PLYMOUTH, MI, October 10, 2010, 2010/PLASTIPAK HOLDINGS, INC - GBTC
ThermoShape™ Breakthrough
Plastipak has successfully commercialized its breakthrough ThermoShape™ lightweight hot fill technology with an integrated high-speed blow and fill packaging line now in full commercial operation in numerous facilities. The original launch of this innovative packaging technology occurred at Al Ain Mineral Water Company, a beverage subsidiary of Abu Dhabi-based Agthia Group (United Arab Emirates). Agthia is a leading Gulf Cooperation Council area food and beverage manufacturer. A ThermoShape™ line is now in place at a beverage manufacturer in France, as well.
Technological Advantages
Plastipak’s Director of Technology Integration Jean-Guy Delage, said, “ThermoShape™ technology offers several significant advantages over alternative packaging options for the global non-refrigerated, high acid-sensitive beverage and food market segments, which include beverages such as 100% fruit and vegetable juice and juice drinks, non carbonated soft drinks, ready-to-drink (RTD) teas, flavored waters, and functional drinks.”
Multiple Savings Features
Specifically, he cited:
• Hot Fill is a proven, low-risk technology requiring less capital investment than aseptic filling. It further avoids the use of preservatives that are rapidly falling out of favor with consumers globally.
• Lightweight Bottle — ThermoShape™ enables food and beverage producers to use existing hot fill process lines, but with the additional benefit of converting to lighter weight, unbreakable PET packaging. For instance, the Al Ain ThermoShape™ bottle was more than 30% lighter than a typical PET hot fill bottle of similar volume.
• Design Freedom — Because ThermoShape™ technology eliminates the need for vacuum-resistant features that are necessary to accommodate conventional PET hot fill processes, producers now have greater freedom to design attractive, eye-catching packages.
• Load Resistance — Bottles produced and filled using the ThermoShape™ process have slightly positive internal pressure, providing superior vertical load resistance for packaging and distribution.
• Extended Shelf Life without Deformation — With Plastipak’s patented ThermoShape™ technology, bottles have a shelf life of up to 12 months at ambient temperature. This technology also ensures that there is no bottle deformation due to standard loss of oxygen in the bottle headspace or water loss through PET bottle walls.
Original Successful Line
Initial production at Al Ain was for a 25-gram, 500-milliliter bottle with a 38-millimeter finish for a juice package. The flexibility of the line allows for expansion to produce 250-millimeter and 1-liter bottles. Fasahat Beg, general manager of Al Ain Water, said, “This investment will enable us to enter value-added beverage segments such as sports drinks and juices while using at least 30% less PET than the existing hot fill bottling lines in the market. This, in turn, means delivery on both cost and energy savings for the company and further demonstrates our corporate social responsibility commitment of reducing our environmental impact.”
Customer Satisfaction
Commenting further, Agthia CEO Ilias Assimakopoulos said, “Al Ain Water’s investment in the new first-class ThermoShape™ technology will enable Agthia to advance further in line with its product diversification strategy. In addition, this investment is an added confirmation of our commitment to continuously deliver innovative high-quality products to our customers.”
Small Footprint
The line was designed, commissioned, and installed by Plastipak, and features globally patented, in-line heat-based reshaping of bottles after they are hot filled. Delage added, “Because of its innovative design, the ThermoShape™ system easily fits into a small footprint space, allowing existing glass or plastic hot fill lines to convert to the ThermoShape™ system seamlessly.”
Full Service Partnership
Plastipak and its network of approved partners can supply specially-designed bottles or preforms, as well as all other necessary consulting services for packaging design and manufacturing, thus offering producers a true complete solution for the “sensitive” beverage and food segments.
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