Production line for ultra-lightweight PET bottles

Sidel is set to unveil its groundbreaking FlexLine at the 2008 International Packaging Machinery, Packaging, and Confectionery Machinery Fair in Düsseldorf, Germany. This innovative high-speed packaging line is specifically designed for producing ultra-lightweight PET bottles, marking a significant step forward in sustainable packaging solutions. The technology not only supports eco-friendly practices but also opens the door to large-scale production of lightweight bottles that reduce material use and environmental impact. Creating and packaging ultra-lightweight bottles is no small feat. Every stage, from design to pallet loading, presents unique challenges. However, more manufacturers are seeking cost-effective, environmentally responsible methods to showcase their PET water packaging. In response, Sidel introduced the NoBottle™ at the K Show in October 2007, a revolutionary 500ml bottle weighing just 9.9 grams. Its success is driven by Sidel Flex™ technology, which leverages the flexibility and shape memory of plastics. This feature enhances the bottle’s durability during transport and distribution, making it ideal for mass production. Flex™ has already been successfully implemented in the Eco-shape™ bottle by Nestlé, one of the world's leading mineral water brands. Today, Sidel offers a complete solution for producing NoBottle™ bottled water through FlexLine. As the first line designed specifically for ultra-lightweight PET static water bottles, FlexLine can blow, fill, cap, label, pack, and stack bottles under 10g at a rate of 43,200 units per hour. The system integrates advanced technology and optimized equipment to ensure reliability, efficiency, and cost-effectiveness. At the core of FlexLine is the Combi unit, which combines blowing, filling, and capping into one seamless process. This eliminates the need to transport empty bottles, making it especially suitable for ultra-lightweight designs. Each stage of the production process—from blow molding to stacking—has been thoroughly tested and refined. Every machine in the line has been fine-tuned to ensure consistent quality while reducing overall costs. Compared to a conventional 500ml bottle weighing 16 grams, the total cost of ownership for FlexLine is reduced by 20%. In addition to being lightweight, FlexLine is a major leap in green production. It uses less energy than traditional lines, with the Combi blow-molding section—typically the most energy-intensive part—using 32% less electricity. An air recovery system allows 40% of the air to be reused, further cutting energy consumption. Energy-efficient capping machines and conveyor belts are also integrated into the system. Another key advantage is FlexLine’s ability to utilize recycled PET preforms, reinforcing its commitment to sustainability. As a global leader in liquid food packaging equipment, the Sidel Group serves over 5,500 employees worldwide and is part of the Tetra Laval Group. With FlexLine, Sidel continues to push the boundaries of innovation, offering a smart, sustainable, and efficient solution for the future of packaging.

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