High-Speed PET Line Upgrade for Beverage Production

Sidel and Refresco are working together to install a complete high-speed PET packaging solution at Refresco’s facility in Rangendingen, Germany. The project focuses on increasing production capacity for carbonated soft drinks while improving line efficiency, energy performance, and operational control.

Context of the Cooperation
Refresco, a global beverage contract manufacturer, operates multiple high-output filling plants across Europe and North America. Growing demand for carbonated soft drinks in PET packaging required capacity expansion at the Rangendingen site without disrupting existing operations.

Sidel, a supplier of beverage packaging equipment and line engineering, was selected to design and deliver a fully integrated packaging line. The cooperation combines Refresco’s large-scale production requirements with Sidel’s expertise in industrial automation, high-speed blowing, filling, and end-of-line integration.

The project required coordination across equipment supply, line layout optimization, and digital infrastructure to ensure compatibility with existing utilities and plant control systems.

Technical Solution and Responsibilities
The installed solution includes Sidel’s high-speed Combi system, integrating bottle blowing, filling, and capping in a single enclosed block. This configuration reduces transfer points and contamination risk while minimizing footprint compared to separate standalone machines.

The line is designed to reach high output rates suitable for large-volume beverage production. Integrated stretch-blow molding converts PET preforms into bottles directly upstream of the filler, improving process synchronization and reducing buffer requirements.

Sidel is responsible for:

The automation layer ensures synchronized machine operation, line monitoring, and data collection for performance analysis. The system supports energy optimization through controlled air recovery in the blowing process and efficient motor management.

Deployment and Integration
The line is installed at Refresco’s Rangendingen facility, where it is integrated into existing upstream syrup preparation and downstream palletizing operations. Engineering planning addressed layout constraints, material flow, and utility connections, including compressed air, water, and electrical systems.

Commissioning was structured to limit production interruptions. Performance testing verified output capacity, filling accuracy, and packaging integrity before full-scale operation.

Applications and Use Cases
The system is dedicated to high-volume production of carbonated soft drinks in PET bottles. Key technical objectives include:

Such configurations are particularly relevant for large beverage co-packers operating multiple SKUs and short changeover cycles.

Expected Operational Impact
By combining blowing, filling, and capping within a single block and aligning automation systems, the solution reduces mechanical interfaces and simplifies maintenance. Energy recovery systems in the blow-molding stage contribute to lower compressed air consumption, a significant operational cost factor in PET production.

The cooperation between Sidel and Refresco illustrates how integrated line design and coordinated engineering can expand capacity while maintaining process stability and energy performance in industrial beverage manufacturing.

www.sidel.com