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Karen Armstrong
5 years ago
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3 Revolutionizing PET Packaging Solutions for high acid sensitive beverages for non-refrigerated distribution advanced technology ThermoShape TM is a simple process utilizing existing Hot Fill Injection/Blow Molding Technology to make lightweight, recyclable PET bottles, for shelf stable drinks. When using the traditional Hot Fill process without ThermoShape TM, bottles are typically processed at heavier gram weights and are designed with outdated vacuum panels and/or features to maintain shape integrity during beverage and head space cooling. ThermoShape Hot Fill technology compensates for the internal package vacuum created in the filling process. This feature increases top load performance, enables lighter gram weight bottles, and creates endless opportunities for modern panel-less designs. The ThermoShape process results in slight residual pressure after the ThermoShape hot plate and mechanical inversion process, which improve bottle top-load performance versus traditional hot-fill bottle of the same weight. This feature continues to flex upward during the bottle s shelf life to compensate for further vacuum created by O 2 head-space absorption and normal H 2 O 2 loss through PET walls while at the same time reducing the risk of bottle paneling during bottle shelf life. juice/ nectar soft drinks flavored/ functional water tea/ coffee

4 advantages of technology ThermoShape TM technology provides beverage customers with numerous advantages. The following leading benefits position this innovative technology as the most advanced packaging solution for juice, nectar, non-carbonated soft drinks, flavored and functional water, and ready-to-drink tea and coffee: Utilizes Hot Fill Technology Enables Lightweight PET Heat Set Packages Facilitates Bottle Design Freedom Enhances Top Load Performance Reduces Fill Level Drop Post Filling Provides A More Stable Product Shelf Life ThermoShape TM opens up possibilities for new consumer-friendly, creative and functional bottles that also enhance manufacturing sustainability initiatives. Removing gram weight and increasing top loads will result in decreased environmental waste and opportunities to reduce distribution and packaging costs. ThermoShape allows high acid, non-carbonated, sensitive beverage manufacturers the ability to reap all the benefits of Hot Fill without compromising important bottle design features. saves money reduces operational & environmental waste

5 lightweight PET PET (Aseptic, Hot Fill, Preservatives) Other Materials (Glass, Carton Can, Pouch) Global Usage Billion Units % AAGR % AAGR Source: Euromonitor Lightweight PET is the fastest growing packaging material for high acid, non-carbonated, sensitive beverages. Plastipak s proprietary ThermoShape technology utilizes recyclable PET bottles, offering increased sustainability to the manufacturer, a benefit appreciated by savvy consumers.

7 bottle design freedom No longer confined to the thick, rigid and visually unappealing bottles common to recent Hot Fill processes, ThermoShape revolutionizes the industry allowing high acid, non-carbonated, sensitive beverage manufacturers the ability to reap all the benefits of Hot Fill and gain the benefit of package design freedom, without compromising important bottle design features. ThermoShape TM technology aids manufacturers with inventive, light-weight packaging designs and avoids the need for weighty vacuum panels. By promoting modern panel-less designs ThermoShape TM technology keeps manufacturers on track with market trends. The added benefits of high sustainability standards and innovative bottle design make ThermoShape an optimal alternative to Aseptic or standard Hot Fill practices. Compared to Asceptic filling, Hot Fill technology used with ThermoShape offers lower risk management, lower capital investment and lower operation costs, and this technology can now be applied to any filling environment. ThermoShape technology maintains the integrity of the lightweight PET, affording customers the ability to promote their innovative products in equally innovative packaging. consumer friendly operational process friendly

8 Sensitive Beverage Options All sensitive beverages distributed at ambient temperatures must first go through a flash pasteurization process before filling. The 3 following options are then used for sterilization and closure. Hot Fill Sterilization Aseptic Fill Preservatives Hot Fill cap and bottle sterilization is the simplest, least costly and efficient method, reducing operational and environmental waste. Hot Fill sterilization simply involves heating the beverage from 85 C to 92 C and filling the bottles. The heated beverage sterilizes all interior surface areas of the bottle and cap. Aseptic fill is complex and capital intensive. This process involves controlling multiple aseptic interfaces, utilizing heavy and complex technology, ultimately putting sterilization at risk. Aseptic fill requires disinfecting the preform or the bottle and the closure with chemical agents followed or not by a sterile rinse. The beverage is then filled at ambient temperatures under stringent aseptic conditions. Also called Cold Sterilizers, Preservatives and Cold Sterilizer involves adding chemical agents to the beverage during the cold fill process, a method falling increasingly out of favor with consumers.

the hot fill solution ThermoShape is a natural

efficient and effective sterilization process.

9 the hot fill solution ThermoShape is a natural response to the consumer demand for sustainable and healthy product packaging, as well as the manufacturer s need for a cost-effective, efficient and effective sterilization process. before after 100% natural shelf stability no need for preservatives

10 the complete packaging solution: ThermoShape Technology offers manufacturers of high acid, non-carbonate, sensitive beverages a complete lightweight PET packaging solution for non-refrigerated distribution. ThermoShape technology offers enhanced bottle design freedom and a reduced carbon footprint. design freedom lower operational costs reduced carbon footprint

11 1 preform injection PET preforms are injection molded with standard injection equipment using slow crystallization PET resin. 2 bottle blow molding PET bottles are blowmolded with increased crystallinity for better resistance to Hot Filling. 3 beverage hot filling Beverages are filled at temperatures of up to 92 C / 198 F, allowing for the sterilization of all internal surface areas of the bottles.

4 bottle 3capping The bottles are sealed using One-Piece

Two-piece standard caps can be used as well with a

5 bottle tilting Bottles are tilted, allowing the inner

12 4 bottle 3capping The bottles are sealed using One-Piece Cap technology. Two-piece standard caps can be used as well with a standard Hot Fill PET neck finish. 5 bottle tilting Bottles are tilted, allowing the inner cap surface areas to be sterilized by beverage temperature. 6 beverage cooling Beverages are rapidly cooled through a cold water bath, maintaining vitamin content and taste integrity. An internal bottle vacuum is created in the cooling process.

13 7 thermoshape TM step Bottles are treated in the ThermoShape machine, creating an internal pressure that returns the bottles back to their original shapes.

14 technology & the sensitive beverage manufacturer ThermoShape Existing Line Compatibility ThermoShape technology can be integrated into an existing PET or glass Hot Fill line Plastipak Preform Supply Heat Set Bottle Blow Molding Hot Filling Capping 4 Water Cooling Bottle Shrinking 5 ThermoShape 6 7 Labeling or Sleeving Case Packaging and Palletization current step can be re-used or modified

15 plastipak s business solution Packaging Line Consulting Services Closure Qualification ThermoShape Machine with in-line Integration* Bottle Design & Qualification Preform or Bottle Supply Barrier Technology Options Recycle PET Material Content Ongoing Technology Support Packaging Line Startup Assistance Plastipak offers full ThermoShape TM Bottle Development to ensure manufacturers obtain the most innovative, functional and consumerfriendly packaging possible while using ThermoShape TM technology. This concept to market development includes evaluation of the manufacturers existing filling line and ensuring a product that works equally well with their current technology and the manufacturers existing operational processes.

16 ThermoShape TM provides manufacturers of Hot Fill consumer beverages with design flexibility. This enables the brand owner to consistently wow, thrill and delight the consumer through sensory marketing. consumers first, always!

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