Energy-efficient packaging machines for beverages

PACKAGING manufacturers are challenged by many issues – the need by beverage companies to package their products in one-of-a-kind bottles, and to be able to offer these while at the same time meet environmental standards and efficient production. Packaging leaders Krones and KHS have introduced equipment to help bottlers meet requirements and cut cost in the long run.

In response to these challenges, Krones aims to reduce the amount of PET used in bottles.  Reduction of the main material would greatly enhance eco-friendly features of the product. The company’s new 0.5 litre “PET lite 9.9 carbonated” bottle weighs only 9.9 grams – about a third less than conventional PET bottles of this size. The design as it is will stand firmly and can be safely transported.

Extra-light PET bottles from Krones weigh a third less than conventional versions (Photo courtesy of Krones)

PET that takes the heat

PET bottles to be filled with hot products need to have a stronger design as they readily shrink when exposed to heat.  The company’s new NitroHotfill process keeps containers stable during filling by raising the internal pressure with nitrogen.  This achieves weight savings in the bottle body and mouthpiece, according to the company.

Further cost reductions in labelling

Manufacturers can cut cost not only in design, production and filling, but in downstream labelling as well. The DecoType direct printing system from Krones can embellish uneven surfaces with a digital inkjet process. Amongst the cost advantages of the printing system is that special labels and adhesives materials are no longer required, even for those who wish to apply classical labelling, the company said.

To reduce energy use, the labelling machine from Krones does away with thermal processes such as hot gluing (Photo courtesy of Krones)

The Adhesleeve rotary labelling machine from the Italian specialist PE Labellers offers potential for cost reduction. To save energy, the machine operates with acrylic adhesive to bond the labels instead of a hot-melt adhesive. According to PE Labellers, the Adhesleeve is capable of using labels 30% thinner compared to conventional ones.

The Dortmund KHS company sees itself as the “First Choice in Technology and Service” in beverage packaging. The KHS INNOPACK Kisters TSP A-H-TPFO packaging machine, is said to be versatile in its use, cuts costs in production and sets new standards of sustainability. “The machine is modular and thus also equipped for future needs and customer wishes,” said KHS expert Frederike Arndt.

A feature on the machine allows it to package PET bottles in fully enclosed packages. It makes packages that are stronger than current conventional shrink packs. Hence, there is no need for extra cardboard trays that are provided for added stability. This can significantly reduce cost.

The packaging machine all-rounder  from KHS operates inexpensively and sustainably (Photo courtesy of KHS)

The wrap-around shrink packing process for packages in the new KHS INNOPACK can also be performed in a shrink tunnel with either electric or gas heating. “Energy costs can thus be reduced by up to 50 per cent over conventional electric heating,” Mr Arndt said. As an option, an energy-saving package can be integrated in any shrink tunnel variant. Here, a roller shutter system automatically closes the opening for product inlet and outlet during packaging machine stoppages to facilitate extra energy savings of up to 20%.