KHS arms Henkel’s Fa shower gel with blow molder for PET bottle production efficiencies

31 Jan 2022 --- Henkel’s Fa body care brand has invested in a KHS stretch blow molder to enhance the energy efficiency of its weight-optimized oval PET bottle production. The move marks the first investment in a KHS stretch blow molder by the beauty segment.

The blow molder enables complex containers to be economically produced in-house, with no need for external procurement. The machine boasts a capacity of up to 21,700 bottles per hour.

Through the blow molder’s preferential heating, Henkel also improves its ecological footprint and simplifies its logistics and production processes.

The chemical and consumer goods company is reducing its bottle weight while increasing the percentage of recyclate used in its bottles at its facility in Wassertrüdingen, Germany.

A flexible partnership
Henkel has relied on KHS’ stretch blow molding technology for decades. The Dortmund system supplier’s tried-and-tested Blomax machines with preferential heating are used to make containers for fabric softener and household detergents in the company’s Laundry & Home Care business unit worldwide – and now also in Germany for shower gels.Henkel has invested in a KHS stretch blow molder featuring preferential heating (Image credit: Henkel).

“With this measure, we’re consistently aiming to further reduce our ecological footprint throughout our value chain,” says Claus Meyer from Henkel Beauty Care.

The company also benefits from a more flexible logistics setup, explains Björn von Lengerke, global product account manager at KHS. “You can make the respective containers for the various products yourself. This makes production plans more flexible,” he says.

Meanwhile, fewer resources are used as trucks no longer have to travel lengthy distances – an important consideration for climate protection.

Reduced weight, increased recyclate
KHS’ holistic Bottles & Shapes container design consultancy is also improving Henkel’s 250 mL bottle’s eco-credentials. The bottle’s now consume 14% less material than previous versions while maintaining quality.

The bottles also consist entirely of recycled PET – 25% of which is known as “Social Plastic.” “We’re planning on also increasing this percentage in other containers to make our entire portfolio even more eco-friendly,” shares Christian Bauer, managing director of Henkel’s Wassertrüdingen production site. By 2025, Henkel has pledged to make 100% of its packaging recyclable or reusable. 

Even with 100% recyclate, “extremely” oval bottles can be formed, notes von Lengerke. “In the preferential heating method, preforms are first heated in the heater as they rotate. In the downstream section, rotation is then stopped so only certain areas of the PET preforms are heated further,” he explains.During preferential heating, the preforms are heated in the heater as they rotate.

A heater box specially designed for this purpose transfers the required heating energy through opposite heater levels. “This [process] optimizes the bottle’s material distribution and stability,” adds von Lengerke.

The process has various advantages in the beauty care range and when processing cleaning agents, laundry detergents or personal care products that are very often filled into oval PET bottles.

Henkel has also partnered with Jokey and Akpol on closed-loop recyclate buckets in Poland.

Meanwhile, KHS’ global reach continues to grow. The company recently equipped Cameroonian beverage giant UCB with its first PET line, Molson Coors’ Serbian plant with an Innofill Can DVD can filler, and Carlsberg China with two new canning lines.

Edited by Joshua Poole