Developments in Packaging Machinery for Filling

104 Pages·0.649 MB·English

by  Pira International Ltd

Developments in Packaging
Machinery for Filling
Gerhard Crossman
Published by
Pira International Ltd
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ISBN 1 85802 543 5
© Copyright
Pira International Ltd 2007
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Contents
3
List of tables v
List of figures vi
1
Filling machinery by type 37
Filling methods 37
Introduction and methodology 1 Filling machinery 38
Introduction 1 Linear layout 38
Scope of report 2 Rotary layout 39
Product and application scope 2 Tabletop filling machines 42
Methodology 3 Mono, tri or quadroblocks 42
Definitions 3 Filling processes 43
Packaging materials 3 Gravity filling 43
Packaging products 4 Pressure filling 43
Products to be filled 4 Volumetric cup filling 43
End uses 4 Liquid filling 44
Abbreviations and technical terms 6 Liquid gravity filling 44
Exchange rates 6 Liquid pressure filling 45
2
Liquid vacuum filling 46
Liquid pressure overflow filling 46
Time gravity filling 46
Rotary gravity filling 47
Packaging machinery for filling: Rotary pressure gravity filling 47
overview 7 Overflow filling 47
Global market scenario 7 Piston filling 48
Packaging materials 9 Positive displacement pump
Applications 10 filling – servo pump filling 49
Types of processes and machinery 10 Peristaltic filling 50
Processes 11 Filling applications 51
Machinery 11 Hot filling 51
Product-related filling 12 Aseptic filling 52
State-of-the-art technology 12 Aseptic blow fill seal machines 54
Key drivers 13 Aseptic bag-in-box filling 54
Consumer driven 16 Capsule filling 55
Packaging-industry driven 18 Tube filling 57
Operational excellence 25 Filling of sachets/pouches 58
Developments in packaging machinery Valve bag filling 58
for filling 26 Intermediate bulk container (IBC)
Tankless filling machine 29 filling 58
Aseptic filling 30 Tablet filling 59
Aseptic cold filling 31 Powder filling 59
Antimicrobial protection 33 Net weight filling 60
Other issues 34 Auger filling 61
Page iii © Copyright Pira International Ltd 2007
Developments in Packaging Machinery for Filling
Contents
Corrosive filling 62 Fast product change 68
Outlook 62 Case study: Packaging Automation 70
Conclusions 63 Case study: Bosch Packaging
4
Technology 71
Ease of cleaning 72
Space 75
Price indication 76
Packaging machinery for filling: Performance 76
5
efficiency 65
Cost performance reduction 65
Case study: All-Fill Inc. 65
Case study: Coffee Bean
International 66 Company activity 79
Case study: Boschi Luigi & Figli and SIG Introduction 79
Combibloc 67 Companies’ activities 81
Case study: Packaging Automation 68 Suppliers in China 97
Page iv © Copyright Pira International Ltd 2007
List of tables
1.1 Packaging materials used in filling 2.3 Key drivers for growth 15
applications 3 2.4 ESL conditions 31
1.2 Packaging container types used in 3.1 Selection criteria for filling
filling applications 4 machines 37
1.3 Filled packaging end use sectors 5 4.1 Clean-in-place (CIP) components 74
2.1 Equipment included/excluded in this 4.2 Price guide for filling machines 76
report 12 4.3 Achievable output rates by filling
2.2 Summary table of technologies for process 76
filling 13
Page v © Copyright Pira International Ltd 2007
List of figures
1.1 Packaging supply chain 1 3.4 Liquid gravity filling 45
2.1 Filling machinery market by region, 3.5 Overflow filling process 47
2006 ($ billion) 7 3.6 Piston filling process 48
2.2 Global packaging machinery market 3.7 Positive displacement pump
by sector, 2006 8 filling 50
2.3 Global beverage market segments by 3.8 Peristaltic pump filling 51
type, 2006 9 3.9 Capsule feeding station 55
3.1 Fully automated filling line 38 3.10 Capsule filling process 56
3.2 Linear filling machine 39 3.11 N et weight filling 61
3.3 Rotary filling machine – top view 40
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1
Introduction and methodology
Introduction The aim of this report is to examine the current state of packaging machinery for filling,
analyse the different types of packaging machinery used and look at the technological
developments in this industry sector. By doing this, there will also be the opportunity
to consider those companies involved and their customers’ future plans, needs and
expectations.
When looking at the integrated supply chain from providing a package, filling
it, closing or sealing it and distributing it, it becomes apparent that today’s suppliers
of packaging solutions and applications operate in a global trading world, with well-
established markets in the western hemisphere and rapidly growing areas in eastern
Europe, in particular Russia, and the Middle and Far East, e.g. China and India.
The application of filling technologies and packaging machinery for filling is part of
a complex supply chain that ranges from material suppliers for manufacturing packaging
materials to end users with all facets of supplies, manufacturing and filling applications in
between.
FIGURE 1.1 Packaging supply chain
(cid:46)(cid:66)(cid:85)(cid:70)(cid:83)(cid:74)(cid:66)(cid:77)
(cid:84)(cid:86)(cid:81)(cid:81)(cid:77)(cid:74)(cid:70)(cid:83)(cid:84)
(cid:49)(cid:66)(cid:68)(cid:76)(cid:66)(cid:72)(cid:74)(cid:79)(cid:72)(cid:1)(cid:78)(cid:66)(cid:79)(cid:86)(cid:71)(cid:66)(cid:68)(cid:85)(cid:86)(cid:83)(cid:70)(cid:83)(cid:84)
(cid:39)(cid:74)(cid:77)(cid:77)(cid:74)(cid:79)(cid:72)
(cid:49)(cid:66)(cid:68)(cid:76)(cid:66)(cid:72)(cid:74)(cid:79)(cid:72)
(cid:78)(cid:66)(cid:68)(cid:73)(cid:74)(cid:79)(cid:70)(cid:83)(cid:90)
(cid:86)(cid:84)(cid:70)(cid:83)(cid:84)(cid:16)(cid:71)(cid:74)(cid:77)(cid:77)(cid:70)(cid:83)(cid:84)(cid:1)
(cid:84)(cid:86)(cid:81)(cid:81)(cid:77)(cid:74)(cid:70)(cid:83)(cid:84)
(cid:49)(cid:66)(cid:68)(cid:76)(cid:66)(cid:72)(cid:74)(cid:79)(cid:72)
(cid:69)(cid:74)(cid:84)(cid:85)(cid:83)(cid:74)(cid:67)(cid:86)(cid:85)(cid:80)(cid:83)(cid:84)
(cid:38)(cid:47)(cid:37)(cid:1)(cid:54)(cid:52)(cid:38)(cid:51)(cid:52)(cid:16)
(cid:36)(cid:80)(cid:79)(cid:84)(cid:86)(cid:78)(cid:70)(cid:83)(cid:84)
Source: Pira International Ltd
This study concentrates on the middle part of the supply chain (as shown in the dotted
box in Figure 1.1): the filling machine suppliers, the current state of technology and the
filling process applications. It is, however, worth noting that due to efficiency and cost
drivers most of the equipment suppliers not only provide solutions for product filling itself,
but also provide either combined or integrated processing plants that can handle bulk
Page 1 © Copyright Pira International Ltd 2007
Developments in Packaging Machinery for Filling
Introduction and methodology
packaging materials, orientating and positioning it, singling it out for the individual filling
application, then either sealing it or applying a third-party cap or closure, labelling it and
accumulating packaged units again for bulk packing or palletising, eventually leading to
complex and completely automated inline packaging, assembling and handling plants.
The status of filling technologies, machinery and equipment is dominated by
packaging applications, as they present themselves today in the market. Although new
applications arise all the time, as well as new types of packaging applications, filling
technology does not necessarily need to change. Therefore development and improvements
will take place on existing processes, rather than experimenting with completely new ones.
However, as it takes time for novelty to assert itself in the marketplace, there are current
filling applications that tend to dominate the market today.
There are lists of various filling types and processes, applications, company names,
trends and so forth, but some characteristics of the huge variety of packaging machines
and filling techniques that are reviewed in this study have been compiled in the following
paragraphs.
Scope of the report The purpose of this report is to present a description of the current filling applications,
technologies, its market status and potential development of the global machinery and
equipment market for filling, including some trends for technology developments over the
coming years.
Filling is understood as a process, in which consumer products in either liquid, paste
or solid form are manually, semi-automatically or automatically accurately transferred into
a container made from a variety of packaging materials.
The main geographic markets that are considered are North and South America,
western Europe, eastern Europe (in particular Russia) and Asia (Japan and China).
Filling applications are typical in four major industry sectors: food and drink, which
is by far the biggest proportion, followed by pharmaceutical and medical applications,
automotive and finally industrial.
Product and The packaged products amenable to filling processing are predominantly in the food and
application scope beverage sectors, where single item filling and closing is a major characteristic. Common
applications are carbonated soft drinks (CSDs), still and sparkling water, juice and juice
drinks, and beer, as well as other alcoholic and non-alcoholic beverages. But filling
technologies can also be applied within other sectors to fill:
 Liquid or solid products, or products of any consistency in between
 Pharmaceuticals, toiletries, cosmetics and personal care items
 Industrial and household products.
This report helps the reader to:
 Understand current and future technology of filling machinery;
 Supply manufacturers with a guideline for business planning in the respective global
markets;
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1
Developments in Packaging Machinery for Filling
Introduction and methodology
 Provide an understanding of the market supply chain and its customers’ future plans,
needs and expectations;
 Supply value-added information for the industry;
 Answer key technical and strategic questions.
Methodology This report is based on an extensive programme of desk research, including detailed
searches within the Pira Packaging Database, exhibition visits, and searches of a wide
variety of publications and internet sites worldwide on the subject of filling machines,
suppliers and technology development. The results are supported by discussions held
during 2006 and 2007 involving a wide range of leading companies that are involved in
some way in the supply chain for filling machines and technology, either as manufacturers
or users, i.e.:
 Filling equipment suppliers
 Packaging users
 Packaging fillers.
Wherever possible, information published by the middle of 2007 has been incorporated
into the report.
To define the global market for filling applications, an evaluation of the global
packaging market as it stood at the end of 2006 has been established and related to the
available data for the market sizes of filled packaging materials.
Definitions Since there is such a wide variety of packaging available for just about every filling
application, it is essential to define the scope of this study in a little more detail. Also, as
processes are so widespread certain processes, such as wrapping, box and tray filling, gas
filling, dosing, palletising and labelling, have been excluded as they are beyond the scope
of this report.
When discussing packaging in the widest sense, this report refers to packaging
material that undergoes filling with product to be packaged before distribution to the end
users. The packaging containers and materials that are used for filling product into are
diverse. They are segregated into packaging materials and packaging products as listed in
the next sections.
Packaging materials The major classification divides the materials used into paper and board, plastics, metal,
glass and textiles, as listed in Table 1.1.
TABLE 1.1 Packaging materials used in filling applications
Material category Examples
Pulp, paper and board Carton and fibreboard, kraft and liner, paper
Plastics ABS, HDPE, LLDPE, PE, PP, PS, PVA, PVC
Metal Aluminium, steel/tinplate, tubes
Glass Bottles, jars, vials, ampoules
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Developments in Packaging Machinery for Filling
Introduction and methodology
TABLE 1.1 (Continued)
Material category Examples
Textile Cotton, jute
Ceramics
Cork
Source: Pira International Ltd
Packaging products The products that are manufactured from the packaging materials for the purpose of
being filled later on in the process are numerous. Many can be manufactured from
different materials and several use a combination. Within the definition of packaging
products and container types suitable for filling, certain non-container items, such as
wooden pallets, are excluded. However, after consultation, intermediate bulk containers
(IBCs) above 300 litres in size are included, such as tanks and reservoirs. Caps and
closures are also listed, as they are required to complete the package and their application
is very often directly related to the filling process.
The major products are listed in Table 1.2.
TABLE 1.2 Packaging container types used in filling applications
Ampoules Foils
Bags Intermediate bulk containers
Bag-in-box Jars
Blister packs Kegs
Bottles Lids
Boxes Pails
Cans Pots
Caps Pouches
Capsules Punnets
Carboys Sachets
Cartons Sacks
Cases Sleeves
Closures Tags
Composite containers Tins
Corrugated products Trays
Crates Tubes
Drums Tubs
Film Vials
Foam
Source: Pira International Ltd
Products to be filled Products packaged by means of filling applications are liquids, pastes or solids. Gases,
aerosols and gas filling applications have been excluded from this report.
End uses The end use sectors for filled products are equally diverse and traditionally comprise food,
drink, pharmaceuticals/health and beauty, chemicals and other products, with food and
drink representing by far the most significant end users, between them accounting for
Page 4 © Copyright Pira International Ltd 2007