Coca-Cola Europacific Partners (CCEP) is elevating energy-saving efforts in its PET bottle manufacturing operations by replacing two older machines with the innovative InnoPET Blomax. This strategic move underscores CCEP’s commitment to sustainability within the food and beverage packaging sector.
The bottler has discovered that the performance of KHS’ latest generation of stretch blow molding machinery, situated in Knetzgau, Lower Franconia—one of Germany’s largest Coca-Cola factories—has surpassed expectations. This impressive performance is largely attributable to KHS’ optional Double Gate (DoGa) heating concept.
The Knetzgau site, which employs around 500 personnel and produces a variety of beverages including Coca-Cola, Coca-Cola Light, Coca-Cola Zero, Fanta, Mezzo Mix, and Sprite, has dedicated itself to creating a more sustainable future through advanced food and beverage packaging technologies.
KHS highlights two standout features of the InnoPET Blomax: First, the heater that warms the PET preforms utilizes near infrared radiation (NIR), which is significantly more efficient than conventional infrared heating systems. Second, the Blomax transports preforms without primary reflectors in two lanes adjacent to the lamps, allowing for more effective heating. This efficient design, combined with specific energy savings, makes the Double Gate system notably compact.
In Knetzgau, project manager Ralph Sauter conducted an extensive analysis before investing, carefully comparing various systems on the market. Ultimately, CCEP opted to replace not one but two aging stretch blow molders—manufactured in 1998—that no longer met the company’s energy efficiency requirements or had reliable access to spare parts.
“In view of the targets we’ve set ourselves, saving energy plays a big role for us. With its new Double Gate technology and the savings this makes, the KHS system was of great interest to us,” says Sauter.
Since the machine became operational a few weeks ago following successful acceptance, Sauter projects savings of up to 560,000 kWh per year.
“All suppliers have understood the importance of this issue,” states Sauter, but he adds, “compared to other systems on the market, the KHS setup generates far greater savings.”
“We’re impressed by the functionality and performance of our new machine,” he continues. “The Blomax processes 20,000 2.0-liter containers and 30,000 1.5-liter containers an hour – and as it’s so flexible, it can be perfectly integrated into our production line.”
Sauter notes that the biggest challenge at the production site was converting the existing bottle air conveyor from servicing two machines to servicing just one. As the conveyor’s position was fixed, the new system required precise centimeter-level alignment in the bottle shop. Marc Harald Eysel, KHS’s sales manager for PET technology, confirms, “This was an exciting task for us.”
He emphasizes, however, that making such adjustments for customer needs is standard practice for KHS. “We don’t just want to convince our clients with the system performance alone.”
While the initial requirements in Knetzgau have been met by this new investment, KHS is witnessing a rapid increase in demand for energy-saving technologies like the Double Gate. “Even in comparison with modern stretch blow molding systems installed up to about the end of the last decade, our machinery saves a maximum of 30% in energy,” Eysel concludes.
