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Page |
About the Authors
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A7 |
Executive Summary
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1 |
Bottle Self-Manufacturing Costs and Purchase Prices
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2 |
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2 |
Innovations and Developments
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3 |
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3 |
Introduction to the Study
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5 |
Section I.
Cold Fill and Hot Fill PET Bottle Manufacturing Cost Comparison
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Introduction
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A. Purchased PET Bottle Costs
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11 |
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B. Bottle Manufacturing Cost Modeling Methodology
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12 |
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C. Bottle Filling Scenarios
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14 |
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D. Bottle Weight Assumptions
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15 |
Preform Manufacturing Cost Estimates
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A. Preform Manufacturing Parameters
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17 |
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B. Preform Injection Molding System Capital Investment
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18 |
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C. Preform Manufacturing Cost Detail
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19 |
Bottle Manufacturing Cost Estimates
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A. Bottle Blow Molding Parameters
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21 |
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B. Blow Molding Line Capital Investment
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27 |
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C. Bottle Blow Molding Cost Detail
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28 |
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D. Total PET Bottle Manufacturing Costs
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28 |
Section II.
Polypropylene Co-Extrusion Blow Molded Bottle Manufacturing Costs
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A. Introduction
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29 |
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B. Co-Extrusion Blow Molded Bottle Manufacturing Line
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29 |
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C. Bottle Blow Molding Mode
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30 |
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D. Bottle Types
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30 |
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E. Co-Extrusion Blow Molded Bottle Manufacturing Cost Models
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31 |
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F. Parameters and Assumptions
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36 |
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G. Manufacturing Cost Detail
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37 |
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H. Purchased Bottle Prices
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37 |
Section III.
Filling Line Economics
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A. Introduction
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39 |
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B. Various Processing/Filling Technologies Used
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40 |
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1. Hot Fill
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40 |
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2. High Acid Aseptic
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40 |
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3. Low Acid Aseptic
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41 |
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4. Extended Shelf Life (ESL)
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41 |
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5. Retort
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42 |
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C. Filling Line Scenarios
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42 |
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D. Filling Line Manufacturing Cost Model
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43 |
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Cost Model Detailed Content
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48 |
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General Comments on Cost Models
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49 |
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E. Key Input and Output Variables
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49 |
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F. Primary Potential Conversion Scenarios and Applicable
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52 |
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Cost Models
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52 |
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G. Summary Five Primary Potential Conversion Scenarios’ Costs
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62 |
Section IV.
Innovations and Developments
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A. Introduction
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63 |
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B. Hot Fill
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63 |
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1. Heat Setting Technology
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63 |
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2. Reduced Bottle Weights
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64 |
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3. Other Factors
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65 |
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4. Conclusion
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65 |
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C. Chemical Sterilization Systems
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65 |
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D. Non-Chemical Sterilization Systems
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67 |
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E. Sustainability
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67 |
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F. Nestle USA, Inc.’s Anderson Facility
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70 |
Section V.
Summary and Conclusions
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A. Filling Line Economics
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73 |
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B. Payback Analysis
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73 |
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Primary Potential Conversion Scenarios
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74 |
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1. High Acid Aseptic
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75 |
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2. Low Acid Aseptic
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77 |
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Secondary Conversion Scenarios
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78 |
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C. Non-Economic Issues
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81 |
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1. Sustainability
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81 |
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2. The Predis Concept
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81 |
APPENDIX 1:
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Cost of Refrigerated Distribution
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82 |
APPENDIX 2:
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Polypropylene (PP) Bottle Manufacturing Cost
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Models for PP bottles used in Primary Potential
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Conversion Scenarios 3 and 4, Projected side
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88 |
APPENDIX 3:
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Filling Line Manufacturing Cost Models for the
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Five Primary Potential Conversion Scenarios
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92 |
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Page |
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Table 1:
Conversion Scenarios
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1 |
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Table 2:
Primary Potential Conversion Scenarios
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6 |
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Table 3:
Secondary Conversion Scenarios
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8 |
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Table 4:
Purchased Bottle Pricing, Dollars Per Thousand Bottles
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12 |
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Table 5:
Bottle Blow Molding/Filling Scenarios
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15 |
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Table 6:
General Preform Manufacturing Parameters and Assumptions
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17 |
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Table 7:
Specific Preform Manufacturing Parameters and Assumptions
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18 |
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Table 8:
Capital Cost Estimates for Preform Injection Molding Lines
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19 |
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Table 9:
Preform Manufacturing Cost Detail, Dollars Per Thousand Units
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20 |
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Table 10:
Blow Molder Cavitation and Output Capability For The Modeled Filling Scenarios
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23 |
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Table 11:
General Bottle Manufacturing Parameters and Assumptions For All Blow Molding Cases
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24 |
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Table 12:
Bottle Manufacturing Parameters and Assumptions For Direct Blow Fill Bottle Blowing Conveyed Directly Into the Filler
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25 |
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Table 13:
Manufacturing Parameters and Assumptions for Decoupled Bottle Manufacture
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26 |
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Table 14:
Investment Estimates For Bottle Blow Molding Lines
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27 |
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Table 15:
Bottle Blow Molding Cost Detail, Dollars Per Thousand Units
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28 |
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Table 16:
Summary Of Bottle & Preform In-House Production Costs, Dollars Per Thousand Units
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28 |
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Table 17:
Polypropylene Co-EBM Bottle Types
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30 |
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Table 18:
Key Cost Components and Commentary
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35 |
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Table 19:
Parameters and Assumptions Used in Models
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36 |
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Table 20:
Polypropylene Co-EBM Bottle Manufacturing Cost Detail
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37 |
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Table 21:
Purchased Bottle Prices Dollars Per Thousand Units
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38 |
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Table 22:
Primary Potential Conversion Scenarios
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39 |
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Table 23:
Ten Filling Line Scenarios
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43 |
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Table 24:
Cost Model Sections and Commentary
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47 |
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Table 25:
Cost Model Components and Detailed Description
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48 |
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Table 26:
Key Input and Output Variables Cost Models for Ten Filling Line Scenarios
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50 |
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Table 27:
Primary Potential Conversion Scenario 1
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55 |
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Table 28:
Primary Potential Conversion Scenario 2
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57 |
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Table 29:
Primary Potential Conversion Scenario 3
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59 |
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Table 30:
Primary Potential Conversion Scenario 4
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60 |
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Table 31:
Primary Potential Conversion Scenario 5
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61 |
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Table 32:
Summary of Data for Five Primary Potential Conversion Scenarios Dollars Per Thousand
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62 |
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Table 33:
Payback Analyses for Primary Potential Conversion Scenarios
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74 |
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Table 34:
Payback Analyses for Secondary Conversion Scenarios
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79 |
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Table 35:
Refrigerated Warehousing Incremental Cost Detail
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84 |
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Table 36:
Refrigerated Transport Incremental Cost Detail
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86 |
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Table 37:
Refrigerated Distribution Incremental Cost Summary
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87 |
