KHS-Alpla returnable PET container redefines ultra-light

29 Jul 2020 --- KHS Group has teamed with Austrian packaging expert Alpla to develop an ultra-light, 1 L returnable PET container. Under KHS’ “Reduce, reuse, recycle” corporate philosophy, the filling and packaging systems specialist focused on weight reduction and optimizing the container’s base and neck to achieve a weight of just 55 g. The container also boasts 35 percent recyclate content and is fully recyclable.

Together with Alpla, KHS has developed a returnable PET bottle that is impressive with its low weight and high recyclate content, says Arne Wiese, Bottles & Shapes Product Manager at KHS. “We aimed to produce a returnable container system that’s as environmentally friendly as possible. Two parameters are of prime importance here: low weight and a high percentage of recyclate.”

By optimizing the bottle base and neck, KHS experts managed to cut down on weight considerably compared to conventional returnable PET containers. At 55 grams, on average, the 1 L bottle is ten grams lighter than its standard counterparts. Compared to glass containers, it clocks up just a tenth of the weight on the scales. “This optimization means that the amount of material used is much lower. At the same time, fuel consumption and thus also CO2 emissions drop during transportation,” Wiese explains.Arne Wiese, Bottles & Shapes Product Manager at KHS.

Despite less use of materials, the returnable PET bottle has effective resistance to caustic, meaning that its quality and appearance are maintained even after numerous washing cycles. 

The returnable container is fully recyclable and remains in the recycling loop, while its high recyclate content is also compelling to the modern-day eco-conscious consumer, Wiese notes. “We’ve had outstanding test results with preforms made of up to 35 percent recycled materials; preforms containing 50 percent recyclate are also feasible for some brands,” he says. KHS and Alpla’s PET system, therefore, trumps the European Commission’s requirement that one-way PET bottles comprise 30 percent recyclate by 2030. 

The optimized preforms can be blown on all KHS stretch blow molders for returnable containers. These include the particularly resource-saving InnoPET Blomax Series V. The new packaging system is suitable for all types of beverage in the returnable container segment. “We’re convinced that we can place our eco-friendly PET bottle on the market quickly and successfully. We aim to implement the market launch in close cooperation with bottling companies,” Wiese concludes.

In other KHS news, the company recently unveiled a tray packer technology that enables cans of food and beverages to be wrapped in paper. The tried-and-tested Innopack Kisters tray packer provides an alternative to hard-to-recycle shrink film or wrap-around cartons and cuts cost by lowering materials and energy consumption. With a few minor adjustments, existing Innopack Kisters tray packer machines can be converted to the new setup.

In May, KHS invested €20 million in modernizing its headquarters in Dortmund, Germany. In a bundle of measures underway since 2015, the global provider of filling and packaging systems for the beverage industry has built a vast, approximately 4,300 m2 production shop and fully renovated another. KHS identified the headquarters modernization as a means to automate further and digitize its production processes and remain competitive in the long-term.

Edited by Joshua Poole