Hot Fill Packaging
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South Asian Petrochem Ltd.
Hot fill Packaging
Hot fill Packaging: 8 Key Aspects Y.Somasundaram South Asian Petrochem Ltd.
South Asian Petrochem Ltd.
Hot fill: Packaging Objectives • To pack fruit base drinks without or with minimum preservatives. – Natural flavor preserved. – No sodium salts.
• Transparent family size packing. • Easy and convenient means to dispense content as per need. • Unbreakable. • Recyclable.
Hot fill Packaging
South Asian Petrochem Ltd.
Hot fill Packaging
PET bottles - Hot fill & Aseptic (USA) 3500 3100
Bottles (million)
3000 2700
2500 2000
2000 Fruit juices
1500 1200
1000 500 0 Fruit juices
600 2000
2001
2002
2003
2004
600
1200
2000
2700
3100
South Asian Petrochem Ltd.
Hot fill Packaging
Hot fill – Indian Scenario • Launched by Maa fruits, Dharmapuri & Fruitnik at Chennai in end 2003. – 28 mm Thick neck bottles, with higher Tg resins. – Neck crystallized bottles. – 500 / 1000 ml bottles
• Pepsi launched its hot fill with Slice in 2004. – Neck crystallized bottles. – 28 mm Alcoa neck. – 500ml bottle.
• Coke followed with Maaza in the same year. – Neck crystallized bottles. – 28 mm Alcoa neck. – 500ml bottle.
South Asian Petrochem Ltd.
What is Hot, for a Hot fill • Hot fill temperature (82 deg C) – High acid fruit drinks (< 4.5 pH)
• Hot fill temperature (92 deg C) – Low acid fruit drinks (> 4.5 pH > 6.0) – Ex. Tomato juice, low acid tea (green tea)
Hot fill Packaging
South Asian Petrochem Ltd.
Hot fill Packaging
1: Resin (PET)
• Faster rate of Crystallization. • Easy process ability.
• PET – Homo polymer. • Lower IV = 0.76 dl/g.
South Asian Petrochem Ltd.
2: Preform • High wall thickness to yield thicker bottle. • Optimum design for strain hardening & crystallinity. • Too much stretching can lead to residual stresses at final bottle, leading to higher shrinkage • Crystallized neck to withstand temperature during filling. • Wide / thick neck to avoid contact of hot liquid & deformation.
Hot fill Packaging
South Asian Petrochem Ltd.
3: Bottle design • Panels to absorb and dissipate vacuum created in bottle during cooling of content. • Base ribs to withstand temperature and liquid filling force. • Rigid circular ribs withstand deforming forces. • Higher post mold shrinkage allowance in mold design.
Hot fill Packaging
South Asian Petrochem Ltd.
Hot fill Packaging
6: Blowing process
• Higher preform temperature for blowing. • Hot blow mold surfaces to increase the bottle wall crystallinity through thermal crystallization. • Reduce the orientation stresses in the bottle wall. • Internal cooling of bottle by stretch rod, to harden inner wall before ejection. • Quick opening of mold cavities to avoid softening of bottle wall after cooling.
South Asian Petrochem Ltd.
4: Bottle Performance • Less than 1% thermal shrinkage on hot filling conditions. • Base clearance to be maintained. • No unequal deformation in base leading to tilting / rocking of bottles. • No warping at neck seal surface. • No leakage at seal surface.
Hot fill Packaging
South Asian Petrochem Ltd.
5: Closures • Closure material to take care of content temperature at filling. • Single piece closure to avoid the effect of warping of wad. • Sealing surfaces to take care of the expansion & shrinkage during filling and cooling.
Hot fill Packaging
South Asian Petrochem Ltd.
7: Filling process • Fill close to brimful in crystallized neck finish. • Fill up to NSR (Neck Support Ring) in non-crystallized neck finish. • Contact of high temperature filling head with the Non-crystallized neck finish avoided. • Quick capping, to avoid product contact with ambient air & cooling. • Caps to be sterilized before capping.
Hot fill Packaging
South Asian Petrochem Ltd.
Hot fill Packaging
8: Conditioning
• Tilt bottle to wet & warm the closure immediately after capping. • Water shower the bottle to lower temperature, before putting on shrink sleeve label. • Water quality in shower to be clean, in order to avoid mold growth between the bottle & shrink film / pilfer proof ring.
South Asian Petrochem Ltd.
Hot fill Packaging
Advantages over TetraPak • Content is visible, gives customer the feel of the product. • User can see the quantity left out in the container after use. • Environment friendly, easily recyclable. • Higher top load strength so more products can be stacked and stored in smaller space & also transported without damage.
South Asian Petrochem Ltd.
New development Panel-less Hot fill bottle
Hot fill Packaging
Hot fill Packaging
Hot fill Packaging: 8 Key Aspects Y.Somasundaram South Asian Petrochem Ltd.
South Asian Petrochem Ltd.
Hot fill: Packaging Objectives • To pack fruit base drinks without or with minimum preservatives. – Natural flavor preserved. – No sodium salts.
• Transparent family size packing. • Easy and convenient means to dispense content as per need. • Unbreakable. • Recyclable.
Hot fill Packaging
South Asian Petrochem Ltd.
Hot fill Packaging
PET bottles - Hot fill & Aseptic (USA) 3500 3100
Bottles (million)
3000 2700
2500 2000
2000 Fruit juices
1500 1200
1000 500 0 Fruit juices
600 2000
2001
2002
2003
2004
600
1200
2000
2700
3100
South Asian Petrochem Ltd.
Hot fill Packaging
Hot fill – Indian Scenario • Launched by Maa fruits, Dharmapuri & Fruitnik at Chennai in end 2003. – 28 mm Thick neck bottles, with higher Tg resins. – Neck crystallized bottles. – 500 / 1000 ml bottles
• Pepsi launched its hot fill with Slice in 2004. – Neck crystallized bottles. – 28 mm Alcoa neck. – 500ml bottle.
• Coke followed with Maaza in the same year. – Neck crystallized bottles. – 28 mm Alcoa neck. – 500ml bottle.
South Asian Petrochem Ltd.
What is Hot, for a Hot fill • Hot fill temperature (82 deg C) – High acid fruit drinks (< 4.5 pH)
• Hot fill temperature (92 deg C) – Low acid fruit drinks (> 4.5 pH > 6.0) – Ex. Tomato juice, low acid tea (green tea)
Hot fill Packaging
South Asian Petrochem Ltd.
Hot fill Packaging
1: Resin (PET)
• Faster rate of Crystallization. • Easy process ability.
• PET – Homo polymer. • Lower IV = 0.76 dl/g.
South Asian Petrochem Ltd.
2: Preform • High wall thickness to yield thicker bottle. • Optimum design for strain hardening & crystallinity. • Too much stretching can lead to residual stresses at final bottle, leading to higher shrinkage • Crystallized neck to withstand temperature during filling. • Wide / thick neck to avoid contact of hot liquid & deformation.
Hot fill Packaging
South Asian Petrochem Ltd.
3: Bottle design • Panels to absorb and dissipate vacuum created in bottle during cooling of content. • Base ribs to withstand temperature and liquid filling force. • Rigid circular ribs withstand deforming forces. • Higher post mold shrinkage allowance in mold design.
Hot fill Packaging
South Asian Petrochem Ltd.
Hot fill Packaging
6: Blowing process
• Higher preform temperature for blowing. • Hot blow mold surfaces to increase the bottle wall crystallinity through thermal crystallization. • Reduce the orientation stresses in the bottle wall. • Internal cooling of bottle by stretch rod, to harden inner wall before ejection. • Quick opening of mold cavities to avoid softening of bottle wall after cooling.
South Asian Petrochem Ltd.
4: Bottle Performance • Less than 1% thermal shrinkage on hot filling conditions. • Base clearance to be maintained. • No unequal deformation in base leading to tilting / rocking of bottles. • No warping at neck seal surface. • No leakage at seal surface.
Hot fill Packaging
South Asian Petrochem Ltd.
5: Closures • Closure material to take care of content temperature at filling. • Single piece closure to avoid the effect of warping of wad. • Sealing surfaces to take care of the expansion & shrinkage during filling and cooling.
Hot fill Packaging
South Asian Petrochem Ltd.
7: Filling process • Fill close to brimful in crystallized neck finish. • Fill up to NSR (Neck Support Ring) in non-crystallized neck finish. • Contact of high temperature filling head with the Non-crystallized neck finish avoided. • Quick capping, to avoid product contact with ambient air & cooling. • Caps to be sterilized before capping.
Hot fill Packaging
South Asian Petrochem Ltd.
Hot fill Packaging
8: Conditioning
• Tilt bottle to wet & warm the closure immediately after capping. • Water shower the bottle to lower temperature, before putting on shrink sleeve label. • Water quality in shower to be clean, in order to avoid mold growth between the bottle & shrink film / pilfer proof ring.
South Asian Petrochem Ltd.
Hot fill Packaging
Advantages over TetraPak • Content is visible, gives customer the feel of the product. • User can see the quantity left out in the container after use. • Environment friendly, easily recyclable. • Higher top load strength so more products can be stacked and stored in smaller space & also transported without damage.
South Asian Petrochem Ltd.
New development Panel-less Hot fill bottle
Hot fill Packaging
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