Beverage Plastic Cap Market
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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 7 6 5 Neck weight 4 Cap weight Total weight 3 2 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 6 5 4 Neck weight 3 Cap weight Total weight 2 1 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.