EXCLUSIVE INTERVIEW
Lightweighted HDPE bottle is the “ideal packaging system” for short shelf life products / James Crick of Nampak Plastics Europe talks to Plasteurope.com about the company's “Infini” bottle, future lightweighting plans and the road towards increase recyclate content
 Nampak business development director James Crick (Photo: Nampak) |
As one of Europe’s leading HDPE bottle producers with nine production sites in the UK, Nampak Plastics Europe (Newport Pagnell / UK; www.eu.nampak.com) is setting the trends for the British dairy sector and beyond. In an exclusive interview with Plasteurope.com, business development director James Crick highlights the success of the company’s proprietary “Infini” design, a more sustainable and environmentally-friendly extrusion blow moulded bottle and talks about plans for licensing deals in the UK and abroad. Alternative packaging cannot threaten Nampak’s bottle, Crick said, adding that it constitutes the “ideal packaging system” for short shelf life products.
Plasteurope.com: What progress is being made on introducing the Infini lightweighted bottle across the full range of sizes?
Crick: The Infini bottle is already demonstrating significant success and up to 2m 4-pint (2.3 litre) Infini bottles have been in the marketplace across a number of UK retailers. Nampak’s total milk bottle production will move to the lightweighted design over a period of two to three years, when the Infini bottle will be available in the full range of imperial and metric sizes from 1 pint to 6 pint, 500ml to 3 litres.
Plasteurope.com: Are non-milk applications for Infini in the pipeline? Has the design been licensed?
Crick: Since Infini’s launch in early 2011, there has been strong interest in licensing opportunities for the Infini concept in the UK and overseas. Nampak is currently investigating these options. Discussions are taking place regarding licensing deals for the Infini design with a number of potential customers outside the dairy sector, both in the UK and abroad. These companies are interested in using the patented Infini design for lightweighting the packaging of handleware and non-handleware applications, such as beverages, laundry and home cleaning products.
Plasteurope.com: Is further lightweighting possible? What is needed to achieve this?
Plasteurope.com: What progress is being made on introducing the Infini lightweighted bottle across the full range of sizes?
Crick: The Infini bottle is already demonstrating significant success and up to 2m 4-pint (2.3 litre) Infini bottles have been in the marketplace across a number of UK retailers. Nampak’s total milk bottle production will move to the lightweighted design over a period of two to three years, when the Infini bottle will be available in the full range of imperial and metric sizes from 1 pint to 6 pint, 500ml to 3 litres.
Plasteurope.com: Are non-milk applications for Infini in the pipeline? Has the design been licensed?
Crick: Since Infini’s launch in early 2011, there has been strong interest in licensing opportunities for the Infini concept in the UK and overseas. Nampak is currently investigating these options. Discussions are taking place regarding licensing deals for the Infini design with a number of potential customers outside the dairy sector, both in the UK and abroad. These companies are interested in using the patented Infini design for lightweighting the packaging of handleware and non-handleware applications, such as beverages, laundry and home cleaning products.
Plasteurope.com: Is further lightweighting possible? What is needed to achieve this?
 Nampak''s "Infini" bottle offers an average weigh saving of 15% (Photo: Nampak) |
Crick: The key objective for Nampak’s innovation team was to develop a product that required a reduced weight of materials without affecting the bottle’s integrity and its purpose.
Infini has been specifically designed to be lightweighted – the new design does not force the material as far into each of the bottle’s corners. In reducing the distance to the bottle’s corners, we have achieved a considerable reduction in the weight of material required. In comparison to the standard bottle, Infini offers an average 15% weight saving across the range, with specific bottle sizes achieving savings as high as 21%, while at the same time continuing to meet current performance specifications. (For more details, see Plasteurope.com of 24.08.2011).
The challenge in developing a lightweighted bottle is to ensure that the packaging remains functional and, for this reason, the latest design of the Infini bottle offers the optimum weight reduction. Nampak will continue to explore opportunities for further lightweighting as the design is further developed.
Plasteurope.com: How do you see the market for milk packaging developing across Europe?
Crick: It will continue to be a mixture of cartons and plastic bottles.
Plasteurope.com: Are new products such as the milk bag a major threat to the blow moulded HDPE bottle?
Crick: No, we do not see alternative milk packaging systems as a major threat to blow moulded HDPE bottles. With dairy customers and retailers coming under increasing pressure to achieve UK government and industry targets, such as Courtauld Commitment 2, Infini currently offers the optimum solution to meeting these lightweighting and environmental challenges. (For more details on Courtauld Commitment 2, see Plasteurope.com of 09.03.2010).
The inherent weight saving of Infini bottles also offers retailers cost-reduction opportunities. Infini achieves these savings while at the same time continuing to meet, and exceed, current performance specifications.
Infini is also receiving very positive consumer feedback. The bottle’s profiled handle is positioned at a corner edge of the bottle. Stored in the fridge door, the handle is positioned facing outwards, making it easier for the consumer to remove, grip and pour the contents of the bottle. Recent consumer research was commissioned to compare the standard 4-pint bottle to the Infini 4-pint bottle and the participants particularly liked the position of the Infini bottle handle, because it is much easier to put the bottle in and take it out of the fridge. A further swing in favour of the Infini bottle was recorded when they were made aware of the carbon footprint saving over the standard bottle, resulting in approximately 75% of them expressing their preference for the Infini bottle.
Furthermore, in comparison to some of the alternative milk packaging solutions that are coming into the market, the HDPE Infini bottle is fully recyclable and can be recycled in exactly the same way as the standard bottle.
Plasteurope.com: Can the HDPE bottle pose a threat to the carton packaging predominantly found in continental Europe?
Crick: Carton packaging in Europe is predominantly linked to long-life milk where the single-ply HDPE bottle does not provide the long shelf life necessary, although, in many parts of Europe, the three-layer, white milk bottle is firmly established as an alternative to cartons.
Plasteurope.com: How has Nampak Plastics met the challenge of Courtauld Commitment 2?
Crick: Nampak is committed to reducing its carbon footprint and in the two years prior to the launch of Infini, achieved a 16% carbon reduction per tonne of material processed. In 2010, Nampak reached a major milestone with the inclusion of over 10% recycled HDPE (rHDPE) in every HDPE milk bottle it produced in the UK and Ireland – approximately 2 bn bottles annually (see also Plasteurope.com of 21.01.2010). This followed on from Nampak’s achievement with its partners in producing the world’s first post-consumer, recycled milk bottle in 2007 (see Plasteurope.com of 04.12.2007). The development of Infini is part of Nampak’s ongoing commitment to further reduce its overall carbon footprint.
Infini has been designed to further assist Nampak’s dairy customers in achieving government and industry targets, such as Courtauld Commitment 2. Courtauld Commitment 2 is closely aligned with Nampak’s own business model and although the development of Infini was in progress well before the initiative’s launch, the new bottle reflects its focus on the need to reduce packaging’s carbon footprint.
The modernised and improved Infini design offers many sustainability advantages over standard milk bottles, including savings of approximately 10,000 t/y of raw materials and a carbon saving of 23,000 t/y.
Infini has been specifically designed to be lightweighted – the new design does not force the material as far into each of the bottle’s corners. In reducing the distance to the bottle’s corners, we have achieved a considerable reduction in the weight of material required. In comparison to the standard bottle, Infini offers an average 15% weight saving across the range, with specific bottle sizes achieving savings as high as 21%, while at the same time continuing to meet current performance specifications. (For more details, see Plasteurope.com of 24.08.2011).
The challenge in developing a lightweighted bottle is to ensure that the packaging remains functional and, for this reason, the latest design of the Infini bottle offers the optimum weight reduction. Nampak will continue to explore opportunities for further lightweighting as the design is further developed.
Plasteurope.com: How do you see the market for milk packaging developing across Europe?
Crick: It will continue to be a mixture of cartons and plastic bottles.
Plasteurope.com: Are new products such as the milk bag a major threat to the blow moulded HDPE bottle?
Crick: No, we do not see alternative milk packaging systems as a major threat to blow moulded HDPE bottles. With dairy customers and retailers coming under increasing pressure to achieve UK government and industry targets, such as Courtauld Commitment 2, Infini currently offers the optimum solution to meeting these lightweighting and environmental challenges. (For more details on Courtauld Commitment 2, see Plasteurope.com of 09.03.2010).
The inherent weight saving of Infini bottles also offers retailers cost-reduction opportunities. Infini achieves these savings while at the same time continuing to meet, and exceed, current performance specifications.
Infini is also receiving very positive consumer feedback. The bottle’s profiled handle is positioned at a corner edge of the bottle. Stored in the fridge door, the handle is positioned facing outwards, making it easier for the consumer to remove, grip and pour the contents of the bottle. Recent consumer research was commissioned to compare the standard 4-pint bottle to the Infini 4-pint bottle and the participants particularly liked the position of the Infini bottle handle, because it is much easier to put the bottle in and take it out of the fridge. A further swing in favour of the Infini bottle was recorded when they were made aware of the carbon footprint saving over the standard bottle, resulting in approximately 75% of them expressing their preference for the Infini bottle.
Furthermore, in comparison to some of the alternative milk packaging solutions that are coming into the market, the HDPE Infini bottle is fully recyclable and can be recycled in exactly the same way as the standard bottle.
Plasteurope.com: Can the HDPE bottle pose a threat to the carton packaging predominantly found in continental Europe?
Crick: Carton packaging in Europe is predominantly linked to long-life milk where the single-ply HDPE bottle does not provide the long shelf life necessary, although, in many parts of Europe, the three-layer, white milk bottle is firmly established as an alternative to cartons.
Plasteurope.com: How has Nampak Plastics met the challenge of Courtauld Commitment 2?
Crick: Nampak is committed to reducing its carbon footprint and in the two years prior to the launch of Infini, achieved a 16% carbon reduction per tonne of material processed. In 2010, Nampak reached a major milestone with the inclusion of over 10% recycled HDPE (rHDPE) in every HDPE milk bottle it produced in the UK and Ireland – approximately 2 bn bottles annually (see also Plasteurope.com of 21.01.2010). This followed on from Nampak’s achievement with its partners in producing the world’s first post-consumer, recycled milk bottle in 2007 (see Plasteurope.com of 04.12.2007). The development of Infini is part of Nampak’s ongoing commitment to further reduce its overall carbon footprint.
Infini has been designed to further assist Nampak’s dairy customers in achieving government and industry targets, such as Courtauld Commitment 2. Courtauld Commitment 2 is closely aligned with Nampak’s own business model and although the development of Infini was in progress well before the initiative’s launch, the new bottle reflects its focus on the need to reduce packaging’s carbon footprint.
The modernised and improved Infini design offers many sustainability advantages over standard milk bottles, including savings of approximately 10,000 t/y of raw materials and a carbon saving of 23,000 t/y.
 Nampak is committed to helping its customers, including Dale Farms Pennybridge, meet UK government and industry targets (Photo: Nampak) |
Nampak’s inclusion of rHDPE in its milk bottles is significant given that data published by the Waste & Resources Action Programme (WRAP, Banbury / UK; www.wrap.org.uk) indicate that for every tonne of HDPE material recycled and used during the manufacture of new milk bottles: 1 t of virgin material is saved; 1 t of landfill (and its associated costs/taxes) is avoided; 1 t of CO2 is saved by the material not going to landfill or incineration.
Nampak’s investment in energy-saving initiatives, from low-energy lighting to utility plant, load management systems, has resulted in a 7% energy reduction across its nine sites over two years. Other upstream and downstream activities, such as sourcing gas-based polymer (lower carbon footprint) and progressing “nil to landfill” programmes at its sites, complement the overall resource efficiency drive of the business.
On a voluntary level, Nampak is a key representative for the milk packaging industry and participates on various bodies, ensuring that it remains at the forefront of sustainable packaging developments. Nampak sits on Dairy UK’s Sustainability Committee, is a member of the British Plastics Federation (BPF, London / UK; www.bpf.co.uk), and has close relationships with the Packaging and Films Association (PAFA, Nottingham / UK; www.pafa.org.uk). Nampak is also closely involved with WRAP and the Courtauld Commitment.
Plasteurope.com: How will companies such as Nampak view Courtauld Commitment 3 (scheduled to be introduced this year) with its expected focus on less packaging and smarter packaging?
Crick: We are waiting with interest for further clarity on what the Courtauld Commitment 3 will entail.
Plasteurope.com: What properties would you like from a rigid plastic that a milk/juice bottle grade of HDPE does not provide?
Crick: For short shelf life products such as milk and juice in a chilled environment, the HDPE lightweighted bottle provides the ideal packaging system.
Plasteurope.com: Do you expect ever to switch to an alternative to extrusion blow moulding to satisfy future market demands?
Crick: Nampak will continue to investigate alternative technologies – both material and machinery – and would not rule out supplying other market areas that require alternative solutions.
Plasteurope.com: What is the current recyclate content and how is this expected to rise in the future?
Crick: As of January 2012, Nampak is achieving an rHPDE inclusion rate of 12% and is on track to increase this further ahead of the targets set in the Dairy Roadmap (30% rHDPE by 2015 and 50% by 2020). The company is currently undertaking blow moulding processing trials under manufacturing conditions to determine the feasibility of including 30% and 50% rHDPE in its milk bottles. These trials build on the study Nampak commissioned with the University of Bradford in 2010 to investigate the effects of adding increasing levels of rHDPE to virgin material. The research confirmed that the addition of up to 50% recycled content is feasible without impacting on bottle performance.
Plasteurope.com: Is there a specific guideline Nampak Plastics has adopted in this regard, and if so, what are its goals?
Crick: rHPDE in the UK meets all the requirements set by the food and beverage industry regulatory authorities such as the US Food & Drug Administration and the European Food Standards Agency, who have approved the use of up to 50% recycled content in the long term.
Nampak’s investment in energy-saving initiatives, from low-energy lighting to utility plant, load management systems, has resulted in a 7% energy reduction across its nine sites over two years. Other upstream and downstream activities, such as sourcing gas-based polymer (lower carbon footprint) and progressing “nil to landfill” programmes at its sites, complement the overall resource efficiency drive of the business.
On a voluntary level, Nampak is a key representative for the milk packaging industry and participates on various bodies, ensuring that it remains at the forefront of sustainable packaging developments. Nampak sits on Dairy UK’s Sustainability Committee, is a member of the British Plastics Federation (BPF, London / UK; www.bpf.co.uk), and has close relationships with the Packaging and Films Association (PAFA, Nottingham / UK; www.pafa.org.uk). Nampak is also closely involved with WRAP and the Courtauld Commitment.
Plasteurope.com: How will companies such as Nampak view Courtauld Commitment 3 (scheduled to be introduced this year) with its expected focus on less packaging and smarter packaging?
Crick: We are waiting with interest for further clarity on what the Courtauld Commitment 3 will entail.
Plasteurope.com: What properties would you like from a rigid plastic that a milk/juice bottle grade of HDPE does not provide?
Crick: For short shelf life products such as milk and juice in a chilled environment, the HDPE lightweighted bottle provides the ideal packaging system.
Plasteurope.com: Do you expect ever to switch to an alternative to extrusion blow moulding to satisfy future market demands?
Crick: Nampak will continue to investigate alternative technologies – both material and machinery – and would not rule out supplying other market areas that require alternative solutions.
Plasteurope.com: What is the current recyclate content and how is this expected to rise in the future?
Crick: As of January 2012, Nampak is achieving an rHPDE inclusion rate of 12% and is on track to increase this further ahead of the targets set in the Dairy Roadmap (30% rHDPE by 2015 and 50% by 2020). The company is currently undertaking blow moulding processing trials under manufacturing conditions to determine the feasibility of including 30% and 50% rHDPE in its milk bottles. These trials build on the study Nampak commissioned with the University of Bradford in 2010 to investigate the effects of adding increasing levels of rHDPE to virgin material. The research confirmed that the addition of up to 50% recycled content is feasible without impacting on bottle performance.
Plasteurope.com: Is there a specific guideline Nampak Plastics has adopted in this regard, and if so, what are its goals?
Crick: rHPDE in the UK meets all the requirements set by the food and beverage industry regulatory authorities such as the US Food & Drug Administration and the European Food Standards Agency, who have approved the use of up to 50% recycled content in the long term.
16.02.2012 Plasteurope.com 853 [221413-0]
Published on 16.02.2012