Carlsberg 500ml PET Bottle
Objective
To develop in partnership with Carlsberg, Schmalbach Lubeca and Maxicrown a packaging solution for Carlsberg Lager in PET superior to that on limited distribution at the time. The offering should provide easy-open for the consumer and ultimately be able to meet the shelf life criteria needed to enter markets outside of limited events both microbiologically and organoleptically.
Project Details
We were approached by Carlsberg to fill a new concept in 500ml PET for beer in order to replace their existing offering filled by another contractor.
The project involved close collaboration with technical functions from both Carlsberg UK and Denmark plus Schmalbach Lubeca, to develop a container suitable for handling at speed on a line usually used for glass bottling. A rip cap closure was the preferred option though the bottle was also developed with crowning in mind. The cap supplier Maxi Crown and KHS were closely integrated into the project to devise a closing solution where our existing crowning unit could be adapted to apply easy open rip caps without crushing the container through excess axial load.
An existing flash pasteurisation set was adapted to supply sterile product to the filler. Chemical and thermal sterilisation procedures were developed to permit a high hygiene, clean-fill operation to be carried out. These disciplines are maintained during normal glass operations to minimise potential for contamination during PET operations. Investment was made in external CIP facilities for the filler to support the clean-fill ethos.
Project Outcome
The solution as conceived was delivered within the time scale required through a close working partnership achieved between all project stakeholders.
The filling plant, a KHS long tube electronic machine, was particularly suited to this type of work due to its almost total absence of oxygen pick-up in pack without any vacuum pre-evacuation.
Shelf life constraints were significantly extended to allow realistic aspirations for small PET within the take-home retail sector.
This project satisfied the requirements of all stakeholder groups throughout its life cycle. Ultimately, Jarvis ceased being active in this area as consequence of evolution of our business model against static conditions in the market place for this type of packaging. Based on development work carried out with ourselves the brand owner took the next step to perform this work inhouse.