From Raw Material to Filled Packaging - The Economics of Retortable Containers in the European Union in 2010

Inhaltsverzeichnis

 Executive Summary12
 
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.Introduction16
2.Glossary and Use of Terms19
3.Scope of Overview23
3.1.Objective23
3.2.Geographical Scope and Population26
3.3.Market Segments27
3.4.Contacted Companies by Number and Field of Activity28
3.5.Methodology of Research29
3.6.Statements of SCHÖNWALD CONSULTING31
4.Volumes by Type of Packaging in 201032
 
Table 4:Demand of retorted food and pet food products by pack type in 2010
32
5.Manufacturers by Type of Packaging33
6.Manufacturing and Other Cost of Containers35
 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 Cans39
6.1.1.3 Piece Steel Cans39
 
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, DRD52
 
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, DWI65
 
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, DRD70
 
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 Jars83
 
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 Pouches96
6.4.1.Stand-Up Pouches, Pre-Made96
 
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 Seal109
 
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 Cartons122
 
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 Data131
7.1.General Comments131
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 Packaging142
8.1.Pros and Cons by Type of Packaging142
8.2.Strengths and Weaknesses by Type of Packaging146
 
Table 71:Strengths and weaknesses by type of packaging
147
8.3.Matrix by Packaging Size148
 
Table 72:Evaluation of 100 ml, 200 ml and 400 ml containers by type of packaging
149
8.4.Trends and Developments150
9.Conclusion152
 
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.Appendix156
 
Appendix I:Tables and Graphs
156
 
Appendix II:Further Multi Client Studies
by SCHÖNWALD CONSULTING
163