Right Weighting Closures Experience pertinent to closure weight

  • Slides: 28
Download presentation
Right Weighting Closures Experience pertinent to closure weight reduction. -1 - 02_2013 opyright© BERICAP

Right Weighting Closures Experience pertinent to closure weight reduction. -1 - 02_2013 opyright© BERICAP “not to be taken lightly”

THE BERICAP GROUP q Family Owned and Operated q Specialized in Closures q Sales

THE BERICAP GROUP q Family Owned and Operated q Specialized in Closures q Sales ~850 million $ in 2014 q 72 billion plastic closures p. a. q 23 closure manufacturing sites in 20 countries in the world q Mould Manufacturing q Sales offices and agents in 70 countries -2 - 02_2013 opyright© BERICAP q 5 R&D centres (USA, France, Germany, Spain, Turkey)

Lightweight 26 mm in 2010 All values in gram (g) Hexacap® 26, 7 Hexa.

Lightweight 26 mm in 2010 All values in gram (g) Hexacap® 26, 7 Hexa. Lite® 26/10 SFB Savings Closure 1, 60 0, 97 - 0, 63 Neck 3, 42 1, 97 - 1, 45 Total 5, 02 2, 94 - 2, 08 -41% -3 - 02_2013 opyright© BERICAP Hexalite® 26/10 Hexacap® 26. 7

Lightweight 29 mm in 2011 All values in gram (g) Hexalite® 29/11 Hexacap® 30/2

Lightweight 29 mm in 2011 All values in gram (g) Hexalite® 29/11 Hexacap® 30/2 5 Hexa. Lite® 29/11 Savings Closure 1, 95 1, 45 - 0, 50 Neck 3, 90 2, 44 - 1, 46 Total 5, 85 3, 89 - 1, 96 -33. 5% -4 - 02_2013 opyright© BERICAP Hexacap® 30/25

JETS – Juice, Energy Drinks, Teas, Syrups Hot Fill E-Wall 38 mm 33 mm

JETS – Juice, Energy Drinks, Teas, Syrups Hot Fill E-Wall 38 mm 33 mm low 33 mm 38 mm 1, 5 mm 1, 3 mm 1, 2 mm 16, 8 mm 15, 1 mm 12, 9 mm 15, 1 mm 17, 2 mm 15 mm 12 mm 15 mm shallow Weight in g 1) incl. transport ring to the top of the neck Closure Height 6, 3 g 8, 4 g - 1, 2 g - 0. 8 g - 0. 7 g 5, 1 g 5, 5 g 7, 7 g -5 - 02_2013 opyright© BERICAP Neck Height 1) Aseptic

Super. Shorty® 28 mm-1881 PCO Product Range 1 chuck for both closure types High

Super. Shorty® 28 mm-1881 PCO Product Range 1 chuck for both closure types High Performance Solution 1 -piece Double. Seal Super. Shorty® CSD still weight 2, 40 gr weight 1, 80 gr Qualifying. For 2. 15 g still & carbonated water & CSD up For Still water & beverages with ATE CSD Still 1 chuck for both closure types For Moderate Climate ® 1 -piece Double. Seal Super. Shorty Eco weight 1, 90 gr CSD Eco For still & carbonated water & CSD up to 8 g CO 2 / ltr For Still water & beverages with ATE Still special chuck 1 -piece Crown Double. Seal Super. Shorty® Crown weight 2, 70 gr (lighter version under development) For CSD & beer up to 8 g CO 2 / ltr Double. Seal Super. Shorty® still weight 1, 70 gr special chuck 2 -pieces CSD Liner. Seal Super. Shorty® CSD weight 2, 50 gr For still & carbonated water & CSD up to 8 g CO 2 / ltr -6 - 02_2013 opyright© BERICAP CSD to 8 g CO 2 / ltr and hotfilled products

Full Circle Rightweighting vs. Lightweighting Consumer convenience Right Package performance Weighing Carbon and Cost

Full Circle Rightweighting vs. Lightweighting Consumer convenience Right Package performance Weighing Carbon and Cost Savings -7 - 02_2013 opyright© BERICAP Ease of application

Rightweighting A short list to consider Determining Closure “Duty” Material Choice + Design Process

Rightweighting A short list to consider Determining Closure “Duty” Material Choice + Design Process Considerations In-Trade Finding Balance 02_2013 opyright© BERICAP • • •

Closure “Duty” Packaging and Process -9 - 02_2013 opyright© BERICAP 1. Process Examples -

Closure “Duty” Packaging and Process -9 - 02_2013 opyright© BERICAP 1. Process Examples - Aseptic, CSD, Hot/Cold, HPP 2. In bound, storage, and filling Environment(s) 3. Filling Speeds and Process Accuracy

Closure “Duty” Weight savings vs. process investment - 10 - 02_2013 opyright© BERICAP Bottle

Closure “Duty” Weight savings vs. process investment - 10 - 02_2013 opyright© BERICAP Bottle + Closure + Neck Finish design affects package characteristics, and consequent manufacturing methods.

Closure “Duty” Interaction with Package Content - 11 - 02_2013 opyright© BERICAP Content +

Closure “Duty” Interaction with Package Content - 11 - 02_2013 opyright© BERICAP Content + Environment will provoke different effects as closure weight is reduced

Closure “Duty” Route to market – Environment Rural vs. Urban Hot / Moderate Containment

Closure “Duty” Route to market – Environment Rural vs. Urban Hot / Moderate Containment and Security • • Physical Exposure Eviro-Exposure Organoleptic Exp. Tampering - 12 - 02_2013 opyright© BERICAP Basic Considerations:

Closure “Duty” Post Consumer - 13 - 02_2013 opyright© BERICAP • Recycling stream? •

Closure “Duty” Post Consumer - 13 - 02_2013 opyright© BERICAP • Recycling stream? • Landfill? • Environmental Impact

Material Choice + Design Ex. 28 mm PCO 1881 Qualifying 2. 15 g DS

Material Choice + Design Ex. 28 mm PCO 1881 Qualifying 2. 15 g DS SUS 7088 @ 2, 4 g DS SUS 7107 @ 2, 15 g PCO 1881 Finish must remain unchanged! ns tio ed op it im What can we safely remove? Inner cap geometry must remain unchanged! 02_2013 opyright© BERICAP L

Material Choice + Design Ø Fact: Shell Wall Reduction leads to loss in radial

Material Choice + Design Ø Fact: Shell Wall Reduction leads to loss in radial tension Ø Result: Increased cap expansion when exposed to elevated temperature Ø Consequences: § Strip torque reduced § Less robust performance under Temp. Cycles § Shelf life performance – CO 2 loss § BLOW OFF RISK !! 02_2013 opyright© BERICAP Consequences of reduction - Example

Material Choice + Design Where to reduce PCO 1881 weight 2, 40 g head

Material Choice + Design Where to reduce PCO 1881 weight 2, 40 g head plate 1, 4 mm PCO 1881 weight 1, 95 g head plate 1, 0 mm After BSDA cycle 1, 2 mm doming 1, 84 mm doming 1, 93 mm doming 2, 60 mm doming * BSDA – British Soft Drink Association 02_2013 opyright© BERICAP ambient

Process Considerations Investment total system Parameters Expected Line performance < 1/30. 000. Machine Closure

Process Considerations Investment total system Parameters Expected Line performance < 1/30. 000. Machine Closure Bottle Whole Application System - 17 - 02_2013 opyright© BERICAP Product

Process Considerations Automation Equipment Maintenance - 18 - 02_2013 opyright© BERICAP Correct and/or Conversion

Process Considerations Automation Equipment Maintenance - 18 - 02_2013 opyright© BERICAP Correct and/or Conversion of Existing Equipment Quality Accuracy of Equipment

Process Considerations Set Up – Ex. 1810 vs. 1881 PCO Ø Position before neck

Process Considerations Set Up – Ex. 1810 vs. 1881 PCO Ø Position before neck / cap thread start contact PCO 1810 - 28 mm ü longer skirt of closure allows precentring on the neck 7, 5 mm Ø Vertical distance to complete closure of the bottle; required capping height Example: 2. If a cam is geometric to 1810 centring and thread engagement could be at risk. 6, 7 mm - 19 - ü No precentring due to short skirt ü Precise centring via the capping machine necessary - 19 - 02_2013 opyright© BERICAP PCO 1881 - 28 mm 1. The Double. Seal Super. Shorty Eco closure e. g. needs 6. 7 mm cam decent to apply

Process Considerations Packaging 10% Allowance - 20 - 02_2013 opyright© BERICAP Closure Ovality

Process Considerations Packaging 10% Allowance - 20 - 02_2013 opyright© BERICAP Closure Ovality

In-Trade Considerations Examples from Carbonated Application Critical CSD Requirements High Temperature Route Vending Temperature

In-Trade Considerations Examples from Carbonated Application Critical CSD Requirements High Temperature Route Vending Temperature Cycling Opening / Closing Performance Strip torque Tamper Evidence Before HRVT After HRVT - 21 - 02_2013 opyright© BERICAP • • •

Finding Balance Safe reduction of neck finish material HDPE Shell 13% 39% Inner seal

Finding Balance Safe reduction of neck finish material HDPE Shell 13% 39% Inner seal Neck softened high processing temperatures: ØNeck supported from inside and outside ØOpportunity to safely reduce wall thickness - 22 02_2013 opyright© BERICAP Outer Seal

Finding Balance Material / Closure Design PE vs. PP - Stability Post Process and

Finding Balance Material / Closure Design PE vs. PP - Stability Post Process and Consumer Materials Green and/or Renewable Materials Processing Methods Removal of Secondary Materials - 23 - 02_2013 opyright© BERICAP • • •

Finding Balance Transport Capability - 24 - 02_2013 opyright© BERICAP Did we think about

Finding Balance Transport Capability - 24 - 02_2013 opyright© BERICAP Did we think about the entire supply chain?

Finding Balance Process Capability - 25 - 02_2013 opyright© BERICAP Are Lightweight closures more

Finding Balance Process Capability - 25 - 02_2013 opyright© BERICAP Are Lightweight closures more challenging to handle?

Finding Balance Does light-weighting compromise the quality of the contents ? 02_2013 opyright© BERICAP

Finding Balance Does light-weighting compromise the quality of the contents ? 02_2013 opyright© BERICAP Integrity in the Trade

Finding balance Customer Satisfaction - 27 - 02_2013 opyright© BERICAP A design that doesn’t

Finding balance Customer Satisfaction - 27 - 02_2013 opyright© BERICAP A design that doesn’t jeopardize consumer experience.

02_2013 opyright© BERICAP - 28 -

02_2013 opyright© BERICAP - 28 -