Container design to your exact specifications
In our holistic container design consultancy program we accompany you throughout the entire design process: from clarification of your initial idea through development and production of the container up to and including its presentation at the point of sale. Here, sustainability is becoming increasingly relevant. We have thus developed a number of suitable environmentally-friendly systems and solutions that need very little material, make use of recycled resources and/or contain a recyclable barrier.
Are you looking for that perfect individual bottle design that stands out from the competition on the market, has consumers convinced and at the same time is gentle on the environment? With our Bottles & Shapes consultancy program we give you professional, trusted support throughout the entire container design process, drawing on over 40 years of expertise in plastic technology. Thanks to our holistic advice and solid line expertise you enjoy great process reliability from the very beginning. And it only takes a few weeks until your new dream PET bottle is ready for delivery! We take the technical parameters on your line into account right from the start. On request we also test your container with regard to specific requirements. We then explain the individual process steps to you:
From the initial idea to the finished bottle.
1. The idea: Together with you, we will discuss the ideas and concepts of your individual bottle design. Even in this first step, it is important to take into account that the high requirements for aesthetics and uniqueness on the one hand are optimally combined with technical functionality on the other. This is the only way that we can ensure that perfect bottles are produced and that they are appealing to consumers both in appearance and with regard to handling.
2. Design: We will prepare a rough full-scale sketch of the bottle design that already takes all underlying data of an optimal production line into account and at the same time is a convincing attractive, individual design. On request, we will offer a label design and cap suggestions to round off the holistic presentation of your new bottle design to create a perfect all-in-one appearance.
3. 3D animation: We will create a 3D animation of your bottle with the help CAD technology which will enable you and us to make an initial assessment of the bottle shape and then systematically optimize it. The data gleaned at this stage also forms the basis for the blow mold which is then built after the final decision on the bottle design has been made.
4. Prototype: With the aid of ultramodern 3D printers we will produce a prototype that is quickly available as a plotted model. We will then simulate all relevant influences on the bottle in virtual trial tests. This saves time and money and the resulting suggestions for optimization of the bottle design can be quickly evaluated and implemented. Once the decision regarding the design has been made, the PET experts at KHS will recommend the ideal preform.
5. Laboratory: Based on this optimum pilot-scale preform, sample bottles are produced on a laboratory stretch blow molder that operates exactly like the one that will be used in practical operation later. Under certified laboratory conditions testers then subject the sample bottles to all factors which will later play a role in production, during transport, and finally in the hands of the consumer.
6. Bottle: When the test results confirm all specifications, we will produce wear-free blow molds in premium "Made in Germany" quality. Even extremely complicated milling contours and individual textures are precisely implemented. Bottle shrinkage factors during cooling after stretch blow molding, individual venting holes, and the perfect release of the bottles from the mold halves all make a decisive difference in the mold design. Any necessary format-dependent modifications coordinated with you during the course of the project then result in an optimally functioning line and perfect bottles.
Good to know
Energy efficient, powerful and reliable: the InnoPET Blomax Series V stretch blow molder has an innovative heating system and processes your PET containers using considerably less energy at a specific capacity of up to 2,800 containers per hour and blow station.
In order to protect the environment, more and more recycled material is being used in the manufacture of PET bottles. Together with our customer share we have developed the first PET bottle made of 100% recyclate and in doing so considerably cut carbon emissions in the production process. This development is an important step towards making PET containers more sustainable.
Plasmax technology is another innovation from KHS: here, a wafer-thin, recyclable coating of glass is applied to the insides of plastic bottles to give the product perfect protection against oxygen pickup or carbon dioxide loss. This means that juice bottles can also be bottle-to-bottle recycled, for instance. With our Beyond Juice concept we have designed a recyclable juice bottle made entirely of [r]PET together with Interseroh, an environmental service provider from Cologne, Germany.
We are also a pioneer in lightweighting where you benefit from considerable cost savings thanks to a minimal use of materials. We continue to develop systems and solutions that help you to identify potential savings in container, cap or label materials in combination with recyclate. Weight can also be saved on very small bottles by using our recyclable Plasmax barrier, for example. Using few raw materials by combining lightweighting and recyclate improves your ecobalance in the long term.
New ideas are constantly evolving from our cooperations with customers and industry experts, such as the one with ALPLA. Together we have designed a returnable one-liter PET bottle that weighs ten grams less than a standard container [of this size]. [r]PET can also be used here.
We would be happy to advise you – and develop the perfect container to suit your requirements together with you. In doing so, we always study the entire filling and packaging line to ensure that the newly developed or optimized container can be reliably transferred to the production process.
