Polymerization plants
From the beginning, Novapet® has carried out a large industrial investment program with the aim of modernizing, expanding and diversifying all its activities, being a leader in adaptation and anticipation in the PET market.
The constant investment has a direct impact on our productive capacity, reaching 260,000 tons annually, with industrial plants that have productive technologies with the highest qualities of the market:
Discontinuous post-condensation industrial plant PO Batch Teijin + SSP Polymetrix. With a productive capacity of 30,000 tons per year, it is dedicated principally to the manufacturing of specialities.
Polymerization plant CP TechnipFMC-Zimmer + SSP Polymetrix. With a productive capacity of PET resin of 100,000 tons annually.
Polymerization plant CP TechnipFMC-Zimmer + SSP Polymetrix. With a productive capacity of PET resin of 130,000 tons annually.
Polymerization plant SSP Batch Protec.
This productive technology has taken Novapet® to a leadership position, being the principal producer of PET resins of the Iberian peninsula, with an outstanding portfolio of products that offers more than 25 different items of resins and a wide variety of specialities, a rarity among PET producers.
All of Novapet’s® productive processes of are highly sustainable and this is shown by our ISO 14001 certification, which Novapet® holds with regard to control and measurement of emissions and effluents, monitoring and minimization of generated waste.
In addition, Novapet® operates its own Industrial Wastewater Treatment Plant (IWPT) consisting of two aerobic membrane biological reactors (MBR) that lower the total organic load of all the water from Novapet’s® productive processes, with a chemical oxygen demand (COD) of approximately 10,000 ppm.
Certified with the ISO 50001 standard for energy efficiency, Novapet® applies 4 MW recovery processes, through the exhaust gases from NG cogeneration engines, for the heating of thermal fluid in the polymerization process. In addition, it has three EFSA authorizations in progress, which will make possible in a short time a total rPET production capacity with post-consumption material higher than 100,000 tons per year.
Our productive capacities are, without a doubt, the result of the excellent quality control to which all our polymerization processes are subjected.
All of the Novapet® industrial plants are controlled by means of Distributed Control Systems (DCS), where 100% of the information from the different equipment and processes is collected. In this way, we have optimal telematic management that makes it possible to know in real time the parameters of the industrial equipment, as well as to make immediate decisions to adjust and optimize this process.
At Novapet®, we work with Industry 4.0 systems by means of mobility applications that permit inspection and monitoring in the field of processes and workers. Specifically, Novapet® uses the Honeywell industrial tool (formerly Movilizer), one of the best on the market. Specifically, Novapet® uses the Honeywell industrial tool (formerly Movilizer), one of the best on the market.
In parallel, Novapet® carries out a continuous sampling plan and analysis of raw materials and manufactured products, which ensures the quality of the properties in the different resin items that Novapet® has in its portfolio.
All this is managed through a specific laboratory program (LIMS), where 100% of the raw material transport units that arrive at our installations are analysed before being unloaded. Likewise, analyses are conducted on intermediate products, but the real control takes place in the fundamental parameters such as the intrinsic viscosity and the acetaldehydeof all our final products.
This quality management of the productive process in the three stages gives us excellent vertical integration with our injection department, supplying information and knowledge of the resin that is consumed, which other transformers do not have.
Injection plants
To speak of injection processes is to speak of integration. Novapet’s® injection plant is 100% integrated within our productive chain and PET transformation. It is here where our resins acquire value in preform formats, so that our clients can transform them in high-quality containers, capable of preserving their products in optimal conditions.
The synergies existing between the different stages of PET transformation and production: polymerization, injection and the logistical operation of our plants, constitute one of the principal competitive advantages of Novapet®, and they can be produced in the safest, most effective and efficient way, considerably reducing the use of resources and energy consumption.
Novapet® excellence is driven by a strong commitment to technological innovation in our manufacturing and quality control equipment and facilities, positioning us at the forefront of the industry.
Our production capacity in injection moulding at the Barbastro injection moulding facility has grown significantly over recent decades. Since 2016, its output has increased from 13,500 tonnes of preforms per year to 70,000 tonnes per year.
This facility is equipped with some of the most advanced production technologies available on the market. It operates 14 PET injection moulding lines and a wide range of moulds, all of which are interchangeable and capable of running with very short cycle times. This provides all our injection moulding machines with a high degree of production flexibility.
In addition, at our injection moulding facilities in Andújar, Jaén, and Marinha Grande, Portugal, we have a production capacity of 14,000 tonnes per year, supported by four additional injection moulding lines serving markets such as olive oil, household chemicals and cosmetics. This enables us to efficiently cover the entire Iberian Peninsula.
Furthermore, our polyethylene closure production facility in Andújar, with an annual capacity of 190 million units, completes our offering for our most demanding and diverse customers, who require a comprehensive, fully integrated packaging service.
Our injection plants have five rotating shifts of highly specialized personnel, who work on a 24-7-365 model. They are all subject to continuous training in the operation and in the use of the latest technologies of the sector.
Our management and control system of the indicators in our injectors provide, in real time, a precise view of what is occurring at every instant of the process, thus optimizing the use of productive resources.
Each one of our employees are key pieces in the value chain. The human team is permanently aligned with the evolution of the business thanks to the information centres for employees. And this is synonymous with the most absolute involvement.
Novapet® is synonymous with safety. We have an advanced statistical control system and management software that lets us make decisions quickly and effectively. Designed by our engineers, it provides absolute control of the principal parameters of the injection process, from the drying of the resin to the colour of the preform, anticipating potential failures or deviations before they can affect the quality of the final product.
Our productive processes would not be the same without the exhaustive quality controls to which they are periodically subjected.
Among many other certificates, we hold the Food Safety System Certificate (FSSC22000), which ensures the highest standards of food quality and safety existing in the market. In the same way, we are backed by strict audits by certifying agencies such as the Institut Fresenuis, the American Institute of Baking, also known as the AIB International. In addition, in our installations we have the latest generation of automated artificial vision systems.
Our system for managing and monitoring indicators on our injection moulding machines provides a precise, real-time view of what is happening at every stage of the process, enabling us to optimise the use of production resources.
Each of our employees plays a key role in the value chain. Our people remain continuously aligned with the evolution of the business through employee information centres, reflecting a high level of engagement and involvement.
Blowing plants
The full integration of our polymerisation, preform injection moulding, blow moulding and industrial logistics processes enables us to ensure complete product traceability, as well as high standards of quality, safety and operational efficiency.
This vertical integration is one of Novapet’s® main competitive strengths, optimising resources, reducing energy consumption and supporting more sustainable and efficient manufacturing.
Our blow moulding facilities are designed to provide comprehensive PET packaging solutions for national and international customers who require flexibility, adaptability and a high level of technological capability. From the initial container design through to final manufacturing, every stage of the process is focused on maximising industrial performance and preserving the properties of the packaged product.
Novapet® technological excellence is supported by continuous investment in automation, innovation and advanced process control. As a result, our facilities incorporate state-of-the-art blow moulding equipment capable of operating with high levels of productivity, dimensional accuracy and stability in highly demanding manufacturing cycles.
Our NOVEN packaging division has achieved one of the Group’s strongest industrial growth trajectories in recent years, consolidating its presence through its blow moulding facilities in Fuenlabrada — Farmaplas NOVEN — with an annual output of 140 million containers, and in Andújar and Marinha Grande — Enso NOVEN — with an annual output of 295 million containers.
Our facilities serve highly diversified markets, including food applications such as dairy products, edible oils, wines and spirits, vinegars and sauces, as well as cosmetics, perfumery, household chemicals, pharmaceuticals and parapharmacy.
Our production facilities are equipped with high-speed blow moulding lines and automated systems capable of manufacturing a wide variety of PET container formats and geometries, flexibly adapting to the specific needs of each customer and sector. The combination of technology, technical expertise and industrial capacity enables us to offer packaging solutions with high levels of aesthetic quality, mechanical strength and logistics functionality.
In addition, NOVEN’s activity is driving the expansion of PET into new sectors where other materials have traditionally had a stronger presence. Thanks to the properties of PET — light weight, transparency, strength and recyclability — we develop innovative solutions that help improve the sustainability and efficiency of numerous packaging processes.
Quality and safety are an essential part of our industrial model. All our blow moulding facilities operate under strict statistical process control systems and advanced real-time monitoring platforms, enabling continuous supervision of critical manufacturing parameters. These systems support the early detection of deviations and help ensure the stability and repeatability of each production run.
Our facilities also incorporate advanced automatic inspection systems and state-of-the-art machine vision technology, capable of verifying the dimensional, aesthetic and functional parameters of each container during the production process, ensuring compliance with the highest quality standards required by the market.
Our integrated industrial management system enables real-time monitoring of the main production, efficiency and quality indicators across all blow moulding lines, supporting the continuous optimisation of resources, consumption levels and operational capabilities.
Novapet’s® injection moulding and blow moulding facilities operate under a 24/7/365 production model, supported by highly specialised teams who undergo continuous technical training and technological upskilling programmes.
The experience and commitment of our professionals are one of the key pillars of our competitiveness and service capability.