Sipa

AFTER months of speculation, Mondipak Plastics Wadeville is happy to report that its brand new blow-moulding machine from Sipa, Italy, has arrived and is now firmly ensconced alongside the company’s multitude of world class machinery.

The company kept everyone guessing with its ‘tantalising empty space’, but after months of investigation and trials it is thrilled with its latest acquisition.
A first in South Africa, the new Sipa technology is producing a specially designed hot- fill HR (heat resistant) PET bottle, capable of handling filling temperatures up to 87°C.
Hot filling eliminates the need for chemicals and preservatives in the filling process of fresh or frozen drinks, fruit juices, isotonic beverages and teas.
A PET bottle requires a special structure to withstand the mechanical constraints of the hot-filling process.
A special PET resin for hot-fill applications is used to manufacture a PET preform. It is specially designed with a re-inforced neck finish, prior to blow- moulding on the SIPA hot-fill equipment; this neck finish allows for hot filling of up to 87°C without previous crystallisation, which is usually required for hot- filling temperatures. The combination of the specialised heat-set blowing process (to provide a relatively high crystallinity of the bottle wall), with the special design features of the bottle base and vacuum panels, results in a PET bottle that can withstand any visual deformation and limited shrinkage; It also maintains cap/neck compatibility and bottle capacity.
The new bottle is strong and recyclable. As the new PET bottle provides a solution to growing consumer demand for preservative-free beverages, Mondipak Plastics believes its introduction will accelerate the transition from glass bottles and metal cans to plastics packaging.
Advanced Sipa technology
So, how does the Sipa technology differ to a standard blow-moulding process? In order to improve the heat resistance of PET the material crystallisation level needs to be enhanced. In the oven the preform undergoes enhanced reheating that initiates the crystallisation phenomena. The bottle is blown in a hot mold at 160°c. The contact of material against the mould surface enhances crystallisation. A standard PET bottle has a low 25% crystallisation level which is highly sensitive to heat. With heat-set treatment crystallinity reaches 30 - 37%, therefore creating high resistance to heat.
Mondipak Plastics is currently geared up to produce four different hot fill bottle designs/sizes on the Sipa HR stretch blow moulding equipment. Standard PET bottles can also be produced on which allows for efficient utilisation.
The Sipa machine project is being driven by Coca-Cola, a long term partner with Mondipak Plastics. It has recently launched the Glaceau Vitamin Water range in South Africa, in a 500ml hot-fill PET bottle.
Coca Cola Canners is the first to install a PET hot-fill line in South Africa. It partnered with Mondi Plastics to ensure that the Sipa technology meets its demands.
‘We believe that this installation allows for flexibility to produce a range of empty bottles,’ comments Carel Engelbrecht, MD, Coca Cola Canners. ‘It also obviously allows for future expansion into other products.’
The Coca Cola Canners plant is situated in Wadeville, adjacent to the Mondipak Plastics plant. The close proximity favoured Mondipak to limit transport and reduce its carbon footprint.
Lyle joins the world class team
With advancements taking place on machinery, Mondipak Plastics also introduces Lyle Bachelor, new general manager, at Wadeville. No stranger to the Mondipak business operation, Lyle has recently moved from Kwazulu Natal, where he was general manager at Mondipak Pinetown, to take on the new challenge in Johannesburg.
The Mondipak Plastics Wadeville operation is recognised as an industry leader in the manufacturing of PET preforms, bottles and jars for the food, beverage, mineral water, edible oil and homecare industries. Mondipak Plastics enjoys the major share of the carbonated soft drinks (CSD) market and is also a leading player when it comes to wide-mouth jars.
The operation comprises of three distinct production areas - the injection moulding of preforms; secondly the stretch blow-moulding of bottles; and thirdly the single-stage moulding of both bottles and wide-mouth jars.
The company has embarked on long-term supply contracts for preform supply for in-house blow-moulding of CSD bottles for various brands and exports into other African countries.
It is safe to say that the latest Sipa investment is opening the door for PET to be used for an even wider range of products. The build-up to the 2010 World Cup is under way and this surely is a major consideration in the minds of the soft drink and beverage industry giants. This should offer further opportunities for new hot-fill PET projects, not to mention an additional welcome boost to production levels at Mondipak Plastics Wadeville. Both Ian and Andre are more than confident that they are ready for the challenge.