Dry aseptic technology arrives in Indonesia
Hokkan Group, Indonesia
Indonesian bottler, PT. Hokkan has installed the country's first-ever Sidel dry aseptic line in less than two years following the success of its first Sidel wet aseptic line. This investment in the latest technology will enable the company to meet the region's fast-growing demand for healthier beverages, while reducing the resources needed for this type of sensitive bottling.
Masaaki Ikezawa, President Director of PT. Hokkan Indonesia understood the value of aseptic packaging in PET bottles from his experience with the Hokkan Group in Japan. "We know that aseptic technology can achieve lightweight PET bottles, a flexible bottle design and a long shelf life. Aseptic technology offers us numerous opportunities for making quality products," he says.
From aseptic wet bottle to dry preform technology
PT. Hokkan's first Sidel aseptic line was equipped with a wet aseptic Combi Sensofill™ FMa that combines blow moulding, bottle rinsing, filling and capping in a single integrated system.
In 2014, they looked at the potential offered by dry preform decontamination technology associated with aseptic filling, in particular the Combi Predis™ FMa. The Sidel Combi Predis FMa is a system whereby preform decontamination, blowing, filling and capping functions are housed in a single production enclosure.
Completely safe production
Dry preform decontamination helps to protect liquid packaging from micro-organisms, thereby preserving the integrity of sensitive beverages and lengthening their shelf life. It offers continuous safe production of up to 165 hours before cleaning and ensures beverage safety at all levels of acidity without the use of preservatives.
Optimal flexibility to cover a wide beverage range
As a co-packer, PT. Hokkan were focused on creating a line that could manage a variety of formats with fast changeover times. The Combi Predis FMa enhances production flexibility by offering:
- Quick and easy format and liquid changeovers
- Minimal downtime
- Only 3-hour cleaning and sterilization needed between two bottle-to-bottle production runs
- Production of all sizes and shapes of bottles
- Fewer materials used for lighter packaging
- Reduced energy consumption
The introduction of the new dry aseptic line has doubled the company's annual aseptic PET production capacity. Together the wet and dry aseptic lines work in parallel to produce milk coffee, milk tea, Matcha, isotonic beverages, teas and healthy soft drinks in PET bottles. In sizes ranging from 250 ml to 500 ml and in a total of 15 stock keeping units, both lines are able to produce the same product range at speeds of up to 40,000 bottles per hour on all formats.
The Combi Predis FMa operates with a strong focus on production costs and environmental impact. It removes the need for water and only requires small amounts of chemicals. All preforms are 100% decontaminated using hydrogen peroxide mist.
Design and training
Alongside equipment supply, Sidel has also been working closely with PT. Hokkan on the design and development of new bottles, in particular a lightweighting of the 500 ml bottle. Sidel was able to research local market trends and create a number of designs in a relatively short time. These designs met both practical and cultural needs and were tested and evaluated with highly positive results.
When the new line was commissioned, Sidel held a number of training sessions for employees. This involved on-site training introducing the new equipment, combined with classroom-based training on the filling and blowing technologies. Advanced training is now being planned to upgrade employees' skills and knowledge of this new technology.
A national move from glass to PET
In recent years, demand for returnable glass bottles in Indonesia has declined considerably as the popularity of PET has grown.
The trend for PET packaging is fuelled by the fact that PET offers consumers and manufacturers:
- 100% recyclability
- Excellent barrier material properties for extended shelf life
- Flexibility and design freedom
- Lightweight form