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PAC: Branded Package (sold in Canada) - Bronze AND Best of Show - Canadian Packaging Magazine ECO-CHOICE Award

Artisan Wine Company's Painted Turtle Wines

Overview

PET plastic wine bottles offer consumer convenience and great weight savings through the supply chain, and PET is the most widely accepted and valuable type of plastic in recycling programs across North America. This bottle like any PET bottle can be recycled into new PET bottles, carpet, car parts, fabrics etc. Ball Corporation is the only PET bottle manufacturer to offer sig plasmax, a commercially proven, transparent, internal silicon oxide barrier coating technology, that protects the wine inside the bottle and is easily removed during the PET recycling process.

Motivation for Change

PET plastic wine bottles offer consumer convenience and great weight savings through the supply chain. The bottles also feature SIG PLASMAX, a commercially proven, transparent, internal silicon oxide (SiOx) barrier coating technology that protects the wine inside the bottle and is easily removed during the PET recycling process.

Cost Effectiveness

Because PET bottles contain far less material than glass bottles, the PET package can be smaller and still hold the same volume of product. Also, the weight savings PET provides over glass is significant for this product; a case of glass weighs 16.3 kilograms vs. 10.1 kilograms for PET. This allows Artisan to add an additional layer of product on each pallet of filled cases, going from four to five layers or a 20% increase in the amount of product on each pallet. Since this product just reached the market a full analysis of system cost savings has not been completed, but the brand owner expects to see significant savings particularly in transportation and secondary packaging, and the mitigation of product loss due to breakage. In terms of productivity, PET bottles have shorter lead times than glass bottles and allow for Just-in-Time delivery.

Performance

The PET wine bottles are designed to run on existing filling lines with minimal modifications. The Plasmax barrier coating is used to ensure acceptable shelf life and the best possible compatibility with the PET recycling processes. No technical performance trade-offs resulted from this entry. The bottles maximize cube utilization (20% increase in the amount of product on each pallet). This in turn allows for additional product to be transported on each truck, cutting the number of trip required to get the same amount of product to the retailer. Shelf life meets customer requirements. Filling speeds are comparable for both packages.

Clean Production

Ball minimizes water consumption and maximizes purification processes in its manufacturing process. Ball utilizes clean production technologies in the manufacturing of PET bottles. No volatile organic compounds are used in the manufacturing process. The only air emissions are those associated with the combustion of natural gas which is used to dry the PET resin so it is void of any moisture. These emissions are negligible. De minimis emissions from the use of a non-hazardous solvent-based parts washers may exist. Ball will eliminate these emissions by using aqueous-based parts washers in the near future. The manufacturing facility has implemented an EMS system based on ISO 14000. It has not pursued certification of the EMS system. No toxic materials are used in package production. Only non-hazardous wastes are generated and those are disposed of in an environmentally sustainable manner. Parts washer solvent is recycled and used oil is sent out for recycling or fuel blending. Light bulbs and batteries are also recycled.

Effective Recovery

The 100% recyclable PET package is manufactured with a resin identification code of 1 on the bottom of the bottle (as well as on the label if the brand owner uses a recycling symbol on the label). PET is the most widely accepted and valuable type of plastic in recycling programs across North America. This bottle, like any PET bottle can be recycled into new PET bottles, carpet, car parts, fabrics etc. Any PET which is not suitable for reuse in production is sent out for recycling into viable products (carpeting / picnic tables, etc.). Bottle-to-bottle recycling tests using PETCORE protocols were conducted by SIG. PTI conclusions:
The results of the study indicate that the coating met all the PETCORE specifications through each processing step as well as test performance associated with these processing steps or bottle performance. The evaluation includes up to a 20% blend level through the solid-stating processing step and 25% incorporation (containing 5% coated material) from injection through bottle performance testing.

There were no effects on extrusion/pelletization, injection molding or bottle blowing that could be attributed to the presence of any coating remaining in the bottle flake after washing up to the 100% recycle blend level. The results of the bottle-to-bottle study showed that there were no
effects attributable to remaining coated material on the flake, pellet, preform, and bottle performance. All flake, pellet, preform and bottle variables passed all the performance test requirements.

Community Benefit

All marketing claims are relevant, credible and verifiable.

Material Health

PET is a safe plastic material, commonly used to package a variety of foods and beverages. Plasmax silicone oxide coating is FDA food grade compliant.

PET is the most widely accepted and valuable type of plastic in recycling programs across North America. The use of a barrier or coating requires special testing to ensure its compatibility in the PET recycling process. SIG Corpoplast, the manufacturer of Plasmax, convened a study by a third party lab, PTI in the US, to determine the compatibility of Plasmax in the PET recycling process.

Resource & Energy Optimization

"Comparing average 750ml glass bottles to PET bottles, bottle weight in grams is 485 - 689 for glass vs. 49-55 grams for PET. Total energy used, (inherent, process & transport) is 6,735MJ/K L for glass and 6,273 MJ/K L for PET (PET as % of glass = 93%). Greenhouse gas emissions (CO2E, GHG) are 603 kg/ K L for glass and 326 kg/ K L for PET (PET as % of glass = 54%). Waste water generated and discharged is 1.32 M^3/K L for glass and 0.243 M^3/K L for PET (PET as % of glass = 18%). Heavy metals (lead, mercury, cadmium, chromium) in air and water emissions for glass are 28.30 g/ K L and 0.2 g/ K L for PET (PET as % of glass = 0.6%). All information above assumes virgin production, and captures cradle to bottle filling. Source: United States Environmental Protection Agency, WARM calculator, http://yosemite.epa.gov/OAR/globalwarming.nsf/WARM?OpenForm Unless otherwise noted, all calculations and information about PET provided by and attributable to the National Association for PET Container Manufacturers, PO Box 1327, Sonoma, CA 95476, USA, 707-996-4207. info@napcor.com. Data sources include the American Chemistry Council, Plastics Europe, and the Swiss Agency for the Environment, Forests, and Landscape.

Categories: PAC Award Winner Polymer (Petroleum-based) Food and Beverage

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