“Reduce, reuse, recycle”: for the KHS Group these three pillars of sustainability are a composite part of its corporate philosophy. The manufacturer of filling and packaging technology consistently focuses on resource-saving, recycling-friendly systems and solutions. Together with Austrian packaging expert ALPLA KHS has now developed a returnable PET container that at 55 grams is extremely light. The 1.0-liter bottle’s high recyclate content of 35 % also has a very positive effect on its overall ecobalance.
Arne Wiese (Photo: KHS)
For decades the KHS Group has been heralded as a technological leader in returnable container systems, chiefly driven by its great innovative strength and striving to develop sustainable, future-proof plant engineering. The various partnerships it has formed with innovative figures in the industry have proved a further recipe for success. Together with ALPLA KHS has now developed a returnable PET bottle that is impressive with its low weight and high recyclate content. With this development the engineering company adheres to its maxim of “reduce and recycle”, states Arne Wiese, Bottles & Shapes product manager at the KHS Group. “We aimed to produce a returnable container system that’s as environmentally friendly as possible. Two parameters are of prime importance here: low weight and a high percentage of recyclate.”
By optimizing the bottle base and neck the packaging experts managed to considerably cut down on weight compared to conventional returnable PET containers. At 55 grams, on average the 1.0-liter bottle is ten grams lighter than its standard counterparts. Compared to glass containers it clocks up just a tenth of the weight on the scales. “This optimization means that the amount of material used is much lower. At the same time, fuel consumption and thus also CO2 emissions drop during transportation,” Wiese explains. Both have a positive effect on the bottle’s ecobalance.
Despite less use of materials the returnable system is ideal for a high circulation. The PET bottle has good resistance to caustic, meaning that its quality and appearance are maintained even after numerous washing cycles.
Sustainable: packaging system with high recyclate content
The aspects of easy recyclability and the use of recyclate also played a major role in the bottle’s development. The environmentally-friendly returnable container is not only fully recyclable and thus remains in the recycling loop; its high recyclate content is also compelling. “We’ve had outstanding test results with preforms made of up to 35 % recycled materials; preforms containing 50 % recyclate are also feasible for some brands,” states Wiese. The PET system devised by KHS and ALPLA therefore more than satisfies the European Commission’s requirement that one-way PET bottles comprise 30 % recyclate by 2030.
The optimized preforms can be blown on all KHS stretch blow molders for returnable containers. These include the particularly resource-saving InnoPET Blomax Series V. The new packaging system is suitable for all types of beverage in the returnable container segment. “We’re convinced that we can place our ecofriendly PET bottle on the market quickly and successfully. Our aim is to implement the market launch in close cooperation with bottling companies,” Wiese concludes.
Jufico, a leading German baby-food producer, will be the first to launch its organic brand FruchtBar® in fully recyclable monomaterial pouches without aluminium (Pouch5®) into the German market. Pouch5® was developed by Gualapack, world leader of premade spouted pouches, and is the first pre-made spouted pouch available in high barrier recyclable monomaterial. The 5 new references will hit the shelves from May 25.
German consumers are well-informed and sensitive to recyclability, and in Germany separate collection and recycling infrastructure of flexible packaging are among the best in the world. Jufico, under the brand FRUCHTBAR® , has indeed captured the momentum and the needs of the market in terms of circular economy, spearheading the recyclable revolution with Pouch5®.
Gualapack Pouch5® is available in 2 versions: for hot-filled and pasteurized shelf stable products, and for cold filling /dairy applications. Pouch 5® guarantees product protection equivalent to conventional pouches thanks to its high oxygen and water vapor barrier.
Pouch5® is certified by Interseroh Dienstleistungs-GmbH for its recyclability. Interseroh is an environmental service provider and is best known for its dual system with the yellow bag / yellow bin. Interseroh’s highly scientific criteria for testing a wide variety of packaging have been developed together with bifa environmental and Fraunhofer IVV institutes. With a score of 20 out of 20, Pouch5® achieves the best possible rating and is proven “very good” for recyclability.
In recent years Gualapack has developed a vast portfolio of sustainable solutions to actively reduce the footprint of packaging. Thanks to the vertical integration of technologies such as extrusion, lamination, printing, pouch making, injection molding and filling equipment, Gualapack can offer proven and market-ready packaging solutions that provide effective answers to the industry, the environment, consumers and legislators.
Pouch5® was recently adopted by Nestle (Gerber®) in the USA and Nestle (Piltti®) in Finland.
Ball Corporation launches infinitely recyclable aluminum bottle line
Ball Corporation is launching a new impact extruded aluminium bottle line that provides a circular solution to plastic pollution. In the hands of our sustainability, innovation and product design experts, aluminum is taking shape as a new bottle – the Infinity™ Aluminum Bottle – that is designed to be made again. Available in various shapes and sizes, this impact extruded aluminum bottle can be customized for numerous food and beverage products. Unlike other substrates in these categories, such as plastic shampoo bottles or jars for cosmetics, Ball’s aluminium bottles are infinitely recyclable, and can be turned into other aluminum products over and over again.
“Plastic waste that ends up in the natural environment has led to more public discussion about packaging, its life cycle and recyclability,” said Jason Galley, director of innovation and sustainability, Ball Corporation. “Consumers are demanding more environmentally friendly solutions for packaging their everyday products. We combined our product design and sustainable aluminium packaging expertise to develop another truly circular packaging solution – the Infinity™ Aluminum Bottle.”
Ball’s new impact extruded product line is suitable for packaging almost any liquid. The innovative aluminum bottles are available in a range of sizes and formats, and are customizable for various products. Ideal categories for the Infinity™ Bottles include shampoos and conditioners, soaps, body creams, spirits, energy shots, yogurt, dressings, syrups, condiments and more. The bottles are available with a re-closable threaded cap that allows consumers to twist the top on and off.
An infinitely recyclable package
The Infinity™ Aluminum Bottle line features all of the sustainability credentials of aluminum. Like Ball’s aluminum beverage cans, cups and Alumi-Tek® bottles, the impact extruded aluminum bottle is monomaterial – it consists of only one material and can be easily sorted and recycled. In fact, aluminum can be recycled an infinite number of times without losing quality. Aluminum also retains its value throughout the recycling process, so it can be kept in circulation indefinitely without becoming waste and ending up in the ocean or in landfills. In fact, 75 percent of aluminum ever produced (since 1888) is still in use today.1 After use, an aluminum bottle can be recycled and returned as a new packaging format in just 60 days. It can also be recycled to take on a new life as another aluminum product, such as consumer electronics or a bicycle. Other substrates achieve much lower recycling rates and, if recycled, are in many cases down-cycled and eventually become waste.
Lightweight product with endless branding options
In addition to strong recycling credentials, aluminum bottles have a number of other advantages that help improve resource efficiency and enable circularity. For example, aluminum is lightweight, which saves energy in transportation. Once bottles are ready for design, they can be branded without the use of sleeves or labels. Even the most creative and complex designs can be printed on aluminum using the full circumference of the bottle. Ball’s innovative high-definition printing and graphic design technologies such as Eyeris® HD printing, UV light reactive ink, Matte & Gloss, or Tactile printing help
1Source: The Aluminum Association
Frost & Sullivan’s latest analysis, Global Food and Beverage (F&B) Packaging Market, Forecast to 2030, reveals that the need to reduce material usage and develop more sustainable, durable and lighter-weight packaging solutions with lower production costs are key drivers supporting steady market development. Utilizing innovative packaging materials, advancing processing and additives through technological improvements and an uptick in eCommerce distribution will further augment market expansion. While revenue is expected to increase modestly, recording a compound annual growth rate (CAGR) of 1.2 % from 2018 to 2030, unit shipment by weight is set to decrease in the short term due to a sustained drive for lighter-weight packaging.
“With rising concerns around plastic pollution and stringent government regulations, manufacturers are seeking alternatives to plastic packaging. This is resulting in an uptick in use of paper and aluminum-based packaging or other non-plastic materials such as biodegradable foods or resin,” said Christopher Shanahan, Global Director, Chemicals, Materials and Nutrition, Frost & Sullivan. “Paper and aluminum are both recycled at high rates and are seen as viable alternatives to plastic with biodegradable plastic films becoming more common as new degradable resin is adopted.”
To differentiate themselves in a well-established, highly consolidated, and competitive market, packaging material suppliers are focusing on specific products such as flexible materials, rigid plastics, and coatings for sachets and pouches. Minimizing packaging costs is a priority so there is strong competition among manufacturers to provide the most cost-effective solutions to customers, including eco-friendly, lightweight products.
“Although manufacturers have already reduced the thickness of bottles and other packaging, they are now looking toward further down gauging and design improvements to make packaging more cost-effective,” observed Shanahan. “For instance, designs such as droplet-shaped bottles have been shown to increase volumes without expanding the package weight.”
F&B vendors can make the most of key opportunities in the market by:
Exploring environment-friendly sources of plastics, such a plastic derived from corn, or natural products such as banana leaves.
Creating novel packaging solutions with advanced materials.
Utilizing the same type of packaging material across several applications to reduce production and processing costs.
Exploring emerging markets such as APAC, the Middle East, and Africa.
Reducing material and transportation costs by decreasing the thickness of packaging materials.
Frost & Sullivan’s recent analysis, Global Food and Beverage Packaging Market, Forecast to 2030, explores the factors and trends that have shaped the food and beverage packing landscape, the challenges that lie ahead, and the opportunities that can be tapped. The market is analyzed in terms of different packaging material segments, including flexible materials, rigid plastics, glass, metal, and other packaging materials used for containers and closures.
