33
Copyright © RPC Group 1999 - 2011. All rights reserved Barrier Packaging Options for SME’s January 2013 1 Copyright © RPC Group 1999 - 2011. All rights reserved

RPC Presentation

  • Upload
    vandien

  • View
    237

  • Download
    1

Embed Size (px)

Citation preview

Page 1: RPC Presentation

Copyright © RPC Group 1999 - 2011. All rights reserved

Barrier Packaging Options for SME’s

January 2013

1

Copyright © RPC Group 1999 - 2011. All rights reserved

Page 2: RPC Presentation

2

RPC Group Overview – Key Facts

50 manufacturing plants in 16 countries

Circa 7,000 employees

Annual sales of circa £1.25 billion

Largest European manufacturer

utilising all three conversion processes

Industry leading innovator

Listed on London Stock Exchange - 1993

Entered the FTSE 250 - March 2011

2

RPC Group: Key Facts

2

RPC Group Overview – Key Facts

Page 3: RPC Presentation

0

10

20

30

40

50

60

70

£0

£200

£400

£600

£800

£1,000

£1,200

£1,400

91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14

3

RPC Group Overview – Corporate History

UK Growth Phase Mainland European Growth Phase Consolidation Renewed Growth

Turnover: Reported

Turnover: Analyst expectations

Number of manufacturing sites

Turnover (£m)

Manufacturing

sites

Flotation

MBO

Acquisition of Wiko division

Acquisition of Continental Plastics Europe

Acquisition of 11 sites from Rexam / Nampak

RPC 2010

Superfos acquisition Various smaller acquisitions

Page 4: RPC Presentation

RPC Group Overview – RPC Market Segments

Source: Proforma enlarged Group 2010/11

Spreads 13%

Coffee 6%

Dairy products

6%

Long shelf-life

6%

Disposables 4%

Sauces 4%

Other food 20%

Pharmaceutical 3%

Surface coatings

9% Personal care and cosmetics

13%

Automotive 3%

Other non food

13%

Food 59%

Non-Food 41%

4

Page 5: RPC Presentation

Thermoforming Blow Moulding

RPC Group Overview – Conversion Processes

Injection Moulding

High volume

Low cost

Barrier applications

Re-closable

Narrow neck

Pourable

Complex designs

High level decoration

High added value

RPC's core capabilities include the three processes which represent over 90% of all rigid plastic manufacturing

processes. This is unique among large-scale manufacturers of rigid plastic packaging and allows RPC to offer the

widest range of options to customers

5

Page 6: RPC Presentation

6

RPC Barrier Packaging

Page 7: RPC Presentation

RPC Corby

7

RPC Corby

1935 Corby started

to grow as a steel

town. The iron ore

was depleted

around 40 years later

and since then

Corby has been the

centre for industrial

growth

Started as a brown field site 1985

Workforce: 112

24/7 with a 4 shift system

BRC and ISO accreditation

Page 8: RPC Presentation

RPC Barrier Blowmoulding Corby

• Site 100% Food and Drink market

• Specialising in High Barrier containers (100% multilayer)

• BRC/ IOP and ISO 9002 Accredited

• Regularly audited by large food groups– Mars, Heinz, Orkla Brands, ..

• Wide range of stock and custom mould products

Page 9: RPC Presentation

Retail Bottles & Jars

Page 10: RPC Presentation

Foodservice (HORECA)

Page 11: RPC Presentation

Can and Glass Replacement

Page 12: RPC Presentation

Stock Containers - from 180ml to 4.25 Litres (5 Kilo)

Page 13: RPC Presentation

13

Multi-layer structure

Outer layer Polypropylene - gloss

Regrind

Outer tie layer

Barrier layer EVOH

Inner layer tie layer

Inner layer Polypropylene

• Excellent Water Vapour Barrier properties (WVTR)

• High stiffness at the cost of drop performance

• Good heat resistance – Hot filling, pasteurization and retorting,

• High melting point at 150°C

• Good transparency and gloss

• Good contact clarity

• Good rigidity for hot filling

• Good organoleptic properties

• Microwaveable

EVOH – aroma and flavour preservation

EVOH – resistance to oils and solvents

EVOH – it has an affinity to moisture

EVOH – the ethylene content dictates the barrier performance,

the higher the ethylene content the barrier performance

decreases and vice versa

EVOH – as the thickness increases the barrier increases

Page 14: RPC Presentation

14

Extruder to melt the polymers

Barrel – with 3 heater zones Extrusion screw

Hopper

Screw drive electric

motor

Feed throat

Molten material

is then forced

into the

extrusion die

head via

connecting

pipes As the plastic pellets travel down the screw the external heat and the intense

pressure and friction melts the pellets into a homogeneous melt

Cooling fans

Rotation

200oC

195oC

190oC

Extruded melt around 220°C

Material is fed into the hopper

Page 15: RPC Presentation

15

Layout of extruders

• Co- extrusion refers to the extrusion of multiple layers of

materials simultaneously.

• This type of extrusion utilizes the use of two or more

extruders to melt and deliver a constant flow of different

viscous plastics to a single extrusion head.

• We use different sizes of extruders (6 in total) depending

upon the thickness of the layer and the out-put for the

particular size of machine.

• Each screw is specifically designed for the material it is

going to process

50m/m dia.

80m/m dia.

30m/m dia.

30m/m dia.

30m/m dia.

60m/m dia.

Outer layer Polypropylene

Regrind

Outer tie layer

Barrier layer

Inner layer tie layer

Inner layer Polypropylene

EVOH

Page 16: RPC Presentation

16

Extruder to co-extrusion head to parison

16

50m/m dia.

80m/m dia.

30m/m dia.

30m/m dia.

30m/m dia.

60m/m dia.

Outer layer Polypropylene

Regrind

Outer tie layer

Barrier layer

Inner layer tie layer

Inner layer Polypropylene

EVOH

Connecting feed pipes from

extruders to co-extrusion head

Page 17: RPC Presentation

17

The Parison

Parison

Page 18: RPC Presentation

18

Blow moulding – manufacturing the container

Parison

Blow Mould

consists of

two halves

with water

cooling

Blow-air @ 6 bar

pressure

Page 19: RPC Presentation

19

Corby Blowmoulding and Barrier Technology

Page 20: RPC Presentation

Closures

• Comprehensive range of standard closures

• Leading supplier of closures for both powder and liquid foods

• Proven track record in technical innovation

– Dispensing systems

– Wadding, foiling and assembly

– Child resistant closures (CRC)

20

Page 21: RPC Presentation

21

Sealing – induction

Page 22: RPC Presentation

22

Sealing – capless induction sealing

Page 23: RPC Presentation

23

Conduction – barrier films

Page 24: RPC Presentation

24

Oxygen scavengers

Page 25: RPC Presentation

25

Haze measurements

25

0

10

20

30

40

50

60

70

80

71%

2.12%

Ha

ze

m

ea

su

re

me

nt

Project Vision PET + 2%

SolO2

oxygen

scavenger

Metocene PP

virgin material

in inner and

regrind layers

Standard material

structure with regrind

8.9%

14.4% 15.5%

17.9%

Virgin only

no regrind

44%

Reduced

regrind level

%

Glass

calibration

9.5%

9.74%

Glass

calibration

2%

Page 26: RPC Presentation

26

Project Vision

New technology – 3 layer co-injection technology (in development)

• Higher clarity over multi-layer technology

• Polypropylene and EVOH

• Bi-axial orientation improves rigidity with less weight

• Very good gloss

• Very good drop performance even @ 4°C

• Injection moulded neck for improved sealing and closure application

• Improved performance over PET in hot fill and pasteurize applications

• Cost of jar is high compared to 6 layer multi-layer technology

• Less flexible with necks and jar sizes (will improve as preform library

increases)

• Investment costs are high due to preform machinery and re-heat machinery

required

Page 27: RPC Presentation

Environmental Web page

Page 28: RPC Presentation

The Comparison

The study compared two 400g ambient food cans in

the following formats: – A tin plated steel food can weighing 47.8g

– A polypropylene (PP) food can weighing 15.5g with a film seal lid (approx. 1.32g)

and a plastic lid (8.5g)

The study included the raw materials used, the production of each can and associated

parts, transport and final disposal in the waste stream.

Page 29: RPC Presentation

Results

The carbon footprint of a plastic can was found to be approximately

51% lower than that of the metal can.

201g CO2e per can 98g CO2e per can

Assuming an annual delivery of two million cans, switching to a plastic

can will save over 200 tonnes of CO2e annually.

Page 30: RPC Presentation

Analysis of results

The graph below shows the carbon footprint of each can format split into a

number of analysis groups to show which areas have the highest impacts.

Method: IPCC 2007 GWP 100a, Impact data sourced from ecoinvent database with the exception of tinplate (BUWAL 250 database)

Carbon Footprint of one plastic can vs. one metal can

0 50 100 150 200

Metal Can

Plastic Can

CO2e (grams)

Raw Materials

Processing

Transport

End of Life

Page 31: RPC Presentation

Plastic is the demonstrably more sustainable packaging material on the key measure of carbon footprint.

RPC is also able to respond to the increasing availability of post consumer recyclate

Market Overview – Sustainability

Rigid plastic alternatives to glass and metal packaging can

significantly reduce the carbon footprint of packaged products

and thus sustainability provides a real growth opportunity

Carbon footprint

31

Rigid Plastic Packaging Market

Barriers to entry

Substitution

Customers Environment

Competitors

Suppliers

100%

100%

100%

54.4%

49.1%

48.7% Glass equivalent

0.058kg CO2

RPC 190ml HiPP baby food jar

RPC 610ml barrier food jar

RPC 5.0 litre plastic paint can

Glass equivalent

Metal equivalent

Source: Denkstatt, 2010, Product Carbon Footprint and

Water Demand of RPC Containers Ltd Products

0.119kg CO2

0.16kg CO2

0.326kg CO2

0.92kg CO2

1.69kg CO2

Recycling of household plastic packaging has increased rapidly -

RPC is responding to this trend by developing innovative

solutions that allow our customers to meet their sustainability

commitments

% increase since 2000/01

93%

227%

518%

Glass Cans Plastics

Use of recycled material

Recycling of household glass, metal and

plastic, tonnes 2000/01-2009/10

Source: Defra

50% rPET 50% rPET 25% rPP

CO2 equivalent footprint - production phase

Page 32: RPC Presentation

Reduce Carbon Footprint With Plastics (“Jug it”) A System Designed & Manufactured by …

32

Page 33: RPC Presentation

Copyright © RPC Group 1999 - 2011. All rights reserved

33

Thank You