BEVERAGE PLASTIC CAP MARKET
Global Market Trends
Alessandro Falzoni SACMI Packaging Lab Director Company profile
2 SACMI Imola
SACMI Imola is the parent company of the SACMI Group. An Italian cooperative that leads the world in the design, production and marketing of industrial technology and manufacturing systems for the ceramic and packaging industries. On the market for almost 100 years, SACMI is now a major Italian enterprise in terms of size, sales, territorial coverage and services offered. A network of over 80 companies with sales 4.305. employees, and assistance services, including SACMI world region employees of whom 1.343 30 production facilities in Italy, Germany, Egypt, Iran, USA, Mexico, Brazil, India, outside Italy Indonesia, China
Germany 326
Russia 33 Europe 119 China 391 N.America 143 Italy 2.962
India Far East 115 88 S.America 44 Africa 16 Middle East 68 Revenues from sales and services
1434 1 394 1 354
1 227 1 196
16% 14.6 13% 15% 12 % %
in millions of Euro Italy
2013 2014 2015 2016 2017 Ebitda
170 165 155 147 156
in millions of Euro
2013 2014 2015 2016 2017 SACMI Businesses
Ceramics Packaging Food Service & Automation . Tiles . Closures . Processing & . Shipping & Logistics . Sanitaryware . Containers molding . Administrative & IT . Tableware . PET preforms . Primary Service . Heavy Clay . Beverage packaging . Quality control . Special . Secondary . Factory data Pressing packaging processing & control . Technical . Wrapping . Inspection Systems Ceramics equipment . Electrical engineering
PVC free lug caps Composite aluminum cap Technology
ENERGY SAVING RUNS FASTER WEIGHT CONSISTENCY DIMENTIONAL CONSISTENCY
Movie Molds
Precise mold manufacturing
Precise coolant flow and temperature control
Short cycle time Technology
Extensive competence incorporated in the same structure…..
CONTAINER DESIGN Food, Dairy, Beverage PREFORM DESIGN Pharmaceutical applications Pilot mold and proto Full testing capability Neck and body light-weighting Full testing capabilities
SACMI LAB R & D center
CAP DESIGN Pilot mold and proto BOTTLE DESIGN Full testing capabilities Market analyses Light weighting 3D-rendering, mock-up and FEA analysis Pilot mold and proto Full testing capabilities Light-weighting Introduction
For the last 10-15 years, the focus of our industry was light weighting: reducing packaging weight (bottles and caps), without affecting performance and consumer experience. The industry collectively spent millions, but reduced resource and energy consumption, CO2 emissions to levels unthinkable, when the whole process started. The combined efforts of all industry players allowed the market to grow, while keeping a stable impact on the environment.
1994 2008 2018 PCO1810 - 5.06 g PCO1881 - 3.81 g GME30.37 - 2.4 g EU Initiative
However, plastic cap manufacturers and their mold suppliers are obliged to direct their efforts towards new directions by other external factors. Soon new EU regulations are expected to be approved. During the next few weeks, the European Parliament is to vote on the directive 2018/0172(COD) “Reduction of the impact of certain plastic products on the environment”. For cap manufacturer and OEMs, the most relevant part of the directive is Article 6, which states the following:
…… Member States shall ensure that single-use plastic products listed in Part C of the Annex that have caps and lids made of plastic may be placed on the market only if the caps and lids remain attached to the container during the product’s intended use stage. …….. Market examples
Aptar - Krones Betapack SACMI developments
It is not clear yet when a cap can be considered attached to the container, for this the market players need to wait for the harmonized standards. SACMI will support its partners on every possible outcome of this changing period, having set developments and activities as follows: 1. new light weight caps for returnable plastic bottles, both with and without liner, should a bottler decide to move from single use bottles to returnable bottles; 2. lightweight metal crown caps, in case the bottler decides for using a metal cap on a plastic bottle; 3. new slitting patterns together with partner company, which allow the cap to stay “attached” to the bottle; 4. ongoing testing for new mold layouts and functions. SACMI developments
Tethered slitting http://www.thiscap.com/
PCO1881
26/22 mm SACMI developments
Snap on cap Other countries expected to follow
+ Some states of USA Europe Africa CSD different caps in different regions, regardless logistic and climatic conditions Korea China CSD – EUROPE
Nearly or standard PCO 1881 +1.8g – 2.0 g caps CSD – Africa
Standard PCO 1881 +2.15 g caps
Europe Africa CSD – China
Standard PCO 1881 +2.4 g caps
Europe China CSD – Korea
Reinforced PCO 1881 +2.6 g caps CSD – Korea Reinforced PCO 1881 +2.6 g caps
Europe Korea CSD – divergence examples
CSD PCO1881 Neck weight Cap weight Total weight Europe 3.6 2 5.6 Africa 3.8 2.15 5.95 China 3.8 2.4 6.2 Korea 4 2.6 6.6
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4 Cap weight Total weight
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1 Europe Africa China Korea AB1881CSD16 1-piece cap
- Industrial mold CSD Low CSD - Weight from 1.8 g to 2.0 g Weight 2.0 g 1.8 g - Moulds available with COOL+ technology only, Cycle time 2.1 s M OPT 3 Passed Passed - One mold, multi purpose cap liters Slip agent 1000 ppm 1000 ppm
28 AB1881CSD17 1-piece cap
- Pilot tool CSD Water - Weight from 1.85 g to 2.0 g Weight 2.0 g 1.95 g - Moulds available with COOL+ technology only, Cycle time 2.1 s M OPT 3 Pass NA - One mold, multi purpose cap liters Slip agent 1000 ppm No
29 Water - divergence examples
USA and Europe Italy Water
Asia China
Global Water - divergence examples
30/25 mm 29/25 mm 26/22 mm 25/22 mm Water – China - divergence examples 30/25 mm Neck – Cap Combination 3.8 g + 1.65 g
Drivers for NOT changing Consumer convenience and acceptance Capping performance Water – N & E EUROPE - divergence examples
PCO1881 or nearly PCO1881 - neck cap combination 3.8 g + 1.4 g
Drivers for using same neck of CSD • Large proportion of sparkling water • Other drinks as such juices, flavored waters filled in aseptic • Consumer convenience and acceptance • Capping performance Water – Global- divergence examples 29/25 mm Neck – Cap Combination 2.4 g + 1.25 g
Drivers for changing - Light weighting Water – Asia- divergence examples 29/25 mm Neck – Tall Cap Combination 2.4 g + 1.5 g Same gripping surface of 30/25 in a 29/25 standard neck
additional portion Water – USA Italy - divergence examples 26/22 mm Neck – Cap Combination 1.9 g + 1 g
Drivers for changing - Light weighting Water – USA Italy - divergence examples 25/22 mm Neck – Cap Combination 0.9 g + 0.8 g
Drivers for changing - Extreme Light weighting Might requires special injection molding equipment Might requires special blow molding equipment Water – divergence examples
Water Neck weight Cap weight Total weight China 30 mm 3.8 1.85 5.65 Europe 3.8 1.6 5.4 Global 29 mm 2.4 1.25 3.65 South East Asia 29 mm tall 2.4 1.5 3.9 Italy 1.9 1 2.9 USA 0.9 0.8 1.7
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Neck weight 3 Cap weight Total weight 2
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0 China 30 mm Europe Global 29 mm South East Asia Italy USA 29 mm tall 30-25 mm Neck finish CETIE 30.21
Even in markets which are sticking to 30/25 mm neck finish the search for weight savings never stopped. From 1.45 grams 3.3 grams
• Pilot tool • For still and N2 pressurized water • Weight from 1.45 g • Moulds available with COOL+ technology, Cycle time 1.44 s 39 Ongoing development
Needs
Light weighting Consumer convenience New light weight Combine neck finish Different beverages towards - CSD GME 30.37 - Still water - Cold Aseptic Filling
Simplify supply and production chain New neck 26/22 13 mm GME 30.37
Up to 4.2 vol CO2, 2 liters bottle
Neck split PL @ 1 mm, enhanced sealing
Extended height , enhanced consumer convenience
Six slots, safe gas venting
680° thread wrap, enhanced safety and sealing New neck 26/22 13 mm GME 30.37
2008 2018 1994 PCO1881 - 3.81 g GME30.37 - 2.4 g PCO1810 - 5.06 g Cap for GME 30.37
SACMI AB26CSD4 Cap for GME 30.37 NECK FINISH
1-piece closure, 1.65 g, 2.0 s cycle time Materials HDPE properties
A lighter and thinner cap poses several challenges to resin suppliers, which have to combine clashing needs.
Environmental Stress Cracking Resistance (ESCR) is a key parameter for CSD caps, but it is also important for still drink caps.
• Thinner caps need a • Thinner caps need an The stiffer HDPE The easy flowing HDPE
• An easy flowing HDPE is • A stiffer HDPE is obtained obtained decreasing the increasing the density Resin Resin molecular weight
• Decreasing the • Increasing the density molecular weight usually usually reduces ESCR Challenge Challenge reduces ESCR Materials HDPE properties
Flow Stiffness properties
ESCR ESCR
Larger diameter neck and cap – Juices Teas
Regardless regional differences, water and CSD show a clear trend towards light weighting and better resource utilization. Cold Aseptic Filled (CAF) and Hot Filled Beverages (HF) do not show the same general trend towards light weighting. New lighter neck finishes 32 mm were introduced, however these neck finishes are very slow in gaining market shares. Why? - High conversion costs - Consumer perception - Drinking experience - Sensitive drinks Trends light weighting for current 38 mm caps
New lighter 38 mm caps were introduced in the market. Another challenge for resin suppliers, as ESCR has to be combined with flow properties and higher stiffness.
Thinner top and side walls, From 2.6 g to 2.9 g for light weighting
Multiple sealing points and tall plug seal, for better sealing
Extended and more robust thread, for stronger engagement
Flexible band for easy capping Trends & Proposals: from 38 to 32 mm
Increasing • Liquid N2 pressurization performance • Venting performance requirements • Break then leak feature
• Cost saving Lighter • Sustainability packages
New smaller light weight necks CAF - From 38mm to 32mm
38 mm 32 mm Cold Aseptic Filling 32 mm, 2 threads
32 mm Neck – Cap Combination 3.2 g + 2.3 g Cold Aseptic Filling weight chart
Large Ø CAF Neck weight Cap weight Total weight 38 mm 3 threads 4.2 2.8 7 38 mm 2 threads 4.3 2.9 7.2 33 mm 3 2 5 32 mm 3.2 2.3 5.5
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5 Neck weight
4 Cap weight Total weight 3
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0 38 mm 3 threads 38 mm 2 threads 33 mm 32 mm HF - From 38mm to 32mm
38 mm 32 mm Hot Filling 32 mm, 2 threads
32 mm Neck – Cap Combination 3.65 g + 2.5 g Hot Filling weight chart
Large Ø hot filling Neck weight Cap weight Total weight 38 mm 7.4 3.6 11 32 mm 3.65 2.5 6.15
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8 Neck weight Cap weight 6 Total weight
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0 38 mm 32 mm Market trends – further input
Beverage industry wants to reach out to more people, providing more affordable packages to more consumers. - Returnable bottles - Small size, single serve bottles - Bulk delivery
55 Returnable PET bottles with 28 mm neck
2-piece cap, 2.8 grams + dedicated liner 1-piece cap, 2.65 grams Very challenging
56 22 mm neck Single serve CSD
Third parties pending patents
22 mm neck cap combination . Cap Weight 1.45 grams . Neck weight 2.12 grams 24 mm neck Single serve CSD
24 mm neck cap combination . Cap Weight 1.55 grams . Neck weight 2.18 grams Single serve water bottles
25/22 mm neck finish based on GME30.39
25/22 mm cap with extended height . Weight 0.85 grams . Extended height 10 mm . Suitable for double tethered slitting . Cycle time: 1.6 s Single serve water bottles
Preform and 220 ml bottle . Weight 4.2 grams . 5,8 s cycle time . Ribbed side Case Study SACMI ultra short 25/22 mm
Back in 2014/2015 we did the following study for single serve bottles
Neck features . < 0.8 grams . 2 threads Cap features . 0.55 grams . Olive plug seal . Slitted tamper band 48 mm – bulk delivery
Cap Weight Mold type Cycle Remarks S48W 5.7 g Standard 3.8 s Recess type
62 48 mm – bulk delivery
63 • Our main focus is the beverage market, however the next machine we are releasing is going to be for multi-layer per coffee pods
• How it works
• Machines to be delivered during 1st quarter 2019
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