The KHS Group is presenting the KHS Supreme system, the result of extensive development work on protecting oxygen-sensitive beverages in PET packaging. The new KHS Supreme PET bottle combines the advantages of glass in terms of product protection with the functionality and handling benefits of polyethylene terephthalate containers. The key element of the solution is the Plasmax barrier technology, used by the company for more than 20 years, a very thin, transparent layer of silicon oxide applied to the inner wall of the bottle.
This layer, less than 100 nanometers thick, creates a glass-like barrier on the PET surface. Its function is to limit the permeation of oxygen into the package interior, which enables a significant extension of the beverage shelf life and preservation of its color, taste and quality over longer periods. According to KHS data, the use of the Plasmax barrier can extend product shelf life by up to ten times compared with bottles without such protection.
The Plasmax technology is developed at the KHS plant in Hamburg, which serves as the company's competence center for PET solutions. Research and development on subsequent generations of barrier systems is conducted there, and the accumulated know-how is used in the design of new packaging solutions for customers worldwide.
Protection for beverages with high quality sensitivity
The manufacturer is targeting the KHS Supreme system primarily at the segment of beverages that are particularly sensitive to oxidation. This applies in particular to ready-to-drink teas and high-quality teas such as green tea, which must meet stringent quality requirements on Asian markets and in other demanding regions.
As emphasized by Philipp Langhammer, product manager for barrier technology at KHS, the Plasmax barrier is intended to ensure stability of product color and taste, as well as safety and long shelf life. Oxidation of tea leads to undesirable sensory changes, therefore an effective oxygen barrier is crucial for maintaining beverage quality throughout the product's life cycle.
The technology, which originated from solutions for pharmaceutical glass containers, has been developed on the basis of many years of research and process optimization. The first Plasmax systems were piloted in the food sector as early as the early 2000s. Since then, KHS has further developed the Plasmax barrier to adapt it to the requirements of industrial filling lines.
Process parameters and industrial scaling
In the latest version of the solution implemented within the KHS Supreme system, Plasmax technology has been adapted to operate at production speeds of up to 60,000 bottles per hour. According to KHS, this has been achieved without any loss of the protective properties of the silicon oxide layer. The result is a solution intended for full-scale industrial production, combining high line performance requirements with advanced product protection.
The technology development has covered both process engineering aspects and coating stability on different types of PET bottles. The objective was to obtain a barrier with consistent properties while maintaining minimal layer thickness and transparency, which is important both from the standpoint of package aesthetics and visual product inspection.
Sustainability and recycling aspects
A key element of the KHS Supreme system is its alignment with the requirements of the circular economy. The applied Plasmax barrier is fully recyclable. In the bottle recycling process, the silicon oxide coating is removed with caustic solution during the standard washing step, without negatively affecting the quality of the recovered PET material.
In contrast to barrier technologies based on chemical scavengers, which can complicate the recycling process and reduce the purity of the material stream, Plasmax maintains a high level of purity of the separated PET. According to KHS, the coating is also fully compatible with bottles made from 100 percent rPET. This means the barrier can be used both on new bottles from virgin PET and on containers made from recyclate.
Philipp Langhammer describes this technology as a fully circular barrier solution. In the manufacturer's view, the packaging system combines high oxygen barrier performance with full material recyclability and compatibility with existing PET bottle recycling streams.
System presentation at interpack trade fair
KHS plans to present the KHS Supreme system together with Plasmax technology at the interpack trade fair in Düsseldorf, Germany. The solution will be showcased in Hall 13 at Booth A31 from May 7 to 13. In this way, the company intends to demonstrate its capabilities in the PET packaging segment and its direction in developing barrier systems for oxygen-sensitive beverages.
The KHS Supreme PET bottle combines high-quality design with the product protection properties of glass bottles.
