HOKKAN GROUP INTRODUCES ASEPTIC TECHNOLOGY TO INDONESIA
Japanese hokkan group is one of asia’s strongest beverage businesses, operating in Japan, Vietnam, Malaysia and most recently Indonesia.
In 2011 they started a joint venture with the large trading company Toyota Tsusho Corp to create a new player in the indonesian market, PT Hokkan Indonesia. The company might be new but its ambitions are high: To provide a wide range of non-carbonated healthy soft drinks to indonesian's demanding consumers. And to achieve this goal, they turned to aseptic technology.
The group is aware of the many benefits of aseptic filling from their operations in Japan and was therefore keen to bring this technology to the Indonesian plant. "From our experience in Japan, we know that aseptic technology can achieve lightweight bottles, a flexible bottle design and long product shelf life. Aseptic technology offers us numerous opportunities for making quality products," says Masaaki Ikezawa, President of PT Hokkan Indonesia.
Launching new products in a new market is a huge undertaking, so PT Hokkan Indonesia needed a supplier who understood the importance of this project and could meet their needs for high quality and speed. They talked to a number of suppliers and quickly realised that Sidel shared their focus on quality. "Sidel understood our needs for food safety, product integrity and had the right equipment portfolio for aseptic technology. They also knew we wanted to get production started as quickly as possible," adds Masaaki Ikezawa.
Using the group's extensive experience gained in other countries, they started work to set up a manufacturing plant with an annual production capacity of 150 million bottles in Ciawi, Bogor in September 2012. This site is close to established distribution networks, as well as the city of Jakarta.
In terms of equipment, the plant has to manufacture PET bottles for so-called 'sensitive' drinks, such as coffee and tea-based drinks, milk-based drinks, fruit drinks and sports drinks, as well as be able to carry out contract filling. This required a line with great flexibility, efficiency and capable of delivering reliable high quality. For this reason, it was decided to use a PET aseptic line, equipped with Combi wet aseptic from Sidel.
With the current success, they are now making plans to look into the possibility of u sing Combi Predis™ FMa for the second aseptic line from Sidel. This unique proven dry preform contamination solution is designed for the types of sensitive beverage products that PT Hokkan Indonesia is going to produce. Using no water and very few chemicals, Predis technology dry decontaminates preforms to ensure total food safety and a longer shelf life for products without the use of preservatives. It allows any bottle shape or size to be produced using fewer materials and with lighter packaging. Operating with a strong focus on production costs and environmental impact, this is good news to PT Hokkan Indonesia.
In addition to working with the customer on the design of the new line, Sidel was also involved in bottle design. The new design has to be suitable for aseptic production and be appealing to Indonesian consumers. "We let the professionals do the job of bottle design. Sidel studied market trends and came up with a good solution that met customer needs and matched the Indonesian market culture," says David Chendra, General Manager of PT Hokkan Indonesia.
The Combi wet aseptic line was installed in 2012 and production started end of 2012. It now runs continuously 24 hours a day.The benefits of this line quickly became evident, such as reduction of manpower at the early stage of distribution and energy saving as there is no conveyor. It also consumes less electricity than expected. Looking ahead, the Combi system allows PT Hokkan Indonesia to further develop the line in tandem with their changing requirements. "With the Combi, we can develop and plan more lightweight bottles in future production," adds David Chendra. Although the line is up and running at the required efficiency, Sidel and PT Hokkan Indonesia are still working to make continuous improvements.
"In our view, Sidel is a company that leads the field of innovation, bottle design, flexibility and services. We will continue to work with them to find ways to further reduce energy consumption and they have presented a highly innovative solution for using Bio-material. At PT Hokkan Indonesia, we appreciate this partnership," says Masaaki Ikezawa.
From glass to PET
Indonesian consumers are turning away from glass bottles as they realise the convenience of PET bottle packaging. Re-sealable bottles match the dynamic urban lifestyle of younger Indonesians, which is reflected in a serious decline in demand for glass bottles.
Top 3 growth categories 2011-2012
RTD coffee 13.5%
Sports and energy drinks 13.3%