The acquisition of Invista’s assets provides access to Latin America, which is a net PET importer with demand growing 7% a year on average. Indorama has also announced its acquisition of the PET and polyester poly-mer assets of Guangdong Shinda UHMWPE in China, with a combined capacity of 406,000t/y. Of the total cost of $93 million, $40 million will be spent to expand the plant’s capacity. The Guangdong base gives Indorama access to the Chinese mainland, which is the largest fi bre and PET market in the world. Yearly demand for PET and fi bre in China is expected to rise from 15 million and 31 million t in 2009 to 24 million and 48 million, respectively, in 2015. Invista’s Spartanburg, South Carolina facility produces polyester resins used in bottles for CSD, water, beer, juice, and wine; food and custom-container applica-tions, and polyester staple fi bre and speciality polymers for a variety of applications. The Spartanburg operation has a total capacity of 470 million t/a. The Querétaro, Mexico, facility produces polyester resins and polyester staple similar to the Spartanburg operation and has a total capacity of 535 million t/a. Invista’s Wilmington, N.C., site is not a part of the transaction, nor is its European Polymer & Resins business, which includes manufactur-ing operations in Germany. Indorama is also reported to be considering the construction of two new plants in India and the Middle East with a combined investment of $1.2 billion.
www.indorama.com
PET recycling increases in the USAThe ‘2009 Report on Post-Consumer PET Container Recy-
cling’, jointly published by the National Association for PET Container Resources (NAPCOR), The Association of Postcon-sumer Plastic Recyclers (APR), and the PET Resin Associa-tion (PETRA), found that PET recycling in the USA during 2009 achieved a rate of 28%, which is the sixth consecutive year of increase. The increase was despite an actual four % reduction in the total of PET bottles and jars available for recycling, by weight. The report also reveals the end uses for a record 937 million lbs (426 million kg) of recycled PET used in manufacturing applica-tions. Strong increases in recycling over 2008 were identifi ed in sheet & fi lm, food & beverage bottles, and non-food bottles end-use categories. This is the fi fth year that NAPCOR, APR, and PETRA have partnered to produce this report and the 15th year that NAPCOR has issued the report in its current format. The full report can be found on the APR and NAPCOR websites.
NAPCOR and the International Bottled Water Association (IBWA) have produced two complementary studies, ‘2009 Post Consumer PET Bottle Bale Composition Analysis’ and ‘2009 Report on PET Water Bottle Recycling’, which analyse recy-cling of consumer products. The national recycling rate for PET plastic bottled water containers (500ml and three and fi ve-gallon PET water cooler bottles) stood at 31% in 2009, up slightly from 2008, the studies found, which continues a trend of annual increases recorded since analysis began, in 2004, when the recycling rates for these containers were just over half the cur-rent levels. Data compiled from bale composition studies at 15 locations in 14 states determined that the total weight of all PET bottles and jars available in the USA for recycling in 2009 was 5.149bn lbs (2.34bn kg), a drop of four % from 2008. Just over one-quarter of the total (590 million kg) was represented by PET bottled water containers. The slight decrease in the total weight is attributed to adverse economic circumstances for consum-ers, light-weighting of bottles and jars and a 37% increase in the use of recycled PET resin (rPET) since 2008. In 2009, the gross recycling rate for all PET bottles is 28%, an increase of one % over 2008’s recycling rate.
www.napcor.com www.plasticsrecycling.org
DAK Americas completes acquisition of Eastman’s US PET business
DAK Americas LLC, headquartered in Charlotte, NC, and a wholly owned subsidiary of Alfa S.A.B. de C.V. of Monterrey, Mexico, has completed the acquisition of the integrated PET and PTA business of Eastman Chemical Company. The acquisition brings DAK Americas’ total PET resin production capacity to more than 1.5 billion tons. The acquisition includes three production facilities in Columbia, SC, USA: two PET resin units and one PTA unit. The trans-action includes the intellectual property for IntegRex PET and PTA. The PET resin production units have a combined annual capacity of 675,000t and the PTA unit has an annual production capacity of 600,000t. The Columbia site will be integrated into DAK Americas PET and PTA business units, which have operations in the U.S in Charleston, SC; Wilm-ington, NC; and Fayetteville, NC. The acquisition of East-man’s assets in Columbia, SC, follows DAK’s purchase of Eastman’s PET International operations in Cosoleacaque, Mexico and Zarate, Argentina, which were completed in autumn 2007.
www.dakamericas.com
IV calculation appPlastic Technologies, Inc. (PTI) has launched a free
iPhone/iPad app for calculating the fi nal intrinsic viscosity (IV) for PET resin. PTI claims that the app is the fi rst of its kind for the plastics packaging industry. The format, called a nomograph, uses a graphic representation of numerical values to produce a fi nal calculation. PTI’s PET Hydrolytic Degradation Nomograph enables the user to indicate the starting IV by sliding a plot point on a vertical scale to the appropriate value. The same is done for moisture percent-age. The two plot points are connected by a moveable line and the intersection of that line, on a third vertical plane, is the material’s fi nal IV. PTI says that the nomograph calculates the fi nal IV in a couple of seconds. The app can be found in the iTunes App Store by searching for ‘PET nomograph’.
www.plasticstechnologies.com
Melt-To-ResinPET resin technology developed by Uhde Inventa-Fischer for all your packaging needsOpt for superior quality resin with our proven MTR® technology that eliminates SSP (solid-state processing).The MTR® process is based on our advanced, proprietary 2-Reactor high i.V. melt technology. Reduced thermal stress and soft reaction conditions, combined with minimum raw material consumption and an economical investment will highly improve your profitability – 30% less conversion cost is feasible.
Think. Invest. Earn.
Uhde Inventa-Fischer
Uhde Inventa-Fischer GmbHHolzhauser Strasse 157–15913509 BerlinGermanyTel. +49 30 43 567 5Fax +49 30 43 567 699
Uhde Inventa-Fischer AGVia Innovativa 317013 Domat/EmsSwitzerlandTel. +41 81 632 63 11Fax +41 81 632 74 03
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DRYING HAS NEVER BEEN THIS EFFICIENT:ETA plus®
LUXOR - now available with ETA plus®
ETA plus® considerably reduces energy consumption and protects materials. When it comes to drying, saving energy is a key concern. We have developed a system that combines airflow regulation with a temperature adjustment feature – that can be disabled if required –and efficient waste heat recovery. The result? A drying system that cuts energy consumption by up to 64%: ETA plus® .
motan-colortronic gmbh [email protected]
www.motan-colortronic.com
New CEO for Mold-Masters Mr William Barker has been appointed Chief Execu-
tive Offi cer of the Mold-Masters Group of Companies, effective December 6, 2010. Mr Barker has over 20 years of experience as a CEO/General Manager of high tech-nology industrial manufacturing companies with a global footprint, most recently with Rexam PLC and Textron Inc. He has been a board member of both publicly traded and private equity owned companies.
www.moldmasters.com
50th anniversary, New ‘Packworld’ centre for Greiner Packaging
Austrian company Greiner Packaging International celebrated its 50th anniversary with the opening of its new ‘Packworld’ innovation and communications centre. The facility, located at the former Llosent & Forschner Korken GmbH factory in Oberwaltersdorf, near Vienna, offers conference and meeting rooms, a gastronomy sector and a lounge. The advanced facility is intended to be used for lectures, seminars, meetings and other communication and presentation events on the subject of packaging. The offi cial opening ceremony, on September 30th 2010, saw a number of long-service and loyalty presentations to com-pany employees. Greiner Packaging International employs a workforce of 2,878 employees at 28 production sites in Europe. The company achieved annual sales of €357 mil-lion in 2009.
www.greiner-gpi.com
Petainer acquires RostiprimpacSpecialist plastics packaging technology business
Petainer has purchased PET packaging manufacturer Rostimprac AB, based in Norrkoping in Sweden, and Rostiprimpac Verpackungen GmbH based in Leinefelde, Germany, from A.P. Moller Maersk. Petainer intends to develop new products and markets following the acquisi-tion. Petainer, a European designer and manufacturer of plastics (primarily PET) packaging has manufactur-ing plants at As in the Czech Republic and Lidkoping in Sweden, where it also has an R&D centre. The company has sales offi ces in Germany and the United Kingdom.
www.petainer.com
Indorama renames PET resins range Indorama Ventures has changed the names of the PET
resins produced at its facilities in Rotterdam and Working-ton, because of the expiry of its Technical License Agree-ment with Eastman Chemical. Indorama emphasised that the move is purely a change of name and there is no change whatsoever to either the raw material make-up or the production processes used and does not indicate anything else. The changes took effect on March 1, 2011. The former and new names can be found on Indorama’s website.
www.indoramaplymers.eu
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Coca-Cola China award for HuskyHusky Injection Molding Systems was presented with the
Best Innovation Award at Coca-Cola China’s Supplier Sustain-ability Summit, which took place in Shanghai, China, November 23-24, 2010. The award was for the development of Husky’s EcoBase preform, which helped Coca-Cola China in its devel-opment of lightweighting initiatives. Coca-Cola China used the summit, attended by nearly 150 representatives, to present its 2020 Vision to suppliers, which focuses on addressing sustain-ability, environmental and social issues.
www.husky.cawww.thecoca-colacompany.com
Gabriel-Chemie Group expands in Russia
Gabriel-Chemie Group’s Russian subsidiary, Gabriel-Chemie-Rus-2, which has production facilities approximately 80km SW of Moscow in Dorokhovo, has completed a number of projects that have increased production capacity from 1,000t to 2,500t. During 2011, capacity will again be increased, to 5,000t. The company has also invested in lab equipment and has increased its Russian-manufactured product range of white masterbatches and additives. Gabriel-Chemie-Rus-2 has appointed anew sales director, Dmitry Grigoriev, a new plant manager, Yury Gribanov, and continues to invest in developing its Russian personnel, with training at Group production sites in Austria, Germany and at other plants.
www.gabriel-chemie.com
Long-term trends re-emerge in new beverage packaging report
Beverage industry information specialist Canadean’s latest special interest report, ‘Innovation in Beverage Packaging 2010’, indicates that the global economic down-turn, fi nancial squeeze, volatile raw material prices and declining consumer spending has resulted in a slowdown or complete reversal of longer term beverage packag-ing design trends. The focus shifted strongly towards cost and cost-related factors, such as materials reduction and improvements in line effi ciency, fi lling techniques and cost-effectiveness. As some countries began to emerge from recession during 2010, longer-term trends towards increased use of added-value and convenience features, more sophisticated packaging materials, smaller ‘on-the-go’ packs and more elaborate shapes, designs and prints, refl ecting economic, demographic and consumer-led changes, have re-emerged. The last two years have seen discount retailers gain market share from supermar-kets, who have responded by extending their own ranges towards the ‘value’ end of the market. Key global trends include continued PET growth in most beverage catego-ries, including refi llable PET gaining share in carbonates and packaged water; increased use of hot-fi ll PET for nectars and juices; a general shift to lighter, more fl exible packages and pouches; and greater emphasis on environ-mental issues. China is now the biggest single source of packaging demand and consumption, with other emerging markets beginning to take off strongly.
www.canadean.com
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An innovative approach from Unisensor/Germany
The power of sortingby Wolfgang von Schroeter
The Powersort sensor system identifi es the “good material” in a PET fl ake fl ow using high-speed laser spectroscopy, separating it from various contaminants in a single pro-cess step. Unisensor, the makers of Powersort claim that, depending on the type of impurity, separation levels of up to 98% can be achieved with a minimum loss of product.
It is common knowledge that PET waste from clean bottles makes clean PET fl akes or pellets. But col-lected bottles are by no means all clean. When collecting PET bottles all ingredients – visible or invisible - are collected as well. The visible ele-ments are metal, labels, etiquettes and glue residue, caps screwed and unscrewed, external dirt and concrete material contamination. Non-visible elements include components inte-grated into the PET material like PVC, PC, PA 66, additives and blends.
The number of possible impurities and material defects is on a permanent increase – one reason being a longer service life time, another the growing complexity of fi nal applications and the repeated recycling of products. Thus the challenges for the industries involved are not going to go away. Most of these unwelcome ingredients - if not all - need to be removed for food contact approved PET fl akes or pellets.
The higher the contamination of collected bottles, the more complex the recycling. There is no single universal answer to solve the problem. Many individual proposals, mainly devel-
oped over long periods of trial and error, have resulted in the possibility of re-using recycled material. Some of these proposals are suitable for less demanding applications such as for fi bre, sheet and strapping. Others require great effort to meet very par-ticular applications, such as for RPET bottles for beverages. Nevertheless and despite numerous costly efforts – the recycling methods known so far were unable to identify and remove all of the unwanted contaminants.
An innovative response to the problem recently came from Unisen-sor – Sensorsysteme GmbH, located in Karlsruhe, Germany. They brought to the recycling equipment market their Powersort sensor system which is able to detect and separate from a PET fl ake product fl ow invisible com-ponents, such as additives or PA 66,
PVC or silicone and any other barrier substances used in food packaging. The fi rst Powersort was sold in 2007. To date, the company has sold units to leading recycling fi rms in Europe, the US and most recently to Mexico.
Powersort uses a measuring proce-dure based on high-speed laser spec-troscopy. It identifi es the “good mate-rial” in a PET fl ake fl ow on its specifi c opto-electronic spectrum, separating it in a single process step from various contaminants previously defi ned. The detection system excites the plastic particles with a powerful laser light, analysing the light spectrum that the individual part then emits. Each mate-rial has its own spectrum, or its own physical fi ngerprint. The sorting system separates out material whose spectrum differs from the reference spectrum of the “good” material. This means that
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the sorting system can evaluate up to a million spectra per second and can detect accurately even the fi nest particles. Materials to be eliminated are identifi ed individually, detected at the threshold and blown out. Unisen-sor claim that “depending on the type of impurity, separation levels of up to 98% can be achieved with a minimum loss of product”.
Powersort was exhibited at K2010 in Düsseldorf. We saw the machine in the Unisensor Technical Centre in Karlsruhe in an impressive demonstration. But laboratory conditions in general differ from the tough conditions found on the shop fl oor. So we visited three customers of Unisensor to ask them about their experience and listen to their comments. They are given below.
References
We fi rst asked Artenius Packaging in France for an opinion. Then we went to Wellman International in the Netherlands and fi nally to RecyPET in Switzerland. We saw Powersort in action and we asked questions such as the following:
Why Powersort and for what particular purpose?
Where – in an established operating recycling line – is the optimum location to install the sensor system, so that it operates effi -ciently and economically?
And, most importantly, how good is the quality of the end product?
We heard the following comments:
Artenius PET Packaging Europe (APPE) recycling plant/ Beaune/France
“Stabilising quality in an established line”
APPE, part of La Seda de Barcelona, has been pioneering PET recycling in Europe. APPE in Beaune has an intake capacity of 31,000t in bales and supplies
24,000t in pellet form to the markets, of which approx. 17,000t are so called high quality SuperCycle pellets with food contact approval. A signifi cant portion of pellets are for APPE in-house conversion into new preforms for demanding customers such as Danone and Coca Cola. Powersort was placed within an existing operating line to improve and stabilise the quality of fl akes before extrusion into pellets.
Frédéric Blanchard, Plant Director at APPE Beaune, commented:
“APPE recycling in Beaune invested in a Powersort from Unisensor last year. The fl akes sorter from the German company – with a laser detection system - is able to sort PET fl akes at a high output rate. We have installed the system just before the extruder.
This amazes even the professionals:oval shapes can also be blow-moulded. Using ProShape – the latest module for the krones Contiform. www.krones.com
interpack 2011
Düsseldorf, 12 – 18 May
Hall 14, Stand D14/E29
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Frédéric Blanchard, Plant Director APPE Beaune
The system is running at 3t/h. Our goal is to set a new European standard with the highest quality PET fl akes, which to date has been diffi cult especially given the numerous exter-nal contaminants that exist in the post consumer baled bottle stream today. APPE has a target to achieve fewer than 10ppm of external contamination (especially of PVC content) and only sophisticated sorting systems like the Powersort can meet our target.
The installation of the Powersort in October 2010 has allowed APPE Beaune to signifi cantly improve its quality of RPET resin suitable for direct food contact. It also allowed APPE to meet the requirements of its customers and - we believe – it sets the standard for others to follow. The sorter has now been running for 2 months (PETplanet: as at time of writing in December 2010) and we expect that following further fi ne-tuning and process stabilisation in the coming month our ultimate goal will be achieved.”
Wellman Recycling plant / AE Spijk/Netherlands
“Eventually, we feel, our quality will become even-more reliable and our busi-ness solid and sustainable.”
Wellman International with head quarters in Ireland is a global player in the development of fi bre technolo-gies, and also the largest European recycler of post-consumer PET bottles, with plants in the Netherlands and in France. The intake capacity of Well-man in Spijk/Netherlands is 60,000t in bales turning out 45,000t in fl ake form, of which approx 40% is supplied to the Wellman sister company in Ireland, where it is used for fi bre. The bal-
ance goes mainly for sheet & bottle to bottle production to numerous external clients. Powersort was installed at the end of the processing line sort-ing fl akes, further removing contami-nants & additives mainly for supply to demanding external customers.
At the Wellman plant in AE Spijk, Neth-erlands, the Powersort is installed at the end of the line.
Ing. Will Dingen, Production Manager, commented:
“The quality of incoming PET waste is unpredictable, since we buy from several sources. When we made the decision to buy Powersort, our existing customers had problems with additives in the fl akes we supplied. We saw that the Unisensor machine was able to cope with the problems by eliminating the additives from the fl ow of fl akes or at least by consider-ably reducing them. So we bought the machine, put it in place and started running. Of course with the new machine we also could separate from the PET fl ake fl ow other contaminants such as PA 66, PVC and coloured PET which we would then be able to sell as a by-product.
The sorting system was installed in late 2009. We are very satisfi ed with the performance – running at a speed of 2.5t/h, sorting currently the major-ity of different additives out of those fl akes which we separate for custom-ers requesting a higher quality profi le for sheet making and food packag-ing. We are still experimenting with the various machine and operational parameters, which require continuous optimisation. We also suffered from the infl uence of a very dusty environ-ment.The critical issues are well on the way to being solved by both sides. Eventually – we feel - our quality will become even more reliable and our business solid and sustainable.”
RecyPET in Frauenfeld/Switzerland
“Powersort is in line - fully integrated.”
Kornel Büsser, Managing Director and Production Manager, RecyPET
The RecyPET company of Swit-zerland belongs to a group of interna-tional recyclers, together with Cleana-way PET International in Rostock/Germany and Norköpping/Sweden, under the holding umbrella of Veolia Umweltservice.
At RecyPET, Switzerland, the Powersortis fully integrated in the processing line.
Swiss bales enjoy a high reputation for cleanliness. The intake capacity of RecyPET is 18,000t in bales contain-ing beverage bottles only, which are collected, manually pre-sorted. The recyclate is returned to the markets in the form of CleanPET fl akes – most of them with food approval for new bottles and sheets. The fi nal sorting of fl akes is receiving top priority at RecyPET. Three sorting systems are installed at the end of the processing line, one for sorting out metals and coloured fl akes, one from Unisensor (Powersort mainly for sorting chemical elements integrated in PET such as additives, PVC, silicone and other defi ned con-taminants) and one more optical sorter for even the slightest contamination of the fl akes sorting out minor black and white crumbs. The fl akes pass all three sorting systems, some of them even two or three times in order to minimise losses and ensure high quality.
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15PETplanet insider Vol. 12 No. 03/11 www.petpla.net EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H.
Unterfeldstraße 3 . A-4052 Ansfelden . Austria . [email protected]
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PET Extrusion SystemVACUREMA® Primeto produce BTB pellets that are EFSA,FDA and brand owner approved
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Continuous software control for • food contact, IV and other parameters
Efficient decontamination and IV increase . low energy consumption, 0.30 to 0.33 kWh/kg
Output capacity from500 to 2,600 kg/h
15
About Unisensor and PowersortUnisensor is a family-run high-tech company
in the fi eld of process analytics and control, more precisely opto-electronics and sensor systems technology. The senior owner - Professor Dr. Gunther Krieg - founded the company, which is close to and connected with the Karlsruhe Insti-tute of Technology (KIT).
Powersort is part of the product portfolio of Unisensor, which specialises in sensor sys-tems technology for gas, fl uid and solid mate-rial. Industries supplied include the beverage, gas, compressed air and recycling sectors. The fi rst Powersort was sold in 2007. To date, the company has sold to leading recycling fi rms in Europe, in the US and most recently to Mexico.
In December 2010 Unisensor/Powersort was one of three nominees for the German Presi-dent’s “Award for Technology and Innovation”, which honours researchers and engineers who develop ground-breaking projects and products for the market. The award not only recognises scientifi c achievement, but also takes account of the marketability of the innovations and the asso-ciated potential for creating jobs.
www.unisensor.de
The developers of Powersort: J. Bohleber, Prof. G. Krieg, D. Fey (f.l.t.r)
Kornel Büsser , Managing Director and Production Manager commented:
„The most signifi cant problem was silicone. In 2006 we installed the newly developed prototype of Powersort in our factory. The problem was instanta-neously solved. We are now also able to recognise those foreign plastic particles, which are not PET, but have the same colour as PET, and eliminate same. In the last four years since installation, we have cooperated closely with Unisensor to adjust their sorting system to a factory environment utterly different from laboratory conditions. Unisensor has benefi ted from our experience. We have recently exchanged the prototype for a new Powersort.”
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16 PETplanet insider Vol. 12 No. 03/11 www.petpla.net
6th China international recycled Polyester Forum Hangzhou 2010
A conference selection
Dr. Ulrich Thiele, of Dr. Thiele Polyester Technology, Bruchkoe-bel, Germany, reports from the 6th International Recycled Poly-ester Forum, which was held in Hangzhou, PRC, September, 15-17 2010. The conference was intended to provide insights into the dynamics of the whole polyester recycling chain, from bottle and waste collection to fl ake processing and product trading. It covered market development and process technol-ogy, especially low-carbon concepts.
There is no more doubt: the poly-ester industry has returned to a healthy growth trend and polyester recycling is more vigorous than ever. China is the front-runner in polyester recycling, as in virgin polyester production. Pres-sure on hotel space in Shanghai during EXPO-2010 led to the Forum taking place in Hangzhou, as on several previous occasions, and was very well organized by the Chinese host organization CCFEI (www.ccfei.net). The conference was well received by the 222 participants from the polyester recycling industry, the majority – 80% - from China, with the balance from 16 other nations. International companies with businesses in China were repre-sented by Chinese staff.
A range of informationThe conference was a real mix of
information about macro economic developments in the PET recycling industry in China and market develop-ment worldwide, plus presentations about new and further development of recycling technology and equip-ment. Li Shidong, secretary General of CCFA (China Chain Store and Franchise Association) Recycled Fibre Commission presented a detailed analysis of the current rPET market in China together with the targets for the coming years. The core devel-opments supported by the Chinese government are energy and water
saving in PET recycling; technology and equipment providers were called upon to intensify their efforts in these areas. The government supports recy-cling companies with subsidies of 100 – 200 Yuan/ton, under certifi cation by national recognition systems. Zheng Yang, of SEPA´s (State Environmen-tal Protection Administration) National Solid Waste Management Centre, focused particularly on the situation of imported plastic scrap and polyester. He highlighted the problem of unquali-fi ed waste imports and linked them to the Chinese government’s measures to fulfi l the strict requirements of pol-lution prevention and control during recycling activities.
Product development: cutting labour costs
Steve Shen, Vice President of Zhejiang Boretech Co. Ltd demon-strated the signifi cantly improved capabilities of Chinese engineering to deliver tailored recycling plants. He emphasised that, with increasing labour costs, the change from hand sorting to automatic sorting systems in unavoidable. One interesting aspect was his observation that bottle pre-washing is included in Boretech lines, which signifi cantly improves fi nal fl ake quality. Gneuss Kunststofftechnik GmbH introduced a complete new line
for processing bottle fl akes; its Multi Rotation System – MRS – is com-bined with automatic fi ltration and in-line-viscometer. The combination of its MRS and an NGR compact shredder provide a robust recycling unit for pro-cessing of all kinds of fi bre and solid waste occurring as in-house-scrap during PET fi bre and fi lament produc-tion. Dr Ulrich Thiele of Dr. Thiele Polyester Technology gave a lecture on prerequisites, organisation and needs of fi bre in-house recycling.
Di Gangli, Deputy General Man-ager of Longfu Recycling Energy Sci-entech Co. Ltd, reported on Longfu´s large scale rPET conversion to POY, DTY and FDY and a newly developed process to increase IV in melt phase for technical yarn spinning. A new sorting technology was introduced by Peter Mayer, sales manager of SE-Sotech GmbH. Its new system sorts fl akes with higher effi ciency and throughput than traditional processes; this new fl ake sorting technology might replace bottle sorting in future. Kurt Pichlmann, Area Sales Manager of Erema GmbH, centred his presen-tation around examples of how the applied technology impacts the eco-nomical success of PET recycling.
Market analyses
A highlight of the conference was the market analysis of Andrew Noone, Managing Director of PCI PET Pack-aging, Resin & Recycling Ltd. Veri-fi ed fi gures on collection, import and processing of PET bottles from PCI´s cooperation with CCFEI authen-tic were provided, together with the global trends in collection and reuse. A quite remarkable fi gure was China’s supply trend to 2019, by which time China alone will undertake 5.8 mil-lion tonnes of PET recycling. Those market fi gures were supplemented by
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17PETplanet insider Vol. 12 No. 03/11 www.petpla.net
Caspar van den Dungen, Vice Presi-dent of European Plastics Recyclers, in his overview about the development of PET recycling in Europe. Arnold Jahn, the new Managing Director of OHL Engineering GmbH presented an outline of the fl exibility and capability of OHL´s recycling and decontamina-tion technology.
As last year, CCFEI Analyst Cao Wenting provided a detailed study on the economy of PET recycling in China. She underlined the problems caused by shortages of fl akes, the narrowing price gap between virgin and R-PET and the need of renova-tion and innovation in China´s polyes-ter recycling industry. The progress in technology was further demonstrated by Li Zunde, General Manager of Shanghai Machine Sorting Technology Co. Ltd. His company is focused on all kinds of automatic sorting, which is a key factor in reducing labour costs and improve R-PET quality. The fi nal presentation, held by Bjoern Walter, Head of Process & Application Tech-nology Centre at Coperion Najing Cor-poration, provided an insight on the conversion of bottle fl akes to stable fi bre without pre-drying, by applying twin-screw-extrusion in combination with automatic fi ltration.
In conclusion, one can say that the 6th China International Recycled Polyester Forum Hangzhou 2010 has evolved from a national event to an international and well-regarded con-ference that presents wide-ranging information on a quickly and robustly-growing polyester recycling industry. Anyone interested in purchasing the preprints of this conference should send their request to [email protected] or order directly from the web site of CCFEI.
www.ccfei.net
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PETplanet speaks to Jean-Marc Rostagno – fi rst President of Forum PET Europe
Forum PET Europe launchedThe Forum PET Europe (FPE) was founded in Paris in November 2010 with the objective improving ad hoc commu-nication on health & safety, recycling and innovation for PET packaging. The Forum PET Europe represents mainly the national PET converters (preforms, bottles, jars, containers and others PET packaging) and is a open source and collab-orative platform of communication and action.
This is in collaboration with Pet-core, the European PET producer association which validates and sup-ports innovative PET solutions from a recycle perspective, supports all PET recycling processes and facilitates sustainable growth for post consumer PET collection. The initiative for the Forum came from the PET associa-tions of France (Elipso) and Germany (Forum PET within IK Industriever-einigung Kunststoffverpackungen) as well as from the Portuguese converter Logoplaste.
Jean-Marc Rostagno, Managing Director of Artenius PET Packaging (APPE) Northern Europe, a leading European converter and also producer of recycled PET was appointed fi rst president of Forum PET Europe. We asked Jean-Marc Rostagno for his comments on the new organisation.
PETplanet: What is the policy of the FPE?
Mr Rostagno: FPE will act as the spearhead for the national Forums. European counterparts want to see one single representative when con-sidering discussions on matters of common interest. The Forum PET Europe is designed to fi ll that gap only.
Some national Forums have already expressed an interest in join-ing and others will follow. Portugal for example has relatively few PET con-verters and will be represented initially by the main converter.
PETplanet: Why yet another association amongst so many existing associations?
Mr Rostagno: Quite simply because there is no such organisa-tion representing PET converters.
Our focus will be on key areas such as enhancing the sector’s reputation, acknowledging risks and opportunities and spreading a proper understanding of PET excellence in recycling (some converters are also recyclers). There is also a considerable amount of work to do on highlighting the untapped poten-tial in PET innovation.
PETplanet: What does all this mean in practical terms?
Mr Rostagno: Let me give you a few brief headlines:
First: Health and safety aspects – food contact information related to PET – in order to reassure stakeholders that our products are safe.
Second: Recycling – integrity of recycling loop from bottle to bottle and the PET converter’s contribu-tion in improving quality of the clear baled bottle fl ow (see last EPBP press release: FPE will help this approach with up to date input on recycling guide lines)
Last but not least: Innovation, which means also caring for new and fast growing PET packaging : barrier bottles for beer, wine, milk, high end fruit juices to be recycled as well..
PETplanet: From what you are saying, it would appear that the inter-ests of the converter come fi rst and recycling comes second?
Mr Rostagno: I’d prefer to put it another way: if attacks on the reputa-tion of PET on supermarket shelves eventually succeed, there will soon be no PET to recycle. Recycling is a very high priority for the FPE. If I can put it this way: We can enhance the reputation of PET if we can show we are taking responsibility for recycling as well.
PETplanet: Let’s turn to Petcore for a moment: don’t you share broadly the same objectives? Could there be areas of confl ict?
Mr Rostagno: No, both organi-sation complete and even reinforce each other. Our strength lies in our signifi cant representation of the con-verting industry at a national level Also our focus is more on health & safety and fostering innovation.
PETplanet: As far as recycling is concerned, is there any need to join both organisations or would there be a confl ict?
Mr Rostagno: Why would converters be in confl ict with resin or additive producers? We talk to Petcore in order to improve the global “package” which we bring to our cus-tomers and hence to provide reassur-ance to the market. Thus: there is no disconnect either in communication nor in what we are doing – hopefully.
PETplanet: What can we expect from Forum PET Europe in the near future?
MrRostagno: We want to fi nish the job of contacting other European associations so that we enlist the sup-port of those working within the PET supply chain. We are also working on the guidelines with European PET Bottle Platform (EPBP), representa-tives and supporting them as men-tioned above.
PETplanet: Who is joining next – to widen the platform for FPE?
Mr Rostagno: The three topics that we have already mentioned: health & safety, recycling and innova-tion have received a broad welcome from those in the industry. We are hoping that this may encourage the formation of national PET forums, which could become at the same time members of the FPE.
PETplanet: Thanks a lot, Mr Rostagno.
www.forumpeteurope
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The European PET Bottle Platform (EPBP)
The European PET Bottle Platform was formed by the European Association of Plas-tics Recycling and Recovery Organisations (EPRO), the European Plastics Recyclers (EuPR), PET Containers Recycling Europe (Petcore), the Union of European Beverages Association (UNESDA) and the European Federation of Bottled Water (EFBW), with the main objective of evaluating packaging technologies and products and to facilitate PET bottle innovation, whilst minimising the economic and environmental consequences for recycling PET in Europe. It will do so by promoting the recyclability of PET bottles on the market by:
Establishing European harmonised guidelines for PET bottles recyclability that will be accepted across the whole value chain.
Encouraging industry to test new PET bottle concepts and/or materials before market launch according to the harmo-nised guidelines.
Giving advice and recommendations to the different stakeholders.
Sharing information and knowledge across the whole value chain.
Members of the platform’s evaluation group are experienced technical experts from the whole PET value chain. They are tasked to evaluate novel technologies, materials and PET structures to verify their effect not only on the PET bottle recycling process but also on the PET chain. Companies develop-ing new resins, additives, technologies and novel processes for PET bottles are urged to approach EPBP at the earliest opportunity so that their applications can be assessed in the most effi cient and economic manner. The full EPBP protocol has been developed from the Petcore protocol and the US Association of Postconsumer Plastics Recyclers (APR) Criti-cal Guidance Document and also takes into account learning from the industry. The pro-tocol is split into quick tests and then more in-depth tests to ensure a speedy, accurate and economic outcome for both the applicant and for EPBP.
The EPBP process can be viewed at:http://www.petbottleplatform.eu/technical.php
More details and documents can be found on the EPBP website. Applicants are asked to discuss their application with EPBP in the fi rst instance. To date EPBP has con-sidered 17 applications. Many are ongoing but there are 6 so far on the positive list.
www.petbottleplatform.eu
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20 PETplanet insider Vol. 12 No. 03/11 www.petpla.net
Recycling is growing rapidly and industry standards are rising; the technology is available to meet regulatory and market demands.
Recycling: maximising useThe growing use of rPET is not just a response to demand from bottlers for more recycled content, it is becoming an important marketing tool – but, at the same time, preform producers need to make sure they achieve the need for high quality by controlling material fl ow. The requirements of brand owners on rPET are actually much stricter than food-contact certifi cations, so it is essential that adequate PET recycling technology is deployed. Starlinger recycling tech-nology supplies high-tech recycling lines for bottle-to-bottle recycling and high-viscosity applications.
Variables infl uencing PET recycling
PET bottle recycling is driven by a number of factors, such as food-contact issues, required quality and quantities of input and output. Other drivers can include the following:
Political pressure that encourages resource conservation;
education for waste avoidance; installation of systems to avoid
land-fi ll; a promotion of the reuse of plastic
waste. The most effective measure is the promotion of recycling through taxation or the threat of it. At the eco-nomic level, virgin resin price is the largest infl uence on recycling; rPET still needs to be cheaper, in order to be considered as replacement. The price for baled material and fl akes is, there-fore, driven not only by supply and demand but also by virgin resin price.
Important social fac-tors include wider accept-ance of rPET in food-contact packaging and employment opportunity for less educated workers in many countries.
Beyond recycling technology availability, recyclability has to be considered when design-ing new packaging.
A whole array of life-cycle analyses confi rms the positive environmen-tal impact of mechanical recycling.
Export or import of PET packaging waste and collection and re-use rate are heavily regulated. Food-contact approval is part of legal regulation in many countries.
A technology supplier wishing to have equipment recognised for food-contact operation has to go through stringent testing, in order to prove cleansing capability. The letter of non-objection from the FDA (United States Food and Drug Administration) is an essential requirement for any com-pany to be considered as a supplier of super-clean recycling processes. As well as a challenge test, smell and taste tests might be required, in addition to migration or shelf-life tests. Precise defi nition and specifi ca-tion of input material is essential, as is a quality management audit of the recycler, in addition to the technol-ogy itself. In the case of the EFSA (European Food Safety Authority),
it is expected that the current, initial authorisation phase will probably last until 2014. Commission regulation 282/2008 covers EU-wide harmonisa-tion of regulations and standards but individual countries’ national law will at least partially apply until the end of the initial phase.
A washing line, for example, has to adapt to the deteriorating quality of baled material unless one is prepared to pay a premium price. The pres-ence of labels and glue are a chal-lenge for separation, which is also the case with bottles made of PVC, PLA and other materials. Extrusion systems have to be fl exible in order to handle bulk densities that are lower due to light weighting, and be able to change process parameters in response to additives in the packaging and other factors. The fi nal applica-tion decides the required rPET quality. In order to satisfy consumers’ highest safety standards, many brand owners require more from their processes than simply being within detection limits. A requirement for ‘non-detect-able VOC (volatile organic content) level’ is an increasingly common demand. A number of national and international certifi cations, including several FDA non-objection letters and brand owner approvals, confi rm that rPET produced using the Starlinger iV+ process is suitable for packag-ing with direct food contact. Graph 1 shows a comparison of headspace gas chromatography of Starlinger rPET, compared with virgin resin.
Starlinger launched its fi rst PET recycling line in 2003 and has gone on to establish itself as a technology-based supplier of recycling lines for bottle-to-bottle and high-viscosity applications, amongst others. The total world-wide installed capacity for the production of rPET pellets used in direct food contact packaging may have been doubled in 2010, reaching over 180,000t/a. Starlinger’s recoStar PET iV+ technology yields recycled PET with properties similar to those of
Graph 1: Headspace gaschromatography: virgin PET vs rPET (measured by Fraunhofer-Institut für Verfah-renstechnik und Verpackung, Germany).
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21PETplanet insider Vol. 12 No. 03/11 www.petpla.net
virgin material: intrinsic viscosity (iV) higher than 0.82 and more, acetalde-hyde (AA) content of less than 1ppm, and excellent decontamination values, which allows packaging to be used with direct food contact.
Customisation at investment
The basic modules of Starlinger recycling technology are extruders for the mechanical recycling of PET bottle fl akes and solid stating of fl akes, pel-lets and others. The modular design can be varied according to application and the Starlinger machine concept covers the complete range of require-ments for food contact and/or iV increase. The two budget versions of the recoStar PET line, recoStar PET FG and recoStar PET FG+, can be supplemented by an SSP (Solid State Polycondensation) reactor, either at outset or subsequently (graph 2). The recoStar PET iV+ solution for bottle-to-bottle recycling has decontamina-tion values that satisfy even brand-owner requirements. In the high-tech solution for very exigent requirements, recoStar PET iV+ Superior, the mate-rial is decontaminated twice under vacuum, before and after the extruder, in order to achieve very high decon-tamination results.
Flexibility is also important and a wide process window allows the modifi cation of parameters in order to adapt to altered input qualities, while continuing to comply with food-grade requirements. Extrusion and SSP modules can operate in-line or stand-alone, which doubles capacity or enables the recycler to produce food-grade fl akes and pellets at the same time. IV level is adjustable by chang-ing residence time in the SSP.
Changing market requirements can be catered for by upgrades and modifi cations, such as: enlarging pre-drying volumes in case of decreased bulk density; increasing output by 25% by changing to high-capacity design; adding SSP volume for higher iV increase, etc. Steam and gas heat-ing can be used to reduce electrical energy consumption. Following the markets’ demand for larger equip-ment, Starlinger recently increased the capacity of the recoStar PET line from 150 to 3,600kg/h. The SSP reac-
tor series has also been extended, to include a new reactor with an increased volume of 18,000l and a solution for fl akes only.
Starlinger is just about to install the fi rst line of its new solution for rPET in fi bre production. Its spe-cially-designed cascade fi lter system enables very fi ne fi ltration, down to 25μm, to meet the fi bre industry’s par-ticular requirements. Continuous clean-ing of the produc-tion line fi lter could be reduced while the percentage of reused rPET could be increased.
Starlinger is permanently offer-ing test runs on the recoStar PET 65 iV+ line in the compa-ny’s recycling show-room at its Weis-senbach, Austria, production site. The company also offers consulting and con-tracting for washing lines in addition to PET recycling lines. Reference lines for almost all kinds of plastics and for a wide variety of appli-cations have been installed globally. Several bottle-to-bottle projects will be installed across
the world by Starlinger this year, including the fi rst bottle-to-bottle proj-ect in Egypt and Peru which will be delivered within the next weeks.
www.recycling.starlinger.com
Graph 2: Flakes to pellets: the recoStar PET IV
The food-grade fl akes obtained at the end of this process are used by Akij
directly for making PET preforms.
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Krones bottle-to-bottle PET recycling line*
Bangladesh recycles
*based on an article by Udo Lanzinger, Krones AG
Production has now commenced on one of the fi rst Krones bottle-to-bottle PET recycling lines in Bangla-desh. Akij Food & Beverage LTD. (AFBL), a subsidiary of the multinational Akij Group and a newcomer to the soft-drinks market, recognised the opportunities offered by recycling PET containers from kerbside collections. In parallel with the installation of its fi fth Krones bottling line, Akij invested in this high-tech recycling line with washing module and decontamination module and is already able to substitute recycled PET fl akes for 30% of the PET raw material required in its in-house PET preform and con-tainer production operation. Cost savings and increasing independence of the global market for PET raw material are the direct consequences of this investment.
A newcomer to the beverage market
The Akij Food & Beverage Com-pany was established as recently as 2004, and marked Akij Group’s fi rst entry into a market that was new to the organisation. The company was set up “because we wanted to meet the demand for products made in Bangladesh to global quality stand-ards, and we expected this market to offer us huge opportunities”, explains Sheikh Jamil Uddin, who is responsi-ble for the group’s marketing opera-tions. Akij Food & Beverage con-centrated on soft drinks, water, fruit juices, milk and snacks, and grouped all of these divisions together in a new factory, located in Krishnapura, Dham-rai, 50 kilometres outside the capital, Dhaka. “For our founder, quality had always been the top priority”, Sheikh Uddin emphasises, which is why this visionary entrepreneur formulated the following maxim: “Uncompromising quality even in adverse market situ-ations is the main force behind our success.”
Recycling helps to reduce garbage
The decision to install an in-house PET recycling line was fi nally arrived at after a long hard look at the pocket calculator, by heeding the manage-
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23PETplanet insider Vol. 12 No. 03/11 www.petpla.net
ment’s sense of responsibility for the country’s environment, and underpinned by another forward-looking perception from Sheikh Bashir Uddin, the Managing Director of the Akij Group. The Senior General Manager of the Akij Food & Beverage production facility, P. B. Barua, singles out three main reasons for the decision: “Firstly, the bottom line has to be right. And it is. At present, we’re already saving up to 30% of the price per container by using recycled fl akes. Secondly, we don’t need so much foreign currency for importing PET granules – that is a crucial factor for a country like Bangladesh. And thirdly, we are able to help to signifi cantly reduce the amount of garbage, specifi cally discarded PET containers, on the kerbside and in lakes and rivers.”
This is why AFBL installed the fi rst PET recycling line of its kind in Asia. In a new aisle of the hall in the Dhaka plant, Krones built a washing module with an output of 1,000kg/h, plus a decontamination module for 500kg/h. The washing module produces non-food-grade rPET fl akes for use in the fi bre, plastics or fi lm industries. Full capacity utilisation is always dependent on the market price but Sheikh Uddin is already talking about converting the remaining 500kg/h of non-food-grade rPET fl akes into polyester fl akes, for use in the group’s own textile factory in a cotton-polyester mixture.
One of the country’s many small plastic collection points. The material arrives in the beverage factory’s courtyard in big bags or already compressed and is in very poor condition.
In a new aisle of the hall in the Dhaka plant, Krones built a washing module (left) with an output of 1,000kg/h, plus a decon-tamination module (right) for 500kg/h.
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Bottle-to-bottle recycling plants
Conveyors for preforms and empty bottles
Caps and closures
Preforms
Perform moulds and SBM moulds
Preform and single stage machinery
2-stage SBM machinery
Compressors
Filling equipment
Resins and additives
Suppliers of conveyors for preforms and empty bottlesLast year, for the fi rst time, we carried out a major sur-vey covering conveyor systems. This is a broad market featuring a number of operators and, in our initial foray in 2010, we successfully included all the key players. Now, in our second survey, we have gone one better. Whereas last year just nine companies featured, this year no fewer than 12 manufacturers are included. On the following pages you will fi nd detailed information on the range of conveyors marketed by Dimark, Europool, GEA Procomac, Intec Solutions, KHS, Krones, Mcon, Posimat, Sidel, Sismatico, SMI, Zecchetti. For further details readers are recommended to get in touch directly with the contact persons specifi ed at the individual com-panies.
Whilst the publishers have made aevery effort to ensure that the information is up to date, no claims are made regarding completeness or accuracy.
03/11MARKETsurvey
Company name KHS Corpoplast GmbH Posimat, S.A. GEA Procomac SpA Postal address
Telephone numberWeb site addressContact nameFunctionDirect telephone numberFaxE-Mail
Meiendorfer Str. 203, 22145 Hamburg , Germany+49 40 67907-0www.khscorpoplast.comFrank HaesendonckxDirector Competence Center SBM+49 40 67907 475+49 40 67907 [email protected]
Avda Arraona 23, 08210 Barberà del Vallès (Barcelona) Spain+34 93 7297616www.posimat.comMaribel RodríguezSales Manager+34 93 7297616+34 93 [email protected]
Via Fedolfi 29, 43038 Sala Baganza, Parma, Italy+39 0521 839411 www.procomac.it Fabio BorriniProduct and Sales Manager Packaging Division+39 0521 333752+39 0521 [email protected]
Preform: From injection moulding machine into box:Box-fi lling system No NoMaximum drop from conveyor belt to base of carton (in cm)In-line Control Preform: From box into SBM machine up to 60,000 preforms/hDumper (Yes / No) Yes NoConversion to different neck diameters (No/mechanical/electrical)
mechanical
In-line control (Yes / No) YesBottle: From SBM to fi ller, air conveyorAir conveyor (incl. vertical) (Yes / No) No Yes YesPurity levels Hepa fi lters DOP at 0,3 micras 99,99% effi ciency 99.99 DOP – photometric test method.Bottle format conversion Yes Yes, automatic Conversion to different neck diameters Yes Yes, mechanical / automatic avaialableBottle storage systemsBottle up-ender (Yes / No) No Yes NoBuffer systems capacity (number of bottles from …to…)
taylor made, can meet any requested capacity
Storage systems capacity (number of bottles from... to…)
taylor made, can meet any requested capacity
Palleter and de-palleter for empty PET bottles
No Yes Yes, depalletiser
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Company name Sismatico UK Ltd SMI S.P.A. MCon Conveyors Pvt. Ltd. EPostal address
Telephone numberWeb site addressContact nameFunctionDirect telephone numberFaxE-Mail
Plumtree Farm Ind Est, Bircotes, Doncaster , DN11 8EW U.K.
+44 1320 719738www.sismatico-uk.comDuncan Griffi thsTechnical Sales Manager01302 719222
duncan.griffi [email protected]
Via Piazzalunga, 3024015 San Giovanni Bianco(BG) Italy+39 0345 40.111www.smigroup.itPietro VolpiMarketing Manager+39 0345 40.316+39 0345 [email protected]
Vishwachaya Indl. Estate, Sr. No. 322, Plot No. 2, Pirangut, Pune-412108. Maharashtra. India0091-20-66749900/1/2www.mconconveyors.comMr. Shriram RahalkarDirector+91-9822615918+91-20-667489903/[email protected]
Vi43Ita+3wwMG+3+3in
Preform: From injection moulding machine into box:Box-fi lling system Yes No NMaximum drop from conveyor belt to base of carton (in cm)
120 cm
In-line Control Yes NPreform: From box into SBM Machine up to 60 000 preforms/hDumper (Yes / No) Yes Yes NConversion to different neck diameters (No/mechanical/electrical)
mechanical/electrical mechanical N
In-line Control (Yes / No) Yes Yes NBottle: From SBM to fi ller, air conveyorAir Conveyor (incl. vertical) (Yes / No) Yes Yes YePurity levels 99,997% G3/F9/H14 99Bottle format conversion Yes Yes YeConversion to different neck diameters Yes Yes YeBottle storage systemsBottle Up-ender (Yes / No) Yes NBuffer Systems Capacity Number of bottles from …to…
depending on bottle diameter
Storage Systems Capacity (Number of bottles from... to…)
depending on bottle diameter
Palleter and De-Palleter for empty PET bottles
Yes N
Company name Krones AG SiPostal address
Telephone numberWeb site addressContact nameFunctionDirect telephone numberFaxE-Mail
Böhmerwaldstraße 593073 Neutraubling, Germany+49 9401 70-0www.krones.comReiner KahlVice President of Division Conveyor Technology+49 9401 70-3065+49 9401 [email protected]
Avsu+3wwSyBu+3+3sy
Preform: From injection moulding machine into the boxBox-fi lling system No prMaximum drop from conveyor belt to base of carton (in cm) NoIn-line Control NoPreform: From box into SBM machine up to 60,000 preforms/h PrDumper (Yes / No) Yes YeConversion to different neck diameters (No/mechanical/electrical) mechanical M In-line Control (Yes / No) Yes YeBottle: From SBM to fi ller, air conveyorAir Conveyor (incl. vertical) (Yes / No) Yes YePurity levels F5, F8, H13(HEPA) G
Bottle format conversion automatic adjustable body guide rail via multi position cylinder (up to 12 positions) or stepless adjustment via linear motor
Yead
Conversion to different neck diameters automatic adjustable neck-ring guide rail via pneumatic cylinders, also in curves
Ye
Bottle storage systemsBottle Up-ender (Yes / No) No NoBuffer Systems Capacity Number of bottles from …to…Storage Systems Capacity (Number of bottles from... to…)Palleter and De-Palleter for empty PET bottles Yes Ye
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Europool S.R.L. Dimark SP. Z O.O. Intec Solutions IncVia G. Ferraris 13 - 43036 Fidenza (Pr) Italy+39.0524.528616www.europoolengineering.comMr. Marco PrieroGeneral Manager+39.0524.528616+39.0524.520125info@europoolengineering.com
Lagiewnicka Street 2, 62-002 Zlotniki, Poland+48 618956002www.dimark.euMonika MickiewiczProduct Manager+48 618956002 Ext 17+48 [email protected]
2382 Bolton Rd Atlanta,Ga 30318USA+1 404 424 9451www.intecsolutionsusa.comArnold Manier President +1 404 424 9454
No No Yes25 cm with arm telescopic option
No No Yes
No No YesNo Yes, mechanical and speed control adjusted
by PLCNo No Yes
Yes Yes Yes99,9% up to 99% Hepa fi lter availableYes for 5l, 1,5l, 0,5l Yes Yes Yes Yes
No No NoNo up 15,000
No up to 400,000
No No Yes
Sidel Zecchetti SrlAvenue de la Patrouille de France, Octeville-sur-;er, BP 204, 76053 Le Havre, France+33232858300www.sidel.comSylvie RakBusiness Communication Manager+33 2 32 85 82 46+33 2 32 85 81 [email protected]
Via Galileo Galilei, 1-1/A42027 Montecchio Emilia (RE) - Italy+39 0522 867411www.zecchetti.itFrancesco ParmaSales Manager+39 0522 867411+39 0522 [email protected]
preform conveyor in mass fl ow available No
NoPreform feederYes YesMechanical NoYes No
Yes YesGRAVI F5, OPA F8, DOP H12 3 levels :
(a) 1-stage fi ltering : G4 – EN779:2002 - min 90% galvanometric (b) 2-stage fi ltering : F9 – EN779:2002 - min 95% opacimetric on 0,4 micron (c) 3-stage absolute fi ltering: H14 – EN1822 Hepa Ffl ter - 99,995 MPPS 0,12-0,17 micron – min 99,999 NaCI – 0,65 micron Filtered air class: 100 (according to the Federal Standard 209) - 5 (according to the ISO Standard 14644)
er Yes, different automatic side guiding + adapted regulation
(a) automatic by means of pneumatic cylinders(b) automatic by means of unlimited position drives
Yes (automatic change over) (a) automatic by means of pneumatic cylinders(b) automatic by means of unlimited position drives
No Yes 1,000 - 50,000 )No
Yes Yes
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Akij GroupThe Akij Group is a heavyweight in Bang-
ladesh with its population of around 150 mil-lion. Named after its founding father, Sheikh Akij Uddin, the company achieves a turnover of just under €400 million, with a payroll of about 50,000 people. In the 1940s, when the country was still under British colonial rule, Sheikh Akij Uddin had built up the group from the smallest of beginnings: as a trader in jute, the ‘golden fi bre of Bangladesh’ into a con-glomerate of enterprises operating in 24 lines of business, which today is managed by his ten sons. Akij is a major player in the cement, printing, chipboard and tobacco industries and operates the world’s biggest jute mill, which employs 7,000 people. Akij is involved in fi ve non-profi t-making institutions, includ-ing a hospital, an orphanage and a college.
The target ratio is 50 : 50The washing module can be run
for as long or as short a time as the client prefers. The downstream decon-tamination module, which refi nes half of the non-food-grade fl akes, uses rel-atively high process temperatures and should run with as few interruptions as possible, in order to make best use of energy – which is what it does. The food-grade fl akes obtained at the end of this process are used by Akij directly for making PET preforms. The three Sipa and Husky injection-mould-ing machines for in-house preform production are located in an adja-cent hall and specially equipped for processing fl akes. At present, AFBL is working with a mixing ratio of 30 - 40% RPET fl akes and 60 - 70% new material (granulated). The target ratio is 50:50. The 30:70 / 40:60 mixture is used to make white preforms for cola, juices and water and green ones for two lime-based soft drinks. In future, P.B. Barua also aims to produce brown bottles from recycled fl akes, for the company’s ’Speed’ energy drink.
Kerbside collections
The Akij Group obtains the start-ing material for the recycling line exclusively from kerbside collec-tions in Bangladesh. It requires at least 12t/day in order to ensure the decontamination module is constantly working to capacity. About 50 size-able collection centres and many more smaller contact points have
covered about half of the nation’s ter-ritory, so far. The plans are to extend the catchment area step by step to include all of Bangladesh. Akij buys the merchandise by weight from subcontractors. Since the project was started, the price per kilogram has already doubled, from around 20 to 40 eurocents, because Akij fi nds itself bidding for the raw material in direct competition with foreign recy-cling companies. So the PET recy-cling line’s cost-effi ciency is all the more important.
The material arrives in the bever-age factory’s courtyard in big bags or already compressed. It is in very poor condition, which presents a real challenge. It is mixed with contain-ers made of different types of plastic, and collected at a host of different locations in Bangladesh. The propor-tion of dirt and sand is very high and the oil content is far from negligible, as beverage bottles are in Bangla-desh often misused as oil storage containers, with consequent diffi cul-ties downstream. Pre-sorting is very important in order to ensure the req-uisite starting quality of the material for the recycling line. This separa-tion function, sorting out non-plastic materials, different types of plastic (including multilayer), or sorting into the different colours encountered, can be handled automatically, semi-automatically or by hand. Akij has opted for manual presorting.
FDA approval “Approval by the FDA was par-
ticularly important for us”, explains P. B. Barua. “We do, of course, monitor both fl ake quality and bottle quality on a permanent basis, with checks on IV value, moisture, density, crystallisation and colour. What’s interesting for us is the fact that the system runs fully auto-matically. For the Krones process, the intrinsic viscosity doesn’t have to be as high as for other technologies, which is a defi nite advantage. The recycling line is high-tech kit, which is why we have to be able to rely on the manufacturer; we need fast feedback and good ser-vice support.” Akij recycles; Bangla-desh profi ts.
www.krones.de www.akij.net
The bottle-to-bottle decontamination module has at Akij been installed on an area of just under 190m².
Decontamination proper is handled in a vacuum reactor.
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From bottles to bags
Outdoor specialist company Vaude is taking PET down the route of fashion - it is using recycled plastic PET bottles to create a new collection of bags. After the bottles have gone through their fi rst use, they are cleaned, shredded and turned into fi bres. This material is then used in the manufacture of seven bags and two backpacks in the company’s Recycled range.
Fashionable bag made from PET bottles
These bags are a long way from the image of an old, beat-up PET bottle. The modern designs with quilted seams give either a clean streamlined business look or a gracefully curved wave format. The material used feels like real fabric, with a fi ne and soft touch. The mate-rial used to line the bags and packs is 100% post-consumer recycled PET bottles. The outer material is made from 55% PET fi bres interwoven with 45% polyester fi bres. Each bag, depending on its size and features, uses about 12 recycled bottles.
Prior to their rebirth as a bag, the bottles must fi rst be properly cleaned and caps and paper labels removed. A shredder processes the plastic into chips, which are then used to make the fi bres. These can be interwoven with other materials, such as polyester, or used on their own to make, for exam-ple, the lining for bags and packs.
Built-in raincovers and padded laptop compartments
The new bags and packs offer a variety of advantages along with their environmental contribution: the haPET and torPet bags, for example, come with built-in raincovers, padded laptop compartments, and can be slipped on to the handle of a rolling bag for easy transportation. The PETon and PETrik backpacks can carry 23 and 24l of volume, respectively. All the products, including PETula, PETeris and PETje, the three laptop and business bags, are available in a variety of colours. The small agaPET shoulder bag is an ideal pick for city outings; the larger PETronella bag offers expandable volume capacity and two carrying handles, for successful shopping sprees.
www.vaude.com
Revolution in PET-extrusion!
Conical co-rotating MAS-extruder| perfect solution for A-PET, G-PET, PET Co-polymer …| prime pellet / melt quality (IV, b*, AA- content)| very low energy consumption| direct extrusion into sheet| stable melt pressure build up | small foot print paired with robust design| sizes available from 200 kg/h up to 1500 kg/h| suitable for food application
M-A-S Maschinen- und Anlagenbau Schulz GmbhA-4055 Pucking, Hobelweg 1T: +43 7229 78 999, F: +43 7229 78 999 [email protected]
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Handling high levels of recyclate in PET preform machines
Raising recyclate in preformsSipa, the supplier of equipment for production of PET bot-tles and containers, has developed a range of solutions to produce preforms containing high levels of post-consumer recyclate in fl ake.
Its preform injection moulding equipment designed for this function ranges from 96 down to 24 cavities. Sipa PPS Preform production systems produce preforms made with PET containing various levels of recyclate, up to 100%. The only change neces-sary to the standard confi guration for handling fl ake at addition rates of up to 50% is the addition of an auxiliary gravimetric dryer. When recyclate content is in the 50-100% range, an upgrade to the plastifi cation unit and fi ltration system is required.
It is now possible to use as much as 50% recycled PET in bottles for mineral water sold in the European Union. In North America, several com-panies already produce bottles using exclusively 100% of rPET for their mineral water product. There are tight restrictions on the quality of recycled PET that can be used in new mineral water bottles. The material must be sourced from containers that were themselves approved for food contact applications.
Sipa has presented the results of production on a standard-confi guration PPS 72, equipped with 72 injec-tion mould cavities and fi tted with a 140-mm plasticating extruder with an output of 1200 kg/h coupled to a 6000g injection pot. In all cases up to a 40:60 virgin: recyclate content, no signifi cant problems were observed in the productivity of the standard equip-ment, nor in the quality of the preforms. Processing temperature of 280°C was set for the extruder, injection pot, hot runners and nozzles. Dimensional controls were performed on the bodies of the preforms and also on the necks. Preform weight at various levels of fl ake, and levels of acetaldehyde within them, were measured. No signifi cant dimensional difference between pre-forms made with 100% virgin PET and those containing recycled PET were observed, through to 50% addition levels. Acetaldehyde levels were actu-ally seen to fall with increasing levels of recycled PET.
www.sipa.com
Sipa PPS preform machine detail
Variation in preform colour depending on level of recyclate, from 0 to 70%.
Variation in preformcolcolourour dedepenpendinding og onnlevlevelel of of recrecyclyclateate, ffromrom 0 to 70%.0 to 70%.0 to 70%.
Table 1: Acetaldehyde levels as a function of recyclate: Falls measured in intrinsic viscosity are in line with virgin PET. The visual quality of pre-forms in terms of colour, presence of impurities and burnt specks depends on the quality of the fl akes used.
0
1.0
2.0
3.0
4.0
5.0
6.0
Ace
tald
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pm]
Number of cavities666397
PETALO A-10% PETALO A-20% PETALO A-30%
virgin PET PETALO A-40% PETALO A-50% PETALO A-60%
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Milky Preform Chapter 18 of the “Rapid Guide to Perfect Preforms” by Rick Unterlander and Ottmar Brandau
Troubleshooting guides have suffered in the past from being locked away in offi ces and not being available to the people that actually need them. Considering the high cost of machine and tools high scrap rates can be a costly prop-osition eating away at already tight margins.
PETplanet’s “Rapid Guide to Perfect Preforms” takes a different approach. Bound in laminated paper that is easy to clean off, the small format of the book of 108mm by 151mm (4.25” by 6”) allows easy storage in back pockets or tool boxes. It has been written for the people on the fl oor of injection moulding companies to sup-port their daily work in making the best pre-forms possible.
The product of two industry experts, Rick Unterlander and Ottmar Brandau, it gives concrete advice on 35 of the most common problems in preform manufacture, most illustrated by pictures. From high AA levels to wavy bodies processors can fi nd help when they need it. Read chapter 18 of the guide.
Recycling line recoSTAR PET iV+Ongoing PET recycling innovation, quality and state-of-the-art technology, a full range of consulting services – brought to you by Starlinger.
Visit us at:ANTEC 2011, Mai 1 - 5, Boston USAHall C, Booth 212www.starlinger.com
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fax: +49 (0) [email protected]
Order your copy now!O d
PETplanet print vol.6
The Rapid Guide
to Perfect Preforms
machine no./name
ol
prices in EUR + VAT.
1- 3 exemplar each 129,- €
4 - 10 exemplar each 99,- €
> 10 exemplar each 69,- €
l.6.6.6 l.lol
prices in EUR + VAT.
1- 3 exemplar each 129,- €
4 - 10 exemplar each 99,- €
> 10 exemplar each 69,- €
Symptom:
Faint white swirls and patches in various spots on the preform.
Cause:
Melt that has been thermally degraded by overheating in a spe-cifi c zone (not oxidized).
Solutions:
1. Check all temperature readings and correct if necessary. PET resin should be melted at about 280ºC (536ºF) +/- 10ºC (18ºF).
2. Check all %-controlled temperature settings and mini-mize if possible. %-controllers provide no temperature feedback and require fi ne tuning.
3. Check that all thermocouples are properly inserted and contacting the bottom of the wells. Having a ther-mocouple incorrectly seated in one zone has a major effect on this problem, especially if the melt stagna-tion time between cycles is long.
4. Make sure the extruder screw cushion is not exces-sive. This should be a minimum of 25mm to com-pensate for any fl uctuations during screw recovery. (Two-stage machines only)
5. Check hardware for worn, damaged or failed com-ponents, specifi cally the machine and mould heaters, and thermocouples.
6. For prevention, always:a. Reduce temperatures by about 40ºC (104ºF) if the
machine stops for more than 15minb. Reduce %-controllers by ½ if the machine stops for
more than 15minc. Shut off nozzle tip heats if the machine stops for
more than 10mind. Never exceed start up temperature soak times.
Machine should be started within 15min of the tem-peratures reaching operating settings. Nozzle tips should only be turned on 5 to 7min prior to start up.
IN EVERY BOTTLETHERE IS ALL OUR
KNOW HOW.
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Automatic handle for edible oil
It has been a constant source of frustration about stretch blow moulding that current technology was not able to allow handles to be incorporated on the same line. The result is that handles always have to be attached manually. Now, for the fi rst time, we have seen an automated solution from Sipa at JRD in Dubai where the handles are fi tted automati-cally using a Sipa machine.
Briefl y, JRD produces packag-ing for the water, dairy and edible oil market in Dubai. The company sup-plies thermoformed cups and plas-tic bottles. The preliminary products necessary for this, such as PET- and PP-sheets or preforms, are likewise produced in-house by the company. We met Mr. Sagar Verma, Business Head of JRD for 4 years.
PETplanet: Mr Verma, there are innumerable companies produc-ing cups and PET bottles for edible oil. Why should bottlers buy from you rather than anyone else?
Mr Verma: You’re quite right, looking at the sheer volume of suppli-ers, but I think that we are, technologi-cally speaking, very advanced and our
prices are acceptable. Have a look at this for example. In the cups sector we are promoting the change here in Dubai from Polystyrene(PS) cups to environmentally-friendly polypropyl-ene (PP) cups. PP can be recycled and keeps its shape even when fi lled with hot liquids. We offer everything, from elaborate in-mould labelling right through to the shrink sleeve and 8-colour printed labels. At the moment we are installing a new Illig RMD 75 K cups machine with a capacity of 600 million cups/a. It just doesn’t get any better than that. We also use Western European technology when it comes to decorating the cups.
PETplanet: Yes and what about edible oil?
Mr Verma: Our injection stretch blow moulding is conducted to a major extent on single-stage Aoki systems but for our Highlight we have, together with Sipa, devised a worldwide fi rst in the shape of a 2-stage solution. Let’s start with the preform. Here we produce our own preforms on a Sipa system. These we store for 24 hours and then they go off for blow mould-
Edible oil bottles: The handles are com-pressed by the new plant before being snapped into the edible oil bottle.
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2-STAGE STRETCH BLOW-MOLDING MACHINES, MOLDS AND NEW APPLICATION DEVELOPMENT FOR:- Extra large bottles and containers- Wide-mouth jars and containers- Standard bottles- Bottles and jars for Hot filling- Special bottles, jars and containers
SHAPING YOURBIG PROJECTSWe want to help our customers maintain their competitive advantage by supporting and developing their business on the market with environmentally sustainable packaging solutions.
Siapi America Inc3190 Reps Miller Road,Suite 320 - Norcross GA 30071P. 678 892 7200 - F. 678 892 7201www.siapiamerica.com
Siapi S.r.l.Via Ferrovia Nord, 45 - 31020 San Vendemiano (TV) Italy T. +39 0438 4096 - F. +39 0438 401016 - www.siapi.it
HandleMatic system. NOW available for SIAPI blow-molding machines. [email protected]
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ing. The preform cartons are automat-ically unloaded, heated and blown out of round. In addition, two edges are pressed mechanically into the bottle in the blow mould.
After the leakage check we move on to the actual new station for auto-matic handle fi xing. Here the handles are loaded in the correct position via a hopper, compressed and snapped into place on the edges. After that we move on to the automatic pack-ing station which is where we load the bottles on to pallets so that they are dust-proof. So you see, nowhere does a human come into contact with the preform or the bottle! This is the best we can offer our customer, too!
PETplanet: An innovation of this sort has got to be maintenance-intensive?
Mr Verma: It isn’t any more but you’re right, in the expansion phase it took us some time to get to where we wanted to be. But at this point I would like to say a big thank you to and express my appreciation of the team from Sipa they were always on hand and, when they needed to, they worked round the clock. I have been buying machines from a very wide range of manufacturers for 20 years and there are technical problems with every machine, but the service provided by Sipa is up with the best I have experienced.
PETplanet: And you produce the handles yourselves too?
Mr Verma: We have 8 injection moulding machines of different capac-ities in operation at our premises and these are primarily used for manufac-turing the handles and the caps for our bottles. This means that we can always offer a complete system with bottle, cap and handle.
PETplanet: Your boss, Anupam Lunavat, has said that JRD is aiming to be the market leader in South East Asia by 2012 and worldwide by 2015.
Mr Verma: We are constantly expanding. Double fi gure growth rates in the higher range during the course of the year are normal. Each year we invest in new machines. Even in the last few years during which the indus-try in general has been reluctant to enter into any commitments. We do all this with our own money and with no help from the banks.
Coming up are a further IML plant and another Sipa installa-tion. So as to clear sufficient space for the new machines of plant we have, for example, moved all our old machines 500m further out into another bay. This is also where our bulk materials store is. But here at the parent plant things have once again become so cramped that the Sipa installation is having to sit alongside the old equipment.
PETplanet: And what about your future plans?
Mr Verma: We intend to expand into the sector of PP hollow plates for construction. As regards this, we have an exclusive agreement with an Italian engineering company. Only just round the corner from here a plant is being built at the moment which will accom-modate four lines.
PETplanet: Thank you very much, Mr. Verma, and I wish you every success.
www.jrddubai.comwww.sipa.com
The new Illig plant shortly before commissioning. It is capable of thermoforming up to 600 million cups/a.
Alessandro Piccino, Sipa and Alexander Büchler in front of the preform installation which produces oil pre-forms as well as preforms for juice bottles.
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�DoubleSeal™ technology for unique sealing performance
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BERICAP Technologyfor hot filled beverages
Com
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ving
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es, R
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as a
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ealth
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DoubleSeal™ 28 mm hot fill
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hall 10 • stand E67
PETproducts
38 PETplanet insider Vol. 12 No. 03/11 www.petpla.net
Post-consumer PET recycling Italian com-
pany Piovan manufactures and markets a line of auxil-iary machines for production of fl at sheet for thermoforming, profi les, fi bres, hoses and wires and dedicated systems for the production of fl exible fi lms, both blown and cast. It has been addressing the particular issues associ-ated with systems using post-consumer PET (PCR PET) fl akes as the main raw material in the production of PET fi bres for car interiors. PCR PET is amorphous, dusty and comes in fl akes with variable granulometry, so that a spe-cifi c treatment is needed in order to provide the mechanical properties required for optimal material processing in the extrusion line. Piovan has developed a solution with a crys-tallising, dehumidifying and dosing system with a capacity of up to 1,200kg/h PCR PET fl akes and up to 1,600kg/h PET granules. Such large capacities are not conducive to easy changeovers or small production batches. In order to avoid material waste and long machine down-times, the company has developed a double dosing process and two separate parallel columns for crystallisation and drying, which allows the user to switch from PCR PET fl akes to PET granules and to vary the percentage of the recycled material to a large concentration of PCR fl akes, without affecting the system’s overall effi ciency. Patented gas chambers heat up process air for the crystallising and drying systems. The entire production process can be managed via SVS, the company’s supervision software, from a remote PC workstation. Simple selection operations enable produc-tion to automatically adapt to different types of materials, depending on densities and capacities, with the intention of optimising energy usage and minimising waste. Piovan is developing its range of products specifi cally designed for the extrusion sector, including dryers, dosers, feeding and conveying systems, crystallisers, granulators and recovery solutions. It also develops customised systems in collabora-tion with OEM and extruder manufacturers.
www.piovan.com
Pre-reduction label remover from Herbold
New designs for bottles and labels, including novel shapes and all-over sleeves, complicate the task of bottle recyclers, according to Herbold Meckesheim GmbH. Labels covering the whole surface of the bottle, for example, are an obstacle to optic sorting. If the labels are made of PVC then maintaining the expected quality standard with conventional technology cannot be guaranteed. Herbold claims to have overcome these problems with a new machine that uses fric-tion to provide a preliminary treatment of the bottles before size reduction. The company says that the machine removes labels without unwanted side-effects, such as bottle-head breakage. Paper labels are removed and separated in a dry process, allowing easier separation of remaining paper fi bres. The company says that all-over, shrink-fi t labels can be almost completely removed and separated, which helps to prevent erroneous NIR identifi cation during sorting. The pre-treatment machine’s technology is also said to enable removal and separation of bottle caps and silicone sealants. The process removes sand and foreign bodies at the same time as the label, which should help to increase the lifetime of cutting knives.
www.herbold.com
Piovan crystallising system
Erratum!In the last issue of Petplanet we printed an unedited arti-
cle on Messrs. PET Verpackungen Deutschland by mistake. Please see below the corrected version. We apologise for this error
Preforms and new bottle designs to the fore
The PET-Verpackungen Germany offers standard pre-forms with 28mm PCO 1810 neck fi nish and a range of new solutions in weight-reduced neck areas. The company also supplies a variety of new preforms PCO 1881 standard, as well as 38mm 2- and 3-start neck fi nishes. Furthermore, the company offers multilayer preforms with tailor-made barrier solutions, designed for sensitive-fi ll goods. PET Verpackun-gen are also producing PET bottles with capacities ranging from 20ml to 5l on fi ve single-stage and two two-stage instal-lations. Possible applications range from water, CSD and spirits as well as applications in the cosmetics and deter-gents sector right through to foodstuff applications. One new in-house development is a wide mouth jar for powdered milk/coffee creamer. In the health and beauty care packaging sector PET Verpackungen has come up with a bottle family for hand sanitizer. A further new development that the people at PET Verpackungen have developed on their own initiative is a small 0.2l champagne ‘piccolo’ bottle.
www.pet-verpackungen.de
ALS compressed air-free automatic guide system
Sidel’s ALS guide for air conveyors is an automatic adjustment system for side guides. It is designed to pro-vide increased fl exibility during format changeovers. It has no pneumatic cylinder, which is intended to enable it to automatically adapt to the majority of bottles currently on the market, on a single conveyor. The operator selects the desired format from the control panel, a gearbox transmits the appropriate movement to the side guides through a fl ex-ible shaft that follows the conveyor layout, and the guides are positioned by translation thanks to a worm gear. The system does not use compressed air, has a small number of parts and requires only one drive up to 30m per side.
www.sidel.com
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39PETplanet insider Vol. 12 No. 03/11 www.petpla.net
Compact inline crystallisationRPET pellets need to have the same parameters as new material, in
order to produce preforms for food-standard PET bottles. This requires crystalline material and Erema is offering a solution with its Compact inline crystallisation (CIC) system. The company’s Vacurema system produces melt-fi ltrated strings that are briefl y cooled in water and then cut into pellets. The material is fed into a container immediately afterwards. The latent ther-mal energy still contained in the pellets is used for crystallisation – without any additional outside energy required and without any process interruption. Downstream of the CIC, pellets with an AA content below 1ppm can be pro-duced with a newly-developed pellet fl usher, enabling production of rPET with the characteristics of new material. Erema claims that CIC can help to save up to €100,000 Euros at a throughput of 1,000 kg/h, with a low investment and machine footprint.
www.erema.at
Prefrom production with recycled PET
Husky Injection Molding Systems’ sustainability solutions now include the company’s HyPET Recycled Flake (RF) system. It is specifi cally designed to sup-port bottle-to-bottle recycling through the manufactures of preforms with high percentages of food-grade recycled PET fl ake, which is intended to enable signifi -cant increases to the amount of bottle-to-bottle recycling. The consistent chal-lenge has been increasing the recycled fl ake content in beverage packaging, while maintaining system performance and high bottle quality. The difference in physical proper-ties and behaviour between fl akes and pellets means that recycled fl ake adds to this challenge. Husky’s HyPET RF system has an injection unit that is specifi cally designed for recycled fl ake. Its mixing performance is designed to offer better material homoge-neity, while continuous fi ltering reduces the presence of black specks. A shortened thermal process minimises thermal degradation. HyPET RF is based on Husky’s High Perfor-mance Package (HPP), and offers the same cycle time, throughput, shot repeatability and weight distribution. By addressing the specifi c issues in manufacturing PET bottles with the use of recycled PET fl ake, it is designed to allow manufacturers to introduce recycled PET fl ake into their products. Those already using recycled PET fl ake can elimi-nate some of the manufactur-ing and quality challenges while enabling an increase in fl ake content. Compared to food grade recycled pellets, the process for producing food grade fl ake does not involve melting or extrusion, which means a lower cost and lower carbon footprint. Husky says it has overcome the tradi-tional disadvantage of food grade fl ake – the inability to melt fi lter – by implementing the continuous melt fi lter. The new extruder on the HyPET RF system is also claimed to eliminate the usual step of upsizing the extrusion screw.
www.husky.ca
PETbottles
40 PETplanet insider Vol. 12 No. 03/11 www.petpla.net40
Coffee enhancersNaples-based Saba, now part of the
CO.DA.P group, has recently launched two new almond syrup product lines in PET bottles, which both use a standard non-drip 38mm cap from Aptar Food + Beverage. The line of almond syrup coffee enhancers comes in fi ve fl avours and is packed in a sleeved PET bottle with a partially transparent back-ground. The products are offered in 700ml PET bottles, capped with a silver-coloured dispensing closure from Aptar. The 38mm PE fl ip-top closure has a tamper-evident ring-pull and a pouring beak to ensure drip-free pouring.
Pizza spray complete with fi lling The French retailing giant Carrefour is market-
ing 250ml pizza spray in an original, transparent PET bottle fi lled with stuffed chilli peppers. The chilli peppers, which are bottled when dry and have the effect of ”turning up the heat“, are easy to see and catch the eye immediately at the POS. A pump spray (also transparent and featuring a snap-on lid and self-adhesive labels with a tear-off tamper-proof seal) puts the fi nishing touches to the appearance of the packaging.
www.carrefour.fr
The spirit of PETAntonio Nadal S.A. from Majorca is marketing an
assortment featuring all kinds of high percentage alco-holic drinks in slightly curved PET 50ml volume bottles. As a result of their slightly curved shape, the bottles – one example being the ”Original Navy Rum“ – can be advan-tageously positioned on the shelf and the curved label has a pleasing appearance. The PET bottle features a printed aluminium screw cap with a tear-off tamper proof seal.
www.antonionadal.com
Striking ShapeThe Spanish company Solan de Cabras
based in Cueno is marketing its 330ml Multi-Fruit Juice in a strikingly moulded PET bottle with a long neck.The bottle is decorated with a shrink sleeve label coordinated with the colour of the juice and features a generously proportioned drinking opening 32mm in diameter. A colour-coordinated screw cap with a tear-off tamper-proof seal makes this modern beverage packag-ing complete.
www.solandecabras.es
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41PETplanet insider Vol. 12 No. 03/11 www.petpla.net
Bio in PETThe Swiss trading com-
pany Coop is marketing a 0.5l bio-cordial made from elderfl owers in a practical, dark brown coloured PET bottle. The manufacturers of the cordial are Messrs. Lammann + Co. in Bi- schofszell, Switzerland. The bottle sports an all-round paper body label and a snap-on dispenser cap with tear-off tamper-proof seal.
www.coop.ch
Good health from NestléUnder the brand name of “Nesfl uid“,
Nestlé France is marketing a range of 250ml drinks such as, for example, “Equilibre“ (with lemon / Vitamin C) or ”Protect“ (with pomegranate, zinc and selenium) in PET bottles for whenever you feel like topping up your fi tness levels. The handy bottles have a square base and are decorated using shrink sleeve technology. A small, stick-on fold-ing label on the cap provides information on the product advantages offered by the energy drink. A screw cap (diameter 32mm) complete with tear-off tamper-proof seal rounds off the profi le of this PET bottle.
www.nesfl uid.fr
Beaujolais goes PET
APPE has announced that it doubled the amount of PET bottles it supplied for Beaujo-lais Nouveau Vintage.
Other recent successes for the company in the wine sector include a major order for both 750ml and 187ml bot-tles for a South African winery and the supply of 187ml bot-tles for in-fl ight wines to two of Europe’s leading airlines. Total PET wine bottle production for APPE during 2010 has already grown by 45%, with stronger growth forecast next year. A 750ml bottle weighs 50g compared to the typical weight of a same size glass bottle of between 350g to 600g. APPE wine bottles also contain an active barrier system. The PET bottles echo the design of the traditional glass bottle, rein-forcing wine’s premium image. They feature a stipple base, which prevents leaks during fi lling caused by conveyor fric-tion, and incorporate a screw top closure for maximum con-venience. They can be fi lled on the same fi lling lines and at the same speed as glass bottles.
www.appepackaging.com
PETbottles
42 PETplanet insider Vol. 12 No. 03/11 www.petpla.net
Personal Care
No-touch dispensingReckittBenck-
iser is selling its 250ml “Dettol“ brand hand cleanser with a no-touch infrared dispensing system and PET refi ll bottle in the USA and England. The PET bottle with its spe-cial valve is placed headfi rst in the dispenser and locked in position by applying slight pressure. In response to an infra-red trigger, the battery-operated dispenser then dis-penses a dose of hand cleanser without the need for any physical contact. According to the manufacturer, 99.9% of bacteria are eliminated and your kitchen and bathroom stay clean. The aftermath of swine fl u in Europe, which has led to enhanced hygiene precautions, is reinforcing sales of the product. The dispenser can be reloaded with a new PET bottle without any problems. The dispenser is sold in a high quality blister pack with pack inserts to provide the customer with further information.
www.dettol.co.uk
Sun protectionThe German drugstore discounter
Schlecker of Uhingen is selling a range of pump spray products in PET bot-tles under the “AS“ brand name. These include, for example, the 150ml sun protection spray “Sun“ in a dark brown PET bottle with gold-coloured spray head along with 400ml room air fresheners in a transparent PET bottle with a secured spray trigger. Both bottles are decorated with modern no-label-look labels.
www.schlecker.com
Taft for designers Henkel Düsseldorf is offering
200ml spray gel under the “taft“ brand name in a blue-tinged PET bottle for the “Designer Look“. The bottle features no-label-look labels to front and rear that enhance the originality in terms of packaging impact of the light blue coloured bottle. A screw on, orange-coloured pump sprayer plus the safety cap round off this modern-look packag-ing ensemble.
www.taft-looks.de
Clearly high quality100ml invigorating, blue coloured
ice gel for regenerating tired feet is being sold by Yves Rocher of La Gacilly in a high quality PET bottle with an innovative shape and featur-ing a practical screw cap. The plastic screw cap– thanks to its easy to handle shape – presents no prob-lems when it comes to opening and is reminiscent of the glass stoppers used in the past. Printed no-label-look labels to front and rear are also part of the decoration and convey the required trading information.
www.yves-rocher.com
Structuring shampoo Under its brand name of “Lavera“,
the German company Laverana GmbH of Wennigsen is marketing 250ml structuring shampoo for regenerating stressed hair. The product is marketed in a round, dark brown PET bottle with a screw-on, black hinged cap and a content of 250ml. High quality printed front and rear labels provide informa-tion about the shampoo with its natural ingredients such as bio-aloe vera and bio-linden blossom.
www.lavera.de
Kneipp creates mood“Mood“ or “Time-Out“ –
Kneipp Werke of Würzburg are selling a range of aromatic pamper foam baths in a round PET bottle containing 400ml of product and sporting a green screw cap. According to the manufacturer, the pamper foam bath is rich in naturopathic features, long-lasting foam and natural oils. The packaging is decorated with a high quality printed shrink sleeve label and it contains, if correctly dis-pensed, enough for eight relax-ing baths.
www.kneipp.de
One step ahead – best solutions for your future.Economical preform and caps production by Netstal.
Netstal has convincing sales arguments with particular competence in the production of preforms and caps.
Netstal‘s business unit organization, with the system strategy, allows customers to confi gure each and every
system according to their own particular needs and capacity utilization requirements. This guarantees the
benefi t of minimum production costs with maximum output.
Netstal-Maschinen AG, Näfels | www.netstal.com
PETpatents
www.verpackungspatente.de
44 PETplanet insider Vol. 12 No. 03/11 www.petpla.net
Base structure International Patent No. WO 2010 / 078341 A1Applied for by: Plastipak Packaging Inc., Plymouth (US) Application date: 29.12.2009
The base shape a plastic bottle for hot fi lling is intended to absorb the thermal expansion and subsequent cooling so as to avoid any permanent distortions of the bottle which may be visible to the user.
Concave base International Patent No. WO 2010 / 061758 A1Applicant: Kogyosho Co. Ltd., Tokyo (JP) Date of Application: 18.11.2009
Described is a plastic bottle with a base that is specially shaped to fl exibly accommodate any change in volume that may occur as a result of hot fi lling without any change to the side walls. As the contents cool the base reverts to its original concave shape.
Extra in the baseInternational Patent No. WO 2010 / 063093 A1Applicant: Antoine Becotte, Montreal (CA) Date of Application: 23.11.2009
A type of vent hole “whistle“ is integrated in the base of a bottle and this can be removed once the bottle is empty and subsequently used to generate noise, e.g. at a football match.
Dispenser cap International Patent No. WO 2010 / 068633 A1Applicant: Graham Packaging Comp., L.P., York (US) Date of Application: 8.12.2009
Closure manufactured as a single section with integrated dispensing chamber and hinged lid.
Buffer area European Patent No. EP 2202163 A1Applicant: Yoshino Kogyosho Co. Ltd., Tokio (JP) Date of Application: 15.10.2008
Plastic container with specially moulded buffer areas to accommodate changes in volume as a result of hot fi lling. Disclosure of the international application was made on 30.6.2010.
Originality seal European Grant of PatentNo. EP 1892194 B1Applicant: Obrist Closures Switzerland GmbH, Reinach (CH) Date of Application: 9.8.2007
Multiple section closure with two lateral, easily identifi able lead segments that are cut off at the point of initial opening and can no longer be reinstated in their original position. This means that the consumer can easily recognise that the container has been opened. European Grant of Patent took place on 23.6.2010.
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Buyer’sguide1.0 MATERIALS
1.1 Materials for bottle and cap production
1.1.9 Additives and colorants
Americhem Europe LtdCustom colour and additive
masterbatches
Pierre Vandekerckhove
Tel.: +44 782 541 9086
www.americhem.com
Clariant Masterbatches
(Italia) S.p.A.
Via Lainate, 26
20010 Pogliano Milanese (MI)
Italy
Tel +39.02.9918.7558
Fax +39.02.9918.7552
http://mb.clariant.it
Advanced Colorants and Additives COLORMATRIX EUROPE LTD.
Knowsley Business Park,
Knowsley, Merseyside.
L34 9GT. UK
Tel: 0044-151 632-8800
www.colormatrix.com
GABRIEL-CHEMIE Gesellschaft m.b.H. (Zentrale)Industriestrasse 1
A-2352 Gumpoldskirchen
Tel.: +43 (0)2252 / 63 630-0
Fax: +43 (0)2252 / 62 725-0
e-mail: [email protected]
www.gabriel-chemie.com
HOLLAND COLOURS NV
P.O. box 720
7300 AS Apeldoorn, Netherlands
0031-55 3680700
0031-55 3662981
www.hollandcolours.com
TM
M.P.I. Srl Moulds Plus International
15050 Villalvernia (AL) – Italy
Tel. 0039 0131 836136
www.ultrapurge.com
Liquid colours and additives
REPI S.p.A.
Via B. Franklin 2
21050 LONATE CEPPINO VA
ITALY
tel. +39 0331 819511
fax +39 0331 819581
www.repi.it
1.2 Packaging components and accessories
1.2.1 Preforms
Gastro PET d.o.o.
Kotna ulica 5
SI-3000 Celje
Tel: +386 (0)3 425 80 30
Fax: +386 (0)3 425 80 31
www.gastropet.si
PET PREFORMS AND CLOSURES
INTERGULF LTD. (EMPOL)
KHALID SEAPORT
P.O.BOX 6131,
SHARJAH, U.A.E.
Tel. 009716 502 9244 / 9246
Fax. 009716 528 5720
www.empol.com
PDG PLASTIQUESF-45330 Malesherbes - France
Tel. 00 33 2 38 34 61 95
www.pdg-plastiques.com
PET PreformPlastic cap and closureRue de la plaine
47230 Lavardac - France
Tel.: +33 (0)5 53 97 41 00
Fax: +33 (0)5 53 65 85 97
www.sbecm.com
Preform manufacturer3 Rue de l’île Macé44 412 REZE FranceTel: + 33 (0)2 40 05 09 37Fax: + 33 (0)2 51 70 00 [email protected]
1.2.2 Bottles
1.2.3 Labels
1.2.4 Caps and Closures
Creative Dispensing Solutions
Seaquist Closures Löffl er GmbH
D94078 FREYUNG
Tel: + 49 8551 975 234
Fax: + 49 8551 975 180
www.aptar.com
BERICAP GmbH & Co. KG
Kirchstr. 5
D - 55257 Budenheim
Germany
Tel. +49 (6139) 2902 0
Fax +49 (6139) 2902 181
www.bericap.com
Idsteiner Strasse 74
D-65527 Niedernhausen,
Germany
Tel. +49 6127 8954 + 8850
Fax +49 6127 78189
www.cct-gmbh.com
www.corvaglia.ch
,
Gulf Packaging System Co
Post Box No. 20266
Jeddah - 21455
Saudi Arabia
Tel +966 (02) 636-0099
Fax +966 (02) 635-2111
www.gulf-pack.com
Has Plastik San. Tic. A.S.
Esenyurt Fabrikalar yolu No: 50
34325 Avcilar
Istanbul, Turkey
Tel +90 212 695 50 00
Fax +90 212 694 97 24
www.hasplastik.com
Georg Menshen GmbH & Co. KG
Industriestraße 26
D-57413 Finnentrop
Tel.: +49-2721-518 0
Fax: +49-2721-518 198
www.menshen.com
2.0 MACHINES AND EQUIPMENT
Bulk conveying and storage specialists for Preform, Closures and Bottles. Bottle and Closure Silos
Totes
Bulk Conveyors
Pneumatic Conveyors
Complete Turn Key Automation
www.teceng.net
Tel.: +52 449 971 06 53
46 PETplanet insider Vol. 12 No. 03/11 www.petpla.net
Buyer’sguide Entries from 5,70 Euro/mm, Call +49-6221-65108-0
2.1 Preform production(machines and equipment)
PREFORM and CAP Production
Hong Kong
Tel: 852-2665 3888
Fax: 852-2664 8202
www.chenhsong.com.hk
2.1.1 Injection moulding machines
DODHIA TECHNO ENGG. PVT. LTD.
TEL: +91-22-66662111
+91-22-24030034
www.dodhia.com
www.dtdotel.com
SKYPE: dodhiagroup
Ferromatik Milacron India Pvt. Ltd.
93/2 & 94/1, Phase - I, GIDC Vatva,
Ahmedabad - 382 445, Gujarat,
India
Tel: +91-79-25890081
www.milacronindia.com
NETSTAL-MASCHINEN AG
Tschachenstraße
8752 Naefels, Switzerland
Tel. 0041-55-618-6111
Fax 0041-55-618-6605
www.netstal.com
2.2 Bottle production(machines and equipment)
Nissei ASB Machine Co., Ltd.4586-3 Koo, Komoro-shi, Nagano-ken 384-8585, JapanTel. 0081-267-23-1565Fax [email protected]
KHS Corpoplast
KHS Corpoplast GmbH
Meiendorfer Str. 203
22145 Hamburg
Deutschland
T +49 40 67907-0
F +49 40 67907-100
E-Mail: [email protected]
www.khscorpoplast.com
Norgren AG
Ventilfabrik
Postfach
8362 Balterswil, Switzerland
Tel +41 71 973 83 00
Fax +41 71 973 83 01
www.norgren.com/sbm
Eugen Seitz AG Spitalstrasse 204
8623 Wetzikon, Switzerland
phone: +41 44 931 80 80
fax: +41 44 931 80 90
www.seitz.ch
SIPA S.p.Avia Caduti del Lavoro,3
31029 Vittorio Veneto, Italy
Tel. +390438911511
Fax +390438912273
www.sipa.it
Your partner for improvement and
innovation for the P.E.T. industry
Krones®, Sidel®, KHS®, SIPA®, others
Wide diversifi ed inventory available
www.umallette.com
2.2.1 Single stage stretch blow moulding equipment
2.2.2 Two stage stretch blow moulding equipment
Amsler Equipment Inc.Swiss Engineered - Canadian Built 1245 Reid St, Toronto,
Canada L4B1G4
Phone 905 707 6704
www.amslerequipment.net
No. 688-1, Zhong-shan road,
Sec. 3, Wuri, Taichung,
414, Taiwan
Tel: 886-4-23388289
Fax: 886-4-23380219
www.chumpower.com
MAG-PLASTIC MACHINERY S.A.
Rue Alfred-Pot 1
P.O. Box 140
CH - 1896 - Vouvry (VS)
Switzerland
Tel. 0041-24-4820-820
Fax 0041-24-4820-819
www.magplastic.com
Stretch Blow Molding Machines,
Preform Molds & Cap molds
Tel.: +86-576-84066853
Fax: +86-576-84020107
www.MegaMachinery.com
www.petkamold.com
PETTechnologies Europe
PET Technologies Europe GmbH
Austria
Tel.: +43-720-555300
www.pet-eu.com
SIAPI S.r.l.
Via Ferrovia Nord, 45
31020 San Vendemiano (TV), Italy
Tel: +39 0438 4096
Fax: +39 0438 401016
[email protected] www.siapi.it
UROLA S.C.
20230 Legaz pi, Spain
Tel. + 34 943 737003
Fax + 34 943 730926
www.urola.com
2.2.3 Coating systems
KHS Plasmax
KHS Plasmax GmbH
Meiendorfer Str. 203
22145 Hamburg
Deutschland
T +49 40 67907-364
F +49 40 67907-353
E-Mail: [email protected]
www.khsplasmax.com
2.2.4 Compressors
ARIZAGA BASTARRICA Y CIA, S.A.www.abc-compressors.com
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AEROFLON ENGINEERS PRIVATE LIMITEDTel: +917926589712
+919824049737
info@aerofl on.com
www.aerofl on.com
www.atlascopco.com/petcompressors
Oil free compressors for PET bottle blowing
Gardner Denver Ltd.
Claybrook Drive, Redditch,
Worcestershire, B98 0DS, England
Tel: + 44 (0) 1527 838600
Fax: +44 (0) 1527 838630
www.gardnerdenverproducts.com
LMF GmbH & Co. KG
Suedbahnstraße 28,
A-2544 Leobersdorf, Austria
Tel: +43 2256 9001-0
Fax: +43 2256 9002
E-mail: [email protected]
www.LMF.at
SIAD Macchine Impianti S.p.A.Via Canovine, 2/4
24126 Bergamo, Italy
Tel. +39 035 327611
Fax +39 035 316131
www.siadmi.com
2.2.5 Heating boxes for blow molding machines
OLICORP
Montbrillant 26
1201 Geneva
Switzerland
Ph +41 22 309 1540
Fax: +41 44 355 3820
www.olicorp.ch
2.2.8 Unscramblers
Unscramblers, Silos and Air
Conveyors for empty plastic bottles
www.posimat.com
2.3 Cap production(machines and equipment)
BMB SpAVia Enrico Roselli 12
25125 Brescia (BS) - Italy
Tel.: 0039 030 2689 811
Fax: 0039 030 2689 880
www.bmb-spa.com
www.imdvista.ch
NETSTAL-MASCHINEN AG
Tschachenstraße
8752 Naefels, Switzerland
Tel. 0041-55-618-6111
Fax 0041-55-618-6605
www.netstal.com
www.packsysglobal.com
SACMI IMOLA
Via Selice Prov. le 17/a
40026 Imola BO, Italy
Tel. 0039-0542-607-111
Fax 0039-0542-642-354
www.sacmi.com
2.3.2 compression moulding machines
2.3.4 Printing equipment
TAMPOPRINT® AGLingwiesenstrasse 170825 Münchingen, Germany Tel.: +49 7150 928-0Fax: +49 7150 [email protected] www.tampoprint.de
2.4 Crate production(machines and equipment)
Werner Koch
Maschinentechnik GmbH
Industriestraße 3
75228 Ispringen / Pforzheim
Tel.: +49 72 31/80 09 0
Fax: +49 72 31/80 09 60
E-Mail: [email protected]
www.koch-technik.com
2.5 Ancillary equipment for the production of preforms, caps and crates
Material Drying and
Mould Dehumidifi cation
Eisbär Trockentechnik GmbH.
A-6840 Götzis
Tel.Nr. 0043 5523 55558 0
[email protected] www.eisbaer.at
Green Box S.r.l.Cooling systems - cap coolers - mould dehumidifi ersTel. +39 049 9703319Fax. +39 049 [email protected]
Moretto S.p.A. Tel. +39 049 9396 711
www.moretto.com
motan-colortronic gmbhOtto-Hahn-Straße 14
61381 Friedrichsdorf
Tel.: +49 6175 792 167,
Fax +49 6175 792 284
www.motan-colortronic.com
Tel. +39 041 57 99 111
www.piovan.com
2.5.3 Dryers
200 West Kensinger Drive
Cranberry Township, PA 16066, USA
Tel.: +1-724-584-5500
www.conairgroup.com
3.0 SUPPLIERS FOR STRETCH BLOW MOULDS AND PREFORM MOULDS
Molds, Change Parts, SBM and
Injection Molding Machinery for
the PET/Bioplastics Industries
284 Pinebush Road
Cambridge Ontario
Canada N1T 1Z6
Tel: 001-519-624-9720
Fax: 001-519-624-9721
www.hallink.com
Production of blow moulds and PET mould partstel.: +359 32 606 821
fax: +359 32 606 888
offi [email protected]
www.itd.bg
48 PETplanet insider Vol. 12 No. 03/11 www.petpla.net
Buyer’sguide Entries from 5,70 Euro/mm, Call +49-6221-65108-0
3.1 Preform moulds
www.wtbvc.com
Preform Moulds, Components,
Refurbishments and Conversions.
Highest Quality, Fastest Delivery,
Lowest Cost.
United States - 937-898-8460
Poland - 48-17-860-1020
UK - 44-1623-658-416
Argentina - 54-11-4753-1111
PET Preform and Blow Molds for Different Application
Guang Dong Xing Lian Precise Machinery Co., Ltd.Baoshi Rd, Xiabei, Pingzhou,
Nanhai, Foshan, Guangdong, China
Tel: (86-757) 8677 7168
Fax:(86-757) 8623 3168
E-mail: [email protected]
Website: www.gdxl.com
HuayanHuayan PET Preform Injection Molding Systems Guangzhou, China
Manufacturer of High Precision
High Performance PET Preform
Injection Molds and Machines;
Tel. +86 20 8226 6148 ext. 8215
Email: [email protected]
Website: www.gzhuayan.com
Single & Two Stage PET Molds
33-4, Wonmi-Dong, Wonmi-GuBucheon City, Kyunggi-DoKorea 420-110Tel.: [email protected]. ksmold.com
KHS Corpoplast
KHS Corpoplast GmbH
Meiendorfer Str. 203
22145 Hamburg
Deutschland
T +49 40 67907-0
F +49 40 67907-100
E-Mail: [email protected]
www.khscorpoplast.com
Specialist for PET Preform Injection Mold, Injection Stretch Blow Mold & PET Blow Moldwww.moltechkorea.com
Tel : + 82-11-224-1571 /
+ 82-32-684-0153
Fax: + 82-32-684-0139
for North American market
for International market
No.1517, Sec.8, Huanjhong Rd, Wurih
Township, Taichung 414, Taiwan
Tel: +886-4-2335-9689
www.passcard.com.tw
www.petkamold.com
via Caduti del Lavoro,3
31029 Vittorio Veneto, Italy
Tel. +390438911511
Fax +390438912273
www.pmci-solutions.com
R&D -Integrated Solutions In PlasticsLeverage - Integrated Industrial DesignHamilton Road
Sutton-in-Ashfi eld
Nottinghamshire, NG17 5LD
England
Tel: +44 1623 556287
Fax: +44 1623 552240
www.rdleverage.com
1009 SE Browning Avenue
Lee’s Summit, Missouri
MO. 64081, USA
Tel: +1 816 525 0353
Fax: +1 816 524 5068
www.rdleverage.com
PREFORM MOULDS / STRETCH BLOW MOULDS Tel: 0039 071 7500214
Fax: 0039 071 7501958
[email protected] · www.simexitaly.it
TOOLING PREFORM
SYSTEMS BV
Moulds & Robotics
PET-related Services
& Technologies
C. Houtmanstraat 42
Emmen, The Netherlands
Tel +31 (0) 591 679768
Fax +31 (0) 591 630616
[email protected] · www.tps.nl
www.wtbvc.com
Blow Molds for All Technologies,
All Machine Types, All Sizes.
Highest Quality, Fastest Delivery,
Lowest Cost.
Canada - 905-574-0010
Poland - 48-81-820-5730
UK - 44-1623-658-416
China - 86-137-646-05384
Argentina - 54-11-4753-1111
Mold-Masters Europa GmbH
Postfach/P.O. Box 19 01 45
76503 Baden-Baden, Germany
Neumattring 1
Tel: +49 7221 50990
Fax: +49 7221 53093
www.moldmasters.com
MHT MOLD & HOTRUNNER
TECHNOLOGY AG
www.mht-ag.de
Otto Hofstetter AG
Zürcherstrasse 73
8730 Uznach, Switzerland
Tel. +41 55 285 22 11
Fax +41 55 285 22 44
www.otto-hofstetter.com
50 Galaxy Blvd. #13
Toronto, Ontario
M9W 4Y5, CANADA
P- (+1) 416 213 9400
F- (+1) 416 213 9379
www.rnaprecision.com
3.2 Stretch blow moulds
Awanti Polymoulds Pvt. Ltd.
25/5A/1/2, Nanded, Sinhagad Rd.,
Pune - 411 041, INDIA
Telefax: - 91 20 24392805
www.awantipolymoulds.com
PET engineering, bottle design, Prototyping, industrial blow mould and services -Rue du buisson Moreau 16100 Cognac FRANCETel : 0033 (0)5 45 36 63 [email protected]
PETplanet insider Vol. 12 No. 03/11 www.petpla.net
BU
YER
S G
UID
E
49
3.3 Cap moulds
www.cantoni.biz
www.corvaglia.ch
Erwes Reifenberg GmbH & Co KG
High Precision Mould Maker
www.erwes-reifenberg.de
z-werkzeugbau-gmbh
Hoechster Strasse 8
6850 Dornbirn, Austria
Tel. 0043-5572-7272-720
Fax 0043-5572-7272-8620
offi [email protected]
www.z-moulds.com
3.6 Mould Cleaning
3.7.3 Hot runner systems and controllers
PET Hot Runner Systems, Moulds,Chillers, Dryers, RoboticsYudo Hot Runner India Pvt. ltd.
TEL: +91-250-3200922
www.yudo.com
4.0 FILLING / BOTTLING
Blow molding, Filling,Packaging equipment
Tech-Long, Guangzhou, China
Tel: +86-20-62956881
Fax: +86-20-82266913
www.tech-long.com
SIPA S.p.Avia Caduti del Lavoro,3
31029 Vittorio Veneto, Italy
Tel. +390438911511
Fax +390438912273
www.sipa.it
4.1 Bottle handling and preparation
4.2 Beverage preparation
4.3 Filling machines
4.3.3 Hot fi lling lines
4.3.4 Aseptic fi lling lines
Aseptic fi lling lines
12 route de Mamers - BP 46
72402 LA FERTE BERNARD
Cedex
Tel.: (33) 2 43 60 28 28
Fax: (33) 2 43 60 28 39
www.serac-group.com
4.4 Labellers and capping machines
4.4.1 Labelling machinery
GERNEP GmbH
Benzstraße 6
D-93092 Barbing
Tel: +49 9401/9213-0
Fax: +49 9401/9213-29
Email: [email protected]
www.gernep.de
P.E. LABELLERS S.p.A.
Via Europa 25
46047 Porto Mantovano (MN), Italy
Tel.: +39 0376 389311
www.pelabellers.it
DEMO Design and Moulds
31020 San Vendemiano (TV) - Italy
Tel.: +39 0438 409048
Fax: +39 0438 409046
www.designandmoulds.com
www.petkamold.com
RÖDERS GMBH
Scheibenstr. 6
29614 Soltau, Germany
Tel. 0049-5191-603-53
Fax 0049-5191-603-36
www.roeders.de
www.sidel.com
PET Packaging design and development, blow molding equipment and molds
North America+1 678 221 3000
Central America+52 33 3952 0324
Latin America+55 11 4668 7000
Western Europe, Northern Europe, Africa+33 232 858 798
Eastern Europe, CIS, Middle East+43 1 370 1661 105
Asia+86 21 5048 4088
Solent Mould Tools Ltd
Tel: +44 (0) 23 9223 9950
SMT Americas Inc.
Tel: +1 905 315 9882
www.solentmouldtools.co.uk
4.5 Downstream equipment
ZECCHETTI S.R.L.
Via Galileo Galilei, 1-1A
42027 Montecchio Emilia RE,
Italy
Tel. 0039-0522-867-411
Fax 0039-0522-866-034
www.zecchetti.it
5.0 RECYCLING
Chemical products and solutions
for PET recycling. Cleaning
agents, antifoams, products to
improve fl otation and fl occulants
for waste water treatment.
CHT R. BEITLICH GMBH Bismarckstraße 102
D-72072 Tübingen
Tel +49 7071 154-0
Fax +49 7071 154-290
www.cht.com
Bühler AGThermal ProcessesCH-9240 UzwilT +41 71 955 3466F +41 71 955 [email protected]
PET-Recycling PlantsConsulting & EngineeringComplete Solutions
Herbold Meckesheim GmbHPET Granulators, Agglomerators, Shredders, Complete PET washing and recycling linesIndustriestrasse 33
74909 Meckesheim
Tel.: 06226 - 932 – 0
Fax: 06226 - 932 – 495
www.herbold.com
50 PETplanet insider Vol. 12 No. 03/11 www.petpla.net
Buyer’sguide Entries from 5,70 Euro/mm, Call +49-6221-65108-0
PET Chemical treatments:
Cleaners, fl otation compounds
and additives
Via Vigevano 61
28069 - San Martino di Trecate
Novara - Italy
Tel. 0039-0321789770
Fax 0039-0321789765
5.6 Melt fi ltration, screen changers
5.8 Complete recycling plants
Complete PET recycling plants, FDA approved, integrated IV increase without Pellet-SSP, process features lowest overall energy consumption, more than 100 plants supplied to industry. EREMA GMBH
Unterfeldstr. 3
4052 Ansfelden/Linz, Austria
Tel. 0043-732-3190-0
Fax 0043-732-3190-23
www.erema.at
“PET washing and recycling plants, turnkey and modules for B2B, fi ber, sheet”SOREMA division of PREVIERO N.srl
Via per Cavolto 17,
22040 Anzano del Parco (Co) -Italy
Tel:+39 031 63491250
[email protected] · www.sorema.it
PET recycling technology:
Recycling extruders with
inline SSP (IV increase,
food-contact, FDA)
Starlinger & Co. Ges.m.b.H.
Sonnenuhrgasse 4
AT-1060 Vienna
Tel.: +43/1/599 55 0
Fax: +43/1/599 55 180
e-mail: [email protected]
www.recycling.starlinger.com
lonely in space – or plugged in to the world-wide PET community? A few ways to benefi t from PETplanet‘s many offers.
Price of the entry:
number of lines
x 3,2 mm line height
x 5,70 EUR
= entry per issue
Stay permanently listed in the
magazine‘s Buyer‘s Guide with
your company logo and contact
information. For only EUR 5,70
per mm you can be present
among top suppliers of PET pro-
cessing materials – in every issue
of the year.
1 Line = 3,2 mm
Example: 1,824.– EUR/year
PETpla.netPETplanet Publisher
Landhausstr. 4
69115 Heidelberg, Germany
Tel. 0049-6221-65108-0
Fax 0049-6221-65108-28
www.petpla.net
32 m
m
contact Ask for your
individual offer – call +49-6221-65108-0
6.0 OTHER
6.1 Laboratory equipment
6.1.2 O2 barrier measurement
Non-invasive oxygen/
pH measurement
PreSens Precision Sensing GmbH Germany
Tel +49 941 94 27 21 00
www.PreSens.de/PET
6.1.4 Bottle and Preform inspection equipment
Intravis GmbHRotter Bruch 26a
52068 Aachen, Germany
Tel.: +49 (241)9126-0
Fax: +49 (241)9126-100
E-Mail: [email protected]
www.intravis.de
EMPTY BOTTLE
INSPECTION SYSTEM
P&S technology Co. Ltd
#326-1, Taejeon-dong
Gwangju-si, Gyeonggi-do
464-805, Korea
Tel.: 0082-31-763-5621
Fax: 0082-31-763-5623
www.pnstech.co.kr
6.2 PET consultancy and support services
6.3 Contract manufacturers
6.3.2 Suppliers of custom designed bottles
Engineering P.E.T. since 1980
30037 Scorzè (Venice / ITALY)
www.novapet.it
P.E.T. Engineering Srl
Via Celtica 26
31020 San Vendemiano (TV), Italy
TEL + 39 0438 403069
FAX +39 0438 408420
www.petengineering.com
7.0 USED MACHINERY
MachinePoint Used Machinery
Parque Tecnológico de Boecillo
Edifi cio C.E.E.I. - 2.01
E-47151 Valladolid (SPAIN)
Tel.: +34 983 549 900
Fax: +34 983 549 901
www.machinepoint.com
PET Preform Engineering SolutionsComplete Preform Molds
• 2 to 144 cavities• Std Guarantee 5 year on plates 3 years on stacks, and 2 million
shots on hot runner
Preform Hot Runner Systems• New systems or retrofit to existing molds
Cold Half Stacks• Replacement parts, or complete re-
engineering for lightweighting, thread conversions.
Hot Runner Stacks• Complete stacks for moldmakers or
spare parts replacement
Manifold Systems• Design / Build manifold systems for
mold makers who manufacture their own plates
Cold Half / Hot Runner Refurbishing• From simple cleaning to complete
rebuild• Service centers in Canada, Europe, and China• All components made in CANADA
Spare Parts • Extensive stock of replacement hot runner
parts for most major brand OEM molds
Engineering Services• Mold Conversions• Light weighting• System Optimization• Turnkey Solutions
Your one stop shop for mold makers and molders
www.rnaprecision.com50 Galaxy Blvd Unit 13, Toronto, Ontario, M9W 4Y5 CANADA : (P) +1 416 213 9400 : (F) +1 416 213 9379
D51
178;
ISS
N:1
438
9452
Application Example
HyPET RF 300 with HPP
72-cavity mold
34.7 gram EcoBase preform
1.5 liter carbonated soft drink bottle
50% recycled PET flake, 50% virgin PET
10.5 second cycle
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