Bottle-to-Bottle and 100% rPET-Compatible Sustainable Production with AOKI ISBM Technologies
An Engineering Approach Integrated with the Circular Economy in Plastic Packaging
AOKI injection stretch blow molding (ISBM) technologies are developed not only with the goals of high efficiency and low production cost, but also with a strong focus on circular economy principles, reduction of carbon footprint, and the effective use of recycled raw materials.
The AOKI Eco Project and the Bottle-to-Bottle approach clearly demonstrate AOKI's systematic and engineering-driven vision for sustainable packaging production.
The Bottle-to-Bottle concept is a closed-loop recycling model based on converting used PET bottles back into PET bottles. The objective of this approach is to use recycled PET raw material (rPET) not only in secondary or low-performance products, but safely and with high quality directly in food and beverage packaging. AOKI ISBM machines are designed to enable bottle production using 100% rPET in line with this objective.
Systems developed within the scope of the AOKI Eco Project directly integrate the mechanical recycling process, starting from post-consumer PET bottles, with injection stretch blow molding technology. The recycling process is handled as a comprehensive process chain extending from the collection of PET bottles through shredding, washing, purification, and pelletizing, all the way to new bottle production. This integration minimizes the need for additional raw materials while significantly reducing natural resource consumption.
One of the most important technical advantages of AOKI ISBM machines is their ability to operate stably with recycled PET raw material that exhibits variations in viscosity, moisture content, and purity levels. The plastification, injection, and process control systems developed by AOKI maintain stable preform weight, dimensional accuracy, and final product quality despite fluctuations in rPET material properties.
Another key feature is the ability of AOKI machines to operate directly with 100% rPET flakes or pellets. This capability allows manufacturers to completely eliminate or significantly reduce the use of virgin PET. As a result, raw material costs are lowered and CO₂ emissions are substantially reduced.
AOKI's sustainability approach is not limited to the use of recycled raw materials alone. Energy consumption, scrap rates, and process losses generated during production are also minimized. Shorter cycle times, Direct Heatcon technology, and optimized mechanical design reduce the energy consumed per bottle. This further enhances the environmental benefits achieved through recycling.
AOKI Series molding technology ensures high process reliability and product quality when using recycled PET. AOKI ISBM machines can consistently meet critical quality criteria such as clarity, mechanical strength, and neck accuracy in bottles produced from rPET. This provides a significant advantage in terms of brand perception and consumer confidence for packaging made from recycled materials.
The environmental benefits targeted within the AOKI Eco Project are also supported by concrete figures. Transitioning to 100% rPET can deliver CO₂ emission reductions of up to 60-70 percent compared to the use of virgin PET. In addition, reducing dependence on petroleum-based raw materials contributes to lower energy dependency and reduced exposure to future carbon taxation risks.
This engineering approach offers packaging manufacturers not only environmental benefits but also commercial advantages. In a global market where demand for sustainable packaging is rapidly increasing, facilities capable of producing with 100% rPET gain a strong competitive edge in the eyes of brand owners, retail chains, and regulatory authorities.
Thanks to their ability to operate in direct integration with recycling infrastructure, AOKI ISBM technologies enable manufacturers to comply today with environmental regulations that are expected to become increasingly stringent in the future. This reduces the need for additional investments and ensures long-term production security.
In conclusion, AOKI's Bottle-to-Bottle and Eco Project-focused ISBM technologies make it possible to produce high-quality plastic packaging using 100% rPET, enabling the realization of a truly circular production model in the plastics industry. This approach provides manufacturers with lower raw material costs, a reduced carbon footprint, and a strong foundation for a sustainable future.