Brazilian Company Jussara Has Become Latin Americarsquos Firstever Dairy Producer To Adopt An Aseptic Blowfillcap Solution Equipped With Dry Preform Decontamination With This Solution From Sidel Jussara Expands Its Portfolio With A New Pet Bottle To Differentiate Its Brands On The Shelves In A Market Dominated By Carton The First Milk To Be Bottled Using This Technology Is A Long Shelf Life Milk Uht Enriched With Added Calcium And Vitamins Branded As Ldquojussara Maxrdquo The Product Has Already Received Positive Reactions From The Brazilian Consumersa Strategic Expansion In The Milk Sectorin 2013 The Brazilian Market Consumed 63 Billion Litres Of Uht Milk A Figure Which Makes Brazil The Largest Consumer Of Uht Milk In The World Uht Milk Is The Main Type Of Milk Consumed In Brazil With A 60 Share Of The Drinkingmilk Market Against 13 For Pasteurised Milk And 27 For Milk Powder Uht Milk Consumption Grew 4 Last Year And Is Still Gaining Market Share With Over 90 Penetration In Brazilian Homesin This Very Dynamic Market The Familyowned Company Jussara Is The Ninth Largest Producer Of Dairy Products In Brazil With Continuously Growing Total Sales And Currently Ranking Fifth In Terms Of The Brazilian Uht Milk Market In Looking To Extend Its Portfolio Of Products Jussara Wanted To Meet Consumersrsquo Demands In Terms Of Innovative Products With Special Formulation And Function Through Userfriendly Packages Which Are Easier To Handle And To Store Therefore Offering Greater Practicalitybrazilrsquos Firstever Aseptic Production Line With Dry Preform Decontamination For Milk In Pet Bottlesin A Domestic Market For Milk Dominated By Carton Jussara Wanted To Differentiate Its Brands On The Shelves And The Pet Bottle Was A Revolutionary Step After More Than A Year Of Investigating The Potential Options And A Long Period Of Discussion With Sidel The Leading Global Provider Of Pet Solutions For Liquid Packaging Jussara Decided To Invest In A New Production Line For Its Premium Uht Milk The Decision Was Taken To Introduce Innovative And Different Packaging Ndash Drawing On The Flexible Design Possibilities That Pet Delivers As A Material Ndash To Offer Greater Brand Recognition For The Consumer Ldquowith Our New High Production Capacity Based On A Complete Aseptic Line Supplied By Sidel Our Company Presents One Of The Most Modern Packaging Technologies In Latin America For Pet Bottles The Firstever Aseptic Production Line Including A Blowfillcap Solution Equipped With Dry Preform Decontamination Technologyrdquo Proudly Comments Mr Odorico Alexandre Barbosa Superintendent Director Of Jussara This New Pet Line Located In The Patrociacutenio Paulista Plant Some Five Hours North Of Satildeo Paulo City In Satildeo Paulo State Was Commissioned In November 2014 Jussara Then Introduced Its Jussara Max Range For Longlife Milk With Added Calcium And Vitamin D In A Revolutionary Pet Plastic Bottle A Real Breakthrough In A Brazilian Market Dominated By The Carton Package The Milk Based On A Special Formulation Is Distributed In Fullfat Skimmed And Halfskimmed Versionsa Marketing Breakthrough To Differentiate The Milk On The Shelfin Brazil Carton Is Currently The Most Widely Used Packaging Format For Uht Milk And Dairy Products With 99 Of Market Share While The Plastic Bottle Despite Offering A Higher Perceived Value For The Consumer Has Less Than 1 Market Share However Pet Has Already Demonstrated Its Benefits In The Beverages Market And Producers Are Increasingly Realising The Creative Costeffective And Sustainable Solution That The Pet Bottle Represents The Package Itself Protects The Integrity Of The Product And Shows Its Attributes It Also Meets The Stringent Requirements Of Global Food Safety Standards While Offering Great Business Opportunities For Brand Differentiation Of Liquid Dairy Products Stored And Distributed At Ambient Temperatures Or In Refrigeratorsldquowe Were Convinced By The Marketing Opportunity The Pet Bottle Could Offer To Our Uht Premium Milk Our Challenge Was To Create Innovative And Functional Packaging Which Was Costefficient And Sustainable To Produce Pet Bottles Have All The Qualities Necessary To Meet Our Expectations They Give A Freedom In Package Design To Differentiate Our Products On The Supermarket Shelves They Perfectly Match With The Consumersrsquo Expectations As They Are Userfriendly Tough And Resealable They Also Offer Great Physical Product And Food Barrier Protection Benefits Retaining Milkrsquos Fresh Taste And Vitamin Contentrdquo Explains Mr Laercio Barbosa Commercial Director And Owner Of Jussara Although Milk And Liquid Dairy Productsrsquo Quality Can Be Easily Compromised By Microorganism Growth And Alterations Caused By The Effects Of Light Oxygen And Temperature Pet Bottles Contribute To An Extended Shelf Life And Safety Throughout The Supply Chain Its Closure Tightness Also Adds To Petrsquos Convenience Even Without The Use Of Aluminium Foil And Pet Is 100 Recyclablefull Confidence In The Sidel Complete Approachjussara Has Extensive Experience In Milk And Is Extremely Knowledgeable About The Milk Process And How To Package It In Carton However When The Company Considered Switching To Pet Bottles It Needed To Learn And To Understand All The Prerequisites And The Basic Knowledge Required In Such A Production Operation Ldquowe Trusted Sidel With Its 15year Experience In Milk In Pet And All The Liquid Dairy Product References Produced In Pet Bottles With Sidel Packaging Equipment Worldwide Gave Us Confidencerdquo Comments Mr Odorico Alexandre Barbosaldquosidel Helped Us To Understand Everything About The Pet Bottle The Way To Produce It And To Fill It As We Had Never Experienced Pet Bottling Before More Than Designing A Pet Bottle And Providing An Aseptic Filling Line They Supported Us With A Complete Approach Sidel Helped Us Look For Local Suppliers And Validate All The Consumables Including Pet Barrier Material Caps Labels Shrink Wrapping And Overwrapping Films In Order To Buy Them With The Best Quality At The Best Pricerdquo Adds Mr Odorico Alexandre Barbosaa Great Bottle For Great Brand Recognitionthe Bottle Project From A Design Point Of View Started With A Thorough Analysis Of Jussararsquos Product And Brand Aspirations As Well As A Detailed Dairy Brief Ldquosidel Shared Its Vision On The Best Packaging For Our Product Both In Terms Of Design And Also In Terms Of Pet Materialrdquo Explains Mr Laercio Barbosa Sidel Compared Both Square And Round Packages In Terms Of Marketing Positioning Consumption Experience As Well As Cost And Sustainability Values To Allow Jussara To Have A Clear Idea In Order To Make The Best Choice Ldquowhen We Met Sidelrsquos Packaging Art Design Managers For The First Time We Were Impressed To Discover Our Potential Future Bottle Lsquoliversquo On The Meeting Table With Our Brand Differentiating Elements Like The Iconic Cow Or Jussara Name Engraved On The Bottle It Was Definitely A Good Way To Convince Us About The Possible Impact It May Haverdquo Continues Mr Laercio Barbosa Ldquothe Validated Jussara Max Bottle Significantly Differentiates Our Brand On The Uht White Milk Shelves Of The Supermarkets It Definitely Breaks The Visual Codes Of The Container The Consumers Are Used To Buying It Is Really Eyecatching And Attractiverdquo Sidel Also Supported Jussara In Evaluating The Right Opaque White Pet Material To Protect Its Milk From Light And Oxygen Through Analysis And Assessment From Sidelrsquos Inhouse Packaging Scientistsa Revolutionary Sustainable Bottling Technology The Choice Of Pet Material Was Also Linked To The Choice Of The Specific Sidel Aseptic Bottling Technology This Includes Blowing Filling And Capping Functions In A Single Production Enclosure And Benefits From Sidelrsquos Unique Patented Dry Preform And Cap Decontamination Solutions The Combi Predistrade Fma And Capdistrade Ldquowe Felt Confident In Our Choice Because Sidel Provided Us With Many Examples Of The Reliability Of Their Aseptic Bottling Solution We Visited A French Dairy Company To See This Aseptic Technology In Action Its Uht Milk Is Aseptically Packaged In Petbottles On A Combi Predis Fma With Great Production Efficiency This Technology Allows Lightweighting Of Bottles By Eight Grams Compared With Its Original Bottles Produced On An Aseptic Line With Wet Decontamination How Can We Not Be Convinced By The Performance Of Such A Technologyrdquo Continues Mr Odorico Alexandre Barbosain Addition To Its High Production Efficiency Another Major Advantage Of The Combi Predis Fma Is Its Contribution To More Sustainable Business Ldquowe Were Really Convinced By The Dry Preform Decontamination Technology Because It Does Not Require Chemicals Or Warm Water To Rinse The Bottles As Is Necessary With The Traditional Pet Wet Packaging Solution This Significant Reduction In Waste And Resources Fits Perfectly With Our Vision Of Protecting The Environment While Ensuring Beverage Quality And Food Safety For The Consumersrdquo Explains Mr Odorico Alexandre Barbosa The Dry Preform Decontamination Solution Allows Tremendous Pet Savings By Reducing The Weight Of The Bottles As They Do Not Have The Thermal Constraints Associated With The Traditional Bottlerinsing Process Ldquotoday Our Onelitre Pet Bottle Weighs 29 Grams And Has A Very Good Technical Performance It Is 100 Recyclable And Does Not Require Aluminum Foil With Excellent Acceptance By The Consumerrdquo Confirms Mr Laercio Barbosafrom Consulting To Successful Project Executiononce The Complete Line Order Was Placed In 2013 Jussara And Sidel Teams Worked Closely To Align On All The Most Important Topics From The Bottle Design To The Consumablesrsquo Validation And From The Scope Of Supply Definition To The Line Layout The Sidel Complete Line Includes An Aseptic Combi Predis Fma A Rollquatro Evolution Rollfed Labeller A Shrinkwrapper Mechanical Conveyors For Bottles And Packs A Palletiser And An Overwrapper Sidel Is Acting As A Consultant To Jussara Working With The Companyrsquos Employees To Help Them Achieve Their Goals Ndash An Important Factor Given That It Was The First Time Jussara Has Managed Such A Pet Bottling Line Projectldquowe Particularly Appreciated How The Sidel Team Shared Knowledge And Best Practice To Help Us Enter As Quickly As Possible Into A Pet Packaging World That Was New To Usrdquo Explains Mr Odorico Alexandre Barbosaa Fast Rampup To Achieve A Successful Jussara Max Commercial Launchthe Aseptic Line Was Installed In The Second Half Of 2014 In Jussararsquos Main Plant For Uht Milk Production The Optimised Line Layout And Its Compact Footprint Simplified The Implementation Process And Allowed Fast Installation And Effective Start Up Ldquothe Technical Expertise Of The Sidel Team Contributed To A Very Quick Installation Phase We Are Also Happy With The Project Execution And The Availability Of The Sidel Teamrdquo Comments Mr Odorico Alexandre Barbosa Sidel Also Provided A Fourweek Training Period At The Jussara Site To Ensure All Employees Understand Exactly What The Equipment Can Achieve This Training Covered The Equipment Operations Cleaning And Sterilisation Programmes As Well As Maintenance Proceduresafter The Aseptic Validation Completed Last September Industrial Production Started With A Very Fast Rampup Phase Sidel Is Also Providing A Team To Monitor The Production For The First Six Months This Contributes To The Continued Sharing Of Knowledge With The Jussara Team And Supports The Effective Performance Of The Line Ldquothe Bottling Line Is Running At 18000 Bph And Has Already Reached An Average Of 95 Efficiency Reaching Up To 98 We Are Satisfied With Its Overall Performance And Its Reliability In Total More Than Three Million Bottles Are Produced On A Monthly Basis On This Line As Consumer Response Is Very Positive With Excellent Acceptance Of Products We Are Targeting The Maximum Line Production Capacity Of 10 Million Bottles Per Month By Midyear We Expect To Increase Our Turnover By The End Of 2015 To One Billion Reales Brasileirosrdquonbspnbspabout Sidelour Purpose Is To Help Brands Protect The Product Inside Preserve The Planet Outside And Touch The Lives Of Millions Of People Every Daywe Do So By Offering Complete And Modular Pet Packaging Solutions Including People Services And Equipmentsidel Has Over 165 Years Of Industrial Experience With 30000 Machines Installed In More Than 190 Nations We Have Been Helping Producers Fill Beverage Bottles For Over 80 Years Blow Them For More Than 50 And Label Them For More Than 35 We Have 40 Years Of Aseptic Packaging Expertise And Were One Of The First Companies To Introduce Pet Bottles To The Beverage Industry Over 30 Years Agopart Of The Tetra Laval Group And Headquartered In Switzerland Sidel Has Over 50 Office Locations 13 Production Sites And 7 Training Centres Worldwide Each Of Our More Than 3400 Employees Spread Over Five Continents Is Committed To Creating The Optimum Liquidpackaging Solution We Call It A Better Match For Our World Our Customers And Ourselves