High-Speed PET Line Upgrade in Beverage Production

[Ahmet Ö.]

## High-Speed PET Line Renovation in Beverage Production

Sidel and Refresco are collaborating to install a high-capacity integrated PET packaging line at Refresco's Rangendingen facility in Germany. This project aims to increase output capacity, improve energy efficiency, and enhance operational flexibility in carbonated beverage production.

Refresco, a global beverage contract manufacturer with high-capacity filling plants in Europe and North America, needed to expand its capacity at the Rangendingen site due to increasing demand for carbonated beverages in PET packaging. In response to this need, Sidel undertook the design of an integrated packaging line.

### Project and Technical Solutions

The new system integrates bottle blowing, filling, and capping processes into a single enclosed block as part of Sidel's high-speed Combi line. This reduces transfer points, lowers the risk of contamination, and minimizes the line's footprint. The integrated stretch-blow molding technology allows PET preforms to be converted into bottles immediately before the filling machine, increasing process synchronization and reducing the need for buffers.

Sidel's responsibilities include line design and engineering, equipment supply, automation and control systems, as well as installation and commissioning of the facility. The automation layer performs simultaneous machine operations, line monitoring, and data collection for performance analysis. Additionally, energy optimization is achieved through controlled air recovery and motor management in the blowing process.

### Technical Specifications

• Integrated bottle blowing, filling, and capping system
• High-speed production capacity
• Stretch-blow molding technology
• Energy saving with controlled air recovery
• Automation-based synchronized machine operation, data monitoring
• Reduced footprint with compact design

### Integration and Applications

The line is integrated with Refresco's existing syrup preparation and palletizing operations. Material flow, space constraints, and infrastructure connections (compressed air, water, electricity) were considered in the facility planning. During the commissioning process, output capacity, filling accuracy, and packaging integrity were tested, minimizing production downtime.

The system is specifically designed for high-volume carbonated beverage production in PET bottles. Key objectives include increased production speed to meet market demand, stable performance in filling high carbonation levels, reduced energy consumption per bottle, and improved line efficiency with integrated control.

### Operational Impact

Consolidating bottle blowing, filling, and capping processes into a single block reduces mechanical interfaces, simplifying maintenance. Energy recovery during the blowing stage lowers compressed air consumption, leading to significant savings in production costs. This collaboration demonstrates that integrated line design and coordinated engineering can increase capacity while maintaining process stability and energy performance in industrial beverage production.