Production line for ultra-lightweight PET bottles

Sidel is set to unveil its FlexLine at the 2008 International Packaging Machinery, Packaging and Confectionery Machinery Fair in Düsseldorf, Germany. This innovative high-speed packaging line is specifically designed to produce ultra-lightweight PET bottles, marking a major step forward in sustainable packaging solutions. The technology not only reduces material usage but also supports large-scale production of eco-friendly, lightweight bottles. Creating and packaging ultra-lightweight bottles is no easy task. Every stage, from design to pallet loading, presents unique challenges. However, more manufacturers are seeking cost-effective, environmentally responsible solutions that still allow their PET water packaging to stand out. Sidel has addressed these needs with its latest advancements. At the K Show in October 2007 in Düsseldorf, Sidel introduced NoBottle™, a groundbreaking bottle that combines elegance with ultra-lightweight design—just 9.9 grams for a 500ml size. This achievement was made possible by Sidel Flex™ technology, which leverages the flexibility and shape memory of plastics. This feature helps bottles better endure the stresses of transport and distribution. Flex™ is essential for the mass production and delivery of NoBottle™, and it's already being used in Nestlé’s Eco-shape™ bottle. Today, Sidel offers a complete solution for producing NoBottle™ on a large scale. FlexLine is the first dedicated line for packaging this ultra-lightweight PET static water bottle. It can blow, fill, cap, label, pack, and stack bottles weighing less than 10g at a rate of 43,200 units per hour. The system integrates advanced technology and optimized equipment to ensure reliable, cost-effective production. The total cost of ownership is 20% lower compared to traditional 500ml bottles weighing 16g. FlexLine also sets a new standard for green production. Beyond using lighter bottles, it consumes less energy than conventional lines. For instance, the Combi section—typically the most energy-intensive part—uses 32% less electricity. An air recovery system reuses 40% of the air, and energy-efficient capping machines and conveyors further reduce consumption. Additionally, FlexLine can utilize recycled PET preforms, enhancing its sustainability credentials. As one of the world’s leading suppliers of liquid food packaging equipment, Sidel operates with over 5,500 employees globally and is part of the Tetra Laval Group. With FlexLine, the company continues to push the boundaries of innovation and environmental responsibility in the packaging industry.

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