Right Weighting Closures Experience pertinent to closure weight
- Slides: 28
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 ~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. 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 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 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 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 Savings -7 - 02_2013 opyright© BERICAP Ease of application
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 - 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 + Neck Finish design affects package characteristics, and consequent manufacturing methods.
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 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? • Landfill? • Environmental Impact
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 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 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 Bottle Whole Application System - 17 - 02_2013 opyright© BERICAP Product
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 / 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
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 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 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 the entire supply chain?
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 Integrity in the Trade
Finding balance Customer Satisfaction - 27 - 02_2013 opyright© BERICAP A design that doesn’t jeopardize consumer experience.
02_2013 opyright© BERICAP - 28 -
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