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15 December, a global event translated into 7 languages. Live from the SACMI parent company, this webinar will showcase the latest ready-to-market developments for the industry, from technology to new cap design solutions. Key advantages include integrated design of cap-preform systems to optimise performance and cost

Following an initial event in June 2020 on complete solutions for tethered capsules, SACMI is now preparing a new live worldwide event: on 15 December, we'll be illustrating all the latest on the lightweighting front, that is, weight reduction in cap and preform production.
Global production exceeds 400 million tons, 98% comes from fossil sources and a third ends up in landfills or, worse, in the environment: these figures refer to plastic, a material essential to our way of life that needs to be re-thought from the perspective of the 3 Rs: reduce, reuse, recycle.
One of the most effective approaches - especially in the closures field, for safety and performance reasons - lightweighting has been the focus of investment by the world's leading technology providers for at least 20 years. Now, SACMI aims to take another major step forward with profitable, ready-to-market solutions. 
Beginning with the numerous technical-technological challenges of lightweighting and the unique production and control systems designed to overcome them, SACMI will go on to illustrate integrated cap-preform design solutions that maximize performance by merging lightweighting with high productivity.
The webinar will present some of the more recently developed solutions available on the market, starting with the new 26 mm capsule-neck systems in which SACMI, together with major brand owners and certification bodies, leads the world.
The event ends with a walk-through of the SACMI workshop, taking in everything from the IPS preform injection press - which incorporates solutions that further reduce weight to enhance performance and design - to the CCM press, the world's leading compression technology cap manufacturing solution, which now features innovative key production parameter control systems and lower consumption.
The event will be streamed live starting at 9 a.m. (and simultaneously translated into 7 languages) and again at 3 p.m. for the convenience of SACMI's international customers around the globe. To take part please register on the https://lightweight-solutions.sacmi.com platform.

Contact:

Valentina Gollini

PR & Communication Dept.

SACMI Imola SC

Via Selice Prov.le, 17/a

40026 Imola (BO) Italy

T +39 0542 607 111 

M +39 347 5216895  

Valentina.Gollini@sacmi.it 

www.sacmi.com

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The Austrian family company Almdudler has decided to use gender-inclusive language, marked in German by using a star

Automated system with four robot arms increases output by about 20 percent

High process reliability and flexibility through the RATILIGHT Puck System
Cosmetics manufacturers like to highlight their products with inventive format designs. However, this is associated with increased demands on the flexibility of the filling lines, since each format change requires a time-consuming changeover of the line. At the same time, the operating costs should be as low and the output as high as possible. For this reason, RATIONATOR Maschinenbau GmbH from Hillesheim, Germany, which is specialized in filling lines, has decisively further developed its bottle handling machine BOTTLEMAT Robot as part of the filling line: By adding a fourth vacuum gripper, which inserts the bottles lying on a conveyor belt into the transport pucks serving as containers, the possible output could be increased by about 20 percent. The RATILIGHT Puck System used in all lines produced by RATIONATOR guarantees high process reliability and compatibility with a multitude of different formats. The handling of PET bottles has been significantly improved through modifications to the machine's loading area. With the plant-internal networking of the individual units in the filling line, the requirements of industry 4.0 are also met - delays can be detected automatically and enable an optimization of the operation.

"Bottle handling systems form the first step in the filling process chain", explains Michael Musat, Sales Engineer at RATIONATOR Maschinenbau GmbH. "At the same time, they are particularly important because the precision and speed at the beginning of the handling process determines how much output is possible at the end". In order to meet the increasing competitive pressure in the cosmetics industry, RATIONATOR has further developed its bottle handling machine BOTTLEMAT Robot so that four, not as previously two or three vaccum grippers pick up the bottles from the conveyer and insert them into the RATILIGHT Pucks.

Due to the additional gripper the BOTTLEMAT Robot can now set up up to 165 bottles per minute instead of the previous maximum of 140 bottles and forward them to the filling process.

80 RATILIGHT Pucks for 1000 different bottle formats

In addition to the highest possible output, the focus for bottling in the cosmetics industry is also on format diversity. "80 percent of our machines are manufactured for the cosmetics industry," reports Musat. "However, as there are no design standards in this area, manufacturers are constantly developing new formats to differentiate themselves. This means that the filling lines must also have a particularly high degree of flexibility in order to process the many different formats. RATIONATOR recognized this problem already in the 1980s and therefore developed the so-called RATILIGHT Puck System, with which all filling lines of the company are equipped today. The special feature is that the bottles do not simply stand on the belt, but are inserted beforehand into a transport module, a RATILIGHT Puck, and therefore cannot fall over. The RATILIGHT Pucks all have the same outer dimensions and are only differently shaped on the inside. This makes it possible to transport a wide variety of sizes and shapes of bottles in a stable manner and to considerably reduce format parts and changeover times.  "80 RATILIGHT Pucks are compatible with more than 1000 different bottle formats," says Musat. "The possible volume of the bottles ranges from 5 to 1000 ml." Moreover, the transport forms produced by injection moulding are available from stock at low cost. Thanks to the combined control of robot unit and machine, no service technician needs to be called in to adjust the system to a new format. The BOTTLEMAT Robot has a common control system so that a single teaching process for the new format via the touchpad of the control unit is sufficient. Separate teaching of the individual robot units is not necessary. Specifically, format adjustment is carried out via the bottle check, which is responsible for coordinating the robot arms with vacuum grippers. The high-performance camera system records new formats simply and easily. "This means that the BOTTLEMAT Robot now also has the ability for supervised learning, the employee only enters the measurements and places the format under the camera for learning. The system takes care of the rest," says Musat. In addition, formats that have already been taught can be activated simply by pressing a button.

Improved handling of PET bottles

A further advantage of the new range of the BOTTLEMAT Robot is the processing of PET bottles. Because freshly produced PET bottles have a very high surface adhesion, which creates a sticky effect and makes handling more difficult. "In the further development of the BOTTLEMAT Robot, we have therefore made various optimizations to improve the handling of PET bottles - especially in the area of feeding", explains Musat. Corners and edges in the bottle infeed area were removed, the transport process was straightened, the elevator belt now rises at a smaller angle and the area of the receiving belt and the return opening were enlarged. As a result, especially bottles with a larger volume can spread better and do not stick to each other.

Machine modules react automatically to delays

In addition to possible problems with PET bottles, other difficulties often occur during filling: Bottles can fall over and leak during transport, so that operation must be stopped and the system cleaned. The BOTTLEMAT Robot is doubly protected against this problem. "Thanks to the RATILIGHT Puck System the bottles always stand securely and cannot fall over. And if a delay does occur, for example in the bottle infeed area, the system modules are networked with each other and automatically reduce the processing speed or stop the system", says Musat. In addition, non-inserted bottles are automatically returned to the circuit and thus neither fall out of the system nor cause a malfunction. With this contribution to the transformation of the industry towards Industry 4.0, RATIONATOR increases the process reliability of its lines and strengthens their independent operation.

Contact:

RATIONATOR
Maschinenbau GmbH
Alsheimer Str. 1
67586 Hillesheim
Germany
T +49 6733 9470-0
F +49 6733 9470-109
sales(at)rationator.de

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Polyfoil MMB® portfolio of tube solutions can be paired with HDPE caps for comprehensive, “ready to recycle” packaging sustainability. 

Oberdiessbach, Switzerland – Hoffmann Neopac, a global provider of high-quality, responsible packaging for a broad array of industries and applications, is launching a novel line of mono-material barrier tubes providing exemplary product protection while being fully compatible with existing HDPE recycling processes. The first tube solution in Europe to receive full RecyClass technology and product approval per the organization’s “Recyclability Evaluation Protocol for HDPE Containers” standards, Polyfoil® MMB tubes are particularly relevant to the oral care and pharmaceutical sectors, as they sustainably yet responsibly house both consumer items like toothpastes and cosmetics and pharma products in the dermatological or pain-relief sectors.

Incorporating a novel mono-directional-oriented (MDO) barrier film technology, Neopac’s Polyfoil® MMB tubes can reduce tube body weight by as much as 50% compared to the company’s conventional Polyfoil® technology. They are also the first tubes incorporating high-density polyethylene (HDPE) caps with low-melt index HDPE to receive full technology approval from RecyClass. The testing of polyethylene cap is a big step forward for the packaging industry, as this advanced technology was not tested before in tubes.

Notably, the Polyfoil® MMB tubes are the first such solutions approved by RecyClass that incorporate a thin film metallization option protected within the tube body structure for excellent chemical decoration stability. This facet provides improved water vapor transmission rate (WVTR) barrier and enhanced metallization optics similar to ABL (aluminum barrier laminate) tubes, which currently are not considered recyclable with HDPE recycling streams per RecyClass criteria. All tests were performed with fully printed tubes. 

Independently from RecyClass testing, fully printed Polyfoil® MMB tubes with HDPE caps have also obtained the AAA rating from Germany-based testing lab cyclos-HTP, Institute of Recyclability and Product Responsibility, which certifies that the product has a recyclability rate of more than 95%.

Neopac’s goal is to create tubes that simplify recycling – a crucial aspect of next-level sustainability practices. Today, multi-layer, aluminum foil-containing barrier packaging is particularly problematic for recyclers as, among other challenges, it is incompatible with existing mechanical sorting techniques. Therefore, eco-conscious advancements in the ways plastics are designed and produced are a must in the nearer term.

The new Polyfoil® Mono-Material Barrier tubes comprise tube bodies made of HDPE-based adhesive laminated barrier structures, containing less than 5% of foreign materials (barrier material, inks, adhesives, etc.) to avoid disruptions in existing recycling processes. Due to the application of innovative oriented and combined barrier technologies as well as pharma grade contact layers, the tubes provide excellent product compatibility and maintain premium product protection while keeping the known aesthetic characteristics of Neopac’s conventional Polyfoil® tubes. 

Polyfoil® MMB Tubes – reduced product carbon footprint
The LCA study performed from an independent laboratory according to ISO 14.040/44 resp. ISO/TS 14.067 demonstrates that the “cradle to grave” carbon footprint of Polyfoil® MMB tubes is reduced up to 35% compared to Al barrier-containing Polyfoil® tubes, depending on the wall thickness and end-of-line scenario selected.

“Combining the RecyClass-approved, lightweight Polyfoil® MMB tubes with our available HDPE closure options creates a new platform of innovative tube solutions unsurpassed in their eco-friendliness,” said Dr. Philippe Kern, Director of R&D and Quality Management. “Producing mono-material-based tube solutions with advanced thin film barrier options that maintain high performance barrier, provide premium product protection and extend shelf life  has been a goal we’ve been moving toward for years. Creating these next generation tubes, which combine our 60 years expertise of barrier technology with premium esthetics, was an interesting challenge, and we are proud to have accomplished what amounts to a new paradigm in tube packaging sustainability.”

About Hoffmann Neopac
Hoffmann Neopac is a privately-owned company, headquartered in Thun, Switzerland. The group produces high-quality metal and plastic packaging in six locations: HOFFMANN tins in Thun and CMP tins in Holland; Polyfoil® and plastic tubes with NEOPAC in Switzerland, Hungary and the US; and 3D Neopac in India. Its longstanding customers include internationally active pharmaceutical, cosmetics and consumer goods manufacturers in the European, North American and Asian markets. 
Including its new production facility in the United States, Neopac employs around 1,250 employees and has a capacity of 1.3 billion tubes. The company is dedicated to sustainability in both its manufacturing processes and corporate culture, including a dedicated eco-conscious packaging portfolio. For more information, visit www.neopac.com. 

client:    Hoffmann Neopac

contact:    Christopher Dale
    Turchette Agency
    (973) 227-8080 ext. 116
    cdale@turchette.com

It’s a wrap!

Stacking loaded pallets saves space in trucks and warehouses and thus contributes to a higher load factor and higher