There have been major moves under way to improve bottle design. Triggered by huge price hikes for plastics last year, the first trend features thin-walling, which is also a green improvement. A process refinement enabled a 19 percent weight reduction, saving over three million pounds of plastic annually in a Kraft salad dressing bottle. The optimized bottle design increased shipping efficiencies by 18 percent by allowing a greater number of bottles shipped per truckload. There has been an explosion in bottle thin walling in the past 18 months.
There has also been a huge improvement in the use of recycled PET in bottles. One of the leaders is Coca-Cola, which is developing a joint venture plant in South Carolina to produce food-grade recyclate. Capacity of the plant will be one billion pounds/yr, with half of the capacity being used by Coke and other half sold to external blow molders. Virtually all of the raw materials will be coming from municipal recycling programs. Coca-Cola Co. said it will boost recycled content of its PET bottles to 10 percent by the end of 2010 and 25 percent by 2015. Coke had reached 10 percent recycled content in North America in 2004 and 2005, but the level slipped to 3 percent or less. Coke’s wants to keep recycled material cost neutral with virgin PET. There is so much demand now for recycled PET that there actually is a shortage of supply.
At the JEC Europe 2015 composites show in Paris last month, makers of composite materials, software, and process equipment showed off their latest innovations. This year's show saw some announcements related to automotive applications, but many of the improvements came in the world of aerospace.
The DuPont-sponsored Plastics Industry Trends survey shows engineers want improved performance in a broad range of plastics and better recycling technology. These concerns top even processing enhancements that improve productivity.
Plastics leader SABIC recently announced a global initiative to help its customers take advantage of additive manufacturing (AM) and also advance 3D printing (3DP) technologies in several application areas. The company's plans go way beyond materials, and also include design, processing, and part performance.
A theme that was reflected in several ways at NPE 2015 was the use of 3D printing to assist in, or improve on, injection molding, as well as improvements in 3D printing materials and processes that are making better functional prototypes and end-use parts.
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