We were among the first to introduce refillable PET bottles, among the first to use recycled materials and among the first to use mixtures of plant resins and PET.
Now we are working with leading institutions, machinery suppliers and PET resin suppliers on the next generation of challenges for PET. Our work is aimed at reducing environmental impacts, improving functional performance and driving down costs while also opening up new markets for PET containers.
Reducing environmental impacts
We are an industry leader in the manufacture of containers using not only PET but also blends of PET and plant derivatives obtained from the waste material produced during sugar production. We have supplied more than 1,000 tonnes of plant-derived bottle material to one customer alone.
We are also a leader in the use of recycled materials. We routinely produce bottles with up to 50 per cent recycled PET content and we have developed unique technology which allows us to work with 100 per cent recycled material.
Improving functional performance
We are working not just with PET (PolyEthylene Terephthalate) but also with PEN (PolyEthylene Naphthalate), a polyester which provides a very good oxygen barrier and is therefore particularly well-suited for bottling beverages such as beer that are susceptible to oxidation.
We are also researching other barrier materials – both passive and active – and barrier technologies to produce containers which maintain carbonation levels and protect against oxygen permeation.
At the same time we are looking at ways to increase the ability of PET and PET blends to handle higher pressures and temperatures, both in use and during filling.
Driving down costs
A key factor in the cost-effectiveness (and environmental benefits) of a refillable bottle is the number of times it can be reused before it needs to be recycled. We are working with brand owners on optimising bottle designs to give the containers a longer life.
We are also working with brand owners on ‘lightweighting’ bottles, reducing the amount of material used while at the same time increasing shelf appeal and functionality. This not only cuts production costs but can reduce transport costs and environmental impacts. We have applied these skills in a variety of sectors including bottled water, beer and carbonated soft drinks.
We have developed innovative production techniques and are able to help brand owners which manufacture their own containers from our preforms to reduce wastage, improve quality and increase productivity.
Within our own manufacturing plants we use the latest Six Sigma and lean manufacturing techniques to maximise efficiency.
Opening up new markets
We continue to innovate to open up new markets for PET containers – and also to open up new markets for our customers.
Our new family of Petainer PET kegs competes directly with metal kegs for beer and other beverages, taking PET into a new market sector.
The PET keg makes it economical for brewers to undertake geographic expansion that would be impossible with metal kegs. The Petainer Keg also offers wider economic and environmental benefits when compared with metal kegs.
We have formed a partnership with KHS – an international manufacturer of filling and packaging systems – to develop and market these kegs. There is more information on the dedicated Petainer Keg website.
Promoting design
To help promote new innovations in PET container design we sponsor an annual student design competition.
Launched in 2010, the competition’s first year involved students at design colleges in the Czech Republic and the UK. They were set a challenge to design an innovative sustainable container with great shelf appeal and high levels of functionality.
The competition gives us an opportunity to engage with the brightest and best of Europe’s next generation of designers. Our intention in future years is to extend the competition to additional countries.
The competition has significant cash prizes and the winning student designers are offered the opportunity to work for Petainer during their next summer vacation.
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