More stability with less material: KHS develops PET bottle with bonded handle

The new PET bottle with bonded handle from KHS reduces material consumption by up to 30%. The bottle body and handle are fully recyclable and made from rPET.

  • Fully circular home care and food container
  • Up to 30% less material used
  • Bottle body and handle entirely in rPET

Dortmund – KHS has perfected its rPET containers for the home care and food sectors. In addition to the mechanically nested bottle handles, the Dortmund company now offers a bonding process which offers many advantages to users: stretch-blown using the preferred heating method, the KHS PET bottle is more stable than extrusion-blow molding polyolefin alternatives currently available on the market. Glued handles also require a simpler outline than the clip-on variety, which again saves material and at the same time increases the efficiency of the stretch blow molding process. The bottle body and handle are fully recyclable and made from rPET.

The development of the 2.3 liter PET bottle with a glued handle is the result of a one and a half year cooperation between KHS and Logoplaste Innovation Lab. The goal was to design a bottle specifically for household cleaning products with the smallest possible carbon footprint. With its ready-to-use system, KHS and Logoplaste Group want to support industry efforts for greater sustainability.

Reduced energy and resource consumption
“Our adhesive technology allows us to reduce the amount of energy and material used in production and to manufacture a container that is both more stable and visually more appealing than standard products currently available on the market,” says Sebastian Wenderdel , commercial development of PET sales. director at KHS in Hamburg, Germany. A direct comparison reveals that up to 30% fewer resources are used in the manufacturing process, with 10% material saved compared to a clip-on handle. Instead of producing the bottle on an extrusion blow molding as is common, stretch blow molding is particularly energy efficient, a significant advantage given the rising prices of energy and raw materials.

In conjunction with preferential heating, KHS provides extremely precise and reliable installation equipment. This proven, energy-efficient heating method allows for even distribution of material during the stretch-blow molding process in plastic bottles with irregular and complex designs, reducing the number of resources used and improving bottle stability. Neck alignment with millimeter precision as an optional component enables precise product dosing using angled spout caps. Additionally, because the new PET bottle has no seams – unlike standard HDPE or PP containers – it has proven itself in rigorous internal drop tests, Wenderdel claims.

When selecting a suitable adhesive, the design team relied on the years of expertise accumulated by KHS during the Nature MultiPack project. The container provides an additional product marketing advantage. “The transparent PET material makes the product visible,” says Wenderdel. Additionally, customers can have their own bottle designed using the KHS Bottles & Shapes service program.

Towards a circular economy
With the development of its new PET bottle with a glued handle, KHS is moving closer to a circular economy in this respect – and with this system wishes to address not only manufacturers of household cleaning products but also producers of foodstuffs. food. “We offer a circular container whose body and handle of the bottle are made from 100% recycled materials and are themselves fully recyclable. This is still quite unusual for containers with an integral handle,” emphasizes Wenderdel. Since PET is the plastic with the highest recycling rate in the world, it is also more readily available on the market than materials such as HDPE or PP. These also have the disadvantage that, unlike rPET, they are not yet circular. “The growing demand for environmentally friendly packaging and the stricter legal requirements governing the use of recycled plastics are perfectly met by our latest development”, concludes Wenderdel.