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Serac and Coveris receive the ecodesign award for Optys


The Optys bottle is produced in a single stage by vertical thermoforming of an extruded PP sheet on Serac’s machine at medium output (up to 10 000 bph).

No further operation is required for bottle’s decoration since the PP sheet is pre-printed by Coveris.

This simple, cost-efficient single step process allows to save on supply and manufacturing costs, as well as to reduce the footprint of the packaging line through the removal of the labelling machine or sleeve applicator.

The artwork, which entirely covers the bottle (from the bottom to the top of the neck), is printed using the rotogravure technology and anticipates the distortions that will occur during thermoforming (anamorphosis). It is also coupled with an indexing spot that will ensure the setting of the PP sheet on the Serac’s machine: final result is thus as good as with a label or a sleeve but with one stage less in the production process.

Optys offers a wide variety of possibilities in shapes, colors (even two-color bottles, one for the outside and one for the inside) and protection properties (light and oxygen barrier).

It can thus be used for dairy products, sauces, juices and non-food products on the homecare and personal care markets.


Designed with carbon footprint in mind

The Optys concept allows to reduce the global carbon footprint of the bottle at every stage of its lifecycle:

›        Source reduction of raw materials: the accuracy of the extrusion process allows to precisely calibrate sheet’s thickness for each model of bottle, so as to ensure the required mechanical properties with a minimum of plastic. As a result, the Optys bottle shows one of the best weight of packaging to volume of product ratio on the market (9 g for 195 ml in the particular case of EKER).

›        Savings on transportation : plastic sheets in reels require far less volume for transportation than empty bottles or preforms, and transportation of sleeves or labels is eliminated,

›        Reduced impact of the production process : the bottle thermoforming process requires less energy than extrusion or stretch blow molding and energy consumptions associated with conventional decoration processes are eliminated,

›        End of life: PP can be recycled and lighter bottles represent less waste to be treated.

An additional benefit for the environment is the good level of hygiene and closed neck of the bottle, which eliminates the use of water and chemical products for decontamination in applications where bottle’s cleanliness can have an impact on shelf-life, the company reported.