Monolayer construction results in savings

Topo Chico is supplied as a glass bottle and a PET bottle. For PET bottles, a wrap-around roll fed label is used, which is of transparent construction. This label was initially developed in a laminated structure of two layers of polypropylene with a total thickness of 40 microns, but in search of environmental responsibility, savings and better performance, a monolayer polypropylene film construction label was developed.MCC developed the monolayer structure in conjunction with Envases Universales. A material of a thickness was used that could meet the standards of application speed and quality.

The challenges

The main objective was to reduce the use of materials and to have savings compared to the two-layer laminated structure, but there were also other considerations. They needed a label that could run at an application rate of up to 37,500 bottles per hour without warping, that applied correctly, and with minimal changes in operating conditions. Since it is a highly carbonated beverage, it was also a challenge to ensure that the label stays adhered during possible bottle expansion and during the transport to the point-of-sale.

The results

The result was a reduction of 6.5% in terms of material and saving of 4% in the sale price of the label compared to the bilayer laminate. In addition, it is a more sustainable solution since the yield is increased by at least 5% in terms of m2 per Kg, eliminating the lamination process in the manufacture of the label and the use of adhesives. An additional benefit in terms of quality is that the curling problems encountered with the laminated label were eliminated.

We achieved this label, thanks to the fact that during the development we were selecting the appropriate materials (films and inks), as well as being on the floor with the label operators and with our technical service team to achieve a good implementation without sacrificing application speeds.” – Armando García, Manager of Research and Development and ST at MCC Monterrey