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International consumer packaging group Rexam unveiled the pilot production line for its novel Fusion aluminium bottle on 7 May at the company’s R&D Centre in Milton Keynes, UK.

The facility, which incorporates a new necking machine, allows customers in the drinks industry to view the production process and commission fully branded sample bottles to use in marketing or for line testing.

The Fusion bottle, which was launched in November 2007, combines standard drawn wall ironed (DWI) manufacturing with bespoke necking technology that was developed with Italian company Frattinni.

The result is a lightweight, 100% recyclable bottle that can vary in size, shoulder, shape and neck length. Rexam hopes to create a new market opportunity based on the Japanese model, where the aluminium bottle accounts for over 10% of the single-serve market.

Executive Vice-President of Technology, Engineering and Process Innovation Nabil Arbache says, ‘Shaping and embossing extruded aluminium is too expensive as it uses too much of the material, but the necking process is advanced and cost efficient’.

He adds, ‘DWI is unknown for long necking because different shapes bring different challenges. We needed to use a material strong enough for the process that can take an impression [embossing] while weighing very little’.

The necking machine is tooled for 33cl and 25cl serving sizes, and Frattinni is working to expand its capabilities.

Both rollover pilfer proof re-closable or crown closure tops are available, and the machine can switch between them with little difficulty.

‘The Fusion pack has sustainability benefits, can be branded and is cold to the touch, which is hugely beneficial to the premium beverage packaging market,’ says Marketing Director John Reeves.

Full production lines are being planned in Europe.

Further information:

Rexam