First 100% rPET recyclable juice bottle by KHS

Maximum product protection for sensitive beverages

KHS’s 100% rPET juice bottle at it’s stand at K 2019. Photo PSA
KHS’s 100% rPET juice bottle at it’s stand at K 2019. Photo PSA

There is an increasing demand from consumers and the beverage industry alike for packaging that saves on resources. Companies that design a container nowadays must also take their entire life cycle into account. KHS is addressing precisely this issue with its new Beyond Juice concept. For the first time, the Dortmund systems provider has developed a fully recyclable juice bottle made of 100% recyclate whose FreshSafe PET barrier system offers a unique product and freshness protection.

In combining its market-proven systems, KHS is taking an interdisciplinary and holistic approach to the beverage industry’s striving towards greater sustainability.

“With Beyond Juice we’re providing concrete answers to the challenges of the beverage industry, taking the juice bottle as an example. Also given the current debate on plastics practical, environmentally-friendly systems are becoming more and more important,” said Philipp Langhammer, product manager for barrier technology at KHS Corpoplast. What is needed is an integral and sustainable type of packaging suitable for the entire spectrum of sensitive beverages.

“When developing the bottle we thus strictly adhered to our credo of environmental protection, recyclability, and maximum product protection,” stated Langhammer. The PET container was designed by the KHS experts from the holistic Bottles&Shapes consultancy program together with environmental service provider Interseroh from Cologne, according to their latest design guidelines.

Environmental service provider issues recycling seal

Following several optimizations, 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.

“Thanks to the seal on the label, for the first time consumers can now allow the bottle’s truly excellent recycling properties to help influence their decision to buy when standing in front of the supermarket shelf. In the medium term, for packaging the criterion of recyclability will additionally become just as important as the aspects of product protection, convenience, and attractiveness – also on an international scale,” said Julian Thielen, packaging engineer from Interseroh.

Unique product protection

The Beyond Juice bottle satisfies all of these criteria – among other things with the help of FreshSafe PET. “We were only able to give top marks when analyzing the bottle’s recyclability because KHS SiO x barrier technology was used. Alternative composite materials utilized as a barrier also often color the recyclate and yield an inferior quality.,” Thielen explained.

Beyond Juice does not apply these otherwise usual composite materials which are added to the bottle material to protect the product and make pure-grade recycling much more difficult or even impossible. This topic is quickly gaining in significance on an international scale, too. This is illustrated, for instance, by the plastics strategy presented by the EU Commission at the start of 2018 which aspires to make all packaging waste in Europe recyclable by 2030.

FreshSafe PET also ensures that sensitive, high-quality juices and spritzers, for instance, keep up to ten 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 from it.

The KHS stand at K 2019. Photo PSA
The KHS stand at K 2019. Photo PSA

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 MultiPack TM 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.

Langhammer further explained that 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.

The impact, resilience, and growth of responsible packaging in a wide region are daily chronicled by Packaging South Asia.

A multi-channel B2B publication and digital platform such as Packaging South Asia is always aware of the prospect of new beginnings and renewal. Its 16-year-old print monthly, based in New Delhi, India has demonstrated its commitment to progress and growth. The Indian and Asian packaging industries have shown resilience in the face of ongoing challenges over the past three years.

As we present our publishing plan for 2023, India’s real GDP growth for the financial year ending 31 March 2023 will reach 6.3%. Packaging industry growth has exceeded GDP growth even when allowing for inflation in the past three years.

The capacity for flexible film manufacturing in India increased by 33% over the past three years. With orders in place, we expect another 33% capacity addition from 2023 to 2025. Capacities in monocartons, corrugation, aseptic liquid packaging, and labels have grown similarly. The numbers are positive for most of the economies in the region – our platform increasingly reaches and influences these.

Even given the disruptions of supply chains, raw material prices, and the challenge of responsible and sustainable packaging, packaging in all its creative forms and purposes has significant headroom to grow in India and Asia. Our context and coverage engulf the entire packaging supply chain – from concept to shelf and further – to waste collection and recycling. We target brand owners, product managers, raw material suppliers, packaging designers and converters, and recyclers.

In an admittedly fragmented and textured terrain, this is the right time to plan your participation and marketing support communication – in our impactful and highly targeted business platform. Tell us what you need. Speak and write to our editorial and advertising teams! For advertisement , for editorial and for subscriptions

– Naresh Khanna

Subscribe Now


Please enter your comment!
Please enter your name here