Tendency of the market: modularity and efficiency in packaging

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

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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

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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

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Traditional plastics

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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

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2.

Polyethylene Polypropylene Polyvinylchloride

ENGEL | Packaging

Defining Biodegradable:

 Renewable resources

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 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

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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.

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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

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 Both are manufactured from renewable sources and recyclable.

ENGEL | Packaging Being sustainable through: Using biodegradable resins

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Processing biodegradable materials Advantages

-

Resin biodegradable within 6 months Products are compostable No shrinkage

Disadvantages

-

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

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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

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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

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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

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Weight reduction

ENGEL | Packaging

Questions: - 2 components/colours - Options for in mould assembly

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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

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For the production of plastic tubes with caps in one injection mouling machine

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ENGEL | Packaging

E-motion cube

Foboha hydraulic rotary table

Engel servoelectric rotary table

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ENGEL | Packaging

Second injection unit vertical on top of moving platen

Second injection unit horizontal on top of clamp unit

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ENGEL | Packaging

ENGEL | Packaging

DUO Combi M

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based on 2-platen Duo machine series

both injection units in standard horizontal positions

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ENGEL | Packaging

DUO 350 Combi M

DUO 800 Combi M

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ENGEL | Packaging

ENGEL | Packaging

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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

-

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

-

•

Quality loss Minimum shelf life Contamination

Advantages of barrier laminate for food packaging

-

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

•

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

•

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

• •

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

-

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

• •

Cycle time: 5,5 sec.

Part weight: 8,7g

•

Simultaneous co-injection

-

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

•

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

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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

•

• 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

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ENGEL | Packaging