Getting started
One point was clear from the very beginning: if bottles are to be reused, they need a marking that identifies them over their entire life cycle. This marking must therefore be so durable that it remains legible even after many intensive cleaning cycles. A similar approach had already been proposed to collect data on the durability and lifetime of bottles under economic aspects. When it turned out that the goal was no longer just efficiency, but sustainability, project “RefPET serialization” was launched. Labels with serialized Data Matrix codes should be vulcanized onto the bottles with existing equipment. Among others, Wipotec was assigned to contribute a vision system that would read these codes. Project teams from various parties set off on a rocky road.
Turning the page
The proof of concept did not lead to the desired results: labels were not durable enough, codes not reliably legible. The initiative was declared not feasible. Participants withdrew from the project. Except for one: at the Wipotec headquarters in Kaiserslautern sleeves were rolled up. After years of experience with serialization in the healthcare industry, the project team was determined to find a solution. It took one year of failed tests, investments and internal discussions to finally achieve the big breakthrough: Wipotec presented a test run with 300.000 bottles, all read and decoded perfectly. However, as good as the news was, there was no production-ready solution for applying the codes at that time. Again, Wipotec was geared up for the challenge. Their TQS portfolio is known for combining several tasks in one system. Therefore, a combined mark and verify unit should be the next logical evolutionary step.
One of the basic principles of these Wipotec solutions is that they prevent vendor lock-in by providing open interfaces to higher-level systems. In this project, the team took this idea even further. Even the code itself should not be limited by a proprietary approach but instead follow global standards. Therefore, they went to great lengths to emphasize the many advantages of the recently introduced GS1 Digital Link standard. Coca-Cola was impressed by the new possibilities and decided to be one of the first to utilize them. After first accomplishments, the biggest setback was yet to unfold.
Lost cause
In simple terms, marking PET bottles with laser means damaging them. For a pressurized container that must be cleaned with harsh chemicals, this does not contribute to longevity. In a crucial test in the Coca-Cola laboratory, the team discovered that the impact of the laser causes cracks in the bottle. As if this wasn’t enough, they had to realize that plastic’s property of swelling or foaming when heated made it almost impossible to apply the small and detailed code in a way that it would be reliably legible. Once again, the project was at risk. Once again, team Wipotec did not give up. From this point on, the “Laser in operation” signal in the Wipotec test center was permanently illuminated. But with each new attempt, it became clearer that the favored approach of applying the code as a standard matrix would not work. It was only with the realization that alternative laser technologies had to be considered that completely new options opened up. Through strong collaboration and trust from Coca-Cola, Wipotec was able to push the boundaries of what is technologically feasible.
„This change took a lot of extra development by Wipotec’s technical team but resulted even better than the original specifications.“
- Alfeu Junior, Specialist for new technologies at Coca-Cola Latin America
The goal within reach
With a new laser setup, the team was able to bring the code quality, then the marking speed and then the product handling to the right level. After all, the system had to be able to keep up with the blow molder. And because the codes were now lasered in superb quality, the system was able to fulfill the GS1 Digital Link standard – which had a major positive impact on the overall project. By connecting the bottle to the online world, the digital link allows all participants in the supply chain to use the same code: bottle producers, filling companies, logistics, wholesalers, retailers and end consumers. The key benefit is that any smartphone can read the QR code. This would become the foundation for the “ReturnApp” and therefore a decisive factor in the acceptance of the new return system. Along the way, Coca-Cola has achieved its goal of collecting data on the durability, cycles and lifespan of the bottles, opening up a completely new level of production forecasting.
Turns for the better
Many challenges had arisen since the original idea. Concepts were discarded. Innovation was required. In the end, the result turned out even better than anyone could have imagined at the beginning:
- Marking is more durable than the bottle itself
- 100 % code readability, with any smartphone
- GS1 Digital Link engages consumers
- Full supply chain visibility
- Full life cycle transparency
Still, two elements should be added to perfect the overall concept: bottle aggregation at the end of the production process and code reading in the filling lines. Both topics are within the Wipotec expertise and therefore solutions are ready to be deployed.
Promising Future
The project started off extremely well in public by winning the prestigious GS1 Brasil Automation Award in the category sustainability. While bottle manufacturers in Latin America are being equipped with systems to provide the new markings, more projects are planned around the world. Even the much more lightweight recyclable rPET bottles might be marked in the same way as the refillable RefPET bottles. The next big milestone is laser coding glass bottles – and Wipotec has already made significant steps towards mastering this challenge. Further developments are in progress and will be pursued with the same determination.
Wipotec has laid the technical foundation for the increased use of refillable containers. Now it is up to legislators and producers to make use of them.
„This project is being followed worldwide by most of our Operating Units.“
- Alfeu Junior, Specialist for new technologies at Coca-Cola Latin America
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In this Interview, Alfeu Jr., specialist for new technologies as Coca-Cola, describes the goal and course of “project refPET serialization”. Wipotec played a central role in this initiative by developing pioneering technology to ensure traceability throughout the bottle lifecycle, marking a significant step towards a circular economy. Alfeu Jr. describes this contribution as decisive for the success of the project – which should turn out unique in many aspects.