Pet

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PET business is in a transition phase since early 2000. Not only is the profitability of PET business reducing; but growth in the sector has also reduced since 2002. With oil prices hovering around US$80-90, there seems to be no respite for this industry. Globally stiff competition has grown, particularly from smaller manufacturers of Asia. Projects b the Middle Eastern producers could also pose tough competition on account of lower feedstock prices. Hence PET manufacturers are concentrating on rationalization and cost reduction. A new technology called a single step process or Melt To Resin (MTR) would help producers reduce manufacturing cost. This new technology has seen some commercialization in the early part of this decade.

PET manufacturing process technology began with 5 reactors. These were then reduced to 4 in the mid eighties. In the MTR process technology, only 2 reactors are used. The conventional process technology consists of polycondensation followed by solid state crystallization. A new reactor design helps MTR process technology to complete the entire work of polycondensation and crystallization in only 1 reactor instead of 2 separate reactors. This new technology can produce PET in viscosity range of 🔒 Bấm Cảm ơn hoặc Trả lời để xem SĐT/Liên hệ. An interesting feature of this technology is that it inherently produces PET with less than 1 PPM acetaldehyde content and with crystallinity level below 45%. This new technology can produce PET at lows of 250-300,000 tpa and as high as 500,000 tpa. Higher production level reduces the fixed cost, offering better economies.

MTR technology offers other advantages. They are: Saving of equipment cost due to lack of solid step crystallizer (SSP)

No labour required to operate SSP plant

Absence of nitrogen blanking reduces energy cost

UHde, one of the technology supplier claims benefits of their MTR technology compared to 4 reactors conventional SSP technology as: 25-26 % lower capital cost

20-21 % lower fixed cost

40% lower energy cost

Overall conversion cost lower 25-30%

Approximately 1.5 % lower cost of raw material (MEG & PTA )

India's Reliance Industries in India was probably the first manufacturer to use this new technology. Another plant was recently commissioned in USA. The total capacity of this technology that is presently in operation is just below 1 mln tons.

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PET

BUSINESS

General

Constar International Inc. (the "Company" or "Constar") is a global producer of

PET, or polyethylene terephthalate, plastic containers for food and beverages.

Constar manufactures PET containers for conventional PET applications in soft

drinks and water and for custom PET applications. Custom PET container

applications include food, juices, teas, sport drinks, new age beverages, beer

and flavored alcoholic beverages, most of which require a combination of

advanced technologies, processing know-how and innovative designs.

Constar's technologies are aimed at enabling the Company to meet the specific

needs of products being converted from other forms of packaging to PET. Oxbar™ ,

Constar's oxygen-scavenging technology, enables the Company to produce the

special packaging required to extend the shelf life of oxygen sensitive

products. The Company believes that Oxbar is the PET industry's best performing

oxygen barrier technology. Furthermore, the Food and Drug Administration

recently approved for commercial use Constar's next-generation monolayer Oxbar

technology. The Company has also developed methods for addressing the challenges

of hot-filling containers. Constar is focused on providing its customer base

with the best service through technological innovation, new product development

and lowest-cost production. The Company actively seeks new business where its

technologies and other competitive strengths can yield attractive and

sustainable profitability.

History

Constar is a Delaware corporation. Originally incorporated in 1927, the Company

was an independent publicly held corporation from 1969 to 1992, when it was

purchased by Crown Cork & Seal Company, Inc. ("Crown"). Constar has been a

public company since its initial public offering in November 2002. The Company's

principal executive office is located at One Crown Way, Philadelphia, PA

19154-4599, and its telephone number is 🔒 Bấm Cảm ơn hoặc Trả lời để xem SĐT/Liên hệ.

The PET Container Industry

The PET container industry is generally divided into two product types:

conventional PET, which includes beverage containers for soft drinks and water,

and custom PET, which includes containers that generally require specialized

performance characteristics.

The conventional PET container industry consists of high volume production of

containers for use in packaging soft drinks and water. The industry is supplied

by independent producers, as well as captive manufacturers.

The custom PET container industry is characterized by complex manufacturing

processes, unique materials, innovative product designs and technological

know-how for products with special requirements. Because of the greater required

manufacturing complexity, many custom PET applications have greater

profitability and higher barriers to entry than conventional PET.

PET products include both bottles and preforms. Preforms are test-tube shaped

intermediate products in the bottle manufacturing process. Some companies

purchase preforms that they process into bottles at their own manufacturing

facilities. Preforms are utilized in both conventional and custom applications.

In the United States, manufacturers generally sell completed bottles. In Europe,

manufacturers generally sell preforms.

The PET container business is a rapidly growing component of the United States

packaging market due to continued growth in water and isotonics, conversion

opportunities from other forms of packaging and the introduction of smaller

sized soft drink containers. Many of these conversion opportunities involve the

use of advanced or proprietary PET technologies.

PET competes in the packaging market against a number of materials including

glass, metal, paperboard and other plastics. Various factors affect the choice

of packaging material. In the food and beverage markets, PET containers have

been gaining market share due to consumer preference for PET containers'

transparency, resealability, light weight and shatter resistance. PET bottles

and jars have also gained acceptance due to PET's custom molding potential,

which allows customers to differentiate their products using innovative designs

and shapes that increase promotional appeal.

Historically, conversions to PET from glass have occurred first in larger size

bottles within a product category, and then proliferated to smaller sizes. This

was the case for two liter soft drinks in the late 1970s, hot-fill gallon juices

in the late 1980s, and 1.5 liter water bottles in the mid-1990s, as well as in

many food conversions such as edible oil, salad dressings, peanut butter, and

mayonnaise. The four main reasons for this phenomenon are:

• Because larger bottles have less surface area in proportion to volume

contained, permeation rates for oxygen and carbon dioxide are less

critical to shelf life.

• The cost of the package in relation to the cost of the product contained

is lower in larger bottles. The higher per-bottle costs needed to achieve

specialized properties in a large bottle have less impact on a product's

cost per ounce.

• Larger glass bottles are proportionately heavier because strength is

achieved partly by increasing the thickness of the glass, while PET's

intrinsic strength does not require significantly greater wall thickness

for large bottles. This issue makes PET bottles cost competitive with, and

lighter than, glass bottles.

• Larger glass bottles are more prone to breakage because of their greater

wall surface and weight. Because of their greater mass, they are

potentially more damaging when dropped and broken. The shatter resistant

nature of PET has even greater importance in larger bottle applications.

Glass conversions in large bottles have typically been followed by conversions

of small size bottles. This has resulted from both lower costs achieved over

time by scale advantages and new technology, and from stronger demand arising

when consumer familiarity and preference for larger sized bottles in PET

transfers to smaller sizes.

Key Markets and Products

The Company is a leading producer of PET containers for food and beverages. The

Company's products are used in a variety of end-use markets, including soft

drinks, water, peanut butter, edible oils, salad dressing, juices, teas, beer

and flavored alcoholic beverages. The Company supplies PET products for such

well-known brands as Pepsi, Coca-Cola, Dr. Pepper, 7Up, Motts, Shasta, Peter

Pan, Aquafina, Wishbone, Smucker's, Veryfine, Snapple and Smirnoff Ice. The

Company primarily manufactures and sells bottles in the United States. In

Europe, the Company primarily sells preforms. Approximately 74% of the Company's

2004 revenue was attributable to sales in the United States and the remainder

was attributable to sales in Europe.

The Company supplies bottles and preforms in both the conventional and custom

PET markets. Preforms are test-tube shaped intermediate products that are

purchased by manufacturers for processing into finished bottles at their

manufacturing facilities.

Conventional PET

The Company's conventional PET sales relate primarily to containers for use in

packaging soft drinks and water. In 2004, conventional PET products represented

approximately 80% of the Company's sales.

Soft Drinks. Constar is a leading independent provider of PET containers to the

United States soft drinks market. The Company is a leading U.S. supplier of PET

containers to PepsiCo, as well as a leading supplier to

Cadbury Schweppes plc, the maker of Dr. Pepper and 7Up. Constar's strategy in

this market segment is to maintain its relatonships with major customers,

improve margins and only invest when projects improve overall conventional

margins.

Water. The Company is the largest supplier to PepsiCo's water brand, Aquafina,

in the United States. Other large water bottlers, including Nestl S.A., Groupe

Danone and Coca-Cola, predominantly manufacture their own containers. Constar

maintains a strong position with a number of independent water bottlers.

Constar's strategy in this market is to maintain current relationships and grow

profitability along with its customers' growth within this market.

Custom PET

Custom PET products represented approximately 15% of Constar's sales in 2004.

The Company believes that custom PET applications represent significant growth

opportunities for the Company. Additionally, custom PET applications generally

provide higher margins and have higher barriers to entry than conventional PET,

due to greater manufacturing complexity.

Propietary Technologies

Custom PET technologies are necessary to produce PET bottles for foods and

beverages that require advanced technologies for packaging, such as

oxygen-scavenger and hot-fill. Scavenger technologies inhibit oxygen from

penetrating the packaging, which can cause the flavor and the color of the

product to degrade. Hot-fill technologies are used to allow pouring of heat

processed beverages into bottles that can withstand high temperatures without

deforming. In the past, products requiring these characteristics were generally

packaged in glass. Currently available technologies allow these products to be

packaged in PET, which is more desirable than glass because of PET's light

weight and shatter resistance.

Oxygen Scavenger. The Company's Oxbar technology increases product shelf life by

inhibiting oxygen from entering the packaging. An additional benefit of Oxbar is

that the barrier technology can be incorporated in the preforms from which

plastic bottles are blown. This is an important competitive advantage since

preforms can be shipped more economically than bottles and allow for the blowing

of oxygen-scavenger bottles on the world's existing base of blow-molding

equipment without modification.

The Company has recently developed "monolayer" oxygen-scavenging bottles as an

addition to its "multi-layer" product offering. Multi-layer oxygen-scavenging

bottles have Oxbar between two layers of PET. Monolayer bottles incorporate the

scavenging technology into a single layer container. This introduces

oxygen-scavenging properties into preforms made on conventional injection

presses, eliminating significant incremental costs of multi-layer injection

molding. Combined with monolayer Oxbar's outstanding oxygen barrier performance,

Constar believes monolayer Oxbar has both a cost and performance advantage over

competing technologies. Monolayer Oxbar bottles are not as transparent as

multi-layer bottles, so customers desiring glass-like clarity may prefer

multi-layer products. The Company's existing Oxbar patents cover monolayer

oxygen-scavenging technology. Constar expects to begin shipping its first

monolayer bottles in the second quarter of 2005.

Food. Constar manufactures containers for well-known brands including ConAgra

Grocery Products' Wesson Oil, Healthy Choice peanut butter, Uniliver's Wishbone

Salad Dressings, and Smucker's Toppings. Constar also produces bottles for some

of the largest producers of quality private-labeled food products.

Hot-fill. The Company possesses expertise and patents that enable it to

manufacture bottles that can withstand the hot-fill process. Products within

this market are filled at temperatures in excess of 180 degrees Fahrenheit.

Hot-fill bottles require specialized equipment and processes that allow the

bottles to withstand this heat without deforming. Hot-fill bottles also use

structural design features that absorb and withstand vacuum

created inside the bottle when the contents cool after filling. In response to

customer requests for new hot-fill packages, the Company has developed a next

generation heat-set container that allows the Company to produce creative

product designs without the structural design features that meet customer

requirements and offer the potential for lighter-weight bottles. Constar is also

working to expand other applications of hot-fill technology. The Company

supplies hot-fill bottles for brands such as Arizona Iced Tea, Snapple, Gatorade

Propel and Veryfine. The Company supplies a full range of sizes, from gallon

bottles for juices to single serve bottles.

Pasteurization. The Company has expertise and proprietary functional design

features that enable its PET bottles to be filled on the same filling lines as

glass bottles for pasteurized beer. During pasteurization, the sealed bottle and

its contents are subjected to heat, which both increases the internal pressure

of the bottle and decreases the rigidity of the bottle. The Company's

pasteurizable bottle has a proprietary base design that resists deformation

during this process, and a proprietary neck design that expands slightly under

heat and pressure to reduce stress on the base. In line with the Company's

strategy for capturing conversion opportunities, Constar plans to apply its

Oxbar technology first to target larger capacity, multi-serve bottle glass

conversions and then target smaller, single serve bottle conversions as the

market expands.

Customers

Generally, Constar supplies its customers pursuant to contracts with terms of

one year or longer. Substantially all of the Company's sales are under contracts

containing provisions that allow for the pass through of changes in the price of

PET resin. In 2004, the Company's top five customers accounted for approximately

60% of the Company's sales, while the Company's top ten customers accounted for

approximately 75% of the Company's sales. During the same period, purchases by

PepsiCo accounted for approximately 30% of the Company's sales while Coca-Cola

accounted for approximately 13% of the Company sales. Other than PepsiCo and

Coca-Cola, no customer accounted for more than 10% of the Company's sales in

2004. The Company is continually seeking ways to expand its customer base.

Sales and Marketing

The Company's management structure includes a senior vice president of sales and

marketing, three regional vice presidents of sales and a vice president of

marketing. In addition to having responsibility for overseeing regional sales,

each vice president of sales also has product line management responsibilities

for certain product lines.

Research and Development

The Company conducts its major technology and product development work, as well

as testing and product qualification, at in-house laboratories. From laboratory

locations in Alsip, Illinois and Sherburn, United Kingdom, Constar's research

and development staff provides project support for the design and development

needs of its existing and potential customers, and is responsible for the full

range of development activity from concept to commercialization. The Company's

research and development staff have advanced degrees in chemical engineering,

mechanical engineering and polymer science. Typical activities of the staff

include:

• determination of ideal design, lightest weight, and optimum finish;

• design development to enhance product preference;

• use of predictive tools to minimize development cycle;

• unit cavity production and the making of samples;

• blow-mold trials in the process lab and in the field;

• setting process parameters and specifications; and

• assisting its customers' tests of new containers.

Sources and Availability of Raw Materials

The Company buys PET resin directly from a diversed base of leading resin

suppliers in the United States, Europe and Asia. While specialized PET resin is

required for some hot-fill and other specific applications, most of the major

PET manufacturers supply a full range of resin specifications. The Company

believes that the large volume of resin that it purchases provides leverage that

assists it in negotiating favorable resin purchasing agreements.

The Company buys labels from several suppliers, mostly in the United States, for

application to bottles for its customers. The Company's ability to work closely

with its customers to forecast, order, and stock the large number of different

labels they need and to deliver labeled bottles as needed is an important

element of the service it provides.

Competition

PET containers compete with glass bottles, metal cans, paperboard containers and

other packaging materials. The Company's major PET industry competitors in the

United States are Amcor Ltd., Ball Corporation, Graham Packaging Company and

Plastipak Holdings, Inc. In Europe, the competitive landscape is much more

fragmented.

Competition in the PET industry is intense. In all of the Company's markets,

high standards of service, reliability, and quality performance are

prerequisites to obtaining significant awards of business from customers.

Margins are tight in the conventional soft drink and water business, and

differentiation is obtained by cost advantage of scale, design and execution

capability, and the ability to bring synergies to the supply relationship

through innovation and organizational integration. While these capabilities are

also valuable for custom PET, the major basis for competition in custom PET

applications is technology, since patent protection, know-how, and highly

specialized equipment and process techniques are required to manufacture custom

PET products. Some of this technology, however, is commercially available.

The PET business is highly capital intensive, with whole manufacturing lines

often committed to the requirements of a single customer. An important element

of competition is the strength of each company's process for evaluation, design,

presentation and execution of new product development opportunities presented by

the packaging needs of customers. Product design, engineering and investment

decisions made when new capacity is acquired, and the financial and contractual

terms obtained with customers to support that investment, are key determinants

of a company's success in this market. Flexibility of the manufacturing

platform, large scale plants that distribute overhead costs broadly and

continuous improvement are sources of competitive cost advantage.

Intellectual Property

The Company's portfolio of intellectual property assets includes U.S. and

foreign utility and design patents and patent applications. Among these assets

are a number of patents on its oxygen-scavenging technology, as well as patents

related to its line of hot-fill bottles. The earliest of the U.S.

oxygen-scavenging patents is not due to expire for approximately three years.

The earliest of the Company's European patents is not due to expire for

approximately two years. The Company also owns registrations of, and/or pending

applications for registration of, the trademarks CONSTAR, OXBAR and other marks

in the United States and various foreign jurisdictions.

The Company's OXBAR technology is subject to a worldwide royalty-free

cross-license with Rexam AB, which owns several patents relating to

oxygen-scavenging technology. The cross-license agreement gives both parties the

right to use and sublicense each other's oxygen-scavenging technology patents

but not each other's know-how. Chevron Phillips Chemical Company LP holds a

royalty-based, exclusive, worldwide license to the Oxbar patents, but not for

rigid polyester packages such as PET containers. Constar has granted

royalty-bearing licenses to some of its competitors for certain applications of

the Oxbar patents.

Table of Contents

The Company relies on proprietary know-how, continuing technological innovation

and other trade secrets to develop products and maintain its competitive

position. The Company attempts to protect its proprietary know-how and its other

trade secrets by executing, when appropriate, confidentiality agreements with

its customers and employees. The Company cannot assure you that its competitors

will not discover comparable or the same knowledge and techniques through

independent development or other means.

Environmental Liabilities and Costs

The Company's facilities and operations are subject to a variety of federal,

state, local and foreign environmental laws and regulations, including those

relating to air emissions, wastewater discharges and chemical and hazardous

waste management and disposal and remediation of environmental sites. The

Company is also subject to employee health and safety laws. The nature of its

operations exposes the Company to the risk of liabilities or claims with respect

to environmental and worker health and safety matters Constar believes its

operations are in material compliance with applicable requirements; however,

there can be no assurance that material costs will not be incurred in connection

with these liabilities or claims. Based on the Company's experiences to date, it

believes that the future cost of compliance with existing environmental and

employee safety laws and regulations will not have a material adverse effect.

Future events, including changes in laws and regulations or their

interpretations and the discovery of presently unknown conditions, may

nevertheless give rise to additional costs that could be material.

Certain environmental laws hold current owners or operators of land or

businesses liable for their own and for previous owners' or operators' releases

of hazardous or toxic substances. Because of Constar's operations, the long

history of industrial operations at some of its facilities, the operations of

predecessor owners or operators of certain of its businesses, and the use,

production and release of hazardous substances at these sites and at surrounding

sites, the Company may be affected by liability provisions of environmental

laws. Various facilities have experienced some level of regulatory scrutiny in

the past and are, or may become, subject to further regulatory inspections,

future requests for investigation or liability for past practices.

The Didam, Netherlands facility has been identified as having impacts to soil

and groundwater from volatile organic compounds at concentrations that exceed

those permissible under Dutch law. The main body of the groundwater plume is

beneath Constar's Didam facility but it also appears to extend from an

upgradient neighboring property. Following the results of recent testing,

remediation is not required to begin until 2007. The Company records an

environmental liability on an undiscounted basis when it is probable that a

liability has been incurred and the amount of the liability is reasonably

estimable. The Company has an accrual of $0.2 million for costs associated with

completing the required investigations and certain other activities that may be

required at the Didam facility. The Company has no other accruals for

environmental matters.

The Comprehensive Environmental Response, Compensation, and Liability Act, as

amended by the Superfund Amendments and Reauthorization Act of 1986, or CERCLA,

provides for responses to and joint and several liability for releases of

hazardous substances into the environment. Constar has received requests for

information or notifications of potential liability from the Environmental

Protection Agency, or EPA, under CERCLA and certain state environmental agencies

under state superfund laws for off-site locations. Constar has been identified

by the Wisconsin Department of Natural Resources as a potentially responsible

party at three related sites in Wisconsin and agreed to share in the remediation

costs with one other party. Remediation is ongoing at two of these sites and

remediation has been completed at the third site. Constar has also been

identified as a potentially responsible party at the Bush Valley Landfill site

in Abingdon, Maryland and entered into a settlement agreement with the EPA in

July 1997. The activities required under that agreement are ongoing. The Company

has not incurred any significant costs relating to these matters to date and

does not believe that it will incur material costs in the future in responding

to conditions at these sites.

Employees

As of December 31, 2004, the Company employed 2,004 employees, with 1,678 in the

United States and 326 in Europe. None of its U.S. employees are unionized, but

there are union workers at its Sherburn, United Kingdom plant and its Didam,

Netherlands plant. The Company believes that its employee relations are good and

that its practices in the areas of training, progression, retention, and team

involvement foster continuous improvement in capabilities and satisfaction

levels throughout its workforce.

Securities Exchange Act Reports

Constar maintains an Internet website at the following address: 🔒 Bấm Cảm ơn hoặc Trả lời để xem Link

The information on the Company's website is not incorporated by reference into

this annual report on Form 10-K. Constar makes available on or through its

website certain reports and amendments to those reports that Constar files with

or furnishes to the SEC in accordance with the Securities Exchange Act of 1934.

These include annual reports on Form 10-K, quarterly reports on Form 10-Q and

current reports on Form 8-K. Constar makes this information available on its

website free of charge as soon as reasonably practicable after it electronically

files the information with, or furnishes it to, the SEC. You may also read and

copy any materials Constar files with the SEC at the SEC's Public Reference Room

that is located at 450 Fifth Street, NE, Washington DC 20549. Information about

the operation of the Public Reference Room can be obtained by calling the SEC at

1-800-SEC-0330. You can also access Constar's filings through the SEC's internet

site: 🔒 Bấm Cảm ơn hoặc Trả lời để xem Link

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ok, đúng rồi đó.

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Cái này cũng hay, đây là công nghệ của UOP sx PET

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