GERMAN systems provider KHS has upped the bar in terms of packaging sustainability and unveiled a fully recyclable juice bottle made of 100% recyclate with a FreshSafe PET® barrier system which offers unique product and freshness protection. The clever design has been named Beyond Juice.
“When developing the bottle we strictly adhered to our credo of environmental protection, recyclability and maximum product protection,” said Philipp Langhammer, product manager for barrier technology at KHS Corpoplast.
The PET container was designed by the KHS experts from the holistic Bottles & ShapesTM consultancy program together with environmental service provider Interseroh from Cologne according to their latest design guidelines.
Following a number of optimisations the Beyond Juice bottle was issued with the Made for Recycling seal by Interseroh – the first PET bottle to score a full 20 out of 20 points.
“We were only able to give top marks when analyzing the bottle’s recyclability because KHS SiOx barrier technology was used,” explained packaging engineer Julian Thielen from Interseroh. “Alternative composite materials utilized as a barrier also often color the recyclate and yield an inferior quality.”
FreshSafe PET® also ensures that sensitive, high-quality juices and spritzers, for instance, keep up to 10 times longer than those filled into uncoated bottles. This is primarily thanks to the wafer-thin layer of glass applied to the inside of the bottle which prevents oxygen from penetrating the bottle and CO2 from escaping it.
Trouble-free recycling of the entire bottle
The label area on the Beyond Juice container has been kept so small that sorting systems recognize it as a PET bottle. This makes sure that the container can be reintroduced to the recycling loop and is not simply used to make energy. It was also important to select the right kind of adhesive so that the label can be separated from the plastic in the recycling process and there is no unintentional soiling during the washing process.
The new KHS bottle concept has also been developed as a film-free pack for recycling purposes. Dots of adhesive which are strong and secure, yet easy to remove, hold the bottles together. With Nature MultiPackTM from KHS the film otherwise used to package the PET bottles as a six-pack, for example, is no longer required. This adhesive is also easily removed during recycling. “By doing away with the secondary film around the pack we’re helping to further reduce this type of packaging waste by up to 90%,” Langhammer claimed.
As the Beyond Juice bottle consists of 100% rPET, it significantly helps to reduce the carbon footprint left by packaging throughout its entire life cycle. New studies by recognized trade associations confirm that PET bottles made of 100% recyclate have a much lower carbon footprint than containers made of what is known as virgin PET. Langhammer concluded that: “At a production of 50 million bottles a year, more than 1,500 metric tons of raw material in the form of new PET could be saved by our bottle.”