XTREME LIGHT PET. Forum 23 rd and 24 th OCTOBER 2014 PET. A new frontier in the field of container-weight reduction and recycling

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1 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel XTREME LIGHT PET A new frontier in the field of container-weight reduction and recycling Anna Horecica Csiki Project Manager-SIPA Maria Teresa Scrivani Project Manager-PROPLAST Organized by: 1

2 XTREME: ROTARY PREFORM PRODUCTION EU CO-FINANCING The project is realized with the contribution of the LIFE financial instrument of the European Union.

3 XTREME: INJECTION-COMPRESSION TECHNOLOGY Floating core BENEFITS VS INJECTION Low-pressure melt (4 times less) Stress reduced Very low AA Low tonnage system Consistent part weight Bottle injection gate Dosing Compression Extraction Dosimeter piston

4 A TECHNOLOGY THAT EXPANDS YOUR POSSIBILITIES In design New preform design possibilities : L/t up to 80 In quality Low AA Levels: up to 40% reduction In flexibility Production of 2 different preforms at same time In efficiency Mold changeove r in 1 hour.

5 XTREME: ROTARY PREFORM PRODUCTION Main Advantages Increased output = up to +20% Reduction of footprint = -50% Reduction of energy consumption = - 10% Preform weight reduction = -10% Reduction of changeover time = -75% Easy maintenance Increased Flexibility Lowest preform cost in the industry

6 XTREME DESIGN imagine weight reductions unlike anything you ve ever seen before SIPA 6 g 500 ml MW bottle 500 MW = 6g (W/T below 1 mm) 500ml CSD = 17g

7 ACTUAL INJECTION PROCESS LIMITS preform wall thickness and L/t ratio Preform wall thickness cannot be further reduced (limit <1.8mm) If wall thickness cannot be reduced, preform L has to be shorter L/t ratios are very critical INJECTION ISSUES! BLOWING ISSUES! < 8 g bottle

8 INJECTION ISSUES! 2. High pressure means high mold clamp force 1. High pressure required to properly fill preforms with L/t close to 50 Vicious Circle 5. Increase of maintenance costs 5 3. Risk of premature mold wear 4 4. Increase of mold refurbishing frequency (2-3 million of cycles)

9 BLOWING ISSUES! Whitening of bottle feet for TSR > 15 (depending on ASR & HSR values) Narrow blowing process window: - high energy required due to high stretch ratios - Difficulty to balance heat requirements Max productivity may not be reached No further lightweighting for applications being border line in terms of L/t

10 EXISTING LIGHTWEIGHT 500ML MINERAL WATER BOTTLE (narrow process technology and bottle quality at the limit) 500ml lightweight bottle: Conventional Preform Design: Total Weight: 9-10 grams Length: mm Wall Thickness: mm Neck Weight: grams Typical Bottle: Total Height: mm Diameter: mm Average ASR: Average HSR: Average TSR: Max L/t: grams bottle

11 SIPA DESIGN 500 ML MINERAL WATER SIPA Preform Design: New Type A Total Weight: 8.9 grams Length: 72 mm Type A Diameter: Same 18.9 length, mm wider Wall body Thickness: than standard 1.78 mm Type B wider body than standard Type C same length, wider body than B Type D longer and wider body than standard Neck Weight: 1.7 grams 8.9 g 8.2 g 7.7g 7.2g

12 WEIGHT COMPARISON TESTS 8.9 gr 8.2 gr 7.7 gr 7.2 gr Bottle weight decreases 8.9 gr 7.7 g -13% 8.2 g -8% 7.2 g -19% saving increases!

13 TOP LOAD COMPARISON TESTS Type Weight Weight reduction TOP LOAD (filled bottles - 2nd peak) variation % grams grams % value (N) vs heavier 8.9g standard (existing design) A B C D

14 COMPARISON TESTS Comparison: 8.9 gr standard bottle performance vs XTREME ones g XTREME Top Load is 275N, more than standard one! Top Load of standard 8.9g bottle Top Load (N) ,0 8,5 8,0 Weight (gr) 7,5 7,0

15 TOP LOAD COMPARISON TESTS Comparison : standard vs XTREME/thin wall preforms/bottles performance Standard type XTREME type Weight (gr) Top Load (N) Top Load (N) Variation % 8, ,4 8, ,6 7, ,3 7, ,5

16 TOP LOAD COMPARISON TESTS Comparison : standard vs XTREME/thin wall preforms/bottles performance Top Load (N) ,0 Standard type 8,5 8,0 Weight (gr) XTREME type 8.9 gr XTREME Top Load is 10% higher than standard one! 7,5 7,0

17 XTREME PLATFORM FOR RECYCLED PET XTREME process melts the material at very low pressure, making it a perfect technology to process recycled PET flakes. A further step will be made shortly to further integrated XTREME process to recycling technologies. Reduced carbon footprint Less Waste Less Raw Material

18 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel Organized by: 18

19 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel Schematic representation of a LCA study. Phases in a Life Cycle Assessment 1 Definition of goal and scope 2 Inventory Analysis 3 Impact Assessment 4 Interpretation of results Direct application: Product development and improvements Strategic planning Public Policy planning Marketing Others Organized by: 19

20 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel Representation impact categories (factors) and the related effects Organized by: 20

21 4 Bottle 500 ml - Traditional process Functional unit = 1 bottle (water content = 500 ml) Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel - Virgin PET granulate, at plant - 8,70*10-3 kg/fu - Injection Moulding - 8,70*10-3 kg/fu; - Blow Moulding - 8,70*10-3 kg/fu; 500 ml Bottle - Energy (palstic drieing) - 7,15*10-3 kwh/fu; - Materials employed in the processing apparatus building up (scaled up to the single bottle production); Bottle 500 ml - New process Functional unit = 1 bottle (water content = 500 ml) - Processing apparatus control units (PC) and LCD sreens (scaled up to the single bottle production); - Energy contribute - 7,29*10-3 kwh/fu; - Virgin PET granulate, at plant - 7,80*10-3 kg/fu - Bottle production process - 1 p/fu; (single step process) 500 ml Bottle Organized by: - Energy (palstic drying) - 7,15*10-3 kwh/fu; 21

22 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel Process tree concerned with the bottle produced through the traditional system. 66,7 % 11,1 % 16,0 % 6,21 % Organized by: 22

23 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel Process tree concerned with the bottle produced through the traditional system. 66,7 % 11,1 % 16,0 % 6,21 % Organized by: 23

24 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel Process tree concerned with the bottle produced through the new system (79,2%) (12,6%) 79,2%. 7,2% 12,6%. Organized by: 24

25 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel Process tree concerned with the bottle produced through the new system Organized by: 25

26 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel Environmental impact categories related to the bottle production Ecoindicators (fu = 1 bottle) Traditional New Methodology System Resp. Inorganics (DALYs) 2,13*10-8 0,95*10-8 Carcinogens (DALYs) 2,61*10-9 1,06*10-9 Climate Changes (Kg Sb-eq) 4,47*10-2 1,71*10-2 Ecotoxicity ((PAF m 2 Yr) 6,71*10-3 5,10*10-3 Fossil Fuels (Kg CO 2 -eq) 1,06*10-4 0,88*10-4 Minerals (Kg Sb-eq) 2,28*10-7 1,68*10-7 Notes: DALY: Disability adjusted life year number of year lost due to ill-health, disability or early death; PAF m2 Yr: Potentially disappeared fraction of species per m2 per year; Organized by: 26

27 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel Main environmental effects Organized by: 27

28 4 Forum 23 rd and 24 th OCTOBER 2014 PET RECYCLED PET Sheraton Milan Malpensa Hotel O% Resp. Inorganics: - 37,18%; Carcinogens: - 48,83%; Climate Changes: - 36,05 %; Ecotoxicity: - 13,65 %; Fossil Fuels depletion: - 25,23%; Minerals depletion: + 15,31%; 5O% Resp. Inorganics: - 55,40%; Carcinogens: - 59,39%; Climate Changes: - 61,75 %; Ecotoxicity: - 23,85 %; Fossil Fuels depletion: - 17,00 %; Minerals depletion: - 26,31%; Organized by: 28

29 4 Forum 23 rd and 24 th OCTOBER 2014 PET Sheraton Milan Malpensa Hotel Organized by: 29