ENGEL | Packaging
Green packaging Jakarta
Welcome
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 1
21st of November 2013
ENGEL | Packaging
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ENGEL Global Bioplastics Trends in Packaging New Technologies Energy saving and sustainability
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 2
Overview
ENGEL | Packaging Family Business with long-term strategies
Ludwig Engel Company founder 1945
Georg Schwarz Internationalization 1965
Peter Neumann World market leadership
2008
1952
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 3
Delivery of the 60,000th machine
ENGEL | Packaging
Small to mid-range machines up to 5,000 kN Schwertberg / AT
Pyungtaek / Korea
York / USA
St. Valentin / AT
Robots and automation systems
Component production
Shanghai / China
Dietach / AT
Hagen / DE
Kaplice / CZ
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 4
Large-scale machines with 3,500 kN to 55,000 kN
ENGEL | Packaging turnover
In Mio. Euro
Turnover by regions 2012/2013
834
950
19%
800 622 600
3% Europe America Asia Rest of world
616
591
360
400
23% 55%
200 0 07/08
08/09
09/10
10/11
11/12
12/13
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 5
1000
ENGEL | Packaging More than 25 years in the market !
Agent: P.T. ADIJAYA BUANASANTOSA since May 2012
1 administrative person at Adijaya for spare parts. Adijaya can deal and import spare parts. From Engel side: 1 x project adviser ( Eric Joussain) and 1 x Service Engineer (adnan Mugeni)
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 6
PT. Adijaya Buanasantosa is responsible for sales and after sales. Sales Coordinator: Sugiarto Sudja After Sales Coordinator: Rudy pattynama 1 Service Engineer
ENGEL | Packaging Drive technology
victory spex tie-bar-less, eco drive
hydraulic
victory tech tie-bar-less, eco drive duo pico 2-platen, eco drive duo 2-platen, eco drive speed Toggle insert vertical, eco drive
e-victory tie-bar-less, eco drive
e-motion Toggle e-insert vertical, eco drive 25 50
100
200
300
400
500
600
700
5500
Clamping force in t
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 7
electric
e-mac Toggle
Caps and Closures
Thin-wall packaging
Pails
Pallets and crates
Industrial and large containers
• Standard and non-standard caps and closures for the beverage-, foodand cosmetics industry
• For the food industry
• Buckets, pails and round containers
• For safe transport
• To collect, store and empty ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 8
ENGEL | Packaging
ENGEL | Packaging
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ENGEL Global Bioplastics Trends in Packaging New Technologies Energy saving and sustainability
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 9
Overview
ENGEL | Packaging
Bioplastics What are bioplastics? Bioplastics
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 10
Traditional plastics
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 11
ENGEL | Packaging
ENGEL | Packaging Bio-based
Bio-based
Bio-degradable and bio-based 1. Cellulose, Acetates, Rubber‌.
4. Polylactide, Starch blends Cellulose Hydrates
5. Bio-PA, Bio-PE, Bio-PET
Non degradable
Degradable 3. Polycaprolactone Polyvinyl alcohol Polyester (PBAT, PBS..)
Petro-based
Bio-degradable
Source: Hans-Josef Endres, Andrea Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, 2011
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 12
2. Polyethylene Polypropylene Polyvinylchloride
ENGEL | Packaging
Defining Biodegradable:
Renewable resources
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 13
The buzz word !!
ENGEL | Packaging PLA (polylactic acid): Processes: Injection moulding, vacuum moulding and extrusion.
Advantages: The material is particularly suitable for transparent packaging and disposables, such as cups, boxes and dishes. Disadvantages: When transparent, the material is not suitable for hot drinks or hot food
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 14
Applications: Disposables, packaging and durables.
ENGEL | Packaging
114 million PLA containers 800,000 barrels of oil (3,000 m³)/ year
To grow about 20%
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 15
0.0024%
ENGEL | Packaging Personal Care & Other 18%
Time to Biodegrade
Apple core
1–2 months
General paper
1–3 months
Paper towel
2–4 weeks
Pharmaceuticals
Cardboard box
2 months
7%
Cotton cloth
5 months
Plastic coated milk carton
5 years
Wax coated milk carton
3 months
Aluminium cans
150–200 years
Glass bottles
Undetermined (forever)
Plastic bags
10–20 years
Soft plastic (bottle)
100 years
Hard plastic (bottle cap)
400 years
Source: Wikipedia
Soft Drinks 39%
Food 12%
Other Beverages 23%
Beer 1%
Total: ~ 730 billion closures The worldwide demand will increase by 6% per year.
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 16
Product
ENGEL | Packaging
Tetra Pak has launched a recyclable HDPE cap (Lightcap 30) Resin producer Braskem has developed PE caps for carbonated beverages
Source: Article from “The Drinks report” magazine. 28th May 2013
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 17
Both are manufactured from renewable sources and recyclable.
ENGEL | Packaging Being sustainable through: Using biodegradable resins
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Processing biodegradable materials Advantages
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Resin biodegradable within 6 months Products are compostable No shrinkage
Disadvantages
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Difficult to process with thin walls (small process window, resin degrading with high process temperatures, not easy to fill ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 18
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ENGEL | Packaging
• • • • •
ENGEL Global Bioplastics Trends in Packaging New Technologies Energy saving and sustainability
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 19
Overview
ENGEL | Packaging Demographic trends World population*
9.2 bio
Ageing 60+ increasingly important
7.5 bio 6.0 bio 1.6 bio 2000 2020 2050
DINKS
Urbanisation
Double Income No Kids
In 2020 more than 50% of world population will live in cities
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 20
1900
ENGEL | Packaging Trends with Packing containers Design Decoration Function Physical characteristics
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ENGEL | Packaging Unique design 2 cups in one 2 colors
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ENGEL | Packaging High quality decoration In Mould Labelling Transparent containers Transparent PS cups – decorated inside and outside through one label
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ENGEL | Packaging Multi-function – convenience packaging Temper evident solutions Funtional containers Double function containers
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ENGEL | Packaging Physical characteristics of the container
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Production of containers with barrier properties to improve shelf life of the product
ENGEL | Packaging
Conclusion: Lower closure weight ďƒ faster cycles
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 26
Closure Trends | Weight reduction
ENGEL | Packaging
CSD PCO 1810 to 1881 3,0g to 2,5g
Water 30/25 to 29.4/ 25.1 2,0g to 1,2g
Water X- light 26 1,0g
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 27
Weight reduction
ENGEL | Packaging
Questions: - 2 components/colours - Options for in mould assembly
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 28
Closure Trends /Special functions: Push pull caps
ENGEL | Packaging
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ENGEL Global Bioplastics Trends in Packaging New Technologies Energy Saving and Sustainability
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 29
Overview
ENGEL | Packaging New technologies | Cube technology
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 30
For the production of plastic tubes with caps in one injection mouling machine
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 31
ENGEL | Packaging
E-motion cube
Foboha hydraulic rotary table
Engel servoelectric rotary table
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 32
ENGEL | Packaging
Second injection unit vertical on top of moving platen
Second injection unit horizontal on top of clamp unit
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 33
ENGEL | Packaging
ENGEL | Packaging
DUO Combi M
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 34
based on 2-platen Duo machine series
both injection units in standard horizontal positions
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 35
ENGEL | Packaging
DUO 350 Combi M
DUO 800 Combi M
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 36
ENGEL | Packaging
ENGEL | Packaging
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 37
New technologies | Production of packaging containers with barrier function
Packaging Container | with barrier function Consideration of the packaging industry Replace glass- and metal cans with plastic containers with barrier function.
Advantages of plastic containers
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Flexible in design Lighter Logistic: Usually stackable
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 38
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Packaging Container | with barrier function Barrier co-injection technology Necessity of barrier
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Quality loss Minimum shelf life Contamination
Advantages of barrier laminate for food packaging
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Extended shelf life Better aroma preservation Protection of flavors and fragrance Obstruct bacterial growth
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 39
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Packaging Container | with barrier function Challenges
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Create a very thin EVOH barrier layer (about 0,05mm) to be competetive against glass and tin formats.
Get the adhesive bonding between the layers
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 40
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Packaging Container | with barrier function Plastic container with barrier function
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Thermoformed container: Already on the market(Packaging containers, laminat tube made of multi-layered material) Disadvantage: - Expensive - Less flexible in design
Injection-moulded container: Already on the market: Bottles with barrier layer (2K-Preform) At the beginning: Thinwall food containers with barrier characteristics
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 41
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Packaging Container | with barrier function Injection moulded container with barrier function Technological approaches
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IML with barrier label (Multi-layer barrier label with EVOH layer, SIOx-coated barrier foil, tin foil) Co-injection Coating
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 42
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Packaging Container | with barrier function Production cell for barrier co-injection technology
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The co-injection technology is a revolutionary alternative to traditional packaging methods e-motion 310H/50V/180 T combi
All electric high performance machines guarantee maximum output and low energy consumption High precision servo driven injection units secures that the barrier layer is reliably implemented up to the edge
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Use of a small 15mm screw for the injection of barrier layer
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 43
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Packaging Container | with barrier function Mould and hotrunner technology
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Mould with 2 cavities for a pet food container Specially designed co-injection nozzles and manifold technology that combines melt streams and provides balanced fill
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 44
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Packaging Container | with barrier function
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Cycle time: 5,5 sec. Part weight: 8,7g
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Simultaneous co-injection
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Minimize barrier layer wall thickness
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 45
Process
Packaging Container | with barrier function Barrier watcher | In-line Inspection of Layers
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Specialized camera system detecting insufficient layer thickness and distribution, holes and defects in comparison to the reference image Capable of inspecting EVOH barriers and additional barrier materials ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 46
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ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 47
Packaging Container | with barrier function
ENGEL | Packaging New technologies | Production of PS cups with PS labels Challenge: Handling of PS labels The label handling is more difficult as a PS label needs to be thicker and stiffer. Label thickness 0,15mm compared to a conventional PP or PE-label with 0,05mm
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 48
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ENGEL | Packaging New technologies | Production line for paper trays with plastic rims
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 49
e-motion 180 T with side entry automation for paper placing and tray take out
ENGEL | Packaging
• • • • •
ENGEL Global Bioplastics Trends in Packaging New Technologies Energy Saving and Sustainability
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 50
Overview
ENGEL | Packaging Megatrend | Energy savings Fully electric machines Energy efficient hydraulic machines with servohydraulic systems
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 51
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ENGEL | Packaging Overview Manufacturing costs Manufacturing costs for a 2,3g closure Raw material 67.5% Energy 7.1% Maintenance 0.5%
Tool costs 6.4%
Waste 0.6%
Premisses & ground Working Capital 0.7% 0.8%
Operating costs 1.2%
Administration Personnel 3.5% Machine 4.9% costs Colorant 4.8% 2.0%
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 52
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ENGEL | Packaging Cup, 6 cavities | shot weight 74.76g PP Hydraulic
Full-electric
(Full-accu machine , YOC 2002)
(e-motion 740/280 T)
Energy measurement
Energy measurement (Figures acc. to customer) •
• Total energy : Spec. Energy :
51.38 kW 1.05 kWh/kg
• Heating :
7.138 kW
• Control :
0.747 kW
• Hotrunner :
3.798 kW
• Total energy : - 60%
11.908 kW
Spec. Energy :
-- confidential | for internal use only --
23.636 kW 0.421 kWh/kg
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 53
• Drive :
ENGEL | Packaging Short Neck closure, 48 cav. | shot weight 51.8 g HDPE Full-electric
(speed 180)
(e-cap 180T)
Energy measurement
Energy measurement
• Drive / Hydraulic:
• Drive
40.076 kW
14.988 kW
• Heating :
8.226 kW
• Heating :
8.660 kW
• Control :
0.697 kW
• Control :
0.567 kW
• Oil filtering unit :
1.237 kW
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• Total Energy :
50.236 kW
Spec. Energy :
0.915 kWh/kg
- 61%
• Total Energy :
24.215 kW
Spec. Energy :
0.443 kWh/kg
-- confidential | for internal use only --
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 54
Hydraulic
ENGEL | Packaging Being sustainable through: Lean manufacturing & Reducing carbon footprint Traditional production: 4 steps
Manufacturing footprint: around 250 m²
Injection moulding: 1 Step
Footprint: 60 m² for comparable output, being 75% less production area
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 55
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ENGEL | Packaging Being sustainable through: Manufacturing performance: saving energy, reducing oil Drive side: ecodrive
Injection side: Insulation
ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 56
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ENGEL Austria GmbH | 11. 2012, BU-PAC | Page 57
ENGEL | Packaging