PRELACTIA success story

PRELACTIA®

Milk bottled the Swiss way.

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What is PRELACTIA®?

PRELACTIA® is the cost-efficient barrier preform for liquid dairy products (LDP) in PET bottles. PRELACTIA® stands for innovative bottle designs and a revolutionary shelf life of up to 6 months.

The PRELACTIA® preform consists of a double-layer design: a gray interior wall that is impervious to light and a white outer skin. Both layers are precisely defined and consist of PET. As a result, PRELACTIA® bottles are optimally suited for recycling.

PRELACTIA® is exclusively available with premium machine technology from Netstal. The PET-LINE 2C production system offers maximum flexibility and, if needed, it can also be used for standard preforms (CSD, water).

 

Highlights

Innovative bottle designs
Innovative bottle designs
Two layers for the best light barrier effect
Two layers for the best light barrier effect
A light milk bottle made from pure PET
A light milk bottle made from pure PET
Resealable and absolutely tight
Resealable and absolutely tight
High-performance and flexible PET-LINE injection molding system
High-performance and flexible PET-LINE injection molding system
32+32 cavity mold from Molmasa
32+32 cavity mold from Molmasa
Additional overmolding application options
Additional overmolding application options

PRELACTIA® advantages

For milk processors and large dairies

For manufacturers of preforms and bottles

  • Custom and ergonomic bottle shapes with which the products stand out at the point of sale

  • Pure white and particularly light bottles that strengthen your product position-ing

  • Absolutely tight and resealable

  • The best light barrier for a revolutionary shelf life of up to 6 months

  • A bottle made from pure PET that is particularly easy to recycle

  • Highly cost-efficient packaging for milk drinks and milkshakes

Highly effective light barrier

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Light transmission of PRELACTIA® compared to mono-layer PET bottles.

 

The double-layer design guarantees a highly effective light barrier. Nearly 100% of the visible light (400 nm to 700 nm) is reliably blocked. The result is a shelf life of up to 6 months.

Prelactia® calculator

With PRELACTIA you can achieve considerable material savings compared to PE-HD bottles. Use the PRELACTIA calculator to determine which savings potential you can achieve for your production quantity.

PET resin is much cheaper than HDPE for blow molding. Please use our Prelactia calculator to calculate your savings potential on raw material and titanium dioxide additive.

 200ml
 500ml
 1000ml
 1500ml

Prelactia®

g
 
 
Million
€ per Ton
%
Tons / Year
€/Kg
 

HDPE

g
* HDPE Bottles are generally 20-30% heavier than their
Prelactia® counterparts
Million
€ per Ton
%
Tons / Year
€/Kg
Current prices between 7-8€
* The additive fraction is subtracted from the raw material

Savings potential on raw material and additive

Download your calculation here     Download

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Potential savings

Compared to PET monolayer

• Up to 70% less titanium oxide added

Compared to HDPE extrusion blow molding

• About 30% lower market price for PET granulate
• About 20% lower weight
• No loss of material during injection molding and blow molding
• Absolutely tight bottle without additional aluminum seal

Manufacturing process of PRELACTIA®-Preforms

PET-LINE (2400 - 5000 kN)

High-performance injection molding systems for the production of preforms

PET-LINE (2400 - 5000 kN) Toggle lever clamping unit
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Toggle lever clamping unit

Toggle lever clamping unit

The clamping unit of the PET-LINE is based on the proven mechanical system of the SynErgy and was optimized in the course of different evolutionary steps with state-of-the-art digital control technology.
It is tailored to the specific requirements of PET preform molds and thereby offers optimal framework conditions.

  • 5-point dual toggle lever with hydraulic actuating cylinder for quick and harmonious movement sequences
  • Robust and stable design
  • Stable support of moving mold plate on sliding guides and columns
  • Perfectly designed for large and high-cavity molds
Removal unit and post-cooling
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Removal unit and post-cooling

Removal unit and post-cooling

  • Dynamic and quick removal gripper with integrated cooling
  • Transfer unit with optional integrated calibration of the neck area and pre-blow stage (Calitec and Preblow Option)
  • Highly efficient cooling station with up to 4 post-cooling cycles
  • Parts release onto conveyor with container change function
  • Removal and post-cooling unit integrated completely into the machine controller
2-stage injection units
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2-stage injection units

2-stage injection units

The injection unit of the PET-LINE is a unique in-house-development. The extremely high throughputs of a preform system are only made possible in the first place thanks to the unique design.

  • High-performance plasticizing unit with electric metering drive
  • Intrusion technology for maximum metering performance
  • Injection piston with hydraulic actuation (ShotPot principle)
  • Innovative and powerful valve technology
  • Highly precise and quick digital control of metering and injection processes
Adaptive drive unit with optimal energy efficiency
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Adaptive drive unit with optimal energy efficiency

  • Variable speed servo motor
  • Double pump design
    • Piston variable displacement pump
    • Internal gear constant delivery pump
  • Completely closed oil tank
  • Oil cooling and filtering in the secondary circuit
  • Integrated storage system
Calitec® – the smart way to reduce cycle times
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Calitec® – the smart way to reduce cycle times

Calitec® – the smart way to reduce cycle times

In order to improve the preform post-cooling, the demolded preforms are actuated with internal pressure via the transfer gripper.
That ensures a more intensive and, most importantly, uninterrupted post-cooling of the preforms. A calibration of the external preform diameter is carried out at the same time

Your benefits:
Faster cycle times and optimal preform quality

CPP option
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CPP option

CPP option

CPP (Controlled Production shutdown after a Power outage) permanently monitors the power supply and provides sufficient energy in an emergency.

  • Brief power failures or fluctuations in the grid lasting milliseconds are reliably bridged
  • If the outage lasts somewhat longer, then sufficient power is provided to reliably and controllably shut down the cycle. Preforms are fully injected and demolded. Meterage for the next shot is stopped and the entire system is controllably brought to a halt.

Your advantage:
CPP increases machine availability in harsh industrial environments and reliably secures your productivity at lowest unit costs.

Two-component version
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Two-component version

Two-component version

The PET-LINE 2C is a high-performance injection molding system for barrier applications and two-component preforms with decorative effects. The lateral injection unit can simply be deactivated. This provides complete flexibility and, if necessary, it can also produce monolayer and standard preforms for water and carbonated soft drinks (CSD) with up to 72 cavities.

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