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New Line Features Two Blow/fill Systems

To maximize the ability to change over from one neck diameter to another and to fill either aseptic, CSD, or still products, Bickford’s doubled down on blow/fill technology.

Bickford's Group

Bickford’s, a family-owned and well-known Australian beverage brand, recently installed a complete PET line featuring one blow/fill system for aseptically filled beverages and a second blow/fill system for  either non-aseptic still beverages or carbonated soft drinks (CSD).

The new line is in response to growing health and wellness concerns around the world that are driving the growth of beverage categories such as bottled water, especially flavored options. Recognizing that this trend represented opportunity, Bickford’s started to search for a highly flexible production line capable of handling both still and carbonated beverages as well as low- and high-acid aseptic products. Moreover, they wanted to run multiple PET bottle designs and to decorate with either a shrink sleeve or a pressure-sensitive paper label.

For this particular challenge, they turned to Sidel packaging machinery, a leader in aseptic PET applications and packaging design, for the first time in their long history. In the process, they became one of the first to invest in Sidel’s dry preform decontamination technology.

“Previously, we were mainly familiar with hot-filling PET applications,” says Angelo Kotses, Bickford’s CEO and owner. “We decided to partially shift to aseptic PET bottling because we wanted to optimize our production set-up and achieve a better TCO, which is of course critical if you plan to attract more consumers. Plus, we really wanted to diversify our product portfolio by introducing new references, including coffee-flavored dairy-based products and coffee-flavored non-dairy product, and by moving some drinks formerly packaged in glass and cans to PET.”

And so it was that Bickford’s and Sidel became collaboration partners in the commissioning of a versatile PET line equipped with an Aseptic Combi PredisTM  blow/fill/cap system for shelf-stable aseptic beverages in three bottle sizes plus a Combi SF300 for non-aseptic beverages, both still and carbonated, in 1-L bottles. Both filling systems feed into the same labelling, sleeving, case-packing, and palletizing equipment, so only one filler runs at a time.

Sidel’s Herve Herambert, Account Director Sales Aseptic South East Asia Pacific, says that it would have been possible for Bickford’s to install one blow/fill system capable of producing all three beverage types—CSD, non-aseptic still products, and aseptic juices and flavored milks. But the firm wanted two different neck finishes: 28-mm for CSD and non-aseptic still products and 38-mm for aseptic products. This made it far more affordable, efficient, and practical to install two separate Combi machines.

Two labellers, too

Also notable is that the line incorporates two labelling machines. The 1-L bottles filled on the SF300 are always labelled on a Fuji Seal shrink sleeve labeller that applies a partial PETG shrink sleeve label. But the 250-mL, 500-mL, and 1-L bottles filled aseptically can either be decorated by this sleeve labeller or they can bypass it and receive front, back, and neck pressure-sensitive labels applied by a Sidel labeller.

By replacing so much of its hot-fill production with aseptic filling, Bickford’s gained great freedom in terms of packaging design and container decoration. In total, the new line now processes more than 20 different SKUs, including still water, CSD, four different flavoured waters, coffee-flavored milk, coffee-flavored non-dairy products,  and eight types of juices. In addition to switching quickly from one product to another, the line also moves efficiently from 250-mL to 500-mL to 1-L bottle sizes.

Throughout the project, Sidel’s packaging experts worked in close collaboration with Bickford’s marketing team to launch their products. “Looking at our water and CSD range filled through the Combi SF300, we wanted to achieve an iconic shape to help our brand stand out in a very crowded marketplace. Our new bottles needed to offer convenient handling to our consumers and be robust enough to hold their ergonomic shape and carbonation once opened,” explains Beverley Reeves, Senior Brand Manager at Bickford’s.

In the case of Bickford’s water and CSD bottles, the Sidel packaging team started from scratch. The bottle they came up with incorporates Sidel’s StarLITETM  base. Formed during blow molding, it gives the finished bottle improved mechanical properties—without the need for adding additional weight to the bottle—that help it resist deformation that might otherwise occur due to top load weight during distribution.

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