Significant decrease in CO2 emissions with new bottle production line

18.3.2021

Maustaja's new blow moulding bottle production line reduces CO2 emissions, decreases amount of plastic and improves Maustaja’s security of supply.

50 000 kg less CO₂ emissions

Shifting to blow moulding recyclable PET bottles ourselves will reduce CO₂ emissions by up to 50,000 kg. This corresponds to the carbon footprint of driving over 360,000 kilometres with a petrol-powered car. The calculation uses the current production volume of the bottle types that will be replaced in the first phase. The emissions are caused by the transportation of the bottles.

“Before, we received about a million bottles every year from the United Kingdom in shipping containers. We are now able to get more or less the same number of bottle pre-forms from a supplier closer to us in Europe. One shipping container holds about 100,000 finished bottles but more than half a million preforms,” illustrates Sami Sikkilä, Materials Manager at Maustaja.

Lighter bottles – less plastic

The blow moulded bottle is designed to be lighter than the polypropylene bottles used previously. Consequently, the volume of plastic used will decrease by approximately 6,000 kilograms per annum, calculated using a 0.3 litre mayonnaise bottle.

“We will produce a few different bottle types in the beginning, for instance mayonnaise bottles and hot-fill ketchup bottles. However, the possibilities are practically limitless for blow moulding any type of bottle, or even canisters and jars,” Sami says.

The PET bottle is completely clear but can also be dyed. Different sizes can be produced from 200 millilitres to 1.5 litres.

Reducing uncertainty, better security of supply 

The bottle production line will also improve Maustaja’s security of supply.

“Until now, we have had to source the bottles externally. There are always uncertainties, such as delays in delivery. From now on, we are able to store sufficient volumes of bottle pre-forms, and thus reduce uncertainty,” Sami says.

The blow moulding equipment is supplied by Lithuanian Terekas UAB. The service agreement also encompasses operation, service and maintenance.