Open Innovation Submission Portal

Glass Strengthening and Lightweighting Technology

Request Number 192409 | Author PepsiCo

Description

PepsiCo is looking to explore non-plastic alternatives for beverage packaging. One such alternative material is glass. It is currently used as a single use or returnable solution in PepsiCo's portfolio. We are looking for a "Superior" substitute for the existing Soda Lime type of glass bottles.

Background

Glass bottles are relatively heavy and brittle. Many glass bottle companies have attempted to reduce the weight of bottles by thinning the bottles to make them lighter. However, because glass weight reduction has a trade-off relationship with strength, it is necessary to increase its strength.

Processes for "glass tempering" (hardening) to produce stronger glass, that is less breakable, were developed back in the 1950s. This involved three different methods:

• Thermal hardening by quenching the glass from temperatures at the softening point at 600°C,
• Mechanical hardening by coating the glass base with another layer, and
• Chemical hardening of the glass surface by ion exchange in contact with molten salts.

In the chemical hardening process, the glass is heated to 400 °C and then sprinkled with liquid potassium nitrate for a certain holding time. Due to temperature and time effects, the smaller sodium ions are exchanged for larger potassium ions in the glass surface. Their size puts the glass surface under compressive stress and thus leads to higher fracture resistance. The outcome by far exceeded expectations: the solidified glasses exhibited as much as a 15-fold increased longevity, were heat-resistant, stackable, and even lighter than conventional drinking glasses!

Key Success Criteria

Ideal partner/vendor will have capabilities in the following areas:

• Chemical Strengthening of glass to improve mechanical performance (applicable for single use or returnable)
• Glass Lightweighting beyond conventional design change.
• Combination of both (lightweighting with strengthening)
• Coating solutions to heal (repair) microcracks. This approach is different than traditional "Chemical Strengthening".

Must-Have requirements

• Compatible with PepsiCo products currently sold in Glass packaging
• Low or no impact on recyclability

Preferred Requirements

• Equivalent "End of Life" stage as existing glass packaging options (for soda lime type glass)
• Lower GHG compared to current glass packaging options
• Ability to create a lightweight glass packaging option for PepsiCo design of bottles/jars (in case of foods)
• Low or no impact on shelf life/taste/appearance of the product.
• Ease of integration with existing glass manufacturing facilities. Most of PepsiCo's glass manufacturing plants are in Africa. The bottlers might not be willing to invest in new equipment/machinery. Thus, the cost will be a crucial factor to seek interest from bottle manufacturers in these areas.
• Labelling and printing on glass should not be affected.

Preferred Collaboration types

Timing: November/December 2024 initiate communication with potential partners.
January 2025 onwards to start working on a dedicated project.

TRL Level: Interested in all TRL levels at this time