Keeping a global partnership local Producing more than 30 million beverage items annually across more than 60 manufacturing sites worldwide, Refresco lays claim to being the world’s largest independent bottler.
The company, which has grown rapidly thanks to a series of acquisitions over the past two decades, has a global partnership with PET preform specialist Retal that is tailored to suit regional markets.
“Maintaining quality is expected across all aspects of working with global partners, but that doesn’t mean that everything is the same everywhere,” says Gennadiy Khmelevskiy, global key account manager at Retal. “The details specific to local markets are important, as is knowing the preferences of each team in different locations.”
Retal produces PET and rPET preforms and HDPE closures for Refresco. The partnership, which began when Retal successfully tendered for a project with Refresco Benelux, hinges on being able to produce and provide the right product at the right volume.
Offering the correct technical solution with the best priceperformance ratio is, of course, imperative, Khmelevskiy says, but it’s what goes beyond this that makes the partnership. “As a dedicated sales and service person, it’s particularly important for me to diagnose any painpoints in the business and find an agile service solution that heals that pain. I also rely on our excellent service team, who can get to any Refresco business unit within 24 hours.”
Khmelevskiy is Retal’s single point of contact for Refresco and regularly communicates with Martijn Tempelaar, Refresco’s senior central purchasing manager, to ensure projects are progressing as agreed. “Keeping open communication with my Refresco contacts means that I stay aligned with Refresco’s headquarters in Rotterdam [in the Netherlands], as well as understanding the evolving needs of each business unit.”
Tempelaar agrees that being able to create solutions that can be quickly adapted for other locations helps to make a profitable partnership for both parties. “It is far easier to work with a smaller number of partners and repeat whatever elements of the project can be repeated, so we’re focused on the aspects that need to be changed. Building up trust is a longterm priority for us, and I trust the Retal team.”
Read in digital edition of Plastics in Packaging (page 21)
The macro-trend of operational excellence has unlimited interpretations when it comes to its micro-integration. To be able to purposefully and accurately define and manage a project that has clear goals is the function of project management, with operational excellence usually at its heart.
So how does that manifest itself in a global manufacturing company that is dedicated to high volumes and high quality – in a sector where regulations are changing? Emma-Jane Batey reports.
Operational excellence is defined as creating value for customers and shareholders thanks to the execution of its operations in the most efficient, effective manner. The idea being that two comparable businesses can have a clear winner depending on who works in the most excellent manner. At a time when globalisation means we can buy almost anything from almost anywhere, that excellence is what makes the difference – and wins the customer.
But what does operational excellence mean on a day-to-day basis? Is it just something that people say because they’ve heard someone else say it in a meeting, or do they actually know how to turn that zoomed-out concept into the hundreds of tiny actions it requires from an engaged team that know what they’re doing?
It’s said that the best time to start a pension is when you started working, and the second-best time is today. The circular economy is rather similar, in that ideal time to start would have been ages ago, and the next best time is now. Thankfully, we can look at how Sweden has done it. Rather than thinking ‘oh, it’s too late for the rest of us now’, we can just jump in and do the right thing from now on.
Let’s imagine that Sweden is our circular economy mentor. Let’s learn from how Sweden manages to recycle over 2 billion bottles and cans every year. Let’s copy how Sweden has integrated its deposit scheme in events arenas, shopping centres and grocery stores. Over 85% of all consumer packaging of cans and PET-bottles for beverages in Sweden is recycled, let’s do that too. There’s even a verb in Swedish - panta - that specifically means recycling packaging in collection points. We may or may not need a new verb.
A 36-year head start
A key element in the successful infrastructure that supports recycling in Sweden is Returpack, which was founded in 1984. Responsible for the Swedish deposit systems for metal cans and recyclable PET bottles for ready to drink beverages, Returpack is a privately owned company, owned by 50 percent by the Swedish Brewery Association (Sveriges Bryggerier), and by 25 percent each by the Swedish Food Retailers’ Federation (Livsmedelshandlarna) and the Grocery Store Association (Svensk Dagligvaruhandel).
An active supporter of Returpack is Spendrups Bryggeri AB, the biggest and most prominent Swedish family-owned and independent brewery, itself established in 1897 and today managed by the fourth generation of the founding family. Producing around 4 million hectoliters of beverages each year, Spendrups has contributed to building up globally recognised beer brands such as Heineken on the Swedish market, and its own sparkling water brand, Loka.
As a company that values both its heritage and its legacy, Spendrups is perfectly positioned to give an insight into how plastic packaging can be sustainable, with the advantages of being part of Sweden’s progressive infrastructure sits comfortably alongside its own dedication to long term responsibility.
Anna Lidström, Head of Sustainability at Spendrups, explains how the company’s philosophy and actions are in tune with how the Swedish beverage industry has had a circular approach to packaging for over 100 years. Lidstrom says, “The family spirit is strong at Spendrups; the long-term vision is that the company is supposed to be handed to the next generation, and so to do that properly, we must work in a way that is sustainable as well as profitable. We work in a circular manner through increasing use of recycled material in our packaging, striving to make our packaging 100% recyclable and utilising reusable packaging wherever possible.”
Read full article online at Sustainable Plastics
In January 2021, RETAL Baltic Films, UAB initiated the project Development and Use of Multilayer Film with Virucidal (Against SARS-COV-2) Properties in the Development of Face Shield Prototype Carrying out R&D Activities.
The aim of the project is to carry out the R&D research in order to develop a composition of a PET film for the development of a prototype of personal protective eye and face shields with a surface of antiviral effect against SARS-CoV-2 virus. The manufactured product will be offered to the global market of personal protective equipment against SARS-CoV-2, with the main target audience various health care authorities, where the use of these products is mandatory or recommended.
The expected end of project implementation is 31 December 2021.
The project is implemented in accordance with the Operational Programme for the European Union Funds’ Investments in 2014-2020 Priority 1 Promotion of Research, Experimental Development and Innovation.
Total value of this project is EUR 652,622.32, up to EUR 522,097.84 of which is financed by the European Regional Development Fund, as European Union response to Covid-19 pandemic measure".
RETAL PA is proud to be an active partner in the BotsIQ future workforce development program, connecting smart students with STEM career opportunities.
The non-profit program was founded in 2004 when industrial manufacturers got together with the Pittsburgh chapter of the NTMA (National Tooling & Machining Association) to create an initiative that harnesses the experience of industry mentors and partners them with technically-impressive students.
An inter-school robotics competition is at the heart of BotsIQ, with the teams of students tasked with building a 15lb robot, with every stage of the design and production carefully developed to support the overall STEM goals of the program.
Maria Campieri, Youth Services Manager at BotsIQ, says, “BotsIQ partners with 60 high schools across southwestern Pennsylvania. Through our program, students gain in-demand technical skills needed for a rewarding STEM career. This school year, we've had to think of creative ways to continue connecting industry and education, as in-person events are difficult, even with social distancing.”
One such creative idea is allowing a small number of BotsIQ representatives to visit RETAL PA's Donora factory, taking all social distancing and health precautions, to film an educational tour of the production site and the administrative functions for a virtual student event.
RETAL's HR manager Elizabeth Giecek says, “We are delighted to partner with such an inspiring program; the BotsIQ team are so motivated and the students themselves show incredible potential. It was great to have them here to gather information for the virtual event and to see first-hand how working with the next generation of STEM experts is important for progressive manufacturing companies like RETAL.”
Donora's nickname "home of the champions" proved to be as relevant today as it was in its 1950s heyday as the company's decision to locate there gave the community another chance.
While the well publicized difficulties of towns and communities throughout the rust belt are also true, the clear characteristics of hard work, loyalty and positivity shine through.
"Steel production started to decline from the early 1980s, and it was also that pollution became more of an issue throughout the valley. So the tone changed; people and families needed to leave to find jobs, and young people graduated and left," she said.
But while the tone of Donora and its neighboring towns changed, that local pride and expectation of hard work remained.
Read online at Plastics News
The modification of APET films to suit the demands of face shields has opened up not just philanthropic avenues for one packaging converter, but also commercial opportunities. Emma-Jane Batey reports
It will be almost impossible to describe 2020 in the future. With so much happening that we could have never predicted, the stories of loss and triumph over adversity may well get forgotten as we try to make sense of it.
Businesses large and small have had to adapt, some with more of a fair wind than others, and as we head into the unknown that is this winter, it is crucial that we take what we have learned and make the best of it.
During the first lockdown in spring, global plastics packaging manufacturer Retal responded to an online shout-out from a non-profit organisation that needed face shields for healthcare workers in Lithuania. The Retal Baltic Films team made the necessary adjustments to the plant’s equipment in order to produce transparent, fog-free APET films that are thicker than the company’s usual food-grade films.
As ‘essential’ manufacturing has been able to continue throughout the lockdown, the company was able to donate the required volume of these particular APET films for the production of more than 70,000 masks. These were requested by Robotikos Mokykla, a non-profit that provides technical education for children, and was spearheading the organisation of creating PPE masks for people in at-risk jobs during the initial phase of coronavirus.
Following the success of this volunteer project, the Retal Baltic Films team was keen to continue with the production of this specific APET film, even though the demand for face shields decreased in urgency as the supply of PPE became more reliable.
Violeta Ruseka, Retal Baltic Films’ APET films sales manager, explains: “We all know that 2020 has been a huge challenge, but the challenge to amend part of our additional production capacity to produce these thicker APET films for face shields was a welcome one. In March and April we found they were in great demand and we created an internal platform so that medical professionals could order them directly; it’s quite probable that the majority of face shields used in Lithuania until May were made from Retal Baltic Films APET film.”
While demand for this film for face shield applications dropped slightly after June, the company found that other applications were fast creating additional needs, in particular for the temporary, transparent hanging screens that have been quickly installed at many shops, coffee bars, and administrative offices with public access.
Ruseka adds: “This APET film is around 5mm thicker than the film used for face shields, but other than that it has the same anti-fog, no haze qualities and can be easily cut to whatever size and shape is required.”
Now that the company has finalised the technical parameters for its various APET film thicknesses, it is able to quickly adjust production according to its customers’ needs, both in terms of donating product for non-profit organisations and selling in quantity for commercial customers.
For example, Swedish packaging converter INP Forpackningar contacted Retal Baltic Films eager to source large volumes of clear films following the news that the company was able to supply thicker APET film with guaranteed anti-fog, no haze properties.
“This is one of two new cooperations that we have established since June and we are seeing new orders come in in smaller quantities too,” admits Ruseka.
Read online at Plastics in Packaging
A leading business media outlet in Ukraine has voted RETAL Ukraine in the country's top 25 innovative companies.
On 4th November 2020, dsnews.ua published an extensive report explaining why RETAL Ukraine has been included, with the long list highlighting considerable sustainability development actions.
Vladislav Mamchych, Technical Director at RETAL Ukraine, says, “Our strong performance was noted for careful use of resources, such as using modern equipment, energy regeneration, and responsible use of water, reducing carbon footprint by implementing ISO 14064 to prove operate efficiently regarding CO2 emissions, and our reduced consumption of raw materials to promote light-weighting and recycling. This award is a great recognition of our team's hard work, motivation and expertise.”
As part of the global plastic packaging manufacturer RETAL, this facility, based in the city of Kyiv, is dedicated to the production of preforms for the food and beverage industries.
Mamchych adds, “We are delighted to receive this award and are fully committed to continuing to lead our industry as a front runner in innovative sustainability performance through smart use of our resources and our capabilities.”
The pace of RETAL’s ongoing development shows no sign of slowing down, even though 2020 has been full of unforeseen challenges.
The global plastic packaging manufacturer has been able to stay close to its investment and progression strategy this year, with its ambitious CSR strategy underpinning its success.
An important example of RETAL’s continued growth is the official opening of its dedicated new laboratory and warehouse at its RETAL Baltic Films facility in Klaipeda, which represents a considerable €4.5 million investment, resulting in enhanced testing facilities and a new 4000 square metre warehouse.
RETAL Baltic Films General Manager, Viktorija Griziene, explained how this investment illustrates RETAL’s focus on development.
“We are delighted that our new facilities will support our ambitions to deliver complete packaging solutions for our customers. We can now offer fast, reliable, expert testing in-house, which guarantees that customers can clearly understand every element of their products from RETAL. Essentially, we can imitate the actual industrial processes that our customers use, including capping and filling, allowing us to smooth out any details that could be optimised.”
This complete packaging solution now includes a highly sophisticated validation process, thanks to the investment in the laboratory at RETAL Baltic Films, which assures guaranteed product quality stability due to the in-house equipment and technical expertise.
“Our highly experienced team can effectively utilise the new equipment to analyse the product and any changes the customer requires, including new additives, slight design changes, or new materials,” continued Ms Griziene.
Read more at insidefoodanddrink
We cannot get away from the fact that plastic packaging is not having a golden time at the moment. It's an easy bogeyman across the media, from wildlife programmes to EU legislation, so it can be hard to be a plastic packaging champion without looking like you're disconnected from the zeitgeist. And of course, we all want to be responsible citizens and leave the world a better place than how we found it, so it's not like packaging professionals want to waste loads of valuable raw materials and just dispose of them in the nearest river.
Yet with plastic packaging being so easy to criticise, it also means that the reality of plastic as a packaging material is also incredibly transparent; both literally (consumer studies show a slow uptake for 'non glass like' packaging with higher recycled content, even though it's more sustainable) and metaphorically (being under the spotlight means there's nowhere to hide).
Read more online at Sustainable Plastics