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Copyright © RPC Group 1999 - 2011. All rights reserved
Barrier Packaging Options for SME’s
January 2013
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Copyright © RPC Group 1999 - 2011. All rights reserved
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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
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RPC Group: Key Facts
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RPC Group Overview – Key Facts
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£0
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£1,000
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91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14
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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
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%
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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
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RPC Barrier Packaging
RPC Corby
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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
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
Retail Bottles & Jars
Foodservice (HORECA)
Can and Glass Replacement
Stock Containers - from 180ml to 4.25 Litres (5 Kilo)
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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
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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
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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
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Extruder to co-extrusion head to parison
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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
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The Parison
Parison
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Blow moulding – manufacturing the container
Parison
Blow Mould
consists of
two halves
with water
cooling
Blow-air @ 6 bar
pressure
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Corby Blowmoulding and Barrier Technology
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)
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Sealing – induction
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Sealing – capless induction sealing
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Conduction – barrier films
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Oxygen scavengers
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Haze measurements
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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%
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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
Environmental Web page
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.
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.
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
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
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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
Reduce Carbon Footprint With Plastics (“Jug it”) A System Designed & Manufactured by …
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Copyright © RPC Group 1999 - 2011. All rights reserved
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Thank You