| Executive Summary | 12 |
| Table 1: | Manufacturing cost, other cost and total cost in Euro per 1.000 units by type of packaging for 100 ml containers |
| 13 |
| Table 2: | Manufacturing cost, other cost and total cost in Euro per 1.000 units by type of packaging for 200 ml containers |
| 14 |
| Table 3: | Manufacturing cost, other cost and total cost in Euro per 1.000 units by type of packaging for 400 ml containers |
| 15 |
1. | Introduction | 16 |
2. | Glossary and Use of Terms | 19 |
3. | Scope of Overview | 23 |
3.1. | Objective | 23 |
3.2. | Geographical Scope and Population | 26 |
3.3. | Market Segments | 27 |
3.4. | Contacted Companies by Number and Field of Activity | 28 |
3.5. | Methodology of Research | 29 |
3.6. | Statements of SCHÖNWALD CONSULTING | 31 |
4. | Volumes by Type of Packaging in 2010 | 32 |
| Table 4: | Demand of retorted food and pet food products by pack type in 2010 |
| 32 |
5. | Manufacturers by Type of Packaging | 33 |
6. | Manufacturing and Other Cost of Containers | 35 |
| Cost chain in Euro per 1.000 units by individual type of packaging and size of 100 ml, 200 ml, 400 ml
The following pack type details, manufacturing details, processing details and cost chains are provided: Pack type details:
- Type of packaging
- Material
- Dimensions of packaging
- Volume of packaging
- Type of product treatment Manufacturing details:
- Nameplate speed (container per minute)
- Line run (hours per day)
- Line run (days per year)
- Line run (hours per year)
- Efficiency factor (%)
- Factory run (hours per day)
- Factory run (hours per year)
- Net units (million per year) Processing details:
- Capital equipment and tooling (€)
- Depreciation schedule (years)
- Man power (person)
- Facilities (sqm)
- Facilities (€/sqm)
- Facilities depreciation schedule (years) Cost chain manufacturing cost:
- Raw material in € per ton or sqm
- Container with or without lid in g
- Lid if applicable in g
- Scrap of container and lid in %
- Other materials in €
- Labour in € per hour
- Utilities in € per kwh
- Depreciation equipment and tooling in €
- Maintenance of capital equipment and tooling in %
- Facilities depreciation in €
- Plant overhead in % of labour
- Line loss in % Cost chain other cost:
- Transport packaging
- Logistics / transport
- Filling
- Closure
- Retorting
- Label
- Secondary packaging | |
6.1. | Steel Cans | 39 |
6.1.1. | 3 Piece Steel Cans | 39 |
| Table 5: | Pack type, manufacturing and processing details of 3 piece steel can, 100 ml |
| 40 |
| Table 6: | Manufacturing cost chain of 3 piece steel can, 100 ml |
| 41 |
| Table 7: | Cost chain of other cost of 3 piece steel can, 100 ml |
| 42 |
| Graph 1: | Manufacturing and other cost of 3 piece steel can, 100 ml |
| 42 |
| Graph 2: | Share of raw material of manufacturing cost of 3 piece steel can, 100 ml |
| 43 |
| Graph 3: | Share of raw material of total cost of 3 piece steel can, 100 ml |
| 43 |
| Table 8: | Pack type, manufacturing and processing details of 3 piece steel can, 200 ml |
| 44 |
| Table 9: | Manufacturing cost chain of 3 piece steel can, 200 ml |
| 45 |
| Table 10: | Cost chain of other cost of 3 piece steel can, 200 ml |
| 46 |
| Graph 4: | Manufacturing and other cost of 3 piece steel can, 200 ml |
| 46 |
| Graph 5: | Share of raw material of manufacturing cost of 3 piece steel can, 200 ml |
| 47 |
| Graph 6: | Share of raw material of total cost of 3 piece steel can, 200 ml |
| 47 |
| Table 11: | Pack type, manufacturing and processing details of 3 piece steel can, 400 ml |
| 48 |
| Table 12: | Manufacturing cost chain of 3 piece steel can, 400 ml |
| 49 |
| Table 13: | Cost chain of other cost of 3 piece steel can, 400 ml |
| 50 |
| Graph 7: | Manufacturing and other cost of 3 piece steel can, 400 ml |
| 50 |
| Graph 8: | Share of raw material of manufacturing cost of 3 piece steel can, 400 ml |
| 51 |
| Graph 9: | Share of raw material of total cost of 3 piece steel can, 400 ml |
| 51 |
6.1.2. | 2 Piece Steel Cans, DRD | 52 |
| Table 14: | Pack type, manufacturing and processing details of 2 piece steel can, DRD, 100 ml |
| 53 |
| Table 15: | Manufacturing cost chain of 2 piece steel can, DRD, 100 ml |
| 54 |
| Table 16: | Cost chain of other cost of 2 piece steel can, DRD, 100 ml |
| 55 |
| Graph 10: | Manufacturing and other cost of 2 piece steel can, DRD, 100 ml |
| 55 |
| Graph 11: | Share of raw material of manufacturing cost of 2 piece steel can, DRD, 100 ml |
| 56 |
| Graph 12: | Share of raw material of total cost of 2 piece steel can, DRD, 100 ml |
| 56 |
| Table 17: | Pack type, manufacturing and processing details of 2 piece steel can, DRD, 200 ml |
| 57 |
| Table 18: | Manufacturing cost chain of 2 piece steel can, DRD, 200 ml |
| 58 |
| Table 19: | Cost chain of other cost of 2 piece steel can, DRD, 200 ml |
| 59 |
| Graph 13: | Manufacturing and other cost of 2 piece steel can, DRD, 200 ml |
| 59 |
| Graph 14: | Share of raw material of manufacturing cost of 2 piece steel can, DRD, 200 ml |
| 60 |
| Graph 15: | Share of raw material of total cost of 2 piece steel can, DRD, 200 ml |
| 60 |
| Table 20: | Pack type, manufacturing and processing details of 2 piece steel can, DRD, 400 ml |
| 61 |
| Table 21: | Manufacturing cost chain of 2 piece steel can, DRD, 400 ml |
| 62 |
| Table 22: | Cost chain of other cost of 2 piece steel can, DRD, 400 ml |
| 63 |
| Graph 16: | Manufacturing and other cost of 2 piece steel can, DRD, 400 ml |
| 63 |
| Graph 17: | Share of raw material of manufacturing cost of 2 piece steel can, DRD, 400 ml |
| 64 |
| Graph 18: | Share of raw material of total cost of 2 piece steel can, DRD, 400 ml |
| 64 |
6.1.3. | 2 Piece Steel Cans, DWI | 65 |
| Table 23: | Pack type, manufacturing and processing details of 2 piece steel can, DWI, 400 ml |
| 66 |
| Table 24: | Manufacturing cost chain of 2 piece steel can, DWI, 400 ml |
| 67 |
| Table 25: | Cost chain of other cost of 2 piece steel can, DWI, 400 ml |
| 68 |
| Graph 19: | Manufacturing and other cost of 2 piece steel can, DWI, 400 ml |
| 68 |
| Graph 20: | Share of raw material of manufacturing cost of 2 piece steel can, DWI, 400 ml |
| 69 |
| Graph 21: | Share of raw material of total cost of 2 piece steel can, DWI, 400 ml |
| 69 |
6.2. | 2 Piece Aluminium Cans, DRD | 70 |
| Table 26: | Pack type, manufacturing and processing details of 2 piece aluminium can, DRD, 100 ml |
| 71 |
| Table 27: | Manufacturing cost chain of 2 piece aluminium can, DRD, 100 ml |
| 72 |
| Table 28: | Cost chain of other cost of 2 piece aluminium can, DRD, 100 ml |
| 73 |
| Graph 22: | Manufacturing and other cost of 2 piece aluminium can, DRD, 100 ml |
| 73 |
| Graph 23: | Share of raw material of manufacturing cost of 2 piece aluminium can, DRD, 100 ml |
| 74 |
| Graph 24: | Share of raw material of total cost of 2 piece aluminium can, DRD, 100 ml |
| 74 |
| Table 29: | Pack type, manufacturing and processing details of 2 piece aluminium can, DRD, 200 ml |
| 75 |
| Table 30: | Manufacturing cost chain of 2 piece aluminium can, DRD, 200 ml |
| 76 |
| Table 31: | Cost chain of other cost of 2 piece aluminium can, DRD, 200 ml |
| 77 |
| Graph 25: | Manufacturing and other cost of 2 piece aluminium can, DRD, 200 ml |
| 77 |
| Graph 26: | Share of raw material of manufacturing cost of 2 piece aluminium can, DRD, 200 ml |
| 78 |
| Graph 27: | Share of raw material of total cost of 2 piece aluminium can, DRD, 200 ml |
| 78 |
| Table 32: | Pack type, manufacturing and processing details of 2 piece aluminium can, DRD, 400 ml |
| 79 |
| Table 33: | Manufacturing cost chain of 2 piece aluminium can, DRD, 400 ml |
| 80 |
| Table 34: | Cost chain of other cost of 2 piece aluminium can, DRD, 400 ml |
| 81 |
| Graph 28: | Manufacturing and other cost of 2 piece aluminium can, DRD, 400 ml |
| 81 |
| Graph 29: | Share of raw material of manufacturing cost of 2 piece aluminium can, DRD, 400 ml |
| 82 |
| Graph 30: | Share of raw material of total cost of 2 piece aluminium can, DRD, 400 ml |
| 82 |
6.3. | Glass Jars | 83 |
| Table 35: | Pack type, manufacturing and processing details of glass jar, 100 ml |
| 84 |
| Table 36: | Manufacturing cost chain of glass jar, 100 ml |
| 85 |
| Table 37: | Cost chain of other cost of glass jar, 100 ml |
| 86 |
| Graph 31: | Manufacturing and other cost of glass jar, 100 ml |
| 86 |
| Graph 32: | Share of raw material of manufacturing cost of glass jar, 100 ml |
| 8 |
| Graph 33: | Share of raw material of total cost of glass jar, 100 ml |
| 87 |
| Table 38: | Pack type, manufacturing and processing details of glass jar, 200 ml |
| 88 |
| Table 39: | Manufacturing cost chain of glass jar, 200 ml |
| 89 |
| Table 40: | Cost chain of other cost of glass jar, 200 ml |
| 90 |
| Graph 34: | Manufacturing and other cost of glass jar, 200 ml |
| 90 |
| Graph 35: | Share of raw material of manufacturing cost of glass jar, 200 ml |
| 91 |
| Graph 36: | Share of raw material of total cost of glass jar, 200 ml |
| 91 |
| Table 41: | Pack type, manufacturing and processing details of glass jar, 400 ml |
| 92 |
| Table 42: | Manufacturing cost chain of glass jar, 400 ml |
| 93 |
| Table 43: | Cost chain of other cost of glass jar, 400 ml |
| 94 |
| Graph 37: | Manufacturing and other cost of glass jar, 400 ml |
| 94 |
| Graph 38: | Share of raw material of manufacturing cost of glass jar, 400 ml |
| 95 |
| Graph 39: | Share of raw material of total cost of glass jar, 400 ml |
| 95 |
6.4. | Stand-Up Pouches | 96 |
6.4.1. | Stand-Up Pouches, Pre-Made | 96 |
| Table 44: | Pack type, manufacturing and processing details of stand-up pouch, pre-made, 100 ml |
| 97 |
| Table 45: | Manufacturing cost chain of stand-up pouch, pre-made, 100 ml |
| 98 |
| Table 46: | Cost chain of other cost of stand-up pouch, pre-made, 100 ml |
| 99 |
| Graph 40: | Manufacturing and other cost of stand-up pouch, pre-made, 100 ml |
| 99 |
| Graph 41: | Share of raw material of manufacturing cost of stand-up pouch, pre-made, 100 ml |
| 100 |
| Graph 42: | Share of raw material of total cost of stand-up pouch, pre-made, 100 ml |
| 100 |
| Table 47: | Pack type, manufacturing and processing details of stand-up pouch, pre-made, 200 ml |
| 101 |
| Table 48: | Manufacturing cost chain of stand-up pouch, pre-made, 200 ml |
| 102 |
| Table 49: | Cost chain of other cost of stand-up pouch, pre-made, 200 ml |
| 103 |
| Graph 43: | Manufacturing and other cost of stand-up pouch,pre-made, 200 ml |
| 103 |
| Graph 44: | Share of raw material of manufacturing cost of stand-up pouch, pre-made, 200 ml |
| 104 |
| Graph 45: | Share of raw material of total cost of stand-up pouch, pre-made, 200 ml |
| 104 |
| Table 50: | Pack type, manufacturing and processing details of stand-up pouch, pre-made, 400 ml |
| 105 |
| Table 51: | Manufacturing cost chain of stand-up pouch, pre-made, 400 ml |
| 106 |
| Table 52: | Cost chain of other cost of stand-up pouch, pre-made, 400 ml |
| 107 |
| Graph 46: | Manufacturing and other cost of stand-up pouch, pre-made, 400 ml |
| 107 |
| Graph 47: | Share of raw material of manufacturing cost of stand-up pouch, pre-made, 400 ml |
| 108 |
| Graph 48: | Share of raw material of total cost of stand-up pouch, pre-made, 400 ml |
| 108 |
6.4.2. | Stand-Up Pouches, Form, Fill and Seal | 109 |
| Table 53: | Pack type, manufacturing and processing details of stand-up pouch, form fill and seal, 100 ml |
| 110 |
| Table 54: | Manufacturing cost chain of stand-up pouch, form fill and seal, 100 ml |
| 111 |
| Table 55: | Cost chain of other cost of stand-up pouch, form fill and seal, 100 ml |
| 112 |
| Graph 49: | Manufacturing and other cost of stand-up pouch, form fill and seal, 100 ml |
| 112 |
| Graph 50: | Share of raw material of manufacturing cost of stand-up pouch, form fill and seal, 100 ml |
| 113 |
| Graph 51: | Share of raw material of total cost of stand-up pouch, form fill and seal, 100 ml |
| 113 |
| Table 56: | Pack type, manufacturing and processing details of stand-up pouch, form fill and seal, 200 ml |
| 114 |
| Table 57: | Manufacturing cost chain of stand-up pouch, form fill and seal, 200 ml |
| 115 |
| Table 58: | Cost chain of other cost of stand-up pouch, form fill and seal, 200 ml |
| 116 |
| Graph 52: | Manufacturing and other cost of stand-up pouch, form fill and seal, 200 ml |
| 116 |
| Graph 53: | Share of raw material of manufacturing cost of stand-up pouch, form fill and seal, 200 ml |
| 117 |
| Graph 54: | Share of raw material of total cost of stand-up pouch, form fill and seal, 200 ml |
| 117 |
| Table 59: | Pack type, manufacturing and processing details of stand-up pouch, form fill and seal, 400 ml |
| 118 |
| Table 60: | Manufacturing cost chain of stand-up pouch, form fill and seal, 400 ml |
| 119 |
| Table 61: | Cost chain of other cost of stand-up pouch, form fill and seal, 400 ml |
| 120 |
| Graph 55: | Manufacturing and other cost of stand-up pouch, form fill and seal, 400 ml |
| 120 |
| Graph 56: | Share of raw material of manufacturing cost of stand-up pouch, form fill and seal, 400 ml |
| 121 |
| Graph 57: | Share of raw material of total cost of stand-up pouch, form fill and seal, 400 ml |
| 121 |
6.5. | Retortable Cartons | 122 |
| Table 62: | Pack type, manufacturing and processing details of retortable carton, 200 ml |
| 123 |
| Table 63: | Manufacturing cost chain of retortable carton, 200 ml |
| 124 |
| Table 64: | Cost chain of other cost of retortable carton, 200 ml |
| 125 |
| Graph 58: | Manufacturing and other cost of retortable carton, 200 ml |
| 125 |
| Graph 59: | Share of raw material of manufacturing cost of retortable carton, 200 ml |
| 126 |
| Graph 60: | Share of raw material of total cost of retortable carton, 200 ml |
| 126 |
| Table 65: | Pack type, manufacturing and processing details of retortable carton, 390 ml |
| 127 |
| Table 66: | Manufacturing cost chain of retortable carton, 390 ml |
| 128 |
| Table 67: | Cost chain of other cost of retortable carton, 390 ml |
| 129 |
| Graph 61: | Manufacturing and other cost of retortable carton, 390 ml |
| 129 |
| Graph 62: | Share of raw material of manufacturing cost of retortable carton, 390 ml |
| 130 |
| Graph 63: | Share of raw material of total cost of retortable carton, 390 ml |
| 130 |
7. | Comments on Data | 131 |
7.1. | General Comments | 131 |
7.2. | Specific Comments
- Raw materials
- Containers
- Lids
- Scrap
- Other material
- Labour
- Utilities
- Depreciation equipment and tooling
- Maintenance of capital equipment and tooling
- Facilities depreciation
- Plant overhead
- Line loss
- Transport packaging
- Logistics / transport | 131 |
| Table 68: | Transport costs of empty and filled 3 piece steel cans of 100 ml, 200 ml, 400 ml |
| 137 |
| Table 69: | Transport costs of empty and filled glass jars of 100 ml, 200 ml, 400 ml |
| 138 |
| - Filling
- Closures
- Retorting
- Labels | |
| Table 70: | Price of paper labels as well as PET and PVC shrink sleeves of 100 ml, 200 ml, 400 ml glass jars |
| 141 |
| - Secondary packaging | |
8. | Statements by Type of Packaging | 142 |
8.1. | Pros and Cons by Type of Packaging | 142 |
8.2. | Strengths and Weaknesses by Type of Packaging | 146 |
| Table 71: | Strengths and weaknesses by type of packaging |
| 147 |
8.3. | Matrix by Packaging Size | 148 |
| Table 72: | Evaluation of 100 ml, 200 ml and 400 ml containers by type of packaging |
| 149 |
8.4. | Trends and Developments | 150 |
9. | Conclusion | 152 |
| Graph 64: | Cost comparison of total cost, 100 ml containers, declining |
| 153 |
| Graph 65: | Cost comparison of total cost, 200 ml containers, declining |
| 154 |
| Graph 66: | Cost comparison of total cost, 400 ml containers, declining |
| 155 |
10. | Appendix | 156 |
| Appendix I: | Tables and Graphs |
| 156 |
| Appendix II: | Further Multi Client Studies
by SCHÖNWALD CONSULTING |
| 163 |