Next Steps in LW PET Bottles ALL - Rtl.270607.ba0d2fd4.4020

Next steps in PET bottle
lightweighting
Tuesday 26th June 2007
Phillip Ward
Director for Waste Implementation
Programmes: WRAP
WRAP:
Waste & Resources Action Programme
Private company, funded by DEFRA and the

devolved administrations
Set up in 2001 from Waste Strategy 2000
200 staff, 7 programmes

Helping businesses and the public to reduce
waste, to use more recycled material, and

recycle more things more often
The role of WRAP

to minimise the production of waste by consumers
and maximise the recycling of materials.
Minimising household waste
Creating markets for recyclate
Increasing recycling infrastructure
Training & increasing collections
Promotion of consumer recycling
Waste minimisation, recycling, composting
The scale of the challenge
European perspective
Waste Strategy for England 2007

Published by Defra on 24 May 2007
Much stronger focus on waste minimisation
Retail and food manufacturing are both seen as
priority sectors
Reducing food waste an urgent issue for
government
Focus on alternative technology investment
Anaerobic digestion and composting favoured
Consultation on incentive charging scheme
The changing retail

environment
Grocery retailers: Green Wars
Strategic targets on:

Reduction in waste and packaging
Specifying recycled content / biodegradable packaging
Recyclability / access to recycling facilities
Sustainable materials
Carbon foot-printing
Courtauld Commitment: Phase 1 Retailers

The signatories commit to supporting WRAP in the achievement of its
objectives, as follows:
To design out packaging waste growth by 2008
To deliver absolute reductions in packaging waste by 2010
To identify ways to tackle the problem of food waste
Signatories represent over 90% of the UK grocery market
Courtauld Commitment: Phase 2 Brands

Expansion of Courtauld Commitment to include top UK selling
brands and suppliers;
Influence the brand sector
Influence own brand
Influence consumers
Partnership working with retailers / WRAP
Focus on suppliers to household grocery sector
Brand signatories now in double figures
Consumers: seeking engagement
Recycling
Incentive charges
Kerbside collection
On-pack messages
Media
Lightweighting PET
Why a conference on lightweighting

PET?
Lightweighting has been happening for a long
time BUT a new step-change is needed
Commercial, consumer and environmental
opportunities
Understanding the challenges
Bringing together technical & commercial
expertise
Future plans
WRAPs PET lightweighting project

overview
Three projects involved:
Esterform Packaging:500ml and 2 litre bottles
Coca-Cola Enterprises
Amcor PET Packaging
Where we want to get to

Shared understanding
Clarity on potential benefits
Awareness of barriers to and challenges in
adoption
Identify areas for collaboration
Thank you
Next steps in PET

bottle light weighting
PET bottle manufacturing and
light weighting- an overview
Professor Edward Kosior
Managing Director
Nextek Limited
Overview
The Light Weighting Issue

The UK PET bottle market
Light weighting design principles
Limitations to Light weighting
Review of current best practice
Potential for future light weighting
The Light Weighting

issue
Light weighting of PET bottles

Light weighting has been occurring since PET bottles
were produced in the beverage market
The target has always been to reduce cost without
reduction in bottle performance and consumer appeal
Savings delivered by light weighting PET

Each one gram saved on a preform used for a
market of 100 million bottles saves
100 tonnes of PET
80,000 of costs for PET resin at 800/tonne
80,000 kWhr of energy for preform moulding
2670 kWhr of energy for preform heating for
blow moulding
36 tonnes of CO2 being generated
27.2 tonnes of Carbon being used
The UK PET
bottle market
UK Soft Drinks Market

Growth from 2000 to 2005 has been at
approx 4% p.a.
Year
Litres (million)
index
% annual change
2000
2001
2002
2003
2004
2005
9,248
9,740
10,239
11,128
10,991
11,123
100
105
111
120
119
120
NA
+5.3
+5.1
+8.7
-1.2
+1.2
Market Sectors
Carbonated Soft Drinks 55% of the market
Juice 20% and Water 19%
PET bottles are the major form of packaging
(66%)
Estimated % Share of the UK Drinks Industry Market
2005
0%
3%
3%
Carbonates
19%
Juice/juice drinks
Bottled water
55%
20%
Sports drinks
Energy & stimulant drinks
Smoothies
Share of the CSD market by brand owners

% Share of the UK Carbonated drinks market by
brand, 2004 M ltrs
Coca-cola
4% 3% 4% 5%
Britvic soft Coca-cola

drinks
Enterprises
5%
7%
14%
3%
4%
10%
Diet Coke
Fanta
Schweppes
Pepsi
Diet Pepsi/Pepsi Max
Tango
R Whites
Virgin Cola
26%
15%
Irn-Bru
Other brands
Own-label
The top three Brand

owners for carbonated
drinks are
Coca Cola
Britvic
AG Barr (Irn-Bru)
They account for nearly
60% of the CSD volume
PET packaging is used for
66% of the total market
Share of the Water market by brand owners
Danone
% share by brand of the bottled mineral water

market 2005 M ltrs
Volvic
Evian
Nestle
Highland Spring
Buxton
Vittel
Aqua Pura
Own labels
Others
Own Label water

dominates the
market at 47%
Nestle, Danone
and Highland
spring are the
other major
players
81% of the
packaging is in
PET bottles
Share of the Juice market by brand owners

% share of the UK fruit juice/juice drinks market
by brand 2004, M ltrs
Ocean Spray
Robinsons
Ribena
Capri-sun
Sunny D
Other brands
Own-label
Own label account for

41% of the market
The top four brands
are
Gerber
Britvic
Glaxo Smith Kline
Coca Cola Enterprises
PET bottles are used
for 25% of the market
Summary of the PET Packaging market
Segment
Total volume
%PET share
Estimated number of
PET bottles
Carbonated S.D.
Bottled water
Fruit juice/drinks
Others
TOTAL:
6,057 m litres
2,158 m litres
2,202 m litres
66%
81%
25%
3,100 million
1,500 million*
1,055 million
820 million
6,475 million
Light Weighting Design Principles
PET Bottle design

Key issues for bottle design:
Manufacturing process
single stage or two stage
(economics, material efficiency)
Size and shape of bottle

(stretch ratio, barrier and rigidity)
CSD, juice or water market

(Resin IV, base design)
Neck and Closure design

(Major weight and waste factor)
Shelf life and oxygen barrier

Wall thickness and construction
Production stability
Available BM machines
Light Weight Bottle Design Principles

The latest advice on bottle and preform re-design is obtained from leaders
in the technology- preform manufacture, moulds, resins blow moulding
machines.
The new, lighter design is created on a 3-D CAD System
Surface stress and deformation test is carried using Finite Element Method
(FEM) analysis to check the bottle performance
The new CAD design is optimised to meet customer specifications.
Manufacture of prototype tooling to make sample bottles on production
equipment.
Testing of prototypes for an additional analysis of all important parameters.
The filling volume and material distribution is checked.
The designs may require further refinement and the moulds adjusted.
Bottles are again moulded and tested.
Bottles are tested at the customer on the filling lines at full production
speed and tested with real products.
Issues that often arise in Light Weighting

Wall thickness can get too low and product rigidity is
lost- poor feel, low top load resistance
Nesting of preforms (body of preform is less than
opening of the neck) leads to preform unscrambling
problems in the blow stage
Very light bottles are difficult to handle and fill at high
speed
Barrier properties and creep of CSD bottles can cause
shelf life and label stability issues.
Stability of base and Stress Cracking of base may
become a problem
Review of current Best

Practice
Best in Class survey Wrap/ Exel 2005

Data for CSD based on 2003 data
Product Size
Position in class
Weight of plastic
packaging (grams)
Estimated weight of
PET (gms) (assuming 3gm
closure weight)
330ml PET
500ml PET
l ltr PET
1.5lt PET
2 ltr PET
Best
Worse
Best
Worse
Best
Worse
Best
Worse
Best
Worse
18.8
19.09
24.5
42.2
31.7
52.91
47.81
50
44
58
15.8
16.09
21.5
39.2
28.7
49.91
44.81
47
41
55
Most common CSD bottle weights

Volume:
330ml
500ml
1 litre
1.5 litre
2 litre
Weight(s):
17.4gms
28.1gms
31.9gms, 39.5gms
44.8gms
44.2gms, 46gm, 50gms,
51.7gms
Best in Class survey Wrap/ Exel 2005

Data for Water based on 2004 data
Product size
Position in
class
Weight of PET packaging

(grams)
Estimated weight of PET

(gms)assuming 2.5gm closure
330ml PET
Best
Worse
17
28.24
14.5
25.74
500ml PET
Best
20
17.5
Worse
45.8
43.3
750ml
PET
Best
Worse
28.79
40.8
26.29
38.3
1 ltrs PET
Best
Worse
29.58
40
27.08
37.5
l.5 ltrs PET
Best
38
35.5
Worse
58
55.5
Best
46
43.5
Worse
66.5
64
Best
Worse
103
147.85
98.0*
142.85*
2ltr PET
5ltr PET
Most common Water bottle weights

Volume:
330ml
500ml
750ml
1 litre
1.5 litres
2 litres
Weight(s):
25.74gms
17.5gms, 23.5gms
26.29gms
36.4gms
39.3gms, 43.8gms, 54.5gms
44.7gms, 46.5gms, 47.1gms
Best in Class survey Wrap/ Exel

Data for Juice based on 2006 data
Product size
Position in
class
Weight of plastic packaging

(grams)
Weight of PET (gms) assuming

3.5gm closure
250ml PET
Best
Worse
19.5
24
16
20.5
500ml PET
Best
23.9
20.4
Worse
41.2
37.7
Best
32.8
29.3
Worse
52.3
48.8
Best
Worse
45.6
60.6
52.1
57.1
1 ltrs PET
l.5 ltrs PET
Most common Juice bottle weights

Volume:
250ml
500ml
1 litre
1.5 litre
Weight(s):
16.4gms
21.8gms, 27.4gms
40.1gms, 46.4gms
58gms
Potential for future light

weighting
What is being achieved.

Esterform reduced 500ml CSD preform from 25g to 20g
Esterform reduced 2000ml CSD preform from 42g to 40g
CCE reduced 500ml CSD preform from 26g to 24g
WRAP sponsored projects in 2005 and 2006
What could be achieved in UK

A reduction of 10 % of bottle weight for the whole
range of UK PET bottles would :
Reduce UK PET usage by 20,000 tonnes ( based on
200,000 tonnes for the bottle market)
This equivalent to 570 million 30g bottles being
removed from the waste stream
Reduce resin costs by 16 million ( based on PET
Reduce power demands for process by 16.5 million
kWhrs
Reduce CO2 production by 7200 tonnes
Reduce carbon use by 5,500 tonnes
Advancements in
Preform Lightweighting
Sylvain Talarico
June 26th 2007
Overview of todays PET market

Why lightweight?
How to lightweight?
Thread Lightweighting Trends
Husky support
Husky Injection Molding Systems
World's largest brand name supplier of injection
molding equipment and services to the plastics

industry
Manufacturing facilities in Canada, the United
States, China and Luxembourg
Over 40 offices in over 100
countries
Beverage Packaging
Preform Products
A Solution For Every Application
More than 3.200 Husky PET M/C

in Production at 750 Customers
Global PET Support
Europe 72% converters / 77 Billion Preforms
Preform Production in Western Europe
France
Italy
Spain
Germany
Benelux
UK
Western Europe
N Installed Cavities
Converters In-House Fillers
Total
3,388
4,404
7,792
6,876
2,040
8,916
4,488
1,968
6,456
4,368
1,696
6,064
3,760
680
4,440
5,264
304
5,568
28,144
11,092
39,236
Technology Improvements
1980 17 Systems
Today 1 System
(96 cavities)
Output (pph)
0
20000
40000
1997
1993
1989
80000
100000
144 cavity G600

96 cavity Index 400
72 cavity Index
96 cavity G600 phase 2
96 cavity G600 phase 1 w/ Servo Robot
96 cavity SX600 w/ Servo Robot, 3
96 cavity XL600 w/ Servo Robot, 3
96 cavity XL600 w/ Servo Robot, 3 Position
72 cavity XL500 w/ Servo Robot, 3 Position
72 cavity XL500 w/ Air Robot
1985
1981

2.0L CSD
20oz CSD
16 cavity H388 w/ TE Robot
1977
120000
216 cavity HyPET650

144 cavity HyPET500 Speed up
144 cavity HyPET500
2005
2001
60000
12 cavity H388 free drop
0.5L Water
Weight
(g)
Cavitation
Cycle
(s)
Output
(parts/hr)
Output /
Capital
1998
21.0
96
11.0
31400
19.6
1999
21.0
96
11.0
31400
19.6
2000
20.0
96
10.0
34500
21.6
2001
17.5
144
10.0
51800
25.9
2002
16.0
144
9.5
54500
27.3
2003
14.5
144
9.0
57600
28.8
2004
14.5
144
8.5
60900
30.5
2005
13.5
144
8.0
64800
32.4
2006
13.0
144
7.0
69100
34.4
500ml PET Water Bottle Output Evolution
PET Price Trend (US$)

100
Cents / Pound
90
80
70
60
50
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
2003
2004
2005
2006
Average PET Prices
Trend (Average PET Prices)
Source: PCI 2006
Resin Prices Continue to Increase
Trends in Preform Lightweighting

60
50
2L CSD
Weight (g)
40
1.5L Water
30
600ml CSD
20
500ml Water
10
0
1996
1998
2000
2002
2004
2006
2008
Significant ongoing weight reduction for most beverage containers

15% 50% over past 10 years
Combination of shorter and thinner preforms and lighter threads
Market Trends
CSD Applications
Mineral Water Applications
Milk / Juice Applications
Oil Applications
The above tables are summaries and do NOT include all possible specifications.
Lightweighting Advantages
Reduce resin consumption
Increase productivity & performance
Maximize cycle benefit (thinner means faster)
Satisfy end consumer demand for sustainable
development
Sustainable Development
because it is made with less plastic
PET Market Trends

Lighter necks
New bottle base and body concepts
5 liters / 38 mm Neck
28 mm CSD
30/25 low, PCF26
500 ml Lightweighted MW Packaging

Bottle:
13.80 g
Bottle:
12.30 g
Closure: 1.73 g
Closure: 1.58 g
Volume: 500 ml
Volume: 500 ml
Height:
Height:
196 mm
205.8 mm
Max Dia: 65.9 mm
Max Dia: 66.3 mm
Thread:
Thread:
PCF-26P-1
PCF-26P-1
Small Size Containers
Options in Preform Lightweighting

Preform change only
Thread conversion
Body conversion (from 0.1g to several grams)
Neck
Thread
side
Body
Core
side
Cavity side
Bottle change including a preform change

Resin change including bottle & preform changes
Thread Lightweighting Projects
Blowing
partner
Husky
Customer
Closure
partner
Case Study ($US)

Assumptions
Bottles or preforms per year
PET resin cost
HDPE cost
Resin Savings Opportunity
Thread
Body
Preform total
Closure
240
1.4
1.15
Million
$/kg
$/kg
Resin (g)
1.3
1.2
2.5
0.6
$US
Sub-total Savings
Investment cost
Injection molding machine and tooling
Blowing molding investment
Capping investment
$
$
$
$
436,800
403,200
840,000
165,600
1,005,600
$US
$
$
$
250,000
250,000
250,000
Sub-total
1,550,000
Additional profit per year

Return on investment (years)
1,005,600
1.5
Additional Profit Every Year
1,005,600
Thread Lightweighting
Focus on:
Carbonated Soft Drinks
Mineral Water
CSD Thread Evolution 28 mm

Alcoa
PCO1810/1816
Common in
Americas
~5.9g
BPFC
~5.1g
Global Usage
Common in
Europe
~5.76g
PCO is the most widely accepted CSD thread finish
CSD Thread Evolution - Whats Next?
CSD Thread Lightweighting
* Non-exhaustive list
500ml Lightweighted Beer Packaging

Volume: 500 ml
Height:
~235 mm
Max Dia: ~65 mm

Thread:
Bericap
MW Thread Evolution
PCF26
Alaska267
Common in
Americas
~3.9g
30/25
~3.7g
Global Usage
Common in
Europe
~3.9g
MW Thread Evolution - Whats Next?
30/25 High
3.9g weight
- 36%
Target weight
below 2.5g
Mineral Water Thread Lightweighting
* Non-exhaustive list
500 ml Lightweighted MW Packaging
9.9 g with Snap on Closure

10.6 g with 3 start threaded closure
13g today
Prototyping with Husky

Preform / mold optimization
performance at production system level
Latest system / mold technology used

Project confidentiality preserved
Design validation
Competitive leadtimes
Get your product to market faster and safer
Preform Development Center

Show Room integrating
2 new HyPET 90 systems
Optimized output with 4 cavity modular mold

Various mold tool options available
Moving Forward
High amount of development activity
Lightweighting demand for all applications
Success of new threads depends on closure
standardization and availability

Need to evaluate overall cost along the supply
chain
Global Impact to the PET Market

~35% of the PET global beverage market
affected
Beverage retailers looking for ~5% weight
savings
Brand owners looking for sustainable packaging
and cost savings
Converters taking proactive measures to meet
market expectations
Husky Initiatives
Add global manufacturing capacity

Add global refurbishing cells
Support new thread development
Work closely with down stream equipment
providers
Introduce new programs for mold conversions to:
Preform prototyping
Include body lightweighting
Minimize customer downtime
Incorporate technical upgrades to improve cycle and/or
preform quality
Advancements in
PET bottles at lighter weight

An integrated approach
Birmingham, June 26th, for WRAP
SIG Corpoplast
Frank Haesendonckx
Date
SIG Beverages history shows a pioneering role in PET,

barrier development and dry aseptic filling
SIG Corpoplast partners with Schott to

develop the PLASMAX barrier coating
system for plastics applications
Heidenreich & Harbeck

establishes SBM
division
1974
1997
Worlds first PET

Stretch Blow Moulding
Machine produced in
cooperation with
DuPont
(8,000 bph 16 cavity)
ASBOFILL (GEA)
develops first purpose
built Linear Aseptic
Bottle Filler
SIG Corpoplast
2000
RANK acquires SIG

And announces to
keep the structure
including Beverages
as is
PLASMAX
12D;
industrializatio
n and pilot
launch
SIG acquires Corpoplast:

revenue 80m / 270
employees (excl. Moldtec)
1968
Corpoplast develops
first plasma coating
machine for bottles
2002
2003
SIG acquires Asbofill

filling assets from
Techne
2004
2005
2006
2007
ASBOFILL 610
with integrated
capper launched at
Drinktec 2005
SIG acquires Schott
equity in Technology
JV for Plasmax
development
Frank Haesendonckx
Date
SIG Beverages - offering comprehensive PET solutions

along the value chain for low speed aseptic filling
Customer
Request
Design and
processing
Stretch Blow
Moulding
Barrier
Coating
Aseptic Bottle
Filling
Packaging and
Process Design
Bottle
Manufacture
Barrier
Coating
Product
Filling
Bottles &
Shapes
Briefing
SIG Corpoplast
Frank Haesendonckx
Date
SIG Corpoplast
focusing on value added bottling for high volume and
non aseptic filling lines
Value added bottling: high quality bottle at lowest cost of ownership
Customer
Request
Bottles &
Shapes
Stretch Blow
Moulding
High Speed Bottle

Filling via partner
Packaging and
Process Design
Bottle
Manufacture
Product
Filling
Bottles &
Shapes
Briefing
SIG Corpoplast
Frank Haesendonckx
Date
Content
The playground
Material influence
Design influence
Processing influence and incorporation into machine technology
Examples
SIG Corpoplast
Frank Haesendonckx
Date
Content
The playground
Material influence
Design influence
Examples
SIG Corpoplast
Frank Haesendonckx
Date
The playground of lightweighing PET containers

combining all elements of the value chain
Preform design
t
or e
pp nc
s u ma
to for
es er
ur al p
at
fe nim
gn i
si d m
De uie
q
Re
al
n
o
cti on
n
fu ti
or tribu
f
ing l dis
s
Bottle design elements
s
ce teria
o
P r ma
Weight reduction
Environment/ specification
n
io
at
nt
ie
Or
dle
n
a ad
h
to g lo
g
in dlin
s
es han
c
/
o
Pr lling
Fi
Material properties
to
ad
lo
fit
SIG Corpoplast
Frank Haesendonckx
Date
Content
The playground
Material influence
Design influence
Examples
SIG Corpoplast
Frank Haesendonckx
Date
Material
Influences on bottle performance and process design
The basics: Strain hardening
Influences on material use
Reaching above the point of natural strain hardening
Re.heat capacity influences freedom in preform design
SIG Corpoplast
Frank Haesendonckx
Date
Strain Hardening
through material characteristics and design
Stress Whitening
Influence of IV on SHP
60
Typical Design Range
CP 559
(IV: 0.808)
50
Force [N]
40
1101
(IV: 0.770)
30
Thicker Preform
CP 552
(IV: 0.719)
20
Higher Orientation
10
0
1
1.5
stretching at 110C
2.5
3.5
ratio
Thinner Preform
Lower orientation
SIG Corpoplast
Frank Haesendonckx
Date
Stretch ratio inside/outside of the preform wall

Consequences on preform re-heat
Preform inside is more stretched
than outside
The thicker the preform wall, the
more important to obtain heat
penetration
Importance of good re-heat resins is

increasing
SIG Corpoplast
Frank Haesendonckx
Date
Content
The playground
Material influence
Design influence
Examples
SIG Corpoplast
Frank Haesendonckx
Date
Preform and bottle design

starting point for good process design
Factors
Stretch Ratio
Wall thickness
Reflects on
Process stability
Re-heat capacity
Container performance
Bottle design
Between technical and marketing optimization
Imperative to respect relation to preform
SIG Corpoplast
Frank Haesendonckx
Date
Preform design
SIG Corpoplast
Frank Haesendonckx
Date
Preform functional sections

Body
Part below support ring
Diameter and
wallthickness defined by
neck finish
Diameter, length and

wallthickness defined by bottle
shape/dimensions, application
and weight
Neck
Defined by bottle
Taper
Base
Length defined by length

of bottle shoulder
Diameter and wallthickness defined

by prefomr body and application
SIG Corpoplast
Frank Haesendonckx
Date
Preform design
incorporating stiffness by orientation
7
6
5
4
Q
3
2
1
Minimize cost (design to cost)
Minimize amount of material employed

Optimize material distribution
Optimize stretching ratio
Optimize grip resistance
SIG Corpoplast
Frank Haesendonckx
Date
Bottle design
performance at low weight lays in the details
SIG Corpoplast
Frank Haesendonckx
Date
Content
The playground
Material influence
Design influence
Examples
SIG Corpoplast
Frank Haesendonckx
Date
The process of bottle blowing

and the required machine characteristics
Aim
What is required
Obtain a uniform material

distribution
Above NSR, to obtain strenght
by orientation, not wall
thickness
Stable re-heat
Small pitch between preforms
Material pull
Repeatable profile
Stable material distribution

Repeatable stretching
Repeatable bubble development
SIG Corpoplast
Frank Haesendonckx
Date
Wall thickness distribution

... Depends on preform re-heat characterisitcs
SIG Corpoplast
Frank Haesendonckx
Date
Preform re-heat profile evolution when traveling in IR oven
Obtaining a perfect heat distribution

with inside temperature > outside
temperature
Stress ( PSI )
Stress / Elongation vs.Temperature

700
600
500
400
300
200
100
0
90 C
95 C
100 C
100
200
300
At minimum required stretch

temperature to have highest stifness
at equal material thickness
400
Elongation ( % )
SIG Corpoplast
Frank Haesendonckx
Date
Reheat optimization
machine technology to obtain stable heat penetration
Smallest pitch possible: 38 mm
Limit is support ring
Re-heat profiling
Neck shielding is more simple
Natural heat convection
No air suction required
Sharp transition under support ring
possible
Top lamp possible
25% less re-heat energy

Allows for smooth heating
where required
SIG Corpoplast
No water condensation from cooling

shield on preform
Frank Haesendonckx
Date
Optimize material use

only there where required, at minimal variance
Mechanical Stretching
Pneumatic Stretching
PFM weight
PFM weight
2
1
MIN limit for bottle property such as TOP

LOAD
SIG Corpoplast
Frank Haesendonckx
Date
= 1 2
The machine: design to cost

high precision and repeatability
Precise oven control, double
guided mechanical stretching
system, precise valves, short
cycle time:
Highest process preciseness
and repeatability, thus light
weighting
Segment weight variation with high precision process
10,20
9,80
1 g saving:
216 T /Year
9,40
9,00
8,60
Average
max
min
8,20
1
10
11
12
13
14
15
16
Mould
Segment weight variation with low precision process

10,20
9,80
9,40
9,00
8,60
Average
max
min
8,20
1
10
11
12
13
14
15
16
Mould
SIG Corpoplast
180 mil bottles/ year (BLOMAX 20 * 5000 h * 95%) , 1l

Frank Haesendonckx bottle
Date
With energy cost of 12 c/ kwh, 0,19 kw/qm
Pet resin cost of 1,2 / kg
Content
The playground
Material influence
Design influence
Examples
SIG Corpoplast
Frank Haesendonckx
Date
Lightweighting in Water/ CSD

Brandenburger Urstromquelle, 1.5 l and 0.5 l CSD, 8 gr CO2/l
0.5 l weight reduction

from 23 g down to 19.5 g
1.5 l weight reduction
from 38 g down to 35.5 g
Pressure reduction from
35 bar down to 21 bar at
speed of 1800 bphm
SIG Corpoplast
Frank Haesendonckx
Date
Lightweighting in dairy
0,119 l Yoghurt bottle
Weight reduction from

7.5 down to 7 g
speed of 1700 bphm
SIG Corpoplast
Frank Haesendonckx
Date
Example for a sophisticate bottle development

Japanese field 2.0 l rectangular Aseptic bottle
Weight reduction from 47

g down to 41,9 g
Wide range of
specification items
Corpoplast task:
bottle shape
Preform design
process design
SIG Corpoplast
Frank Haesendonckx
Date
The Bottles & Shapes concept links material, processes,

machines and requirements
to deliver a customized bottle at the best performance / price
Bottle Concept
Product to be filled
Aseptic integrity
Heat resistance
Required shelf life and barrier
Bottle
CO2 / O2 transmission
Concept
Differentiation
Process / Operations
Material costs (resin / cap /
sleeve)
PaT parts/ change over
Blowing costs
Barrier costs
Filling costs
Process/
Industrial
solution
Design
validation
Design Validation
3D mock-up
Pilot molds
Pilot bottles / Performance
tests
Consumer focus groups
SIG Corpoplast
Bottle
Design
Bottle Design
Differentiated
shape
Corporate identity
Product suitability
Coat-ability
Filling
Pressure
resistance
Stability of
contours
Handling
Preform
Design stability
Thank you
very much
Preform
Design
Design to give best material

distribution
Minimum heat for maximum

shape
Mold
Design
Mold Manufacturing
Design optimized for preform
Bottle finish
Frank Haesendonckx
Date
Seminary
"Next Steps in PET Bottle Lightweighting"
Solihull, West Midlands June 26, 2007
PET Resins
Enabling
Lightweighting
Roland Leimbacher
Market Manager Polymers EMEA
Eastman Chemical Company
Content of Presentation
Introduction to Eastman
Market Trends & Requirements on PET
Light-Weighting of PET bottles
Vorcalor & Aqualor PET - Eastman's New PET Resins
Reheat Process & Performance of PET
Outlook for PET Resins & Technology
Eastman At A Glance
A global manufacturer of
chemicals, plastics and fibers
World's largest manufacturer of
PET polymers for packaging
2006 sales revenue of $7.5B
11'000 employees
Headquarters in Kingsport,
Tennessee
Eastman - History
Began in 1920 when George Eastman acquired
wood distillation plant in Kingsport, TN
Expanded manufacturing production to
include new products such as:
Acetate yarn and acetate tow

Acetic anhydride
Cellulosic plastics
Polyethylene terephthalate (PET) polymers
Became first to operate a commercial coal

gasification facility in U.S. in 1983
Won Malcolm Baldrige National Quality
Award in 1993
Spun from Kodak in 1994; became independent,
publicly traded company on the NYSE
Eastman - Markets
2006 Sales Revenue by Markets
2006 Sales Revenue by Region
20%
57%
13%
9%
Eastman - Products
Coatings, Adhesives, Specialty
Polymers and Inks
Fibers
Performance Chemicals and
Intermediates
Performance Polymers
PET: Poly-(ethylene terephthalate)
Specialty Plastics
copolyesters (PETG)
cellulosic plastics
Performance Polymers
One principal product line:

Polyester (PET)
Eastman is the leader in PET for

packaging; used in packaging of:
Carbonated soft drinks

Water
Juice
Personal care item
2006 sales revenue of $2.6B
Specialty Plastics
Highly specialized copolyesters and
cellulosic plastics valued for their
unique characteristics
Strength
Durability
Heat and chemical resistance
Used in a variety of
value-added end uses:
Shrink labels
Food and beverage packaging
Store fixtures and displays
Personal care and cosmetic packaging
Medical devices and packaging
2006 sales revenue of $818M
Eastman's Polyester History

1975
1978
1988
1994
1996
1997
1998
2006
2007
First PET packaging resin from converted fiber plant (SC)

Eastman begins manufacturing PET resin for containers
First PET plant in Europe (Workington / GB)
Eastman Chemical Company is spun off from Eastman Kodak
PET plant start-up in Cosoleacaque - Mexico
PET plant start-up in San Roque - Spain
PET plant start-up in Rotterdam, Netherlands
PET plant start-up in Zrate -Argentina
First world-scale PET plant based on IntegRex Technology
Parastar Resins - commercial since 1Q 2007
450'000 MT PET as of 2008
PET plant in San Roque - Spain sold to La Seda de B.
PET Manufacturing in Europe

2007
2007PET
PET Capacity
Capacityin
in Europe:
Europe: 340'000
340'000MT
MT
Workington - UK
1988 built
Rotterdam - NL
1998 built
150 KMT PET
190 KMT PET

315 KMT PTA
Produced in Europe
Eastman PET
PET CB11E
CB11E (0.82
(0.82 IV)
IV)
Eastman
Eastman PET
PET 9921W
9921W (0.80
(0.80 IV)
IV)
Eastman
Eastman Aqua
Aqua PET
PET 18696
18696 (0.71
(0.71 IV)
IV)
Eastman
Eastman PET
PET 9921P
9921P (0.80
(0.80 IV)
IV)
Eastman
Imported
PET Portfolio in Europe
EastmanPET
PET PJ003
PJ003(0.80
(0.80IV
IVglass
glasslike)
like)
Eastman
EastmanPET
PET 5214A
5214AAmber
Amber(0.74
(0.74IV
IVpharma)
pharma)
Eastman
Trends in European
Packaging Market (1)
Pressure on overall Cost Effectiveness

Differentiated packaging with standard resins
PET packaging the choice over glass, aluminium, carton
Trend towards smaller packaging size
Sustainability PET the best overall choice
PET has established recycling infrastructure
PET is a light and durable packaging without compromise
CSD Market is mature

Water continues to grow but less in Western Europe
Growth in juices, sports & functional drinks, dairy, beer
In film & sheet PS is being substituted by PET, PP, PLA
Prices of Plastics in Europe

PET is a very competitive commodity plastic for packaging
PET has had relatively stable, predictable prices since 2004
Source: PIE
www.pieweb.com
2007
2006
2005
2004
2003
2002
2001
2000
1999
1998
LDPE
PP
PS
PVC
PET
Trends in European
Packaging Market (2)
Market Drivers - Specific for PET Packaging
Bottle fillers increasingly blowing their own bottles
More efficient operations, less manpower needed
Less experience/knowledge
Low inventories
Weight reduction in finished articles
Changes in preform design
Use of PCR polymer even in food contact applications
(bottle to bottle recycling)
Emphasis on cost savings
Energy savings
More creative use of standard resins
Requirements on PET
rating from Eastman
market study in 2005
Improved blow moulding consistency
Energy and cost reduction
Increased barrier (CO2)
Control over AA
Balance between reheat and color
Cycle time reduction (injection moulding)
Ability to light-weight
Same IV for carbonated and still water
Light-Weighting PET Bottles

Technologies Enabling Light-Weighting
Design of Bottle / Preform
Blow Molding Machine
Process /Technology Improvement
PET Resin
Light-Weighting PET Bottles

PET Resin Parameters Enabling Light-Weighting
For blowing at maximum stretch ratio, following
PET properties need to be optimized:
Viscosity
Reheat Performance
Consistent Reheat
Consistent Viscosity (IV)
Resin Formulation, e.g. Modifications
Barrier properties
Eastman's Solution
Eastman PET
PET CB11E
CB11E(0.82
(0.82IV)
IV)
Eastman
Eastman PET
PET 9921W
9921W(0.80
(0.80IV)
IV)
Eastman
Eastman Aqua
AquaPET
PET 18696
18696(0.71
(0.71IV)
IV)
Eastman
enabling light-weighting by improved processing,
reheat, and barrier performance
VorcalorPET
PET CB11E
CB11E(0.82)
(0.82)
Vorcalor
VorcalorPET
PET 9921W
9921W(0.80)
(0.80)
Vorcalor
Aqualor PET
PET 18696
18696(0.72)
(0.72)
Aqualor
Review of New PET Resins
Vorcalor PET CB11E
The Premier Reheat PET Resin

0.82 IV PET resin
up to 60% energy savings
Highest reheat without compromise
on clarity
The best choice for:
- carbonated soft drink (CSD)
- beer applications
- ideal for blends with lower IV (PCR)
Clarity of Vorcalor CB11E
Vorcalor
CB11E
Current
CB11E
Old
Vorcalor CB11E - Benefits

Better reheat & colour consistency than current
CB11E
allows blowing of more complicated shapes
allows efficient blowing of light-weighted
preform/bottle designs
Haze free appearance, glass-like colour Wider
range of use, less resins in stock needed
Drop-in replacement of current CB11E
Needs up to 60% less energy for reheating preforms
Very compatible with recycling of PET
Vorcalor PET 9921W

Versatile, General Purpose PET
0.80 IV PET resins

maximum light weighting
perfect PET for complicated bottle shapes
- carbonated soft drink (CSD)
- carbonated and still water
- juices
- dairy
- personal care & household
- pharmaceutical
- high quality film & sheet
Vorcalor 9921W - Benefits

Even with its reheat performance, Vorcalor 9921W
looks like a non-reheated PET wide use of
applications
Needs up to 30% less energy in reheating preforms
Better reheat consistency than PET without reheat
allows blowing of more complicated shapes
allows efficient blowing of latest, light-weighted preform/bottle
designs
Wider processing window in injection moulding

Improved CO2 barrier 5 to 10% longer shelf life
Improved AA suitable to replace PET of 0.76 IV
Aqualor PET 18696

Best PET Resin for Still Water
0.72 IV PET resins

fastest for moulding preforms
maximum light-weighting
superb clarity & sparkle of bottles
- still water
- non-carbonated containers
- small, difficult to mould - containers
Aqualor 18696 - Benefits

Moderate level of reheat without compromise on
bottle appearance
Needs up to 30% less energy in reheating preforms
Fast injection speed, potential for reduced preform
cycle time
Low energy consumption in injection moulding of
preforms
Low injection pressure long lifetime of moulds
High definition of bottle imprints (embossing &
engraving)
Reheat Performance of PET

Reheat performance
is a key element enabling lightweighting of PET bottles
but what does "reheat" mean ?

graphics provided by
What is Fast Reheat? (Blow Stage)
Quartz-infrared lamps are used

to heat preforms to about 100 110 C for blowing bottles.
Maximum power output from
lamp at these temperatures
occurs at about 1100 -1200 nm
PET absorbs poorly in this range
Infrared absorbing compounds
are added to the PET to
- increase productivity or
- reduce energy consumption
Reheat Process
stabilisation
distribution oven
penetration oven
stabilisation
distribution oven
stabilisation
penetration oven
Reheat Comparison
of 6 PET Resins
Comparing:
Eastman PET 9921W
Vorcalor PET 9921W
Vorcalor PET CB11E
Resin A - no reheat
Resin B - moderate reheat
Resin C - "high reheat"
Measurements:
Preform outside temperature
Preform inside temperature
Energy consumption of the
blowing machine
Results from trials with
Preform Temperature
Preform Surface Temperature at 80% power setting
Preform Surface Temperature

Outside [ C]
140
128
130
120
110
112
104
110
114
104
100
90
80
9921W
Vorcalor Vorcalor PET A 9921W

CB11E
No reheat
PET B Moderate
reheat
PET C "High
reheat"
Preform Surface Temperature

to Avoid Pearl-Whitening
Preform Temperature (C)
106
Preform Surface
Tem perature Outs ide
104
102
Preform Surface
Tem perature Inside
100
98
96
94
92
90
88
0.90
1.00
1.10
1.20
1.30
1.40
1.50
Reheat Level (indexed)
1.60
1.70
1.80
Energy Savings
70.00
Benchmarking
Benchmarking with
with Competitive
Competitive Resins
Resins
Energy Savings (%)
60.00
50.00
40.00
30.00
20.00
10.00
0.00
PET A
no reheat
(reference)
Eastman
PET 9921W
PET B
moderate
reheat
Vorcalor
PET 9921W
PET C
"high
reheat"
Vorcalor
PET CB11E
But Reheat is More

Than Energy Saving
The lower outside preform temperatures results in
following benefits:
Less risk of (local) overheating
Less crystalline outside layer / gate
Positive effect on all properties that have to do with
avoiding crystallinity
The faster heat absorption of the inside layer leads to:
Less risk on overstretching / white feet
Less critical process, wider processing window
But Reheat is More

Than Energy Saving
"Fast Reheat" PET results in additional benefits:
More consistent blowing operation
Reheat functions as processing aid
Less scrap
Faster heat absorption

Higher output on heat limited machines
Allows blowing of light-weighted and more

complicated bottle shapes
Very suitable for heat-set process
Outlook for
PET Resins & Technology
Polyester Value Chain
PTA
PTA
fibre
fibre
p-xylene
p-xylene
23'000 KMT
70% of polyester stream
1-3% growth
OR
InI teg
ntegrar ted
atedProc
Proceess "
ss "PPX to
X
toPPET" solid
melt
melt E T" solid
DMT
DMT
phase
phase
PET
PET
state
state
PET
PET
ethane
ethane
ethylene
ethylene
EO
EO
EG
EG
film &
film &
sheet
sheet
preforms bottles
preforms bottles
bottlers
bottlers
11'000 KMT
27% of polyester stream
7-10% growth
1'400 KMT
3.5% of polyester stream
or 12% of PET bottle stream
10-15% growth
propane
propane
Eastmans position shown in green
retailers
retailers
IntegRex PET Technology

New Plant in South Carolina - 350 KMT per annum;
2008 debottleneck to 450 KMT per annum
marketed as ParaStar for the American Market
"Next Generation PET" with new product attributes and
benefits
IntegRex Plant #2 Study Phase
New, World-Class North America Site
Full IntegRex Technology (PX PET)
Logistics Optimization
Potential Future Developments: large scale,
fully-integrated, new technology sites
Next Generation PET
IntegRex PET plant in South

Carolina producing ParaStar
Next Generation PET
Twice the capacity

Half the footprint
PET Barrier Technology
To improve the CO2, O2, and Light barrier of PET

Numerous technologies & solutions available:
coatings (internal & external)

mono-layer blends
multilayer
special polyesters
labels (for light barrier)
No "single best" solution depends on total system

cost, application, volume, logistics, design, recycling ...
Total cost of many solutions are becoming more
acceptable for end-users
Sustainability of PET
attractive PET recycling system unique amongst plastics !
an effective bottle collection systems is in place
economically attractive outlets are available for PET
All outlets/reuse of RPET have a similar, positive influence on

the environmental profile of PET containers
In collection system, like the German DSD, the environmental
effects of one-way PET are similar to those of refillable glass
Negligible effect on fossil resources of "one-way PET" versus
refillable glass: similar to an average German citizen driving
40 km extra per year in a standard car
PET containers use less than 0.1% of global oil production
PET packaging is proven to be the best material for beverage
containers best overall performance regarding properties,
life-cycle, cost a true sustainable solution.
Use of Oil for Plastic
Transport
45%
87%
burnt
Energy & Heating
42%
5%
Other
Chemistry 8%
> Plastics 4%
Plastics (all) use 4% of global oil consumption

PET for fibers and packaging uses 0.3% of oil consumption
PET for packaging uses less than 0.1%
Plastics protect food and other goods most efficiently
Source: Plastics Europe
Recycling where to go ?
Oil / Gas
EG + PTA
Incineration (burn)
PET
or landfill
PET
Preform
Bottle
In Use
Collection
Recycling
RPET
Chem.
Sheet
Recycling
Strapping
Fibre
Bottle
Conclusion
Only the right PET resins allows maximum lightweighting! Therefore, Eastman launches this year
three new resins in Europe:
Vorcalor PET
PET CB11E
CB11E (0.82)
(0.82)
Vorcalor
Vorcalor PET
PET 9921W
9921W (0.80)
(0.80)
Vorcalor
Aqualor PET
PET 18696
18696 (0.72)
(0.72)
Aqualor
Vorcalor & Aqualor PET resins are the best resins
for making PET containers
PET Containers are proven to be the most
sustainable solution for beverage packaging
Contact to Eastman
For more information on the new resins, please

consult your Eastman sales representative or the
following websites:
www.VorcalorPET.com
www.AqualorPET.com
Eastman Chemical International AG
Hertizentrum 6
6300 Zug, Switzerland
Phone: +41 41 727 58 70
Fax
+41 41 727 58 50
E-mail: emeapet@eastman.com
www.eastman.com
Eastman, Vorcalor, Aqualor, IntegRex, ParaStar and the Eastman logo are trademarks of Eastman Chemical Company
DISCLAIMER: Eastman Chemical Company and its marketing affiliates shall not be responsible for the use of this information, or of any
product, method, or apparatus mentioned, and you must make your own determination of its suitability and completeness for your own
use, for the protection of the environment, and for the health and safety of your employees and purchasers of your products. No warranty
is made of the merchantability of fitness of any product, and nothing herein waives any of the Seller's conditions of sale.
Roland Leimbacher June 22, 2007
Reducing PET bottle weight

with new low profile necks
and lighter closures
Speaker: Alexander Krautkrmer,
Bericap Holding GmbH
Position: Director Marketing & Sales
What is the Bericap Group

sales 435 million in 2006
44 billion plastic closures
per year
18 closure manufacturing
sites in 17 countries in the world,
2 mould factories (Hungary
and Poland
4 R&D centres
(France, Germany, Spain,
Turkey)
Strategic allies in Australia
and South Africa
sales offices, and agents in
70 countries
Bericap Package
Some of the significant contributions of BERICAP to the

packaging industry of the last 30 years
1975
Pull-up
telescopic
spout
SuperShorty
2007
Push & Pull

sports cap
1995
Tear off
membrane
BO2S
passive &
active barrier
1998
light
weighting
DoubleSealTM
28 / 38mm
and O2S
GALILEO
2005
2000
THUMBUP
sports cap
Bi-injected
closures for
hinge cap and
VALVELOCK
2003
TAPSEAL
tap closure
TERXOCUT
self piercing
carton fitment
Light weight
HEXACAP
Presentation structure
Reducing PETbottle weight for
carbonated soft drinks and water
still water
milk and juices
edible oil and vinegar
Short Neck Standard

PCO 1881
CSD
carb water
Neck PCO 1881

as currently under evaluation by ISBT
- Technical committee bottle and closure

within ISBT selects in November 2006
PET short neck standard PCO 1881
- currently under evaluation - ISBT = International Society of Beverage
Technologists (www.bevtech.org)
- approval of PCO 1881 as voluntary standard
foreseen for Oct 2007
- members of ISBT are brand owners (Coca-Cola,
Pepsi-Cola etc.), preform manufacturers (Amcor,
Plastipack etc.), closure manufacturers (GCS,
Alcoa, Bericap, OI etc.) and machine manufacturers (Sacmi, Husky, Sidel etc.)
- CETIE (European standardization body) will adopt
PCO 1881 for Europe
PCO 1881 is the target neck for the industry
all closure technologies work on PCO 1881
1-start thread neck

Pitch: 2,7mm
Thread length: 650
Neck weight: 3,74gram
weight saving to
PCO 1810 (PCO 28):
1,31 gram
CSD
Short Neck Standard PCO 1881
carb water
- technical details Neck PCO 1881
as currently under
evaluation by ISBT
Neck PCO 1810

called PCO 28
40 angle for easy application
Drop height sufficient

for all TE band offers
21,0 mm
17,0 mm
Centering ring
for TEband
Thread length 650

extension to 680 feasible
pitch 2,7mm
Usable thread length:

650
PCO 1881 is the target neck for the industry.

All closure technologies work on PCO 1881
Short Neck Standard

PCO 1881
CSD
carb water
PCO 1881 neck drawing

as pdf-file or 3D-edrawing
available in the Internet with following link:
button on www.bevtech.org at
Technical comittee Packaging Technology
www.profileservices.ca/files/tidbits/tidbits_missc.html
(profile services is member of ISBT)
or try
Google: PCO1881 or PCO 1881
CSD
The lighter option
carb water
- a proposal from Bericap Short neck standard
PCO 1881
under evaluation by ISBT
Lighter
but off-standard
Short neck proposal

Bericap ENG-00-014132
- weight saving through:

+ reduced angle at PP ring
+ deletion of centering ring
below PP ring
+ light weighted support ring
Neck weight: 3,74gr

PCO 1881 is the target neck for
the industry - all closure
technologies work on PCO 1881
Neck weight: 3,45gr

Limitations of neck 14132:
Neck 14132 is a off-standard neck
only SuperShorty works properly
on neck 14132
SuperShorty
from Bericap
CSD
carb water
History of SuperShorty from Bericap

- Bericap has started SuperShorty
development in 2004
- development project triggered by emerging
market of beer in PET in Germany
market introduction:
- production start end of Feb 2007 in
Germany. Initial capacity 300mln
- capacity to be extended in the course of
2007 to 2.000 mln for beer and CSD
SuperShorty provides safe
bottle Performance for up to
2ltr bottles and 8gr CO2/ltr
In the market since March 2007
SuperShorty
- closure design -
CSD
carb water
Product program
SuperShorty CSD look

weight 2,40 gram
SuperShorty crown look

weight 2,60 gram
SuperShorty still
weight 1,70 gram
Product features
Double Seal
- outer seal
- inner seal
Tamper evidence band
- slitted
- with flexible wings for
easy application
Option for inshellmoulded oxygen

scavenger liner
SuperShorty + PCO 1881

economics
1.000
reference volume
closure
closure weight
CSD
carb water
mln units
SuperShorty systems
gramm
PCO system
CSD
CSD
crown
1-pc closure
2,40
2,40
2,60
3,00
3.000
resin weight for 1.000 mln units
to
2.400
2.400
2.600
weight saving from closure

neck
to
-600
-600
-400
neck weight
gramm
neck 14132
PCO 1881
only SuperShorty
(under evaluation)
PCO 1810
(PCO 28)
3,45
3,74
5,05
5.050
PET resin weight for 1.000 mln necks
to
3.450
3.740
weight saving from neck
to
-1.600
-1.310
total resin weight saving

compared to PCO 1810 (PCO 28) to
valued at 1.300 EUR/to
EUR
off-standard
-2.200
-2.860.000
-1.910
-2.483.000
-1.710
-2.223.000
Saving = 1,7 to 2,2gr/bottle

2,20 to 2,80 EUR/1000
Figures acc. best knowledge
CSD
carb water
SuperShorty and PCO 1881

- step blow off -
BC Germany
Preforms
Amcor
kind of neck:
NR
PCO
PCO HC
BPF
other X
REF
MCA1
MCA2
7,5R
ENG #.:
Eltex 1331
12 bar
[174 psi]
1 min.
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
O direkt
O direkt
x
x
x
O direkt
X
O @ 40s
x
x
O @ 40s
10
11
12
7 bar
[101.5psi
] 1 min.
6 bar
[87psi]
1 min.
5 bar
[72.5psi]
1 min.
4 bar
[58psi]
1 min.
3 bar
[43.5psi]
1 min.
2 bar
[29psi]
1 min.
1 bar
[14.5psi]
1 min.
sawed off
preform
Temp. 38C
SuperShorty holds pressure at

elevated temperature (38C)
till 7 bar
16 inchlbs
CC - F
CC - N
GDB short
PCz
manual
explanation
X pass
O fail / leak
3 Blow off
leakproofness (Process)
device
no.
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
12 bar
[174 psi]
1 min.
12
11 bar
[160psi]
1 min.
11
x
x
x
x
x
x
x
x
x
x
x
x
11 bar
[160psi]
1 min.
10
10 bar
[145psi]
1 min.
x
x
x
x
x
x
x
x
x
x
x
x
10 bar
[145psi]
1 min.
9 bar
[130.5psi]
1 min.
8 bar
[116psi]
1 min.
7 bar
[101.5psi]
1 min.
6 bar
[87psi]
1 min.
5 bar
[72.5psi]
1 min.
adjustment:
topload:
closing torque:
CO2 formula:
1
2
3
4
5
4 bar
[58psi]
1 min.
revolutions p. min.
3 bar
[43.5psi]
1 min.
Temp. 23C
number of heads:
kind of head:
line speed:
core no.:
kind of closing:
automatic Torque Tester
Line Trail
Capper
mechanical Torque Tester
OPT and by hand
leakproofness (Process)
device
no.
filling date:
25.10.2006
test start:
27.10.2006
test end:
tested by: E. Bergmann
material
screw cap
F 02-05-1122-02
2 bar
[29psi]
1 min.
SuperShorty holds pressure at

ambient temperature (23C)
till 11 bar
DS28/16 FB 7077 O2S

Closure:
00-012100 b
ENG - PRO # :
Comparison CSD
Prod. Info:
9 bar
[130.5psi
] 1 min.
Customer:
bottler:
filling:
bottle size:
bottle manufacturer:
AA 02-05-1028
06G181
Beverage
8 bar
[116psi]
1 min.
work procedure:
order no.:
sawed off
preform
Result:
BC_Step Blow off
F-2-01-01
1 bar
[14.5psi]
1 min.
Procedure:
- closure applied on preform
- 1 bar applied over 1 minute
- pressure increased over 1 minute
to 2 bars
- 2 bar pressure hold over 1 minute
- cycle repeated with pressure
increases of 1 bar until closure leaks
explanation
0 @ 20s
x
x
x
x
x
x
0 direkt
X pass
O fail / leak
3 Blow off
0 direkt
0 direkt
0 direkt
x
x
0 direkt
0 direkt
0 direkt
0 @ 35s
x
x
0 @ 10s
0 @ 20s
0 direkt

- opening performance test -
CSD
carb water
CSD
- blow-off performance on 2l bottle -carb water
Measurements taken by the Opening

Performance Tester (OPT). The OPT
measures gas venting.
Opening Perform ance after

torque dependent clos ing 19 lb.in. /
2 litre - 1 litre gas - abs.4,0 bar Pres s ure
abs.Pressure [bar]
OPT test for SuperShorty

shows safe venting
on 2l bottle
5,0
absolute pressure
4,5
#1 Sk28/16 7077 FB (Eltex 1331)
4,0
#2 Sk28/16 7077 FB (Eltex 1331)
3,5
ope n s e al ~ 201
3,0
2,5
2,0
1,5
Pressure
Tests have shown that a half-full
2 litre bottle (meaning 1l gas volume)
filled with CSD can build up a maximum
inside pressure of 2,7 bar.
-> therefore opening performance
measured on 4 bar total pressure or
3 bar overpressure
Opening speed
100rpm means almost 2 turns per second
1,0
0,5
0,0
0
100
200
300
400
500
600
700
Ope ning Angle []
Technical informations:
Simulated bottle:
2,0 litre
Rest volumne/liquid:
1,0 litre
Gasvolumne:
1,0 litre
Opening torque speed:
100 rpm.
Abs. pressure:
4,0 bar
overpressure:
3,0 bar
Technical performance of
SuperShorty on PCO 1881
CSD
carb water
Total weight saving of 1,9 gram realisable with PCO 1881
Weights saving can be increased up to 2,20 gram with offstandard neck

No blow-off risk also for large size bottles
Secure seal up to 11bar at ambient temperature and up to 7bar at
38C realisable
PCO 1881 has satifactory performance under hot climate conditions
SuperShorty with DoubleSeal shows superior performance
CO2 retention comparable with current PCO 1810 / PCO28
solutions
Line adjustment
CSD
carb water
The following bottling line elements need adjustment:

- preform infeed
- neck rings of blow molds and transfer pins in blowing machine
- bottle conveying
- bottle grippers in rinser/filler/capper
- capper sorter and feeding equipment
- capping heads to be equipped with new springs to counterbalance
reduced pitch
- new CAM for cappers which cannot adjust to lower bottle height
- adaptation of down-the-line equipment to reduced bottle height
total cost of adaptation 50.000 to 150.000 EUR/line
total saving appr. 300.000 EUR/line/year (150mln fillings p.a. per line)
payback in less than 6 months!
SuperShorty
- good look on all bottle sizes -
CSD
carb water
Lightweight options for

still water
HEXACAP 30/25
still water
at 1.90 g
on 3.91 g
neck finish
HEXACAP 30/25
ultralight
at 1.50 g
on 2.90 g
neck finish
HEXACAP 26,7
ultralight
at 1.20 g
on 2.50 g
neck finish
total weight:
5,81 g
total weight:
4,40 g
total weight:
3,70 g
Savings -2,11g or -36,3%

compared to
standard 30/25 necks and closures
Galileo I for
juices and milk
Galileo I
juices
milk
38mm
screw cap
Traditional neck: 38mm 3-start

(in use since 12 years)
Proposal from Bericap:

Galileo I
- press-on light-weight neck
- 1-piece hinge cap made from
HDPE, completely closed from
outside before first opening
- no market application yet
weight saving: 2,9gr/bottle
weight
-2,9 gr
2-piece
Sportscap
40 % light weighting
for juices and milk
Ref. 3419
Current 38 mm
neck finish
and closure
3.3 g
- 25 %
4.5 g
2.5 g
GALILEO I 38
neck finish
and closure
- 46 %
2.4 g
7.8 g
Total saving
- 37 %
4.9 g
juices
milk
Neck 26/21 for

Traditional neck: PET 29/21
(in use since 20 years)
Proposal from Bericap:
neck PET 26/21
- same inner diameter as PET29/21
less changes on blow moulding
equipment
- first introduction with Castelo, Brazil
others follow
- 1-piece and 2-piece closure
available from Bericap
weight saving: 3,7gr/bottle
edible oil
vinegar
45 % light weighting for

current neck
PET 29/21
and 2-piece
closure
edible oil
vinegar
5.6 g / 6.6 g
- 43 % / 51 %
3.2 g
2.7 g
- 49 %
1.4 g
8.3 g / 9.3 g
- 45 % / - 51 %
4.6 g
Total saving
neck finish
PET 26/21 and
2-piece closure
GALILEO II 26/21
There is a lot of plastic to be saved.
Thank you!
Presentation on Bottle & Cap Lightweighting using

induction cap sealing.
Stopping Leakers is only the beginning

Presented by: Mr Simon. S. Measures
The Point is..

The reduction of food packaging materials and the
recycling of them, is currently one of the top priorities for
the Planet/governments/large supermarkets/food
companies/bottle manufacturers/cap
manufacturers/packaging line machinery
manufacturers/contract packers and the end user us
How does Induction Sealing Work ?
For many years now, in fact over

30, we at Enercon Industries Ltd,
have been successfully sealing
foils onto containers to aid
packaging weight reduction.
The cap sealer mounts over the

conveyor and from the induction
coil emits a controlled
electromagnetic field through which
the containers complete with the foil
normally placed in the cap are
passed.

The electromagnetic current
induced into the foil layer of
the inner seal creates a
circulating current within the
foil, causing it to heat up due
to its internal resistance

The heated foil then makes active the
polymer coating on the heat seal face,
bonding the foil
to the neck of the container and creating a
hermetic seal.
What to do.
I will now give an example of how we have helped in a real
world application
Within the Milk Industry in the UK some 15 years ago
Enercon Industries worked very closely with a large SuperMarket to solve an issue
What to do.
The bottle manufacturer and cap manufacturer were at the time
listening to the Milk Industry, who wanted a lower priced
container and cap for their customer the Super Market.
As a by-product of this exercise they received a light weight
bottle and cap which was also recyclable and
crushable.Unfortunately it leaked due to the many stresses the
container under went in transit from the filling line to the home
What to do.
After many new cap designs with a varying lack of success, the
dairies came up with a credit system for leaking bottles.
This however created a lot of waste not only in production but
also in the whole supply chain network
The issue of transit, storage & leakers was eventually
solved by sealing the plastic milk bottle
hermetically with foil, coated with polymer
Issue Resolved!
What to do.
The Super Market ended up with the
product they required. Which SAVED
MONEY, helped the planet by using less
plastic, and it was RECYCLABLE.
The bottle and cap suppliers pulled back
their investment with the higher volumes
of product they sold and we all WON.
But; Stopping Leakers is only the beginning!

Induction cap sealing creates an hermetic foil seal. Its Air Tight.
It also reduces:9Bacterial Contamination and Product Oxidation
9Improves Storage and Transit Conditions
9Reduces rejects and Scrap in Packaging and Filling Lines
9Induction Sealing also seals in freshness and can extend
shelf life (ESL)
But stopping leakers is only the beginning!

But a MAJOR benefit often missed by the industry especially Large
Outlets and the Prime Food Suppliers is the proven fact that
Induction Cap Sealing allows the cap and bottle to be;
Reduced in Thickness
Reduced in Weight
The foil seal will not stop or hinder the RECYCLABLE nature of the
bottle
The strength and flexibility of the seal means that the cap or
closure will NOT require a tear band
The foil seal also means that a Bore Seal is not required
Which will reduce cap weight

The bottle can be reduced in its thickness at the neck and shoulder
because ;
It no longer has to withstand high application torques for cap or
closure transit requirements
Air carriage rings on and around the neck can be reduced in
thickness and weight as they are no longer need to give additional
support to the neck

Add to this an increase in size of the market the packing company
can attack means
Every one benefits.
And the cost for all this?
Machinery Less than 20,000 per
Production line
Packaging modification costs & addition of foil normally paid back
by material savings in a short period
Last Thoughts to Take Away with you.

With a Foil Seal you can
9Remove the Tamper Evident Band on the cap Saving Weight
9Remove the Inner Bore Seal in the cap Saving Weight
9Remove the knurling on the neck for the TE Band Saving Weight
9Reduce the neck thickness and weight as it does not need to be so
strong Saving Weight
9Move from Screw Caps to light flexible clip on covers Saving Weight
9For Single Dose applications the cap can be removed altogether
Last Thoughts to Take Away with you.

Target Industries;
Dairy
9 PE, PP, PET
Food and beverage (Non-Carbonated)
9 PE, PP, PET, Glass, CO-EX & Barrier Materials
Pharmaceutical
9 PE, PP, Glass
Agrochemical
9 PE, PP, PET, CO-EX, Fluorinated & Barrier Materials
And on & on & on..
Any Questions?
Optimising Packaging and

Engaging Consumers
Peter Skelton
WRAP: Retail Team
Challenging time for plastic packaging ..
Recyclable
Recycled (PCR)
content
Compostable
Innovation
Biodegradable
Biodegradable
Low carbon
Weight reduction
Material switch
15g
49g
PET packaging
PET is growing in popularity:

Performance
Weight
Recycability
Recycled content
Polymer switch & material switch
Thermoformed sheet: move from PVC, PS to PET
Bottle: move from PVC, glass to PET
Still has opportunities for lightweighting but
increasingly challenging
Best in Class benchmarking ..
Sector and product level pack weight data

Enables benchmarking for optimum pack weights.
Data covers all pack inc cap/label.
Moving to best in class
Product
Packaging weight in 2003

(Tonnes )
Packaging weight reduction if all moved to the

BIC
(Tonnes)
Wine bottles
274,817
107,000
Beer bottles
51,608
19,641
Ketchup table sauce
21,632
13,666
Frozen ready meals
18,100
11,601
Whisky and vodka
49,129
10,546
Carbonates (cans)
28,158
9,972
Beer cans
27,602
9,171
Carbonates (PET)
74,218
8,833
Frozen pizza
12,003
8,005
10
Cooking sauce jars
62,984
7,170
11
Fruit juice cartons
30,175
5,595
12
Pet food (cans)
47,773
5,435
13
Cows milk (cartons)
7,597
4,419
14
Water bottles (PET)
25,371
3,468
15
Cows milk (plastic)
62,570
3,076
Estimated total
756,472
222,375
WRAP Innovation fund:

PET Bottle Lightweighting projects
and their relevant supply chains & customers
but why the need for trials
Challenges
Lowest practical best in class weights

Branded: shape retention
Design options
Processing options
Step change opportunities
Esterform project
2L CSD bottle, 500ml water bottle
Reduction:
2L:
42g to 40g : 4.8%
500ml: 25g to 20g: 20%
Both new best in class for category.

2L: Own brand CSD
500ml: carbonated Radnor Hills water
Focus on lightweighting through design of
body/base.
500ml CSD bottle
Retained std neck

Body and base design changes
25-20g incremental steps using
different preforms
Different preforms designs
4 & 5 foot bases trialled
Overcome nesting challenge
500ml CSD bottle
Findings:
5 foot base provides better material distribution, strength
and stability. Less distortion by carbonation.
4 foot base is standard and accepted design.
Shorter preform with wider diameter performed best.
20g bottles with 4/5 feet were trialled successfully for
production, filling, capping and labelling.
Esterform
Energy saving due to resin reduction
Esterform total = 200MWhr
Coca-Cola Enterprises Ltd

CCE's 500ml light weighting progress
40
38
34
32
30
28
26
24
22
20
19
94
19
95
19
96
19
97
19
98
19
99
20
00
20
01
20
02
20
03
20
04
20
05
20
06
20
07
Bottle Weight (g)
36
Coca Cola Enterprises

Challenge:
To move evaluate feasibility of moving all UK production
from 26g to 24g 500ml bottle for all 500ml CSD bottles c7.5% reduction
Retain iconic bottle designs
Stringent internal testing procedures
4 UK production sites
Varying blow mould equipment
Trials
Developed a new innovative preform design to allow
material distribution and retain wall strength.
Shorter preform pilot tooling trials
Stepped trials on all 4 CCE sites
Culminating in 4m bottles being produced for market
trials from 2 sites
Outcomes
24g Bottle successfully produced and approved for

use.
CCE committed to move to 24g in Sidcup (Sept 2007)

and Wakefield (part production start 2008).
Bottle blowing equipment at some sites less capable
of blowing 24g bottle efficiently
Investment needed to allow roll out to all production
- pending.
Reports, case studies etc .

Reports or case studies available for
projects that have completed.
www.wrap.org.uk/retail
Future picture for PET packaging..
PET recycling
Consumers increasingly engaged with recycling
Plastic collection will grow
UK reprocessing capacity is increasing
Post consumer plastic collection
Mixed bottles collected c45% is PET, 45% PE, 10% other/caps
c132,000t of post-use mixed plastic collected (annualised Q4 2006)

50% of homes have plastic collection
Material cost ..
Oil prices?
As a general rule, less packaging = less cost ..and less carbon
Consumer behaviour
Will
want convenience, Value, Choice

But is going to be more demanding:
Green shopper
Carbon
Recycability
Excess packaging
Greater need for education
904g
486g
Filled weights
Glass to PET
Carbon
Carbon foot printing/labelling is likely to be more
understood and important
Greater need to look at carbon not just recycability,
weight etc more complex.
What we do know:
less material = less carbon
lightweight packaging = less carbon
recycled content = less carbon
WRAP LCA on 500ml non-carbonated drinks bottles:
PET, PE, PLA, Cartons, Glass
Recycling, composting, landfill, incineration
considered.
Due to be published in August
Summary
Its a changing world!
PET lightweighting needs to continue:

Incrementally
Step change
Carbon debate will require a more radical approach.
PET has a great opportunity in retail packaging.
Thank you
peter.skelton@wrap.org.uk
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
WRAP Conference
Next Steps in Bottle Lightweighting 26th June 2007
Where is the Market Going?

Robin Young
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
1981-2007
Gradual weight reductions
2.0 litre Carbonates

500ml Carbonates
500ml still
1981
60g
1997
34g
28g
2007
44-42g
26-24g
18g
Saving
26%
23%
36%
Average
1%/yr
2.3%/yr
3.6%/yr
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Historical Barriers to Lightweighting
TECHNOLOGY
CONSUMER RESISTANCE
Fit for Purpose
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
TECHNOLOGY
CONSUMER RESISTANCE
Fit for Purpose
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Technological Improvements
Improved Oven, stretching and air control with closed loop monitoring
Improved PET material grades and improved temperature uptake.
Improved preform and bottle design technology
Introduction of FORM/FILL/SEAL technology for PET bottles.
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
FORM/FILL/SEAL
Form/fill seal is a lightweighting tool

The bottle is handled by the neck as it is blown, filled and capped.
Removes the need to handle flimsy empty bottles allowing thinner wall
sections
Permits ULTRA LIGHTWEIGHTING
Conclusion: The technological barrier to ULTRA lightweighting has been

removed
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
TECHNOLOGY
CONSUMER RESISTANCE
Fit for Purpose
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Consumer Resistance
POLITICAL and CULTURAL CHANGE OF

CLIMATE
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Consumer Resistance
POLITICAL and CULTURAL CHANGE OF CLIMATE
The constant barrage of media publicity/propaganda which will only increase

as it is at the top of the political agenda, has already affected our
consciousness and lifestyle.
We are already aware of our carbon footprint and we have already adapted
our habits by sacrificing convenience for the greater good of the planet
some examples:
Re-useable shopping bags a return to the shopping baskets of old?
Fortnightly bin collections
Separating household waste
Switching off computers and their transformers
Eco friendly light bulbs
Road miles
Congestion charges
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Consumer Resistance
POLITICAL and CULTURAL CHANGE OF CLIMATE
Conclusion
The consumer is aware that plastic packaging uses non renewable resources
and contributes to landfill
The consumer will accept some inconvenience as his or her contribution to a
reduction of their carbon footprint
Has this removed the Consumer Resistance barrier to Ultra Lightweight
bottles?
There is already a challenge to the PET bottle from the flexible Pouch
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
On The Market Today in PET
330ml Still Water
Ultra
4.5g
Standard
18g
Saving
75%
1.0 litre Edible Oil
15g
24g
37%
1.5 litre Still Water
20g
30g
33%
100ml Probiotic
5g
7g
28.5%
100ml drinking Yogurt
2.4g
--
--
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Conclusion
TECHNOLOGY Barrier Removed
CONSUMER RESISTANCE Barrier
Removed
Fit for Purpose
When considering any level of
lightweighting, the consumer should be
made aware of the carbon footprint benefits
. . . . . . . . . . LINRO LIMITED . . . . . . . . . .
Thank You
Next steps in PET

bottle light weighting
Triple Bottom Line SavingsWaste, Carbon and Costs
Professor Edward Kosior
Managing Director
Nextek Limited
Overview
The Light Weighting of existing
bottles
Target weights for PET bottles
Savings in materials, carbon and costs
250 ml Bottles
Estimated weights of 250mL bottles in the UK marketplace
30
Weight (gm)
25
20
15
10
5
0
0
Millions of Bottles Produced
10
12
330 ml Bottles
Estimated weights of 330ml bottles in the UK marketplace
25
Weight (gm)
20
15
10
Recommended Target Weight: 16gm
Key Targets
5
0
0
20
40
60
80
Millions of Bottles Produced
100
120
500ml CSD Bottles

Estimated weights of 500ml csd bottles in the UK marketplace
30
Weight (gm)
25
20
15
10
Key Targets
5
0
0
100
200
300
Millions of Bottles
400
500
600
1000 ml CSD Bottles

Estimated weights of 1L csd bottles in the UK marketplace
50
Weight (gm)
40
30
20
Key Targets
10
0
0
10
15
20
Millions of Bottles
25
30
35
1000 ml Water Bottles

Estimated weights of 1L still water bottles in the UK
marketplace
60
Weight (gm)
50
40
30
20
10
0
0
10
15
Millions of Bottles
20
25
30
2000 ml Bottles
Weight (gm)
Estimated weights of 2L bottles in the UK marketplace

48
47
46
45
44
43
42
41
40
39
Key Targets
100
200
300
Millions of Bottles
400
500
600
The Savings
Savings delivered by light weighting PET

Each one gram saved on a preform used for a
market of 100 million bottles saves
100 tonnes of PET
80,000 of costs for PET resin at 800/tonne
80,000 kWhr of energy for preform moulding
2670 kWhr of energy for preform heating for
blow moulding
36 tonnes of CO2 being generated
27.2 tonnes of Carbon being used
Assumptions for savings calculations

The best in class weights or feasible targets were used
to model savings
Tonnage savings greater than 90 tonnes /year were
considered financial viable
This is equivalent to savings in resin of more than
200,000/yr
The ratio of data submitted by fillers was used to model
the UK industry
Data submitted to the seminar
Fillers
Moulders
Fillers
Volume
millions pa
Tonnes
used
Ave bottle
weight
total
total
3648
953
109148
24103
28
26
Annual
weight
saving
tonnes
PET
12425
3166
% Weight Ave % Light

saving
weighting
11%
13%
14%
24%
Cost
savings
9,940,351
2,532,400
Potential weight saving projects

Bottle Type
Fluid
(carbonated, Capacity
water, or juice)
(ml)
Juice
Juice
juice
Juice
Juice
Juice
Juice
Juice
Juice
Juice
Juice
Juice
Juice
Carbonated
Carbonated
Still
Carbonated
CSD
Juice
Juice
juice
Juice
Juice
Juice
CSD
Carbonated
still water
Juice
CSD
200
200
250
1000
200
200
200
200
200
300
300
330
440
500
500
500
500
500
1000
1000
1000
1000
1000
1000
1000
1000
2000
2000
2000
Quantity
Current
produced
Bottle
per annum weight (g)
(millions)
22,087
26,099
5.5
4,280
28,197
41,984
47,182
67,559
107,272
25,571
30,043
60
12,147
13,679
23,526
60
88,016
800
5,609
5,600
7.9
13,187
13,191
16,242
80
118,044
70
156,084
500
17.5
17.5
20
39
17.5
17.5
17.5
17.5
17.5
20.5
20.5
21
31
26
28
25.5
26
26
40
43
40
38
40
40
36.5
36
43
43
42
Light
weight
target
saving
grams per
preform
14.5
14.5
14.5
25
14.5
14.5
14.5
14.5
14.5
16
16
16
20
20
20
20
20
24
25
25
25
25
25
25
30
30
40
40
40
3
3
5.5
14
3
3
3
3
3
4.5
4.5
5.0
11
6
8
5.5
6
2.0
15
18
15.0
13
15
15
6.5
6
3.0
3
2.0
Total
Annual
weight
saving
tonnes
PET
66
78
30.25
60
85
126
142
203
322
115
135
300
134
82
188
330
528
1600
84
101
118.5
171
198
244
520
708
210
468
1000
8346
tonnes
used
387
457
110
167
493
735
826
1182
1877
524
616
1260
377
356
659
1530
2288
20800
224
241
316
501
528
650
2920
4250
3010
6712
21000
74994
% weight Cost savings

saving
17%
17%
28%
36%
17%
17%
17%
17%
17%
22%
22%
24%
35%
23%
29%
22%
23%
8%
38%
42%
38%
34%
38%
38%
18%
17%
7%
7%
5%
11%
53,009
62,638
24,200
47,936
67,673
100,762
113,237
162,142
257,453
92,056
108,155
240,000
106,894
65,659
150,566
264,000
422,477
1,280,000
67,308
80,640
94,800
137,145
158,292
194,904
416,000
566,611
168,000
374,602
800,000
6,677,156
Summary of savings that could be achieved

by companies at this conference
Based on 74,994 tonnes of current PET useage
Average weight saving is 11%
Tonnage saved is 8346 tonnes of PET
Cost savings of 6,677,156
Ratio of viable projects was 69%
Projections for the UK PET market

PET resin savings of 15,300 tonnes per annum
Equivalent to 510 million bottles diverted from waste
Energy savings 12.6 million kWhrs
CO2 emission savings of 5500 tonnes
Carbon savings of 4160 tonnes
Cost savings of 12.2 million
Tonnes saved
Bottles
equivalent
Energy
Saving
CO2
Saving
Carbon
Saving
Tonnes pa
Millions at
30 gm/bottle
kWhr
tonnes
tonnes
15294
510
12,643,420
5506
4160
Resin Cost
saving
Power cost
saving
0.05/kWhr
12,235,074
632,171

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Next steps in PET bottle

Waste & Resources Action Programme

Private company, funded by DEFRA and the

Set up in 2001 from Waste Strategy 2000

200 staff, 7 programmes

waste, to use more recycled material, and

The role of WRAP

Waste minimisation, recycling, composting

The scale of the challenge

Waste Strategy for England 2007

The changing retail

Grocery retailers: Green Wars

Strategic targets on:

Courtauld Commitment: Phase 1 Retailers

Signatories represent over 90% of the UK grocery market

Courtauld Commitment: Phase 2 Brands

Influence the brand sector

Influence own brand

Partnership working with retailers / WRAP

Focus on suppliers to household grocery sector

Brand signatories now in double figures

Consumers: seeking engagement

Why a conference on lightweighting

WRAPs PET lightweighting project

Where we want to get to

Next steps in PET

The Light Weighting Issue

The Light Weighting

Light weighting of PET bottles

Savings delivered by light weighting PET

UK Soft Drinks Market

Share of the CSD market by brand owners

Britvic soft Coca-cola

The top three Brand

Share of the Water market by brand owners

% share by brand of the bottled mineral water

Own Label water

Share of the Juice market by brand owners

Own label account for

Summary of the PET Packaging market

Light Weighting Design Principles

PET Bottle design

Size and shape of bottle

CSD, juice or water market

Neck and Closure design

Shelf life and oxygen barrier

Light Weight Bottle Design Principles

Issues that often arise in Light Weighting

Review of current Best

Best in Class survey Wrap/ Exel 2005

Most common CSD bottle weights

Best in Class survey Wrap/ Exel 2005

Weight of PET packaging

Estimated weight of PET

l.5 ltrs PET

Most common Water bottle weights

Best in Class survey Wrap/ Exel

Weight of plastic packaging