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In-house blow molding reduces CO2 by 90%

Swedish ketchup producer Orkla brings PET bottle blow molding in-house to reduce its environmental footprint, allow for cold filling, and increase its production line efficiency.

Orkla brought blow molding of its ketchup bottles in-house at the Fågelmara plant in part to increase its production efficiency.
Orkla brought blow molding of its ketchup bottles in-house at the Fågelmara plant in part to increase its production efficiency.

Orkla Foods Sweden is one of 10 businesses belonging to Orkla Foods, the parent company of which is one of Norway’s leading suppliers of branded consumer goods. At its plant in Fågelmara, Sweden, Orkla produces nearly 25 million bottles of its Felix-brand ketchup each year, which are sold in its home country as well as in Finland and Denmark.

In 2013, as part of its commitment to sustainability, Orkla brought blow molding of its ketchup bottles in-house at the Fågelmara plant in order to increase its production efficiency and reduce its greenhouse gas emissions. Orkla has committed to a number of aggressive sustainability goals to minimize its environmental footprint by 2020, including the development of more environmentally friendly products and packaging and the reduction of its GHGs by 20%.

In addition to addressing these sustainability goals, bringing blow molding in-house also allowed Orkla to redesign its Felix bottle for greater consumer convenience and shelf appeal, reduce packaging costs, switch from hot filling to cold filling, and increase its production line efficiency.

Says Fågelmara Plant Manager Bill Wigren, “We needed to upgrade our design of the ketchup bottle and at the same time we needed to invest in new filling equipment and increase our efficiency.”

Custom-designed bottle

Felix ketchup is a premium, preservative-free product requiring premium packaging. In making a switch to a new bottle design and in changing the packaging material from high-density polyethylene to PET, Orkla worked with plastic packaging supplier Petainer.

According to Åke Larsson, Nordic Sales Director for Petainer, Orkla had several requirements for the new bottle design. “Orkla was looking for a bottle that would have better shelf appeal as well as be more convenient in terms of getting all of the product out of the bottle,” he says.

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