PET Beverage Packaging Barrier Technologies- TOC - TOC

The Barrier Performance Challenge............................................................................... 1
Addressing Barrier Performance.................................................................................... 4
Market Overview ......................................................................................................... 8
Barrier Options............................................................................................................ 8
Thick Sidewall Containers ............................................................................................ 9
Modified PET Resins.................................................................................................... 10
PET With Additives...................................................................................................... 10
Multilayer Preforms .................................................................................................... 11
Surface Coatings........................................................................................................ 11
Combination Of Treatments ........................................................................................ 12
Pluses And Minuses .................................................................................................... 13
Market Share Of Barrier Containers ............................................................................. 15
Marketplace Changes ................................................................................................. 17
Increased Barrier Options ........................................................................................... 17
Improved Manufacturing Economics ............................................................................. 19
PET Containers In Smaller Sizes .................................................................................. 23
High-Output Barrier Treatment Systems ....................................................................... 23
Markets For Beer In PET Containers ............................................................................. 24
Oxygen-Sensitive Beverages In PET ............................................................................ 24
Container Deposits...................................................................................................... 25
Lower Cost Of PET Bottle Manufacturing Infrastructure ................................................... 26
Metal And Glass Container Cost Inflation ...................................................................... 27
Safety Attributes Of PET Bottles ................................................................................... 32
Markets Available For Conversion To PET ..................................................................... 33

Section II: Technology Overview...................................................................................... 35

Barrier Purpose.......................................................................................................... 35
Oxygen Barrier .......................................................................................................... 37
Carbon Dioxide Barrier................................................................................................ 40
Other Considerations .................................................................................................. 41
Ultra-Violet Light ........................................................................................................ 41
Beverage Oxygen Content .......................................................................................... 41
Closure Effectiveness ................................................................................................. 42
Flavor Scalping .......................................................................................................... 42
Beverage Chemistry Instability ................................................................................... 42
Assessing Shelf-Life Performance ................................................................................ 45
Barrier Methods And Technologies................................................................................ 46
Resins And Additives .................................................................................................. 46
Mxd-6........................................................................................................................ 46
Imperm..................................................................................................................... 47
Amosorb ................................................................................................................... 47
Aegis......................................................................................................................... 48
Valor ........................................................................................................................ 48
Sirius 101.................................................................................................................. 48
Eval.......................................................................................................................... 48
Economics ................................................................................................................ 49
Monolayer Barriers .................................................................................................... 52
Heavy Weight Containers ........................................................................................... 53
M&G’s Actituf And Bicopet........................................................................................... 53
Invista’s Polyshield .................................................................................................... 54
Performance ............................................................................................................. 55
Monolayer Economics ................................................................................................ 56
Representative Multilayer Preform Barrier Technologies ................................................ 57
Major Multilayer Technology Suppliers ......................................................................... 57
Graham Packaging .................................................................................................... 58
Kortec ...................................................................................................................... 60
Materials................................................................................................................... 60
Performance.............................................................................................................. 61
Representative Multilayer Economics ............................................................................64
Representative Plasma Coating Technologies ............................................................... 67
Major Coating Technology Suppliers ............................................................................ 67
Coating Technology Descriptions.................................................................................. 68
Actis ......................................................................................................................... 69
Plasmax .................................................................................................................... 73
Mitsubishi’s Diamond-Like Coating................................................................................ 76
Representative Plasma Coating Economics ................................................................... 78
Base Plasma Barrier Treatment Cost Estimate .............................................................. 79
Economic Impact Of Asset Utilization............................................................................. 81
Economic Impact Of Production Output Rate.................................................................. 81
Economic Impact Of Operating Efficiency ...................................................................... 83
Comparison Of Barrier Bottle Manufacturing Costs......................................................... 86
Attributes Of Barrier Technologies................................................................................ 93
Developmental And Emerging Barrier Technologies ...................................................... 97
Wellman Hp867 ......................................................................................................... 97
PET – PTN Blend ........................................................................................................ 97
Barrier Materials ........................................................................................................ 97
Active Oxygen Scavenger ........................................................................................... 97
Polyglycolic Acid Resin................................................................................................ 98
Internal Coating ........................................................................................................ 98
External Coatings ...................................................................................................... 98
Summary................................................................................................................. 100

Section III: Commercial Barrier Package Applications ................................................. 101

Beverage Packaging Trends...................................................................................... 101
Beverage Packaging Types And Market Share ........................................................... 101
Packaging Market Growth ........................................................................................ 102
Market Share Trends................................................................................................ 103
Commercial PET Barrier Methods .............................................................................. 104
Carbonated Soft Drinks ........................................................................................... 105
Market Dynamics .................................................................................................... 106
CSD Container Performance Requirements................................................................ 107
Barrier CSD Package Performance............................................................................ 107
Economics .............................................................................................................. 108
Beer Beverages....................................................................................................... 115
Market Dynamics .................................................................................................... 116
Performance Requirements....................................................................................... 119
Barrier Beer Container Performance ......................................................................... 119
Barrier Blends ........................................................................................................ 120
Multilayer ............................................................................................................... 120
Plasma Coatings...................................................................................................... 120
Economics .............................................................................................................. 120
Juice Beverages....................................................................................................... 123
Market Dynamics .................................................................................................... 123
Juice Drink Barrier Performance Requirements .......................................................... 124
Juice Container Barrier Performance ......................................................................... 124
Economics .............................................................................................................. 125
Other Beverages In Barrier-Enhanced PET Packaging ................................................. 125
Ready To Drink Tea................................................................................................. 125
Sparkling Water ...................................................................................................... 126
Wine....................................................................................................................... 126
Summary................................................................................................................ 128

Section IV: Barrier Technology Drivers ....................................................................... 129

Economics Of Barrier PET vs. Metal Cans And Glass Bottles ....................................... 129
Barrier Carbonated Soft Drink Containers ................................................................ 129
Barrier Beer Containers ......................................................................................... 130
Summary - Drivers/Inhibiters ................................................................................. 132
Availability............................................................................................................. 132
Manufacturing Scale ............................................................................................... 132
Recyclability Concerns ........................................................................................... 132
Cost Of Barrier Treatment ...................................................................................... 133
Existing Beverage Bottle Manufacturing And Filling Models ......................................... 133
Operational Complexity ......................................................................................... 133
Barrier Technology Performance.............................................................................. 133
Metal Can And Glass Bottle Infrastructure ................................................................ 134

Appendix..................................................................................................................... 135

Barrier Technology And Material Suppliers............................................................... 135
Plasma Coating Efficiency Impact On Blow Molding Cost .......................................... 137
Barrier Treated PET Bottle Manufacturing Economic Model......................................... 139
Barrier Bottle Manufacturing Economics .................................................................. 143

Tables

Table 1 Key Barrier Technology Requirements ........................................................... 5
Table 2 Desired Barrier Technology Attributes ........................................................... 7
Table 3 Trade-Offs Of Barrier Treatments Methods ................................................... 13
Table 4 Commercial Barrier Options......................................................................... 18
Table 5 Small PET Bottle Cost vs. 12 Oz Cans And Glass Bottles. ............................... 23
Table 6 Barrier Technology Output Capabilities ......................................................... 24
Table 7 Beer Bottle Manufacturing Cost Estimate. ..................................................... 26
Table 8 Change In Energy, Metal, And Resin Costs 2000 – 2006. ............................... 32
Table 9 Drivers Encouraging Growth Of Barrier PET Beverage Bottles......................... 34
Table 10 Beverage Tolerance To Oxygen ................................................................ 37
Table 11 Oxygen Permeability Of Packaging Materials............................................... 38
Table 12 Barrier Resins And Additives ..................................................................... 46
Table 13 Mxd-6 And Imperm Permeation Properties.................................................. 47
Table 14 Added Material Cost $/Lb For Blend Combinations Of Mxd-6 And Amosorb..... 50
Table 15 Added Material Cost $/Pound For Blend Combinations Of Imperm And Amosorb.. 51
Table 16 Monolayer Barrier Resins And Suppliers ..................................................... 52
Table 17 Barrier Improvement Factor For Monolayer/Mxd Blends ............................... 55
Table 18 Added Material Cost $/Lb, Mxd-6 With Actituf & Polyshield, Pigmented Container.. 57
Table 19 5 Percent Blend vs. Multilayer Carbonation Loss .......................................... 61
Table 20 Multilayer Technology Cost......................................................................... 65
Table 21 Comparison Of Monolayer And Multilayer Cost With Nylon Additive................. 65
Table 22 Comparison Of Monolayer And Multilayer Costs With Nylon And Amosorb........ 66
Table 23 Actis 20 And Actis 48 Performance Capabilities............................................. 73
Table 24 Plasma Coating Cost Estimates At Rated Speed ........................................... 80
Table 25 Output Penalty On Bottle Manufacturing Cost Due To Coater Speed Restrictions... 82
Table 26 Coating Cost With Investment To Treat At 30,000 Bottles/Hour..................... 83
Table 27 Barrier Treatment Cost At Rated Output And 30,000 Bottles Per Hour............ 88
Table 28 Plus And Minus Attributes Of Commercial Technologies................................ 93
Table 29 Developmental And Trial Barrier Technologies ........................................... 97
Table 30 Manufacturing Cost Of 26 Gram Preforms And Bottles ............................... 109
Table 31 Manufacturing Cost Of CSD Bottles Containing A 3 Percent Blend Of Mxd-6.. 110
Table 32 Manufacturing Cost Of 26 Gram Multilayer CSD Bottle................................ 111
Table 33 Plasma Treated 26 Gram CSD Bottle Manufacturing Cost Estimates............. 112
Table 34 Cost Of A 21 Gm Multilayer CSD Bottle .................................................... 113
Table 35 Plasma Treated 21 Gram CSD Bottle Manufacturing Cost Estimates............. 114
Table 36 Beer Barrier Preform Manufacturing Cost Estimates................................... 121
Table 37 Barrier Half-Liter Beer Bottle Manufacturing Cost....................................... 122
Table 38 Barrier Technology Suppliers................................................................... 135
Table 39 Efficiency Impact On Cost At Actis And Plasmax Rated Speeds ($/1,000)..... 137
Table 40 Efficiency Impact On Cost At 30,000 Bph Operating Rate ($/1,000) ............ 137
Table 41 Efficiency Impact On Cost At Actis 48 Operating Rate ($/1,000).................. 138
Table 42 Global Parameters For Cost Modeling Cases ............................................ 140
Table 43 Manufacturing Cost Assumptions ............................................................ 141
Table 44 Manufacturing Cost Elements For 26 Gram CSD Preform .......................... 143
Table 45 Blow Molding Cost Elements For 12 Ounce CSD Bottle .............................. 145
Table 46 26 Gram CSD Barrier Preform Blow Molding Cost .................................... 147
Table 47 Blow Molding Cost Of 12 Ounce Barrier CSD Bottle .................................. 149
Table 48 Manufacturing Cost Of 26 Gram Multilayer Barrier Preform ........................ 151
Table 49 Blow Molding Cost Of 26 Gram 12 Ounce Multilayer Barrier CSD Bottle ...... 153
Table 50 Actis 20 Treated 12 Ounce 26 Gram CSD Bottle Blow Molding Cost............ 155
Table 51 Plasmax Treated 12 Ounce 26 Gram CSD Bottle Blow Molding Cost............ 157
Table 52 Actis 48 Treated 12 Ounce 26 Gram CSD Bottle Blow Molding Cost............ 159
Table 53 Manufacturing Cost Of 21 Gram Multilayer Barrier Preform ....................... 161
Table 54 Blow Molding Cost Of 21 Gram 12 Ounce Multilayer Barrier CSD Bottle ...... 163
Table 55 Manufacturing Cost Elements Of 21 Gram Monolayer CSD Preform............ 165
Table 56 Pigmented 28 Gm Monolayer PET Preform Cost ....................................... 167
Table 57 Pigmented 28 Gm Monolayer Blend Barrier Preform Cost ......................... 169
Table 58 Half-Liter Barrier Beer Bottle Manufacturing Cost...................................... 171
Table 59 Manufacturing Cost Elements For 28 Gram Multilayer Preform ................... 173
Table 60 Blow Molding Cost Elements For 28 Gram Multilayer Bottle ........................ 175
Table 61 Manufacturing Cost Elements For 28 Gram Multilayer Preform ................... 177
Table 62 Blow Molding Cost For 28 Gram Multilayer Bottle ...................................... 179
Table 63 Blow Molding Cost Of 28 Gram Plasmax 12d Treated Half-Liter Beer Bottle.. 181
Table 64 Blow Molding Cost Of 28 Gram Actis 20 Treated Half-Liter Beer Bottle ........ 183
Table 65 Blow Molding Cost Of 28 Gram Actis 48 Treated Half-Liter Beer Bottle ....... 185