Lightweighting and hot filling - making both possible in PET

LIGHTWEIGHTING developments are continuing in response to growing industry demand to lower container and logistics costs. This requirement is sometimes, but not always, related to sustainability efforts. Reduction of PET weight per bottle has become such the norm that, along with consumers purchasing less bottled beverages and rising rates of PET recycling, it has contributed to a decele ration in PET demand. Over all, world PET polymer consumption slowed further in 2009 as a result of the global recession. However, it is expected to pick up, growing at an average annual rate of approximately 4.3% during 2009-2013 according to a report by CEH Marketing Research. There is no turning back on lightweighting requirements, however, with accelerating high tech developments in preform molding and greater understanding of the performance tolerances of the polymer as well as advances in blow molding solutions. Weight-reduced hot-fill option Hot - fill bottle technology that significantly reduces weight and cost is being used for the first time in a 16- oz PET container for organic fruit juices and functional drinks. The new, patented active hinge technology from Amcor (Melbourne, Australia) opens up new opportunities for companies who continually strive to take cost and material out of their bottle, allowing them to meet their sustainability goals. "The ability to reduce both weight and cost, while not sacrificing performance is a major development for beverage companies," says Scott Dreesbach, western regional sales manager for Amcor. The 16-oz PET containers for Purity Organic Inc. of San Francisco, California, use 20% less material and cost 20% less than its previous PET containers, according to organic beverage company founder Paul Geffner. "We can have our cake and eat it too," says Geffner, referring to not only the bottle抯 strong performance but also its significant cost benefit. "This translates into a major advantage in terms of our bottom line." Purity Organic touts the lightweighting benefit with a sticker on the cap that reads "20% less plastic" Moreover, the company was able to meet its sustainability commitment by choosing a lighter weight and recyclable bottle. Active hinge technology incorporates a unique design that elevates hot-fill bottle options to a new level. It makes use of horizontal hinges which exhibit vertical movement and absorb the vacuum as the liquid cools. The result is an attractive appearance and feel that approaches that of a straight wall container, according to Amcor engineer Pankaj Kumar. The active hinges provide high radial stiffness and give the 31- g container excellent top load strength - almost 30% better than competitive hot-fill bottles. In addition, the bottles are more durable, dent resistant, and exhibit strong stacking capability. Aesthetics are also significantly enhanced, according to Geffner. "The label fits more securely and the bottle has a better feel in the hand; overall we have a more integrated product," he explains. The bottle also offers consumers easier drinking and less spillage by reducing the bottle抯 finish from 43mm to 38mm. Less than 19 grams Sidel of France is claiming to have made the world抯 lightest hot-fillable PET bottles that combine aesthetics with technical prowess on two new models: the ""Skyward"(right) and "Curvy" These two small 500ml bottles weigh only 18.9g and their design is a real breakthrough for the shape of hot-fill bottles, which traditionally have six or eight panels, and help differentiate them from other bottles. Sidel has just developed Technical solutions that extend the limits of lightweighting for heat-set packaging have also been developed and blowmolding speed of 1,800 bph with a standard HR process has been obtained due to heating optimization with Sidel抯 SBO Universal rAir Huarache Run Ultra BR