Actis

barrier process
The plasma coating solution
for your PET bottles

Actis extends the shelf life
of sensitive drinks
eXtending BeverAge
sheLf Life
Actis (Amorphous Carbon Treatment
on Internal Surface) is a thin layer
of hydrogen rich carbon deposited
inside a PET bottle.
This deposit strengthens the barrier
properties of PET packages to gases
(O2 and CO2).
2 _ ActisTM
BArrier treAtment
for sensitive
AppLicAtions
The Actis process makes it possible
to package sensitive drinks, like beer,
sodas, tea, juices, carbonated water,
and even sauces, in PET and to meet
TO MEET THE DEMANDS OF CARBONATED BEVERAGES AND
OXYGEN-SENSITIVE DRINKS PACKAGED IN PET, SIDEL HAS DEVELOPED
ITS ACTIS AND ACTIS LITE BARRIER SOLUTIONS.
the market requirements in terms of
shelf life for these products. This barrier
solution is designed for small size PET
containers (less than 600 ml), which are
especially susceptible to gas exchanges
(ingress of oxygen (O2) and loss of
carbon dioxide (CO2)).
Actis process tailored to applications
Sidel proposes two barrier solutions: Actis and Actis Lite.
O2 barrier CO2 barrier Solution

Beer, cider x x Actis

CSD, sparkling water x Actis Lite

Juice, tea, sauce x Actis Lite

Actis offers a complete machine range up to 40,000 bph

Actis Actis Lite

Actis 20 10,000 bph 12,000 bph

Actis 48 30,000 bph 40,000 bph

ActisTM extends the shelf life of sensitive drinks like beer, sodas, tea, juices.

3
 Actis coating
by acetylene plasma
The carbon layer is deposited
on the inner wall of the bottle.
4 _ ActisTM
Actis and Actis Lite:
two customized
processes
The Actis process comes in
two versions to satisfy the barrier
requirements of various applications.
In both cases, composition of the
carbon layer is the same. However,
its thickness and slight coloration are
directly related to the plasma process
time:
- Actis = 2.5 sec
- Actis Lite = 1.2 sec
Actis process time = 2.5 sec
Benefits of an internal
barrier layer
Because it is inside the bottle, the
Actis barrier is protected from
mechanical impact.
Actis Lite process time = 1.2 sec
The inert layer, in direct contact with
the beverage, prevents any PET-
related migrations (acetaldehyde). It
protects the packaged product from
any gases coming from PET (O2, etc.).
Because the carbon layer completely
adheres to the inner wall of the bottle,
Actis treated PET is resistant to
delamination, particularly under hot
and humid conditions.
 P2 P0

P1 P0

1 2 3 4 5 6

1 ......................... Vacuum is created inside and outside the bottle (p1 = 0.08 mbar, p2 = 50 mbar)
2........................ Acetylene is injected into the bottle
3 & 4 ......... Microwave energy causes acetylene to reach its plasma state
5........................ Amorphous carbon is deposited on the inner wall of the bottle
6........................ Bottle and treatment station are returned to atmospheric pressure (p0 = 1 mbar)

Barrier performance of Actis treated PET

Barrier improvement factor*
O2 CO2

Actis 30 x 7x

Actis Lite 10 x 3x A
B

*: values compared to an empty, untreated PET package.

Bottle specifications
Actis 20 Actis 48
Bottle height
A 140 mm < h < 218 mm 140 mm < h < 254 mm
under neck ring C

B Bottle diameter 55 mm < < 75 mm

C Max. neck height < 25 mm

D
D Neck ring external diameter 43 mm 41 mm

Vacuum resistance > 50 mbar

5
 Industrial process
In-line integration
Actis is an industrial solution in
production on three continents (Asia,
Europe and the Americas). Its suc-
cess is built upon the Sidel Groups
well-known capabilities in rotary
kinematics and reliable mechanics.
The Actis range of equipment
guarantees availability rates of over
95 percent. For that reason, it can be
smoothly integrated into a complete
production line.
With a range of output rates from
10,000 to 40,000 bph, Actis
technology can meet the full range
of needs on the liquid food market.
This technology can be used in a
blowing-barrier treatment-palletizing
line (for empty bottle production) as
well as in a complete, integrated
production line configuration.
Quality control
Real time control of key process
parameters is made at each treatment
station on the Actis machine. These
parameters include vacuum levels
inside and outside the bottle, acetylene
flow rate, microwave power and plasma
6 _ ActisTM
luminosity. If readings do not fall within
the acceptable minimum and maxi-
mum limits set for each parameter,
the bottle is ejected. This control gua-
rantees top-quality barrier treatment
on each bottle. A bottle marking system
also ensures production traceability
by identifying the production date
and treatment station number.
Recycling
Actis treated PET can be recycled
in traditional PET recycling streams.
The deposit represents less than 0.04
percent of total PET bottle weight.
Sidel has proven, through various
protocols (APR / Association of Post-
consumer Plastic Recyclers, PET-
CORE / PET Container Recycling
Europe), that Actis technology has
no negative impact on recycling. The
recycled material can be reintroduced
at very high rates into material used in
bottle production. These rates vary
depending on the protocol. However,
they are far superior to the best
estimates for this technologys ability
to penetrate these markets.
Recycling has no impact on PETs Functional barrier
thermo-mechanical properties. The
only limiting factor is residual color Actis treatment meets criteria
(factor b*), but this only concerns established by the FDA for the use of
transparent, Actis treated bottles. up to 50 percent recycled, non-food
Also, the slight coloration of the Actis compatible PET to produce bottles
layer fades considerably during PET for liquid foods. The barrier created
washing operations. When recycling using Actis technology sufficiently
colored Actis treated bottles, there blocks any contamination accidentally
is no impact on recycled PET. present in the recycled material. This
functional capacity of the Actis
deposit has been confirmed by a
Food compatibility no-objection letter from the FDA.
In the United States, the FDA (Food &
Drug Administration) has issued a no-
objection letter stating that Actis
technology is safe for use with food
products. In the European Union, the
TNO (Technische National Onderzoek
applied scientific research lab based
in the Netherlands) also confirms that
Actis complies with European
Directives for use in PET packages
for food applications. Finally, Actis
meets food safety standards in
countries such as Brazil, Canada,
Japan, etc.
1 - Actis is a commercial-scale technology in production
1 on three continents.
2 - Actis treated PET is recyclable.
3 - The five major process parameters are controlled in real
2 3 time.
7
 Actis 20
for barrier treatment at rates up to 12,000 bph
With its rotary kinematics, proven in
the blowing sector, the Actis 20
machine offers output rates between
10,000 (Actis) and 12,000 (Actis
Lite) bottles per hour.
Reliable conveying
by the neck
An advanced system conveying bottles
under the neck guarantees reliable
transfers at the bottle entrance and
exit. Fed into the machine by an
infeed screw, the bottle is then
8 _ ActisTM
conveyed, by the neck, through a
transfer wheel.
Each station on the treatment wheel
is equipped with a pneumatic nozzle
to load and unload the bottle by the
neck. This limits any mechanical
stress on the bottle shoulder as it
exits the treatment wheel and also
expands the possibilities for treating
different bottle shapes.
The bottle is then transferred to the
air rinser while still being held by the
neck as it is turned over for the air
rinsing step (compressed, dry air, 7 Ergonomic machine
bars). Then the exit wheel guides the
bottle to downstream conveyors. Compact and accessible, functional
and user-friendly, the Actis 20
machine was designed to guarantee
Optimized vacuum availability rates of over 95 percent.
system
The user-friendly control panel has a
The vacuum rotary union distributes touch screen to simplify control of the
the vacuum evenly among the 20 machine and supervision of process
treatment stations. This patented parameters.
system effectively controls pressure
levels before and during the process. Maintenance on the machine is
The pressure level outside the bottle facilitated by the accessibility of the
is regulated according to a set point, equipments main systems.
generally at 50 mbar. Once this
threshold is reached, pumping occurs
only inside the bottle to reach a
pressure level of around 0.08 mbar.
Control of both of these successive
pumping operations makes it possible
to treat lightweight bottles (vacuum
resistance of at least 50 mbar).
Actis 20 is a compact, ergonomic
machine for output rates
up to 12,000 bph.
With its 20 plasma treatment stations,
the Actis 20 guarantees availability
rates of over 95 percent.
 C

A ............... Bottle infeed

B ............... Treatment wheel
G C ............... Electrical cabinet
D ............... Supply (acetylene
and compressed air)
E................ Vacuum pumps
F ................ Vacuum device
G ............... Air rinser
E
H ............... Bottles out
I ................. Control station
H
Machine dimensions:
F 5.20 m (l) x 4.60 m (w) x 3 m (h)

I w

l
Actis 20 energy consumption*
Actis 20

Process type ActisTM Actis LiteTM

Output rate (bottles/hour) 10,000 12,000

Nitrogen (1) (max flow rate in NL/day) 15 15

Acetylene (2) (average flow rate in Nm3/h) 0.099 0.057

Compressed air (7 bars) Average air flow rate (pumps Nm3/h) 6 6

Compressed air (7 bars) Average air flow rate (air rinser Nm3/h) 180 180
* Estimates for a 500 ml bottle
Power consumption (KW/hr) 56 54 (1)
ow in case of purge only
(2)
laboratory quality minimum 99.7 % C2H2
Cold water (closed circuit - m3/hr) 3.6 4.2
9
 Actis 48
offers barrier treatment at rates up to 40,000 bph
With its rotary kinematics, proven in
the blowing sector, the Actis 48
machine offers a range of output rates
from 30,000 (Actis) to 40,000
(Actis Lite) bottles per hour.
Innovative design
The basic principles of the Actis 48
machine are identical to those of the
Actis 20: vacuum system, plasma
technology, process time, treatment
of lighter weight bottles, positive
transfer. The process guarantees the
same level of performance in creating
a barrier to oxygen (O2) and carbon
dioxide (CO2) for both the Actis and
Actis Lite processes.
The new mechanical design found
on the Actis 48 is the fruit of Sidels
latest advances. Some of these include
loading bottles by the base at the
treatment station along with a system
that maintains a constant vacuum
until bottles reach the treatment stations.
These latest advances are patent
protected.
High speed solution
Unlike the Actis 20, bottles on the
Actis 48 are loaded by the base to
limit moving mass. Combined with the
48 treatment stations, this guarantees
a considerably shorter cycle time per
treatment station and increases speed
by up to 40 percent compared to the
Actis 20 (from 500 to 625 bottles/
station/hour for the Actis treatment,
and from 600 to 833 bottles/station/
hour for Actis Lite).
The air rinser also features an innovative
mechanical design. The bottle turning
mechanism ensures an extremely
reliable solution for high-speed
applications.
Reducing maintenance body guiding. This reduces the number
time of customized parts required for bottles
and considerably speeds up format
The Actis 48 is designed to changeover times.
guarantee availability rates of over 95
percent. Its ergonomic and functional For example, changing a bottle height
design offers complete accessibility without neck modification requires
to all parts of the machine and makes thirty minutes of work by a technician
maintenance easier. and less than one hour to change a
bottle shape with a different height
Daily maintenance is required to and diameter.
guarantee the optimum pressure level
for the process. This is partially auto-
mated with a robot that replaces the
injectors and used nozzles with a set
of clean parts.
Quick format
changeovers
At the machine entrance, bottles
are fed by an infeed screw and an
under-neck guide. Bottles are then
conveyed by the neck or under the
neck using transfer grippers with no

Actis 48 meets the needs Because bottles are loaded by the base, Neck conveying reduces the number
for high speeds often demanded the Actis 48 can reach a speed of up to of customized parts needed for bottles.
by the liquid food market. 40,000 bph and is the fastest
equipment in the world for PET bottle
barrier treatment.

10 _ ActisTM
 B
B

C
D

F
A ............... Bottle infeed
B ............... Vacuum pumps
C ............... Electrical cabinet
D ............... Supply (acetylene
and compressed air)
E................ Treatment wheel
F ................ Bottle outfeed
G ............... Air rinser
H ............... Control station

Machine dimensions:
G A 8,30 m (l) x 6,10 m (w) x 4 m (h)

H w

Energy consumption for the Actis 48*

Actis 48

Process type ActisTM Actis LiteTM

Output rate (bottles/hour) 30,000 40,000

Nitrogen (1) (max flow rate in NL/day) 50 50

Acetylene (2) (average flow rate in Nm3/h) 0.296 0.205

Compressed air (7 bars) - Average air flow rate (pumps - Nm3/h) 144 144

Compressed air (7 bars) - Average air flow rate (air rinser - Nm3/h) 720 720
* Estimates for a 500 ml bottle
Power consumption (KW/hr) 122 111 (1) ow rate in case of purge only
(2) laboratory quality minimum 99.7 % C2H2
Cold water (closed circuit - m3/hr) 11.4 13.2

11
 Beer

Beer is a very oxygen-sensitive sheLf Life of more Specifications of Actis treated PET
carbonated drink. Its unique properties thAn siX months Barrier property improvement factors
like foam, carbonation, color, aroma, for Actis treated PET
flavor and bitterness are fully protected Beer packaged in an Actis treated
in an Actis treated PET bottle. PET bottle now reaches a shelf life O2* 30 x
of more than six months. An Actis
CO2** 7x
treated PET package guarantees :
QuALity depends on *values compared to an empty, untreated PET package.
pAckAge performAnce Superior performance with oxygen **values compared to a filled, untreated PET package.
ingress below 1 ppm over 6 months.
Protecting the characteristics of beer Number of weeks
depends on the type, storage conditions Excellent barrier to CO2 with loss of to reach 1 ppm of O2
and performance of its package. less than 10 percent over 6 months. 40
30 BIF > 10
During filling, oxygen is present in the 20
of weeks
Number

beer itself and in the headspace. 10

Oxygen from the surrounding air and 0
from PET then penetrates into the PET Actis treated PET
liquid. After a few weeks, if there is Test conditions: - 500 ml bottle, 28 g, 20C
no barrier treatment, the oxygen - Carbonated water at 5.5 g/l CO2
concentration in the product reaches
a critical threshold of 1 ppm. Beyond
that level, the taste of beer is altered
to a point that is no longer acceptable Number of weeks
to market standards. Thats why Sidel to reach 10 percent loss of CO2
developed the Actis barrier solution 80
to reduce gas exchanges (O2, CO2). 70
60 BIF > 7
50
40
30
20
of weeks
Number

10
0
PET Actis treated PET
Test conditions: - 500 ml bottle, 28 g, 20C
- Carbonated water at 5.5 g/l CO2

12 _ ActisTM
Carbonated
drinks
Carbonated beverages are especially
sensitive to the loss of carbon dioxide.
Actis Lite treated PET packages
maintain a suitable level of carbonation
in these beverages over time.
soLution for smALL
contAiners
The Actis Lite barrier solution
extends the shelf life of carbonated
drinks packaged in PET packages.
The process is primarily used for small
formats, less than 600 ml, which are
particularly susceptible to losses of
carbon dioxide (CO2).
Generally, bottle weight is increased
to compensate for standard PETs
lack of barrier properties in small
containers. However, gains in shelf
life are considerably inferior to Actis
Lite treated PET containers.
BottLe Lightweighting Specifications of Actis Lite treated PET
Barrier property improvement factors
Actis Lite treatment guarantees for Actis Lite treated PET
significant savings in material costs
thanks to a reduction in bottle weight CO2* 3x
of 15 to 20 percent (vacuum resistance *values compared to a filled, untreated PET package.
of at least 50 mbar).
For example, a 600 ml PET carbonated Shelf life and lightweighting
drink bottle that weighs 28 g has a shelf of Actis Lite treated bottles
life of about eight weeks. That same 50
bottle, when treated with Actis Lite 40
and reduced to 23 g, has a shelf 30
life of over 20 weeks and represents 20
of weeks
an 18 percent savings in PET resin.
Number
10
0
In spite of the lightweighting, the 23 g 24 g 28 g
bottles mechanical performance
remains the same thanks to advances PET Actis Lite treated PET
in preforms and bottles that are
produced by Sidels range of blowing Test conditions: - 600 ml bottle weighing 23 g, 24 g and 28 g, 23C
equipment. - Carbonated drink at 4 vol/CO2 or 8 g/l CO2
- Number of weeks to reach 17.5 % loss of CO2
Number of weeks
to reach 17.5 % loss of CO2
30
20 BIF > 4
of weeks
Number
10
0
PET Actis Lite treated PET
Test conditions: -12 oz (355 ml) bottle, 21 g, 23C
- Carbonated beverage at 4 vol/CO2 or 8 g/l CO2
13
 Oxygen-
sensitive drinks

Juice and tea are oxygen sensitive
beverages. Actis Lite treated PET
packages keep oxygen from getting
into the bottle thus increasing the
shelf life of these products.
of vitamin C, Actis Lite guarantees Specifications of Actis Lite treated PET
a minimum level of 300 mg/l after six Barrier property improvement factors
months. of Actis Lite treated PET
O2* 10 x
hot And Aseptic fiLLing
*values compared to an empty, untreated PET package.

soLution for Juices Sterilizing agents used in packaging

liquid foods, such as peracetic acid Concentration of vitamin C
For fruit juices, oxygen in the heads- (PAA) or hydrogen peroxide (H2O2), and losses analysis over 6 months
pace and in the product itself is linked have no effect on Actis Lite treatment.
450
to a significant loss of vitamin C. Also
30
contributing to this loss are anaerobic Similarly, hot filling has no impact on 400 95 30
reactions. All of these vitamin losses an HR (heat resistant) PET package
occur independently of the type of treated with Actis Lite. Green tea 350 BIF > 3
package, with or without barrier. filled at 92C is a perfect example of 30 90
this type of application. 300
Actis Lite creates a passive barrier 90
in the package and significantly reduces 250
Concentration of vitamin C in mg/l

the ingress of oxygen.

200

For orange juice packaged in a 330 ml 150

bottle, Actis Lite significantly limits 300
the monthly loss of vitamin C. Thus, 100 235
for an initial concentration of 450 mg/l
50

0
PET Actis Lite treated PET
Package-related losses
Anaerobic losses
Losses related to headspace and beverages
Concentration of vitamin C

Test conditions: - 330 ml bottle, 23C

- Initial concentration of vitamin C: 450 mg/l
- Minimum threshold of vitamin C: 300 mg/l

14 _ ActisTM
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Sidel Blowing & Services, hereinafter Sidel, - Avenue de la Patrouille de France - F-76930 Octeville-sur-mer - RCS Le Havre B 424 623 759 - EN - As we constantly strive to improve production, Sidel reserves the right to modify its equipment.
Therefore, this document cannot be considered as contractually binding. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, without the previous written approval of Sidel.
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