Inhaltsverzeichnis:

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

Page

 

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

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