Archive | Bottling

Whyte & Mackay Works With Ideagen to Boost Quality, Safety and Compliance

Whyte & Mackay, the global drinks brand company, is working with leading software vendor Ideagen to improve quality, safety and compliance management at its bottling operations. Ideagen’s Q-Pulse software has been rolled out across Whyte & Mackay’s plant in Grangemouth, Scotland, to improve document and audit management and ease compliance with standards such as BRC.

Q-Pulse, an electronic quality management system, has replaced a series of paper based processes helping the organisation improve all aspects of its operations, including enhancing levels of safety reporting.

Norman Elliott, Compliance Manager at Whyte & Mackay, says: “The management of document control and easing of compliance were huge drivers for us ahead of this project. Previously we had been using a series of manual systems and processes which were becoming dated and at times a hindrance to what we were trying to do in regards to both quality and safety.

whytemackaylogo“After choosing Q-Pulse and implementing the software, everything we require is now in one system and for document management and control that is excellent. It means we no longer need to check if the correct processes are being followed or the most up-to-date documentation being used as the system does that for us automatically.”

He continues: “Q-Pulse has encouraged more ownership of the quality system across the entire bottling plant and also makes it easier to comply with standards such as BRC and ISO45001 (OHSAS 18001). Now, when we are audited, it’s a case of quickly and easily finding the information the auditor requires and also presenting them with the history of our actions. The auditor can historically see what we have done and why we have done it – quickening audit times and simplifying the compliance process.

“Previously, we would have been under pressure trying to prepare for those audits. But Q-Pulse is a one stop shop for us to go and find any quality, safety or compliance information that is required – whether that’s for our own internal staff or external auditors.”

Whyte & Mackay, based in Scotland and founded in 1844, produces single malt and blended Scotch whiskies, liqueurs and vodkas with brands including Whyte and Mackay Blended Scotch, The Dalmore, Jura and Fettercairn single malts; Glayva liqueur and Vladivar Vodka.

ideagenlogoSince implementing the Q-Pulse software within its bottling plant, the company has extended the system to adopt processes linked with health and safety, near miss reporting and safety improvement programmes.

Norman Elliott adds: “As well as the improvements from the quality side, Q-Pulse has helped us improve our investigations into safety incidents. Now, to get to the root cause of an incident, we can record corrective and preventive actions through the Q-Pulse incident management functionality, known as IMS, and this fits very nicely with our overall health and safety management. One of our major successes was in encouraging staff to come forward with safety improvement suggestions using Q-Pulse and its IMS functionality.  Our staff are taking more ownership in overall safety around the plant. By tackling safety in this proactive way, and because everything is recorded in the Q-Pulse system, we can show inspectors exactly how we have tried to prevent accidents.With Q-Pulse, we have been able to become more proactive in terms of risk and safety management.”

Ideagen’s Q-Pulse is used by over 2,200 organisations globally including some of the biggest names in the Manufacturing, Aviation, Rail, Energy and Life Science industries.

 

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The Pott’s Brewery Invests in New Inspection Technology

The Pott’s Brewery in Oelde, Westphalia, is synonymous with swing-stopper bottles and also demonstrates this expertise when it comes to contract-bottling for beer and beer-based mixed drinks. To upgrade the quality of its products still further, Pott’s has now invested in a new Linatronic empty-bottle inspector from Krones combined with a ModulCheck rubber seal monitor, both of which have been integrated into the existing Krones bottling line. Numerous advantages of this improved inspection unit contribute towards ensuring that the brewery’s 24,000-bph filling line for swing-stopper bottles is now way ahead of its time. The line is run in two-shift operation throughout, and is used both for filling the brewery’s own beer specialties and for contract-bottling.

Rubber Seal Inspection by a ModulCheck

Pott’s placed an order with Krones for a new ModulCheck rubber seal monitor and for a Linatronic 735 empty-bottle inspector. The upstream ModulCheck verifies the presence and correct colour of the rubber seals on the swing-stopper bottles’ porcelain heads; it can do this for all positions of the rubber seal. Moreover, the unit detects soiling, faded rubber seals, and any labels/label residues still adhering to the swing.

krones2november2016The new ModulCheck offers numerous advantages: it does not touch the bottles, and can also be relied upon to detect soiling in the area of the porcelain head. What’s more, it doesn’t consume any wear parts, and can easily be matched to a new variant at change-overs

Impeccable Monitoring and Upgraded Quality

The latest model of the Linatronic 735 contains a variety of modules like base inspection, sealing-surface inspection, side-wall inspection or lateral-neck-finish inspection. When inspecting swing-stopper bottles, the Linatronic also takes a long hard look at the stopper itself: if the clamp-type lower part of the swing-stopper and the porcelain head are on different sides of the neck area, a four-mega-pixel neck-finish camera can be relied upon to detect this fault, and to check the sealing surface as well.

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Plenish drinks get plush new bottle design

RPC Promens Consumer Llantrisant has provided a new custom-moulded 330ml bottle for London-based Plenish that will pack three flavours of their Water+ range.

The clear bottle creates an enhanced on-shelf impression, with a svelte and imposing aura, according to RPC. They also indicate that the bottle’s understated curves merge into a large area, which is ideal for eye-catching labels.

The new bottle will be used for Plenish’s cucumber, pineapple ginger and blueberry pear ranges.

Plenish operations and supply chain manager Amanda Grace says: “We designed this bottle shape to fit in with our existing range of cold press juices that come in 250ml and 500ml, and we’re really happy that RPC could turn it into a reality.

“They were even able to work with their tooling partner to reduce our lead-time and provide the bottles ready for our nationwide launch. We wouldn’t hesitate to work with them again in the future.”

RPC Promens provides packaging solutions for markets including food and drink, cosmetics and pharmaceuticals.

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JDO gives Baltika beer a new bottle design

One of Russia’s most popular beer brands, Baltika 3, is set to get a facelift with a new bottle design from JDO Brand & Design.

The Carlsberg-owned beer was aiming to elevate its position among international premium beers, while countering the threat of counterfeit beer products.

JDO was tasked with creating a more premium and modern design for the brand, retaining existing elements such as the label style and Baltika crest.

The result is described as a more contemporary, cleaner representation of Baltika 3. A deeper blue, an enlarged crest and a larger red hotspot all offer “a bold, confident and modern expression.”

JDO also added medal embossing around the neck to communicate brewing credentials and a strong ingredient story for the brand.

Paul Drake, JDO co-founder and executive creative director, commented: “The more defined structural profile delivers power, strength and masculinity to the brand, while the medal embossing and graphic detail cue authenticity and naturalness.”

Tatyana Chernaia, brand manager at Baltika, said: “JDO’s new design has succeeded in appealing to our existing loyal consumers as well as to a younger audience which will help establish opportunities for growth.”

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Coca-Cola HBC sets new sustainability targets

Coca-Cola HBC has published a series of seven targets to build on their initial sustainability commitments for 2020.

One of the aims to recover for recycling 40% on average of total packaging placed on their markets. Furthermore, they intend to source 20% of the total PET (polyethylene terephthalate) from recycled PET and/or PET from renewable material, as well as reducing the amount of primary packaging by 25% per litre of beverage produced.

These objectives form part of Coca-Cola HBC’s wider plan to reduce water and direct carbon emission intensity of the company by 30% and 50%.

Over the past few years, Coca-Cola HBC has reduced the global carbon footprint of its products by 1.07 tonnes through investment in energy efficient and low-carbon technologies. The company has also reduced its water usage by 2.1 billion litres. Last year, the company invested 2.3% of its pre-tax profit, or €8.2 million, to support community wellbeing, environmental, water stewardship and youth development.

Dimitris Lois, Chief Executive Officer at Coca-Cola HBC, said: “These are part of our overall strategy that established Coca-Cola HBC as a leader in sustainability among beverage companies, and show that we are determined to grow our business responsibly, profitably and sustainably.

“Coca-Cola HBC also focuses on offering its drinks in innovative packaging. By employing state-of-the-art technologies, we have introduced bottles which contain more than 50% recycled material. Further, our “Twist” bottles are 22% lighter than previous containers. PLANTBottle usage significantly increased by an outstanding 254% last year. PLANTBottles contain 30% plant based material, and are fully recyclable.”

Coca‑Cola HBC (Coca‑Cola Hellenic Bottling Company) is a bottling partner of The Coca‑Cola Company.

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New limited edition Absolut bottle designed by Ardagh Group

Luxembourg-based glass container manufacturer Ardagh Group has designed and produced a new limited edition bottle for vodka brand, Absolut.

The new range, Absolut Facet, will be launched at a global event in Amsterdam on the 19th October. Around two and a half million bottles of Absolut Facet, featuring an asymmetric design and new colour, were produced at the Ardagh plant in Limmared, Sweden.

Absolut global communications director Gaia Gilardini says: “With the Absolut Facet limited edition bottle, we want to celebrate the unexpected and encourage people be open to the different journeys a night could take you. To further demonstrate this, our latest #AbsolutNights campaign aims to inspire people to celebrate spontaneity and the connections you make along the way.”

Ardagh Group Sweden and Denmark glass development manager Fredrik Källqvist comments: “Each new project encourages us to raise the bar even higher and Facet is no exception. Bringing such a complex design into volume production required painstaking and very detailed preparation, as did replicating the colour to the highest degree of consistency across the complex design and to the required wall thickness.”

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PepsiCo faces US lawsuit over misleading packaging

PepsiCo are set to face a lawsuit in the US relating to its marketing of its Naked Juice range. They complainants allege that PepsiCo “misleadingly markets Naked Juice as predominantly containing high-value ingredients such as acai berry and kale, when the predominant ingredient is usually cheap, nutrient-poor apple juice.”

The Center for Science in the Public Interest (CSPI) claims that the drink’s packaging is misleading. They point to Kale Blazer, which features in the Naked Juice range as an example of this. The label features leaves of kale and cucumber slices. The caption reads “Kale is king of the garden” and the label also references the inclusion of cucumber, spinach, celery and ginger. The primary ingredient, however, in Kale Blazer is orange juice, with apple juice the third most common ingredient.

The CSPI says: “Advertisements for the product on social media and elsewhere similarly exaggerate the presence of kale in the product. Outdoor advertising for Kale Blazer has included statements such “have your kale and drink it too”, implying that the product is predominantly, if not exclusively, kale.”

The claimants in the lawsuit allege that, by naming these drinks after a food or ingredient perceived to be highly nutritious, PepsiCo are being “false and misleading because the ingredients do not have the ingredient profile represented.” Instead, say the claimants, the drinks are made up of cheaper and less nutritious ingredients.

For its part, PepsiCo completely refutes the claims. It says: “This is a baseless lawsuit. There is nothing misleading about our Naked Juice products. Every bottle of Naked Juice clearly identifies the fruit and vegetables that are within. For example, the label on our Kale Blazer juice accurately indicates each bottle contains 5 ¾ Kale leaves.”

The CSPI has filed a suit alongside law firm Reese LLP, in the US District Court for the Eastern District of New York this week, ‘on behalf of customers in California and New York’.

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Sacmi to provide labelling solutions for US bottler

label-1Italian company Sacmi is to provide its labelling solution to an undisclosed multinational bottler from the US.

As part of the deal, Sacmi will provide two of its Opera 300 24T automated labellers for the customer’s soft drink production facility.

Equipped with an automatic reel splicing system, both labellers are designed to help reduce maintenance requirements and offer downtime-free operation.

Capable of handling 30,000-60,000 bottles per hour, the UL certified labellers will help with the US company’s plant renewal and reorganisation plan.

Sacmi said that the labellers require cleaning only once per shift, thereby increasing productivity and reducing maintenance costs.

Featuring roll-fed technology, the selected Sacmi labelling solutions comply with US mechanical, electronic and electro-mechanical regulatory standards.

Sacmi recently provided plant engineering equipment for an Amin Tile-owned tiles factory in Iran.

Under the deal, Sacmi supplied four PH 3200 presses and machines for the plant’s firing department.

The company also provided new suction systems to ensure the plant’s compliance with environmental and emissions standards.

Meanwhile, Saudi Arabian production and packaging firm Almarai selected Sacmi’s roll-fed technology for its 2l milk and laban container production lines.

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Planinka selects Sidel Matrix bottling equipment for Prolom Voda facility

sidelSerbia-based bottler Planinka has selected a complete polyethylene terephthalate (PET) bottling line from Sidel for its Prolom Voda mineral water production facility.

Planned to be installed by October, the new 13,200bph line will be added to Planinka’s existing PET bottling manufacturing line for its Prolom brand.

The compact Sidel Matrix Combi features a Matrix blower SBO 6 and a Matrix Filler SF100 FM with 36 valves.

Integrating blow-fill-cap functions in a single unit, the Sidel Combi system enables lightweight bottles to be produced by a single operator.

The Sidel Matrix SBO blowers offers blowing stations in three sizes and up to 200 possible blower configurations.

The systems produce ultra-lightweight bottle in different shapes and sizes, ranging from 1l to 3.5l.

Equipped with high-efficiency particulate air (HEPA) filters, the contactless Matrix Filler SF100 FM helps prevent the filling environment being contaminated.

Planinka Prolom Voda head Dragoslav Ilic said: “As top producers in the beverage business, we are looking for great performance and the lowest possible total cost of ownership (TCO) from all our production lines.

“The main challenge of this particular project related to space constraints.

“However, Sidel’s line project team was able to offer the solution to fit all the component machinery needed for the line into the available space in a safe and functional way.”

In 2007, Planinka bought a blower, Universal SBO 6, from Sidel for its water bottling line at its facility in Prolom Banja.

In 1990, the company launched its bottled Prolom water in order to meet the demand for healthier drinks in the local and international market.

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Beverage packages: the perfect blend of individuality and efficiency

In the beverage sector, the packaging industry has to kill two birds with one stone. Firstly, consumers expect individually designed packages, if possible with supplementary functions. And secondly, increasingly eco-minded drinks consumers are showing a growing thirst for resource-conserving containers manufactured with environmentally compatible methods. The industry achieves this balancing act with new packaging strategies and efficient production equipment.

It is no longer enough for guests to bring their host a bottle of wine, sparkling or otherwise. The latest trend in gift packages involves celebrating the act of giving and stimulating the emotions with new materials and finishes. The companies in this segment develop cartons, folding boxes, baskets, wooden crates, decorative items and carrier bags so that gifts make a big impression. Bottles of wine are presented in exclusive gift boxes with the feel and appearance of real wood. Or the packages come with intriguing extra features – such as a miniature lamp shade for easily converting the empty bottle into a decorative table lamp. Exclusivity and diversity are all-important as far as gift packages are concerned.

What applies to this packaging segment is evident throughout the beverages market: selling just wine and beer in standard bottles is hardly capable of inspiring consumers any more. The selection of alcoholic, mixed and flavoured drinks and thus of ornate bottles as well has now become so vast that the consumer can afford to be choosy. Anyone who wants to take the consumer’s fancy has to have a product that stands out of the crowd at first glance. “There is a growing emphasis on packaging aesthetics – and hence on the emotions – and this is increasingly important in goods consumption. In a complex world, this applies all the more, as it saves time if decisions are taken not rationally but intuitively,” says Andreas Steinle of the Zukunftsinstitut (Future Institute), a think tank for trend and future research.

Noble brand evian is fully in line with current trends with its individualistic bottles. (Photo: Danone Waters)

Noble brand evian is fully in line with current trends with its individualistic bottles. (Photo: Danone Waters)

Top trends: individuality and differentiation

For example, the mineral water brand evian, which is owned by Danone Waters, goes to huge lengths to highlight the uniqueness of its products. For its prestigious plastic bottles, it exploits the new Nature MultiPack technology, a packaging innovation that uses specialised adhesives to join the individual PET bottles together in such a way that they can be individually positioned and later released from the others with ease. In the design field, Danone is also going unusual ways. Since 2008, evian has issued nine Limited Editions of mineral water bottles styled by well-known fashion designers. In 2016, the American couturier Alexander Wang has taken up the barcode as a package theme and rendered it with black-and-white stripes on the glass bottles. The spaces between the stripes and the purist design are intended to express evian’s natural purity. But individuality and differentiation are highly popular not only among upmarket brands, as a growing throng of drinks manufacturers are marketing their mineral water and lemonade additionally in smaller, 0.5 litre returnable bottles to appeal to smaller households. Or they sell their product in elegant faceted bottles to improve their chances of selection by high-class restaurants, for example.

The benefits notwithstanding, lavish packages do have their drawbacks. The greater the individuality and complexity of the product’s packaging, the more elaborate and expensive its production. The higher production costs are ultimately passed on to the customer in higher prices – a point that consumer activists often criticise. What is more, elaborate production methods and disposable bottles burden the environment. To minimise the impact, some countries have set in some cases ambitious targets for bottle reuse. Germany, for example, wants to achieve an 80 per cent reuse rate, although this has fallen since 2004 from two thirds to 45 per cent. At the same time, the quantity of waste from one-way drinks packages has since increased by 30 per cent. According to current statistics from the German Federal Government, package consumption rose from roughly 465,000 tonnes to 600,300 tonnes in 2014. Retailers and manufacturers are regarded as the instigators of this single-use boom. In the mineral water sector particularly, price wars are taking place in drinks markets and supermarkets, but the special offers only work with single-use bottles, as the collection, cleaning and refilling of plastic bottles is a costly process. Among other things, politicians are therefore demanding the development of the single-use deposit into an environmental steering charge on one-way packages and the extension of the obligatory deposit to juices and nectars.

Demand for resource-efficient packaging technology

Packaging manufacturers are also under an obligation. They have to achieve the balancing act of spectacularly presenting the package with a consumer-friendly design while conserving raw materials and thus easing the burden on the environment. The requirements that have to be met by packaging machines are therefore becoming more exacting as well. “Treating natural resources responsibly and doing business in an environment-friendly way have high priority among manufacturers of food processing machines and packaging machines. They know that sustainable production processes are hugely important for their customers,” says Vera Fritsche, expert at the VDMA (Mechanical Engineering Industry Association) association for food processing machines and packaging machines. Intelligent control and automation technology and energy-saving drives, compressors, fans and pumps rank, she claims, rank among the classic solutions for saving power and other resources and boosting energy efficiency. Efficient motors perfectly adapted to the machine’s motions and acceleration processes reduce power consumption. In addition, Fritsche continues, innovative and improved processes lower the consumption of energy and water while innovative machine strategies extend service and maintenance intervals and service life and thus save energy.

At interpack 2017 in Düsseldorf from 4 to 10 May 2017, visitors can find out about the strategies and products that companies are adopting to meet market requirements. The accompanying “components – special trade fair by interpack”, held for the first time in 2014 and taking place again with a revised concept at interpack 2017, also offers interesting insights into the latest production technologies. “components” is mainly targeting component suppliers to the packaging industry and companies offering drive, control and sensor equipment, products for industrial image processing, materials handling equipment, industrial software and communication, and complete automation systems for packaging machines. Manufacturers of machine parts, components, accessories and peripheral equipment are also being addressed, as are producers of components and auxiliaries for packaging materials.

Upcycling – second life for packages

The versatile lid of the True Fruits smoothie bottle can be unscrewed and replaced by a salt sprinkler or tea strainer attachment. Customers appreciate opportunities for upcycling. (Photo: True Fruits)

The versatile lid of the True Fruits smoothie bottle can be unscrewed and replaced by a salt sprinkler or tea strainer attachment. Customers appreciate opportunities for upcycling. (Photo: True Fruits)

The example of smoothie manufacturer True Fruits demonstrates that environmental protection in the drinks industry has now become a key factor and can even be turned to one’s own advantage. Unlike many other manufacturers, the company markets its drinks not in plastic bottles, but in ceramic-printed, cylindrical 250 and 750 millilitre glass bottles in order to communicate the values of honesty, purity, high quality and transparency that go with the purist design. To ensure that the bottles are not simply discarded into the bottle bank after consumption of their contents, the True Fruits team has given the matter of bottle reuse a good deal of thought. The solution they have come up with is what is known as “upcycling”, where the used object serves as the basis for a new product. True Fruits has developed attachments that are simply fitted to the tops of the emptied bottles: at present, the company is offering durable tops, a sprinkler for sugar, salt and spices, a pourer for oils, vinegar and sauces, and a tea strainer. The combination of vitamins, extravagance and sustainability is evidently appreciated by customers: True Fruits is currently one of the market leaders with smoothies.

Bio-plastics are another avenue for sustainable beverage packages. Last year, Coca-Cola unveiled its new PlantBottleTM generation made entirely of renewable resources and announced market launch in the near future. These bio-based materials of its “first generation” are to be produced in the long run from biomass, e.g. from wood wastes. In a research project, scientists at the University of Hohenheim are testing another promising natural resource as a bottle material – chicory root, used until now for the production of biogas. The inedible root amounts to 30 per cent of the plant. From it, researchers are obtaining unpurified hydroxymethylfurfural (HMF) which can be used for the production of PEF bottles.

Innovation potential in production

However, quite a bit of development work will be required before plant-based bottles succeed the currently widely used PET bottles. All the same, big potential for cost savings can be found not only in the materials sector, but also in production equipment. Industry is therefore doing all it can to improve production methods. An example of this is the Doğuş Çay tea factory in Izmir equipped by Krones. In 2015, at its Ödemiş site in Izmir, the Turkish company commissioned a NitroHotfill line from Krones with an output of 22,500 containers per hour. A year after installation, a Krones team on site at the line launched tests to improve the compressed air system. After an upgrade and simple optimisation of the Contiform 3 blow moulding machine, the line went back into normal operation. A test run has achieved extraordinary results, the company claims. With unchanged container quality, this modification has achieved 44 per cent savings in compressed air consumption. The upgrade yields cash savings amounting to some EUR 40,000 per year based on a calculated machine running time of 6,000 hours per year.

One of a kind: the direct printing of bottles is an effective way of appealing to customers with individualised designs. (Photo: KHS)

One of a kind: the direct printing of bottles is an effective way of appealing to customers with individualised designs. (Photo: KHS)

The Dortmund company KHS is also showing that the innovative potential of production equipment is still far from fully exploited. The company Mineralbrunnen Teinach GmbH has been using the KHS stretch blow moulding machine InnoPET Blomax Series III for the production of PET bottles since 2007. To cut the line’s energy consumption, the KHS experts have modified its heater box in which the PET preforms are heated for subsequent stretch blowing. For Mineralbrunnen Teinach GmbH, this has yielded over 40 per cent energy savings – savings made possible essentially by the use of new, advanced ceramic reflectors and precision-adapted geometry in the heater boxes, explains Frank Goebel, Head of Service Engineering at KHS. Thanks to the special design, the physical properties of the ceramic elements have had a markedly beneficial effect on energy distribution, so less energy is needed to heat the preforms. In addition, the reflectors and infrared radiators have been conPhotod in such a way that the bottle’s delicate thread zone is not unnecessarily heated. The cooling of this area can be reduced, says Goebel, thus saving further energy in Teinach. “Thanks to greater efficiency, it is often possible to shorten the heating section,” he adds. If fewer heating elements are necessary in the oven, energy consumption by the infrared radiators also drops as a consequence.

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Ardagh Group launches two new amber glass beer bottles

us-beerLuxembourg-based glass container manufacturer Ardagh Group has unveiled two new 500ml amber glass beer bottles.

Made in the US, the new EURO and Vichy bottles are provided in Natural Kraft 12-pack cases with partitions.

Both of the fully recyclable bottles will be made available for sale on Ardagh Group’s BOB site.

Ardagh Group sales vice-president John Orr said: “BOB listened to craft brewers when they asked for alternative glass packaging options for their brews.

“The addition of the 500ml EURO and 500ml Vichy bottles provides an expansion of our bottle portfolio to offer craft brewers increased flexibility for their offerings.

“The old-world design of these 500ml bottles adds to the overall enjoyment the drinker has when they pry open one of their favourite brews.”

The company’s BOB platform enables craft brewers to buy glass beer bottles by the pallet directly from the manufacturer.

With the addition of the two new bottles, the BOB site will now offer eight different amber beer bottles, which include two 12oz bottle styles, a 22oz bottle, two 750ml bottle styles and a 64oz bottle.

Ardagh Group has been producing innovative glass beer bottles in the US for more than 125 years.

Last month, Germany-based herbal liqueur brand Jägermeister unveiled a new range of limited edition bottles, manufactured by Ardagh Group at its glass factory in Nienburg, Germany.

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Limited Edition Jägermeister Bottles by Ardagh Group

BottoleHerbal liqueur brand Jägermeister has unveiled a new range of limited edition bottles, which have been manufactured at Ardagh Group’s glass factory in Nienburg, Germany.

Part of the 0.7l Jägermeister square bottle range, the new collection comprises 800,000 bottles in 18 different screen printed versions.

Print and coating specialist PSL Hehlen is also involved in the project.

Jägermeister purchasing and materials management head Carsten Doliwa said: “We are delighted with the end result of this latest packaging innovation for our brand using directly printed decoration.

“Our close cooperation and teamwork with Ardagh and PSL Hehlenon this complex process was crucial.”

The new printed versions include the flags of nations that took part in the 2016 European Football Championships in France, and will be only be sold in those countries.

The company noted that highly pigmented and customised organic UV inks have been used to screen-print the flags directly onto the surface of the square green bottles.

Designed to have a good shelf presence, the newly launched bottles also feature a glossy surface and sharp edges.

Last month, Ardagh launched a range of 187ml wine bottles to meet the growing demand for wine miniatures.

The company offers 150 standard wine bottle designs in a range of more than 12 different colours.

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Kosme 3Bloc – Block Configuration Featuring Three Machines

The trend towards combining several units to form a single machine continues unbroken, for quite a simple reason – the advantages this offers to the users far outweigh the disadvantages involved. In the shape of the 3Bloc, Krones’ subsidiary Kosme has now presented its first concept for a block configuration featuring three machines available in two different variants – one for PET and one for HDPE containers.

3Bloc For PET Containers

This consists of the following three concatenated machines:

  • blow-moulding machine
  • filler
  • labeller
    • either for applying pressure-sensitive labels
    • or for reel-fed wrap-around labelling.

This configuration is suitable both for cylindrical or square PET bottles and for special-shaped containers. The maximum output is 16,000 bottles an hour.

3Bloc For HDPE Containers

This consists of the following three concatenated machines:

  • unscrambler
  • filler
  • Labeller.

The unscrambler is tasked with putting the already-blow-moulded HDPE bottles in an upright position before they reach the filler and here takes the place of the blow-moulder needed for PET containers. This 3Bloc variant can handle up to 25,000 bottles an hour.

The 3Bloc concept has been based on technically sturdy components, and when compared to a layout featuring individual machines scores highly in terms of its substantially lower energy consumption, its higher efficiency and its enhanced user-friendliness. Needless to say that the block configuration also benefits the machine’s footprint, plus the capital investment and operating costs involved. No intermediate conveyors are needed, for example, and the times required for format change-overs and maintenance routines are shorter as well.

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New Home For S.Pellegrino

S.Pellegrino, the world’s leading sparkling mineral water, has decided to reshape its bottling plant in San Pellegrino Terme, Italy, where the source is located. Starting in 1899, S.Pellegrino has always been ahead of its time, and is now looking for a project that not only conveys an artistic vision, but also set new standards in terms of efficiency and compliance to environmental sustainability, all while providing a favorable working environment.

Thus, the decision was taken to launch an international-scale tender to secure a truly innovative and futuristic project by involving four of the world’s most distinguished architecture firms: NY & Copenhagen’s BIG (Bjarke Ingels Group), the Dutch MVRDV, the Oslo & NY based Snøhetta and Italy’s Michele De Lucchi.

This leap forward is also a testimony of S.Pellegrino’s commitment to its terroir, the place where everything started, and a relevant contribution to bring San Pellegrino Terme back to its golden age, at the height of the Belle Époque, when the town was an exclusive society rendez-vous for European aristocracy.

On September 15th, the four projects will be presented to a Judging Committee, coordinated by Professor Luca Molinari, Architecture Consulting & Curatorship, curator of the tender. The Committee will be composed by, Marco Settembri, Executive Vice President Nestlé, Head of Nestlé Waters, Magdi Batato, Executive Vice President Nestlé, Head of Operations, Stefano Agostini, President & CEO of Sanpellegrino and international personalities will be invited to join in.

“I am particularly proud of this project,” says Stefano Agostini, President and CEO of the Sanpellegrino Group. “With it, we intend to further promote the quality, uniqueness, international nature and the territory of origin of S.Pellegrino. Our brand is one with a rich history that is deeply-rooted in Italian tradition, which is recognized worldwide for its elegance, taste and excellence. We have invited four architecture studios of international stature to take part in this tender to design the home of S.Pellegrino mineral water, which is to become the signature of our Group, welcoming visitors from all corners of the world”.

By the end of September, S.Pellegrino will announce the winning project and its timeline.

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E&J Gallo launches 35cl format of New Amsterdam vodka

NewAmsterdamVodkaE&J Gallo Winery has launched in the UK a new 35cl format of New Amsterdam vodka, a five-times distilled and triple-filtered premium USA vodka brand.

The 35cl category holds a 13% share of all vodka sales in the UK and is growing steadily at 2%, E&J Gallo said, meaning the new size will be a natural addition to its New Amsterdam Vodka range. It joins the existing 20cl, 70cl and recently launched 1 litre formats.

The launch of the 35cl bottle continues to raise the profile of New Amsterdam vodka in the UK alongside the It’s Your Town campaign, which will reach over 14 million consumers in 2016, the company said.

David Mallory, UK channel director, impulse and on trade for E&J Gallo Winery, said: “Following its huge success in the US, New Amsterdam vodka has firmly established itself as a key player in the UK market. The addition of a 35cl size to the range will offer retailers the chance to capitalise on the growth of smaller pack formats across all spirits categories.”

The new 35cl format has been made available in the impulse and convenience channels with a recommended retail price of £8.99. The launch will be supported with promotions in cash and carry outlets throughout the summer.

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Purely Sedona adds lightweight PET bottle

Purely-Sedona-photo-2Artesian spring water product, Purely Sedona, has been launched in lightweight PET containers designed by ScorCreative, the structural design studio co-located at plastic packaging manufacturer Amcor Rigid Plastics.

The 500ml and 1 litre proprietary bottles deliver “a highly attractive and eye-catching look which differentiates Purely Sedona from competitive products in the highly competitive premium water category”, Amcor said.

Sedona Bottling already offers the premium spring water in glass but sought to create a PET bottle family as well for certain venues, according to Cady Gokey, president of Sedona Bottling Co. In collaboration with ScorCreative, Sedona Bottling undertook a rebranding of an existing stock PET bottle.

“We wanted a package that looked like glass and had the same performance,” said Gokey. “PET bottles are a necessary option in certain venues like tourist events, pools, schools, hotels, and restaurants, thus allowing the brand to be more accessible.”

Purely Sedona originates from a protected artesian spring in the Oak Creek Canyon in Sedona, Arizona. The water that emerges from the canyon is naturally purified, yet it retains the trace minerals and electrolytes that set it apart from competitors, according to Sedona Bottling. The water’s natural filtration process eliminates contaminants while retaining key minerals that deliver better flavour and nutritional benefits, it said. Oak Creek Canyon water also has a natural pH of 8, making it naturally less acidic than other spring water, and that perfect balance – enhanced by a proprietary filtration and ozonation process – allows the water to help detoxify the body while supporting optimum health and vitality.

ScorCreative focused on a medicinal style design to showcase the purity and healing properties that are said to be derived from the spring water. The novel retro design is tall and sleek and similar to a Boston round-style bottle. The glass-like container incorporates a 28mm black closure to convey the look of an old-time pharmacy tonic bottle, Amcor added.

The ScorCreative design team worked closely with Sedona Bottling to meet its branding requirements while also satisfying engineering demands surrounding the base, shoulder, and stacking issues.

“ScorCreative did a phenomenal job of converting the glass bottle into PET,” concluded Gokey.

 

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ACMI’s new communication campaign: Bottle in Wonderland

PicACMI has launched a new communication campaign to present the line of systems for multipacks: Easypack and Easymax. With the collaboration of the illustrator from Parma Camilla Locatelli, a fantastic story was created through a series of animated gifs.

The protagonist of this story is a PET bottle in search of a new type of packaging as an alternative to the usual old-fashioned 3×2 packs. On a journey that will lead it to the most beautiful places on our planet, the bottle will come to understand that a new concept of packaging is not only possible but has already been achieved thanks to the innovative capacity of ACMI.

What this system is and the way in which the protagonist of the story becomes aware of it cannot yet be revealed. However, you can have a foretaste of it by clicking here: www.acmispa.com

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Coca-Cola Sabco opens new bottling plant in Mozambique

CocaColaChinaSouth African-based beverage company Coca-Cola Sabco has opened a new bottling plant in Matola Gare, Mozambique, with an investment of $130m.

The plant is part of a ten-year, $17bn investment plan by Coca-Cola in Africa, where it currently employs more than 70,000 people across 145 bottling facilities.

Coca-Cola chairman and CEO Muhtar Kent said: “We have continued to increase investment in our business in Africa and are proud to be one of the largest employers across Africa as well as Mozambique.

“This facility, which is proudly operated by our local partners from Coca-Cola Sabco, is the latest example of our continued commitment to refresh African consumers, while at the same time creating opportunities for enterprise and employment along our supply chain.”

The new green-field facility is equipped with modern energy, waste water recycling and building management systems.

It is the largest facility that Coca-Cola Sabco has developed across its seven-country market in Southern and East Africa.

The new Mozambique plant has 400 full-time employees and two bottling lines, including one for glass bottles and another for PET plastic bottles.

A third line for glass bottles could be added to the plant in the future.

The Coca-Cola Company, along with Ericsson, Medshare, Pentair, Philips, Solarkiosk and TIGO Rwanda, recently opened an ekocenter site in Ruhunda, Rwanda.

The solar-powered site will benefit up to 25,000 local residents with access to services, such as Wi-Fi, mobile charging, a retail store, a fully lit football field outside Rwanda’s capital of Kigali, improved medical resources and purified water.

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Union and Climeworks are joining forces in CAPDrinks project

UntitledFunded by the Eurostars programme a project between Swiss company Climeworks and Danish Union Engineering is taking shape. The objective of the proposed project is to develop a standardized, competitive, low cost, modular, standalone, and onsite plant for delivery of beverage grade CO2 to bottling companies.

The CO2 stems majorly from atmospheric air and is in a first step concentrated to 99.9% by a Climeworks direct air capture (“DAC”) plant.

In a second step CO2 is purified and liquefied (“conditioning”) to achieve beverage grade CO2 purity by Union technology.

Climeworks provides solutions for efficiently capturing CO2 out of ambient air and hence offer a competitive and environmentally friendly CO2 supply to the customers. The upcycled CO2 can be used in the food and beverage industry, as a feedstock for production of various chemicals as well as it enables the production of carbon-neutral renewable fuels allowing for efficient storage of renewable energies.

Union Engineering is a world-class engineering company, specialized in sustainable technologies for capturing, recovering and purification of carbon dioxide. Main activities are engineering, procurement, construction and maintenance of modular and individually designed CO2 plants.

The joint project started March 2016 with a duration of 18 months. The project budget is €1,070,580.

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Acqua Lete’s 40,000 bph Compact Line

At the plant in Pratella, a few kilometers away from Caserta (Italy), Acqua Lete SpA, one of the most famous Italian brands of mineral water and main sponsor of SSC Napoli, purchased from ACMI a compact line with a nominal filling speed of 40,000 bottles per hour. The line in question can handle both round 1.5 L. bottles and square 2 L. bottles, with which, however, the speed drops to 36,000 bottles per hour. The compact line concept proposed by ACMI is enjoying great success among mineral water bottlers that are looking for a product with increasingly good performance and efficiency.

The “Compact Line” Concept

The “Compact Line” represents a new bottling concept in which the production line mainly consists of two highly efficient blocks: the filling block and the packaging block. To date, ACMI is the only company able to design and build a so-called “compact” system because it is the only company that designs and builds with the same high technology all the machines that make up the part of the line dedicated to packaging. The application of this innovative concept produces advantages in terms of efficiency, reduction of space, management costs and TCO, assembly and start-up times.

Fenix shrink wrapper with automatic film changeover.

Fenix shrink wrapper with automatic film changeover.

A Single Accumulation Table

The “Compact Line” requires only a single accumulation table placed between the filling block and the packaging block. This detail provides a simple precaution to harmonize any fluctuations in the production that may concern the two blocks. With this solution, the “Compact Line” proves to be suitable to handle any type of PET container, especially thin-walled bottles and square bottles of still water, because the pressure exerted is very limited.

Labeller/Shrink Wrapper Synchronism

From a technical point of view, if the labelling of the bottles is not performed within the filling block, it is necessary to apply an electronic synchronism between the labeller and the Fenix shrink wrapper. This synchronism, which is possible thanks to the use of specific algorithms processed by ACMI, makes it possible to manage the production speed oscillations of the labeller and shrink wrapper and eliminates the need for any intermediary accumulation table. With the application of the “Compact Line” concept, these two machines work synchronously reaching very high efficiency values.

Twisterbox layer formation system.

Twisterbox layer formation system.

Automatic Feeding

For the “Compact Line” concept to be applied it is necessary for all the packaging block machines to share the same technology and the same level of efficiency. Moreover, they must all be equipped with automatic consumable material feeding and changeover systems, since it is essential for the continuity of operation of all the components of the line to be constantly guaranteed. Precisely for this reason the Fenix shrink wrapper is equipped with the external reel carrier box and the automatic (continuous) film changeover, the Viper two-lane handle applicator is built with an electronic spacing system (which avoids the use of spacing screws) and is equipped with the automatic handle joining system, the Thunder palletiser with the Twisterbox® continuous layer formation system is designed with automatic interlayer and pallet feeding systems, and the Rocket model rotating pallet stretch wrapper is equipped with an automatic pre-stretching unit changeover system which ensures perfect continuity of operation.

The Compact Line Operator

The “Compact Line” is a highly automated system that requires only one operator for each block. The operator of the ACMI end of line block mainly has to deal with feeding the automatic stores by loading consumable materials. That’s all.

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Evian to roll out new pack technology

evian_multipackNMP Systems partnered up with Danone Waters to roll out its Nature MultiPack technology across bottles of Evian in France and Belgium.

The technology, which consists of the bonding together of PET bottles with specially developed adhesives, will make its debut this month. Convenient handles and individual bottle orientation effectively convey marketing messages, NMP Systems said, while the pack is designed to endure transportation and merchandising logistics while remaining easy for consumers to separate bottles from the pack.

Compared with paperboard, shrink film and plastic ring based multipacks, Nature MultiPack uses dramatically less packaging material and delivers a premium look and feel, the Düsseldorf-based KHS subsidiary said.

Danone Waters global engineering vice-president Frederic Maetz said: “Our leadership committed immediately to the partnership and earned first-in-market advantages. Danone Waters R&D, engineering, industrialisation, quality, and marketing people enjoy working closely together with the dedicated people from KHS and NMP Systems.”

Professor Niemeyer, chairman of the executive management board for KHS, continued: “Disruptive innovation is an important part of our strategy at KHS, as well as within the Salzgitter group of companies. Nature MultiPack will change the future of packaging. With this innovation, we have reinvented ourselves. After introducing the world to shrink packs over 50 years ago, with this packaging we are again proving to be successful with a market-defining hit.”

 

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Schweppes highlights heritage with new labels

Schweppes-line-upBeverage brand Schweppes is revamping its pack design in a bid to showcase its “premium credentials”.

Schweppes 1 litre mixers will feature new black labels, designed to demonstrate the brand’s heritage. According to the brand’s owner, Coca-Cola Enterprises, the new design is also “peppered with adult wit and humour” and is aimed at consumers aged 30-plus.

The new packs are supported with point-of-sale, cinema advertising and a digital campaign.

Simon Harrison, commercial director, Schweppes and new brand development at Coca-Cola Enterprises, said: “Schweppes is an iconic brand that will benefit from a bold new look that drives home the brand’s unique heritage, distinctive sharp taste and premium quality. Many people are not aware that the founder of Schweppes actually created the art of bottling the bubble, and the brand has been perfecting the product since then to make it a proven consumer favourite.

“With mixers performing well, we have impressive plans for Schweppes this year, and this is the first in a line of activations that will encourage trial and build brand loyalty by emphasising Schweppes taste preference, distinctive British style and sharp sense of humour.”

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Dr Pepper to release limited-edition label designs

dr_pepper_designDr Pepper is to release hundreds of “one of a kind” label designs for its 20oz bottles, as it debuts a new summer marketing campaign.

Pick Your Pepper will “celebrate millennial self-expression and gives Dr Pepper fans a chance to let their individuality shine every time they grab a bottle,” the soft drinks brand said.

The label designs are inspired by various millennial types – including retro fans, cat lovers, vinyl collectors, fashionistas and gamers – and consist of brightly coloured.

Every case of Dr Pepper regular delivered by bottlers to retailers will feature a unique combination of designs. The new labels go in market this June and will be supported with social, digital and traditional media.

“Individuality is a trait that Dr Pepper has always celebrated and, like our consumers, each of these new labels has its own unique personality,” said Derek Dabrowski, director of marketing for Dr Pepper. “Dr Pepper is known for its one-of-a-kind flavour and this campaign brings that to life and encourages fans to do the same with each drink.”

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Expansion of Europe’s Largest Wine Bottling and Distribution Facility

Accolade Wines, the leading global new world wine company, has officially opened a £8.5 million bottling line at Accolade Park, Europe’s largest wine warehouse and distribution centre in Bristol, England. The new sixth bottling line means the state-of-the-art facility can fill 1200 bottles of wine every minute. Thirty new jobs have been created taking the onsite workforce to 500. The supply chain that enables wine to be delivered to the consumer employs nearly 3000 people – including glass, carton and label manufacturers as well as logistics experts, haulage workers and sales teams.

Accolade Park is one of the businesses that comprise the wider UK production network producing around 600 million bottles, nearly one third of all wine consumed in Britain each year.

The facility, which last year was recognised as ‘World Class Manufacturer of the Year’ in the Manufacturer MX Awards against competitors including Rolls Royce and Siemens, delivers quality, value and better environmental outcomes through bottling wine from around the world in Bristol.

Paul Schaafsma.

Paul Schaafsma.

Shipping in volume halves the transportation greenhouse footprint as a container can carry 25,000l of wine, compared with 10,000l transported as pallets of bottles. Volume shipping and bottling in the UK allows lighter, recycled glass to be used, rather than the heavy glass needed for long-distance shipping, delivering additional environmental benefits.

Paul Schaafsma, chief executive of Accolade Wines, says: “Accolade Park is the lynchpin of Accolade Wines’ European marketing strategy allowing the business to deliver quality, reliability, flexibility and range to its customers in the UK and in mainland Europe. Accolade Park allows our business to provide leading brands such as Hardys, Mud House, Viña Anakena, and Stowells– all from one world-leading facility. The facility is critical to our ability to deliver quality wines and packaging innovation to the major retailers in the UK and our customers across Europe.”

Accolade Wines is one of the world’s largest wine companies, delivering over 35 million cases to 143 countries. It is the largest wine company in the UK with a 13% share of the market. Brands include Hardys, Echo Falls, Kumala and Stowells.

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Nampak Plastics creates 20 jobs investing in Springkerse plant

NampakWebOne of the UK’s leading producers of plastic packaging, Nampak recently concluded a lease on 6,100sqm of industrial space at Springkerse Industrial Estate to manufacture a range of plastic milk bottles, creating 20 new full time jobs.

Nampak has been manufacturing in Scotland for a number of years from its plant in Bellshill.

Eric Collins, managing director of Nampak Plastics Europe, said the decision to invest in the area was driven by the business opportunities that exist in Stirlingshire within the food and drink sector, the unrivalled accessibility to Scottish market places and the proactive approach taken by Stirling Council in the site identification process.

One of Nampak’s key Scottish customers, Graham’s The Family Dairy, intends to finance the new facility – which would be supplied by Nampak – via the Airthrey Green housing project.
Collins said: “The business climate in Stirling, the enthusiasm of local people and the professionalism of Stirling Council has provided us with the confidence to open our latest European plant in Stirling. We’re now looking forward to working with partners in the area to expand our manufacturing operation.

“Looking forward, the new dairy project planned for Hill of Drip would enable a step change in our investment in Stirling, allowing us to create 40 further new full time jobs, in addition to those created by Graham’s The Family Dairy.”

However, some reports say development on the site requires planning consent, which Stirling Council is expected to rule on later this month.

Nampak Plastics is the UK’s leading producer of plastic milk bottles, with 600 staff and nine sites across the UK, producing around two billion bottles annually.

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Purity’s Juiceburst new branding design

APPLE_CORE_ON_WTPurity Soft Drinks has undertaken a major update of its Juiceburst brand of drinks, with a new bottle design and more prominent logo enhancing the range’s promise of a full portion of fruit in every bottle.

The company has also revised the contents of the bottle, cutting the amount of added sugar by 20% across the range, equating to a 40% added-sugar reduction in three years after the changes it made in 2013.

following the changes made in 2013. At the same time, taste scores are improving as research from independent consumer panel tests show. No mean feat – and one that the business is proud to have achieved.

Juiceburst has seen growth of 20% in each of the last two years and latest figures suggest that the brand is proven to grow the juice and juice drink category, with retailers who stock the range seeing an average category growth of 22% against those that don’t.

Purity Soft Drinks CEO David Bell said: “We are not afraid to take risks and take on challenges, a great example being the Schools Approved range. We had just 12 weeks from idea to launch to get the product out there in the market. The industry needs change and we are helping to drive this. We have relaunched with what we believe is a better-for-you soft drink, whilst still delivering great taste to our key consumer.

“A key point of difference is our use of technology. Juiceburst is the world’s first digitally interactive soft drink brand – all packaging is interactive, meaning consumers can find out more about the product and play games using the Blippar app. This really appeals to our target audience, who are the generation of technology.

“Our aim is to cut the added-sugar by a further 10% come 2017 and we have just began to produce a multi-pack of our Schools Approved Juiceburst range for the lunchbox market. Around half of all school meals are taken as a packed lunch, so this represents a good opportunity for us and the retailers.”

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Bodega Matarromera has developed the first PLA wine bottle designed by AIMPLAS

botella MatarromeraBodega Matarromera has successfully completed the development of a new sustainable bottle for their wines. It is a packaging manufactured from bioplastic, specifically PLA, and it is the first bottle manufactured with this material to reproduce the design of traditional glass bottles for wine, with some main advantages: it is lighter (50 grams) fully-recyclable and has a lower environmental impact in its manufacturing process.

AIMPLAS, the Plastics Technology Centre, has been subcontracted by Bodega Matarromera among this project to design the new sustainable packages, as well as the preform mould and the blowing mould of these sustainable bottles. Then, it has also carried out the characterisation of the new packaging that, thanks to an inner coating with silicon oxide it has been noted a considerable improvement of the permeability to different gases.

This project has counted on the funds of the programme EEA GRANTS, funded by Norway, Iceland and Liechtenstein, as well as by the Ministry of Science and Innovation from Spain through CDTI. The research is framed within the company’s commitment with environmental sustainability, what will allow a differentiation and increase of competitiveness in new markets with a high environmental awareness as well, as the Nordic countries and specifically the Scandinavian airlines.

matarromera fabricaciónAIMPLAS, the Plastics Technology Centre is located in Valencia, Spain and is recorded at the Register of Technological Centres of the Spanish Ministry of Economy and Competitiveness. The institute is member of FEDIT (Spanish Federation of Innovation and Technology Entities) and REDIT (Network of Technological Institutes of the Valencia Region).

AIMPLAS is a non-profit research association with the object to operate as a technological partner for enterprises from the plastics industry and thus offering them integral and customized solutions by coordinating research, development and innovation projects as well as technology services (analysis and testing, technical assistance, formation as well as competitive and strategic intelligence).

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Celtic Pure Plans €5 Million Plant Expansion

Celtic Pure, the Irish mineral water company, has unveiled plans for a €5 million new bottling facility at its plant, located on the outskirts of Corcreagh in County Monaghan. The new development will create up to 60 new jobs during the construction phase of the expansion, as well as securing the future for the 50 people currently employed at the facility.

Padraig McEneaney (pictured), chief executive of Celtic Pure, comments: “The investment in our facilities will further create 25 plus new jobs, increase our annual production capacity by 65% and see our annual turnover rise twofold by 2017. Our target is to bring the business to the stage where we can target sales of €18 million to €20 million.”

He continues: “We’ve come a long way since 2000, with only two employees, supplying local customers with water in 5 litre drums. This investment is a tremendous vote of confidence in our staff who have produced and sold record volumes of bottled water last year, in Ireland and worldwide via indirect exportation to China, United Arab Emirates, USA and Australia.”

The new development will commence construction on 12 acres of adjoining land to the current premises in May of this year. The state of the art 6,600 sq m warehouse will house a technologically advanced management and tracking system, new bottling lines and additional office space for the company’s expanding workforce.

The investment will see a C02 machine with dosing unit installed which will accommodate the addition of flavoured water to the Celtic pure product range by 2017. A glass bottling line will also be installed to provide glass bottles to the food service industry with production due to commence in 2018 with an estimated 10 million glass bottles to be produced per annum.

The WCS (warehouse control system) and WMS (warehouse management system) will allow the automated packing and transfer of pallets from the production lines to the storage area via a line of robot palletisers which has output speeds of up to 7 cycles/minute. The computerised system, will ensure the latest in end-to-end traceability of each pallet using intelligent self-diagnosis and control systems of machines’ functions.

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Grolsch appears in ‘modernised’ bottles

Cartils-Grolsch-Design-2016Branding and packaging design consultant Cartils has redesigned Dutch beer brand Grolsch’s primary and secondary packaging to bring its new brand platform, Unconventional by Tradition, to life.

Cartils has simplified and modernised Grolsch’s packaging while retaining the recognisability of the brand’s strong legacy and authenticity. Cartils simplified the logo design and made it more contemporary by removing the outline and shading effects and by using a more “serious” green, it said. The red heritage mark has evolved to convey the Grolsch Unconventional by Tradition brand story, two hops and a swingtop. The icon has also been made more prominent on pack with “elements of discovery” incorporated too.

The circular main shape has been simplified in an effort to connect to the past, and to the origin of the swingtop, while layered lines and storytelling details emphasise the lager’s premium cues. The white-based colour is more refreshing and differentiated, yet ensures beer-cues, Cartils said.

The secondary packaging has been given added authenticity, with both “craftsmanship and artistry” and “unconventional by tradition” supporting texts providing a confirmation of Grolsch’s soul and spirit.

“The new design,” Netherlands-based Cartils said, “is connected to the past, showing 400 years of authenticity but in an up-to-date interpretation.”

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Stephenson Innovation’s SUSTAIN® series reduces fobbing to deliver greater bottling productivity.

Environmental concern is driving major transformation in the global food and beverage sector, which faces enormous financial and operational risks as more sustainable solutions are increasingly in demand. Producers are adopting a more proactive approach to reduce environmental impact and mitigate risk across the supply chain – from grower, to manufacturer, to consumer.

At Stephenson Group, we assume a proactive approach too – with sustainability and innovation at the heart of what we do. It drives our operational strategies, research, and new product development activity. We proactively understand market trends, and are agile in our ability to adapt to, and meet customer needs.

Stephenson Innovation is a specialist business unit, focused on research and development for innovative new specialty chemicals products, and bringing these products to market in collaboration with our commercial and technical teams. The SUSTAIN® series is the first product range to have been developed within Stephenson Innovation’s portfolio; a range of patented non-silicone derived processing aids designed to optimise filling speeds in carbonated beverage manufacture.

The problem:
Carbonated drinks that are prone to excess fobbing (‘foam’) are bottled at a much slower rate; because the speed affects the amount of fob, thus affecting the profitability of the bottling run, explains Jonathan Stott, business manager for Stephenson Innovation’s SUSTAIN® series: “Fobbing can cause overflow at the point of filling, meaning the packaging requires external rinsing. This increases maintenance costs and uses more water. Not only that, production is less efficient due to slower line speeds. This increases processing time, and reduces productivity”.

How SUSTAIN® works:
The SUSTAIN® series is designed to safely and efficiently reduce the amount of fob created during the bottling process, by retaining CO2 in the carbonated beverage. Unlike silicone antifoams which are surface active; SUSTAIN® works in the bulk of the liquid, coating the micro bubbles and preventing them from joining together to form larger bubbles, leading to more foam.

This delivers four core benefits:

  • 25% average increase in filling speeds, leading to better and more consistent filling, increased yields and fewer rejects.
  • Extended shelf life of finished products: CO2 is retained in the beverage, and reduces the amount of CO2 leaching from the liquid into the headspace and through the plastic.
  • Enhanced consumer experience: The poured carbonated beverage will maintain the expected level of ‘fizziness’, giving the consumer an enhanced beverage experience; improving the product and brand image.
  • Reduced carbon footprint: As CO2 is retained in the beverage, it allows for thinner plastic to be used in the packaging, therefore lowering plastic consumption and reducing the amount of plastic that goes to landfill. Water consumption is reduced significantly, as there is no need to ‘wash’ excess fob from the bottles.

Ultimately, productivity is increased, production costs are reduced and this saves money. The latter three benefits are exclusive to SUSTAIN®, and you won’t achieve the same performance with any silicone-based processing aids or antifoams.

For more information about SUSTAIN®, please contact Jonathan Stott, business manager, Stephenson Innovation, on +44 (0) 7880 035289, or via email at jonathan.stott@stephensongroup.co.uk.

 

You can also visit our website at www.stephensoninnovation.com

 

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Tennent’s to add nutritional info on cans and bottles

Tennents NutritionValues_19The managing director of Tennent Caledonian, Alastair Campbell,  said the Scottish drinks giant wanted to extend its commitment to promote the responsible consumption of alcohol.

“There is increasing interest amongst consumers around the nutritional content of the food and drink that they consume. We feel that it is a natural next step to include calorie information on our cans and bottles to sit alongside the responsible drinking messaging and number of alcohol units already displayed.

“Calorie content is an easily understandable way to help people make better choices about what and how much they consume.  They can see this information on the foods they eat, we therefore believe that the packaging of our beer and cider brands should carry these details too.”

Maureen Watt, Scottish minister of public health, added: “The Scottish Government supports any measures which will deliver improved alcohol product labelling. Many people are unaware of the calorie content of alcoholic drinks so this is an important step forward in informing consumers and as such, we are happy to support Tennent’s commitment today.

“Raising awareness on alcohol labels is an important tool to allow consumers to make informed, positive lifestyle choices, change their drinking habits and drink more responsibly.”

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Perrier Jouët unveils champagne bottle with luminescent label

Luminous_Label_Brut_75clPerrier Jouët has partnered with packaging innovator Dapy Paris to develop new electroluminescent labels for its bottles of champagne.

Perrier Jouët’s Belle Epoque champagne has adopted the new labels with floral decoration, which becomes luminous and glows in the dark. It will be seen across the brut and rosé varietals of Belle Epoque in 75cl, magnum and jeroboam sizes, adding value and providing a novel innovation that was perfect for lovers of nightlife, the champagne producer said.

“Thanks to a process patented by Dapy Electronics, the label replicates the anemones by a multi-layer four-colour printing process,” Dapy explained. “This label merges with the decoration of the bottle.

“By simply pressing a button hidden in a compartment in the hollow base of the bottle, the light illuminates the anemones and logo for the delight of night owls. As the entire system is waterproof, the bottle can be immersed into an ice bucket to be kept cool.”

The Paris-based packaging studio said that the label made each champagne bottle “an exclusive edition to be seen by all”.

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Sarson’s adopts limited-edition retro bottle

Sarsons_Limited-Edition-01-copy-1Vinegar brand Sarson’s has launched a limited-edition retro bottle for “chip lovers”, which will be adorned by the brand’s vinegar-loving mascots.

The new bottle label sees the brand change its background colour from red to blue, and is decorated with imagery from artist Paul Thurlby. The 250ml vinegar bottle retains its iconic tear drop shape and aims to make the product appeal to younger consumers with the inclusion on pack of the characters Fish and Chip.

The limited-edition packaging will be available in UK supermarkets until the end of the month.

Research carried out by the brand identified the positive brand associations that the Fish and Chip illustrations generated among consumers, particularly its strong connotations of Britishness and vintage advertising.

Parker Williams was responsible for both the label design and revamped colour scheme.

Sarson’s brand manager Noa Hasegawa said: “When we debuted the Fish and Chip characters, consumers told us they loved them. We knew at once they’d work well across other parts of the marketing mix and Parker Williams did a stellar job of incorporating the illustration into our packaging. We can’t wait to see how customers respond.”

Parker Williams creative director Jo Saker added: “Sarson’s is really on to a winner with these amusing, thoroughly British characters. The classic Sarson’s malt vinegar bottle already has unmistakable packaging that has stood the test of time. It’s been a great opportunity to work on such an iconic design and celebrate our national dish too.”

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Yake Food launches premium brand for Chinese water market

Yake_Food_Render_550_FRONTChinese company Yake Food, a leader in the country’s confectionery industry, has entered the mineral water market with a new premium brand offering.

Changbai Springs emerges out of growing consumer demand within China for high-quality products and is packaged in PET Engineering’s “avant garde” 1851 bottle design, which took the best bottle in PET award at the World Beverage Innovation Awards 2014.

The packaging was created with the idea of lending a precious design and glass-like finish to the polyethylene terephthalate (PET) packaging, making it possible for brands to communicate elegance, character and refined simplicity to consumers while still being affordable, unbreakable and lightweight.

“In a market like the Chinese one, the association of a quality product and a container with strong shelf-appeal is the key to secure and lasting success,” explained PET Engineering CEO Moreno Barel. “Yake Food, after a careful analysis of the competitors, decided to be aside the economic waters on the market, with a current market price of CNY 2 per half litre bottle, and propose higher quality water at CNY 3 per half litre in packaging that materialises and transmits this premium quality. Therefore, from the very first meeting, Mr. Chen Hua Sheng, general manager of Yake Food, chose 1851, a registered model which has already won many awards.”

Yake Food chose 1851 in particular for the connection between the message that it communicates and the brand strategy choice for the Changbai Springs brand: the 3D decoration symbolises the geometric shapes of ice crystals and, by extension, the idea of purity that Yake Food has placed at the centre of its brand proposition for Changbai Springs.

The registered design for 1851 has been licensed to Yake Food for use across the whole of China.

Yake Food general manager Chen Hua Sheng said: “It has been an honour working with PET Engineering in the development of the bottle for Changbai Spring. It has become the focus of attention since it was launched. First of all, we like the bottle internally, the experts of the industry fancy the bottle too, but more importantly, the bottle has managed to get the appreciation of distributors and consumers, which has given us great confidence. Thanks PET Engineering for the bottle design of this project.”

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Report: Packaging reduction “driven by consumer perception”

09_-_Bouteilles_d_eau_Aqua_dans_un_supermarche2Packaging decisions are driven by consumer perceptions and lifestyle requirements, according to the conclusions of a new report.

Consumers tend to equate quality with quantity, with both price and product weight influencing consumers’ perception of quality, despite the potential environmental and social costs. Their pursuit of active and healthy lifestyles can also help to contribute to inefficiencies because the demand for packaging to deliver convenience, ease of use and portion control is often translated into smaller pack sizes.

The research, from environmental newsletter the Use Less Stuff (ULS) Report, found that reducing the packaging weight of a product continues to offer significant opportunities to reduce net discards and conserve both materials and energy.

It also claimed that the best way to minimise material to landfill was through the use of lighter weight packaging, while source reduction continues to play a significant role in the effort to reduce material usage and waste.

Larger product or packaging sizes are significantly more efficient than their smaller counterparts, regardless of their material, and food products that require greater preparation are generally more efficiently packed than those that are ready to consume.

The ULS Report has also published figures that show total municipal solid waste in the US fell by 16.5m tons between 2000 and 2013, from 254.1m tons to 237.6m tons.

ULS Report editor Robert Lilienfeld said: “There are three legs on the sustainability stool – economic, environmental, and social. The study clearly shows that, over the past 20 years, packaging has evolved to more effectively deliver on these sustainability requirements.

“In general, the environmental impact of food is up to 10 times greater than the impact of its packaging. So, a bit more portion control or ready-to-eat food packaging can actually reduce waste, as these packages ensure that the food inside is actually eaten rather than thrown away.”

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Aegg to launch a new glass bottle range at Packaging Innovations 2016

Jar-Beer-Bottles-AeggUK based Aegg Creative Packaginghas announced that it will officially launch its new glass bottle product range at Packaging Innovations in Birmingham.

The company will also offer at its stand an exhibition space to Tecnocap, the worldwide metal closures specialist, so it will be able to provide an overview for integrated closing solutions as part of its already established packaging offering. Alongside the launch, Aegg’s recent glass and plastic jar designs will be showcased, including a unique 540ml glass sauce jar, 250ml sauce glass jar and a new injection stretch blow moulded recyclable plastic ‘PET’ pot, known as the ‘milk churn’.

Packaging Innovations sees the official launch of Aegg’s beer bottles, an extension to its already established food packaging lines. The standard bottles are available from February 2016, with bespoke design options available through Aegg’s in-house product design team later in the year, in line with the company’s unique turnkey project management solutions.
Aegg will also launch an all-embracing glass jar service at the show, by offering integrated packaging solutions thanks to the presence of Tecnocap. It will mean that not only can the company offer its existing bespoke jar packaging solution from developing a product from initial design concept right through to managing manufacturing and setting up the supply chain; it can now also offer a capping referral solution through Tecnocap’s know-how in metal closing systems, making Aegg the ‘go-to’ brand for complete jar packaging for both large and small projects. The Aegg stand will feature Tecnocap’s metal closures including its special lithographic, embossed, coatings and colour options. The Tecnocap Group is the third largest worldwide player in the production of metal closures for glass jars, bottles and plastic containers which are utilized in the food and beverage, pharmaceutical and beauty industries.

Tecnocap’s UK and Ireland Sales Manager, Jeff Edwards, added “We are delighted about this experience and confident that our presence at Aegg’s stand, focused on packaging innovations, will give a chance to discuss any cap and capping machinery related queries visitors to the stand may have.”

Aegg’s Packaging Innovations stand will also feature its most recent glass and plastic jar designs, with its unique 540ml glass sauce jar, 250ml glass sauce jar and plastic ‘milk churn’ yogurt pot, all of which are currently on supermarket shelves. The 540ml glass sauce jar, which Aegg calls the ‘subtle dog bone’, is taller than existing ones on the market and not so rounded at the top, giving it better shelf space and a more striking appearance. The unique and innovative ‘milk churn’ design has a brim-full capacity of 135ml and was developed by Aegg using a lightweight recyclable plastic, PET, for a major UK supermarket’s premium dessert.

Aegg’s managing director, Jamie Gorman, said “although we’ve exhibited at Packaging Innovations before, this is the first time we’re launching two new services at the show. The two services actually reflect how Aegg is different to our competitors; the bottle launch demonstrates our ‘off-the-shelf’ range, whereas the complete glass jar service showcases our bespoke design to delivery service. Also, as a forward-thinking company, we’re able to launch new services and innovate relatively quickly, as we don’t have the ‘baggage’ of manufacturing products in-house. Instead, we create the product design, drawing on our own team’s expertise and partner with the right manufacturer for each product we work on, giving us and our clients ultimate flexibility.“

Aegg is a specialist food and beverage glass and plastics packaging company. Aegg packaging can be found in the premium shelves of all major UK supermarkets. All Aegg’s packaging is manufactured at accredited production sites. Its plastic products are manufactured in the European Union, which lends itself to short lead times and flexible delivery options. Its glass is manufactured in world class production factories with recognised accreditations. Aegg offers both a catalogue of ‘off-the-shelf’ products as well as a turnkey project management service, with its own in-house design team, ideal for more bespoke or creative packaging.

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Art bottles by Ardagh win WorldStar award

The Warsteiner Art Collection range of 330ml shaped aluminium bottles produced by Ardagh Group has now achieved a coveted WorldStar award.

The bottles gained the world’s most pre-eminent packaging accolade for their use of enhanced printing techniques to represent the work of 6 distinguished contemporary European artists.

They are printed in HD dry offset with sharp screens on a metal base at Ardagh’s specialist facility in Beaurepaire, France. The application of solid covering colours on brushed transparent metal effects and gold tones help to convey the brand’s approach to use modern culture to attract consumers, and particularly a younger and influential target audience, throughout the more than 60 countries where the beer is sold.

“Working with Warsteiner our aim has been to create a strikingly beautiful bottle that would appeal to their existing and new customers everywhere, and we are delighted to receive such international recognition from packaging experts throughout the world,” said Woep Möller, Chief Commercial Officer at Ardagh’s metal division.
The World Packaging Organisation is a non-profit, non-governmental, international federation of national packaging institutes and associations, regional packaging federations and other interested parties including corporations and trade associations.

WorldStars are presented only to those packages which, having already won recognition in a national competition, are compared by an expert panel of judges to similar packages from around the world. Awards are based on the judges’ consensus that a package is superior in its own right and better in its class in execution or innovation by comparison.

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B L Agro Oils installs new PET bottling line

B L Agro Oils, an indian mustard oil producer,s has installed a new PET bottling line from liquid packaging solutions provider Sidel at a purpose-built facility near its existing refinery unit in Parsakhera, Uttar Pradesh.

The bottling line comes with Sidel Combi that combines blow moulding, filling and capping in a single integrated system.

The Combi system is said to reduce operating costs by up to 12% and offer efficiency levels that are up to 4% higher than standalone machines.

Suitable for all liquids packaged in PET, the Combi system eliminates conveying, empty bottle handling, accumulation and storage, thereby optimizing line layout with a smaller footprint.

The Combis are designed to increase packaging hygiene and ensure food safety and be further improved when configured with Predis or Capdis for caps, Sidel’s dry preform decontamination technology.

B L Agro Oils is planning to extend the bottling of its oils in PET in a bid to grow its business and increase domestic volumes.

The Sidel line with Combi, labeller, bottle & pack conveyor, case erector, case sealer, case packer and palletiser is capable of producing 400 bottles per minute or 24,000 bottles per hour.

It is currently producing 200ml, 500ml and 1l formats for various products within the B L Agro Oils range, including its flagship brand, the Bail Kolhu Kacchhi Ghani mustard oil.

Additionally, the company is working with Sidel to develop completely new 2l and 5l formats with new bottle designs.

B L Agro executive director Ashish Khandelwal said: “Testing how our oils performed in PET and in different environmental conditions allowed us to arrive at the optimum packaging solution for our products.

“PET allows us to maintain the taste of our oils – especially important to our Bail Kolhu Kacchhi Ghani mustard oil which has a particularly distinctive taste – as well as their nutritional properties through the vitamins and minerals they contain.”

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Three in one: the Kosme 3Bloc

The trend towards block-synchronising several units to form a single machine continues unbroken. For a very simple reason: the advantages for the client are indeed persuasive. The Krones subsidiary Kosme s.r.l., Roverbella, has now, in the shape of the 3Bloc, unveiled the innovative concept of a block configuration available in two different variants, for PET and for HDPE containers.

The 3Bloc for PET comprises three concatenated machines: blow-moulder, filler and labeller. The particular version of the Flexa labeller can vary, either featuring pressure-sensitive labelling with a Flexa Sensicol station or wrap-around labelling with a roll-feed capability. This version is suitable both for cylindrical and square PET bottles and also for containers with special shapes. The maximum speed is 16,000 bottles per hour.

In the case of HDPE containers, the blow-moulder is replaced by an unscrambler for erecting them as they are fed in. This 3Bloc variant is able to handle up to 25,000 bottles per hour.

The 3Bloc’s technically sound design concept scores particularly well with its significantly reduced energy consumption compared to individual machines, and alsowith its higher efficiency and enhanced operator-friendliness, thanks to the Human Machine Interface (HMI). The block configuration likewise, of course, benefits the footprint of the machinery layout, plus the capital investment and operating costs. For example, intermediate conveyors are no longer needed, and the times required for change-overs and maintenance work are shortened as well.

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Nestlé Waters to Build New Bottling Plant in Italy

Sanpellegrino Group, part of Nestlé Waters, is investing SFr17 million (€15.7 million) to build a mineral water bottling plant in Italy. The plant in Castrocielo, Frosinone province, will open in mid-2016. It will draw water from the ‘Naturae’ source, and is expected to produce around 220 million liters for sale under the Nestlé Vera brand in its first year.

In line with Nestlé’s commitments to environmental sustainability, the factory will only use green energy from renewable sources such as solar power. It will also incorporate LED lighting and systems for heat recovery and storage. All packaging materials used will be recyclable.

The Castrocielo plant will provide work to 24 people, mostly young who are high school graduates, and it will generate a significant direct and indirect linked industry.

With the activation of the new Naturae source in Castrocielo, Nestlé Vera will add a third water source in Italy for the brand. It already has a source in the North in San Giorgio in Bosco, in the province of Padua (Bosco source) and one in the South in Santo Stefano Quisquina, in the province of Agrigento (Santa Rosalia source).

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Coca-Cola launches limited edition Christmas on-pack bow-design

 

Featured across Coca-Cola, Coca-Cola Zero, Diet Coke and Coca-Cola Life variants, the bottle is designed to help attract shoppers in-store, as well as making for a gift over the festive season.

The idea behind it is for consumers to add the bottle to the dinner table over Christmas and pull on the label to transform the bottle into a gift with the bow-design when sat with guests.

Users pull away part of the label in the middle to reveal a little lever, which opens up into three parts, forming four loops that are pulled tightly to the side of the bottle.

However, users should carefully read the instructions, as, yours truly, found out when ripping the label apart in a rush and failing miserably!
The soft drinks giant has a long affiliation with Christmas advertising and packaging – and the Coca-Cola Christmas truck tour is a mainstay of the festive season – this year it will feature a recycling initiative in partnership with Every Can Counts.

The bottles have been extremely well received with users on Twitter and other social media sharing pictures of their Coke Christmas bows.

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Ardagh and Harrogate Water won the Bottle Design Award

Harrogate Spring Water and Ardagh Group celebrated a memorable win at the UK Packaging Awards in London, as they recieved the Bottle Design Award.

The diamond glass bottle design – described by judges as ‘inspirational’ – was created at Ardagh’s Design Centre in Knottingley and produced in Ardagh’s factory in Doncaster for Yorkshire based Harrogate Water Brands.

“We are very proud of this collaborative effort. It demonstrates how a ten year business partnership can deliver world class packaging for a product that not only has a genuine wow factor, but also impressive environmental credentials with 50% recycled content,” said Stuart Santon, Sales Manager, Ardagh Glass, UK.

James Cain, Managing Director of Harrogate Water Brands, commented: “The diamond design has proved hugely successful. Taking its inspiration from Harrogate’s classic architecture, it creates a sparkling effect that engages the consumer and really helps the brand to stand out on both shelf and table. Without doubt it has played a major part in our recent success, and in gaining us a number of prestigious awards.”

Ardagh a global leader in glass and metal packaging solutions. The company has 89 glass and metal manufacturing production facilities in 21 countries.

Harrogate Water bacame in 1740 first British bottled water. By 1914, the company was the biggest exporter of bottled water.

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Adnams and O-I create the lightest branded beer bottle in UK

Adnams of Southwold and O-I glassmaker has partnered to develop the UK’s lightest branded 500ml glass premium ale bottle.

At 280g, the innovation shaves a further 19g off the brand’s already market-leading lightweight bottle creating an additional annual carbon saving of 100 tonnes and removing 115 tonnes of glass from the waste stream.

Adnams pioneered the use of lightweight branded glass in the premium packaged ale sector when it worked with O-I to launch a 299g bottle in 2007. This style of long-neck, lightweight pack has since helped regenerate the entire sector, which had grown to £490 million by the end of 2014. Adnams hopes its latest move will inspire other brewers to seek further carbon savings.

O-I’s designers and manufacturing personnel at Harlow were able to shave weight off while retaining the distinctive shape and height of Adnams bespoke bottles. This meant that there was no impact on the filling equipment or tertiary packaging. The brewer is steadily moving production of all its bottled beers into the new container.

Benedict Orchard, environmental sustainability manager at Adnams, commented, “Constant environmental improvement is part of the DNA at Adnams. We wanted to see how far we could push our bottle as it is a key component of our overall carbon footprint. We had done it before and knew O-I. They are very forward thinking and share our ethos, so it was logical to work together.”

Paul McLavin, marketing and business development manager for O-I in the UK, said, “We are aware that other glassmakers offer standard bottles at 280g but are excited to be able to offer customers an embossed bottle, with all the branding benefits that brings, which advances sustainability. O-I is constantly working with customers and in its own Innovation Centre to push forward the boundaries of glass production; with its infinite recyclability, glass is the most sustainable packaging brands can choose.”

Owens-Illinois, Inc. (NYSE: OI) is the world’s largest glass container manufacturer and preferred partner for many of the world’s leading food and beverage brands. The Company had revenues of $6.8 billion in 2014. Following the acquisition of Vitro’s food and beverage business, the company now employs approximately 27,000 people at 81 plants in 23 countries.

Adnams, the brewer, distiller and retailer, is an independent values-based family business committed to a sustainable future. It has been brewing from its base at Southwold on the Suffolk coast for over 100 years and produces a range of cask and bottled beers, which are available in pubs and supermarkets nationwide.

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Brazilian water bottler began using lightweight PET bottles

Extremely lightweight PET bottles for still water have now reached the Brazil market.

Premiere of extremely lightweight PET bottles for still water in South America: thanks to Bottles & Shapes™ lightweighting expertise from KHS 0.5-liter PET bottles weighing just 8.9 grams and 1.5-liter PET containers at 22 grams are now available in Brazilian stores for the first time ever.

The German systems provider of packaging and filling machinery has developed special bottle designs and preforms for both formats, making the PET bottles much lighter than the plastic bottles commonly found in South America while giving consumers the high degree of bottle stability they expect. Water bottler Água Mineral Santa Joana recently began filling its new, lightweight PET bottles and is now making considerable cost savings in both materials and energy.

“The lightweight PET bottles developed by KHS mark the start of a switch to extremely lightweight bottles on the South American market,” emphasizes Prof. Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH. To date, relatively heavy PET bottles have been commonly used to bottle beverages on the subcontinent. “With the expertise provided by KHS beverage producers can now cut down considerably on their use of resources in the long term.” This applies to energy, personnel and space – and not just to simply saving on bottle material.

Great savings potential through less use of material

The new 0.5- and 1.5-liter PET bottles for still water weigh significantly less than the bottles usually found in South America. Here, a 0.5-liter PET bottle normally weighs 13 grams, with the 1.5-liter PET bottle notching up 26 grams on the scales. KHS clearly reduces these weights, with the new 0.5-liter PET receptacle weighing just 8.9 grams and the 1.5-liter PET container only 22 grams – a saving of 31.5% and 15.4% respectively.

In both sizes of bottle material is specifically saved by the bottle thread being much lighter. This now weighs in at 1.9 grams only for bottles with a neck diameter of 26 mm. KHS also makes sizable material savings in the bottle body. “Despite this much lower use of resources our lightweight PET bottles still boast undiminished high stability,” states Arne Wiese, product manager for Bottles & Shapes™. This refers to the processing of bottles on the line, storage, shipping and finally handling in store. Within its Bottles & Shapes™ program KHS has redeveloped the lightweight PET bottles according to design specifications while taking the special requirements of the established Brazilian beverage producer into account.

“Around 70% of the manufacturing costs for a PET bottle are attributable to the material used. Beverage producers can therefore considerably cut their costs by reducing the amount of materials consumed,” explains Wiese. For example, with an annual production capacity of 300 million 1.5-liter PET bottles and a reduction of four grams in the packaging weight the potential saving amounts to up to €1.8 million – €450,000 per year for each gram saved.

Light PET bottles in store in northeastern Brazil

Água Mineral Santa Joana recently began filling its still water into lightweight PET bottles and selling them in northeastern Brazil. The company produces its bottles on an InnoPET Blomax 12 S machine which outputs up to 27,000 0.5-liter and up to 26,400 1.5-liter PET bottles per hour.

“Europe and the USA are a big step ahead of South America when it comes to lightweight PET bottles. However, we see great potential here for boosting efficiency and providing sustainable PET bottling systems,” says Niemeyer. The Água Mineral Santa Joana project confirms this assessment; KHS has already received a number of further inquiries for lightweight PET developments from the South American continent.

The KHS Group is one of the leading manufacturers of filling and packaging systems for the beverage, food and non-food industries. The KHS Group includes, among others, the following companies: KHS GmbH, KHS Corpoplast GmbH, KHS Plasmax GmbH and NMP Systems GmbH.

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Benefits of new labelling achieved in just five days for Maltese producer

A project for the General Soft Drinks Co ltd (GSD) of Malta, the country’s sole licensed bottler of Coca-Cola products, has demonstrated the capacity to add new technology to an existing line with minimum disruption following the installation of a new Rollquattro rollfed labeller in only five days.

The decision to acquire the new Rollquattro labelling machine from Sidel the world’s leading global provider of PET solutions for liquid packaging was taken after GSD had considered the retrofitting of an existing rollfed labeller.  “With the high season about to start, we consulted Sidel – originally to have our existing Rollquattro rollfed labeller retrofitted with all the relevant upgrades,” commented Brian Galea, Technical Manager at GSD.  “Sidel undertook a careful evaluation of the whole situation on our behalf. When they presented the results of this thorough analysis and the comparable improvements we would likely be faced with by investing in the new machine, we quickly saw the value and sense of the option that they were suggesting, particularly when we realised the potential for installing it in such a short timeframe” he continued.

Staying competitive in a cost-driven market

Within the local bottled water market Malta effectively competes with neighbouring Italy, a country with an annual bottled water per capita consumption of 176 litres.  Water volume sales for the whole of Italy – one of the largest producers of bottled water in the world – totalled 11 billion litres in 2014 according to reports by market analyst Euromonitor. Italians and Maltese generally treat mineral water as an everyday drink, rather than a luxury item.  However, the number of competing brands inevitably results in a fiercely tough marketplace where the price is driven low and great profitability is difficult to achieve.  GSD is consequently run on measurable performance indicators that are regularly monitored to ensure every aspect of production is kept competitive and profitable.  This naturally includes the performance of any labelling equipment involved in the process.

Consulting with Sidel to improve TCO

GSD first started working with Sidel in 2002 when it purchased its first Sidel line to produce water in both glass and PET bottles.  In 2007 a second line was added, this time devoted to only the PET bottling of carbonated soft drinks in a new modern plant and the old line relocated. Both the original lines were moved and subsequently updated with a line conversion in 2012.  Then, when the company decided to improve the efficiency and total cost of ownership (TCO) of the older line originally supplied 12 years earlier, the company naturally again turned to Sidel.  The flexible line – used to produce still, sparkling and flavoured water in 0.5, 1.0 and 2.0 litre bottles in both glass and PET – is equipped with standalone equipment.  This includes a single blow moulding machine with different fillers and labellers for each packaging material.

Set up to make installation fast and simple

The original PET labelling machine that had given seven years of such efficient and reliable service on the line was a Sidel Rollquattro labeller. Following the evaluation of the options, this was replaced by the new labeller to provide even further benefits.  Just like the previous machine, the new Rollquattro from Sidel is for the application of rollfed labels.  GSDs’ new labeller has the same overall dimensions as the old machine, with a potential output rate of up to 25,000 bottles per hour, and makes use of the same changeover parts.  This in itself contributes to the reduction of the overall cost of the GSD investment.

The machine is fully tested by Sidel technicians before shipping to ensure it is simple to install in place of an existing machine, keeping stoppage time to an absolute minimum and reducing the impact on production.  For GSD, the whole process, from dismantling the old labeller to the production of the first sellable bottles on the new Rollquattro, took only five days. “With the new machine fitted within a matter of days – and Customer Acceptance Validation reached in under three weeks as we had requested – we were able to tackle production for our high season with even greater labelling efficiency.  At the same time, we have optimised the TCO of labelling PET bottles on the line” commented Brian Galea.

Efficient and highly precise

Qualitative plastic labels are applied on all the different waters and formats by the new Rollquattro, supporting the market positioning of the brand Kristal water.  The label transfer drum, glue and cutting modules of the new machine are designed to deliver high accuracy and quality time after time.  The patented label transfer drum ensures high quality labels fit to bottles.  The automated vacuum, with easy and programmable settings, increases label tension and stability control.  The label application and overlap alignment are precise at every speed, even for shaped bottles, with no additional wipe-down system required for label overlap closure.  Each of the four integrated single rotating cutting blades is highly durable and designed for up to 5,000 working hours.  The glue roller’s knurled pattern design leads to significant savings in glue and the roller unit ensures the adhesive remains in excellent condition and, with accuracy and simplicity, always achieves optimal application.

Flexible labelling solution and low maintenance

Brian Galea continues: “GSD production is changed roughly three times every day. So production flexibility in terms of changeover of materials, formats and labels, is essential to us.  With a compact footprint, the new Rollquattro linear station design makes access to machine modules easy, thereby making changeovers in format faster.  With adjustments for both bottle and label configurations made via the human machine interface (HMI), we now find that we can carry out changeovers within only thirty minutes.”

The ergonomic linear design of the new Rollquattro provides control of all labelling processes and allows for simpler maintenance procedures.  Modules can be removed from the station and worked on separately.  Reduced wearing between the glue-vacuum-drum-cutter roller and the lack of lubrication decreases the need for maintenance.  The glue tank, located under the machine base, can be easily and safely accessed by the operator and the vacuum prevents labels from entering the glue roller area to reduce the need for cleaning.

About General Soft Drinks

GSD produces and bottles an extensive range of soft drinks for distribution throughout the whole of Malta and neighbouring Gozo. GSD is owned by the holding company of the Mizzi Organisation, a conglomerate with a portfolio of business units covering various different industries.  The company employs over 225 people at its manufacturing plant, offices and its distribution centre on the island.  As an independent bottler, GSD is the sole licensed bottler of products for The Coca-Cola Company on the island.

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Ozone-free Filling For Water – Bromate in Drinking and Mineral Water

Ozone is one of the strongest disinfectants employed in the beverage industry. Its use when bottling water has many advantages, since this molecule provides disinfection for simply everything: water, filler, bottles, closures, and the bottle’s head space as well. But, under certain preconditions, bromates may be produced during disinfection with ozone, and these constitute a possible health risk. The larger beverage producers, in particular, are therefore reducing the internally permissible values for the bromate content in the water for their own products, or want to eliminate the use of ozone entirely. In order to make this possible, Krones has developed a holistic machinery concept for microbiologically safe filling of mineral and table water without featuring ozonisation.

Strategies For Avoiding Bromate Formation

The possible strategies for avoiding bromate formation include:

  • Do not use sodium hypochlorite as disinfectant
  • Fully demineralise the water prior to ozonisation, and subsequently remineralise it (table water)
  • Set the pH-value appropriately prior to ozonisation (e.g. by means of CO2)
  • Optimise the dwell time (CxT)
  • Use membrane filtration instead of ozone (ultra-filtration).

Ozone-free Filling Concept For Mineral and Table Water

If, for the above-mentioned reasons, a client wishes to discontinue ozonising his water, an ultra-filtration routine can replace treating the water with ozone. For filling table water, it would also be possible to use reverse osmosis in a Hydronomic RO unit, and where appropriate subsequent mineralisation in a Hydronomic MDS (Mineral Dosing Station). After that, ozonisation may continue to be run in the standard mode. Depending on the national legislation applying in each case, it would also be conceivable to use a UHT process in the Krones AquaAsept sterile water UHT unit.

Krones2September2015For mineral water, by contrast, it is prohibited, almost everywhere, to use reverse osmosis as a treatment option, because of the national legislation applying to natural mineral water. On the other hand, the use of ultra-filtration in mineral-water treatment is permitted in some countries. For this purpose, Krones offers a holistic concept in which all the machines of a line are harmonised with each other for optimum hygiene. The aim here is to ensure that the water after treatment exhibits less than one colony-forming unit per millilitre. The Hydronomic UF ultra-filtration unit, which removes particles up to a size of 0.02 micrometres from the mains water, statistically achieves a germ figure of one germ per ten 1-litre bottles, corresponding to a reduction of log 6.

The water treated in the ultra-filtration system is then passed to the filler, which is supplied with PET containers by a blow-moulder. In its simplest configuration, the concept here features a Contiform 3 blow-moulder, with a preform feed system in hygienic design and a preform rinser. If the bottler wishes a higher standard of hygiene, then one of the following options can be used:

  • a Contiform 3 with Contipure preform decontamination
  • a Contiform 3 with an UltraClean preform rinser
  • a Contiform 3 with PreBeam preform sterilisation by means of electron beams
  • or a Contiform AseptBloc, an aseptic blow-moulder/filler block.

In the simplest case, however, a Contiform 3 blow-moulder with a preform feed system in hygienic design and a preform rinser is sufficient. In this case, there is no need for a bottle rinser upstream of the filler.

The filler itself is a Modulfill model in hygienic design, but enclosed inside a cleanroom, and fitted with a foam-cleaning feature, UV closure treatment and neck steriliser, so as to avoid recontamination. Here, too, there are various other options if the client wishes a higher standard of hygiene, for instance:

  • a Modulfill with an UltraClean two-channel rinser
  • a Modulfill Asept modularised aseptic filler a PET-Asept L2 aseptic block.

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Sidel’s CSR rating places it among top 30% of companies

The commitment that Sidel is making in terms of Corporate Social Responsibility (CSR) has been independently evaluated, placing the leading global provider of PET solutions for liquid packaging in the top 30% of the 20,000 companies assessed in 2015.

Sidel received a Silver CSR rating from EcoVadis, a sustainability rating platform used to understand, track and improve environmental, ethical and social performance worldwide. Respect for the environment and a strong focus on CSR and Corporate Governance is fundamental to Sidel’s operations. Nicholas Bloch is Executive Vice President for Communications at Sidel and comments – “Sidel’s purpose is to help brands protect the product inside and the planet outside. We continue to implement CSR in everything we do to help us achieve this and are pleased to see our EcoVadis rating this year is an improvement on last year.”

Supply chain focus

As a rating platform, EcoVadis focuses on the whole supply chain with a system which brings together buyers and suppliers to accelerate transparency and foster more sustainable business. For Sidel, this makes it a particularly relevant method of benchmarking CSR performance given the importance that Sidel attributes to the role of PET packaging throughout the whole supply chain – from raw material to recycling – and how it can help turn those supply chains into value chains. In addition to EcoVadis, Sidel also works with SEDEX (Supplier Ethical Data Exchange), the largest collaborative platform for sharing ethical supply chain data.

EcoVadis carries out an extensive and tough evaluation of a company’s CSR management system, looking at its policies, actions and results. Sidel achieved an above average performance in all the areas evaluated. EcoVadis monitors the sustainability performance of 20,000 companies across 150 sectors and in 95 countries and is used by many global companies, including Nestlé and Coca-Cola.
Further details on Sidel’s sustainability practices are available at sidel.com/sustainability.

Posted in Bottling, Environment, Packaging, Packaging & EnvironmentComments Off on Sidel’s CSR rating places it among top 30% of companies




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