Planning a New Glass PET Line?

As Marketing and Operations are usually not well aligned before kicking off a new project, here it is what you should consider in a PET line before going all in to purchasing officers

The Bottle Shape

PLEASE GO CYLINDRICAL!
Here the advantages of a cylindrical bottle:

Easier change parts (and cheaper) and a quicker start-up after the change format
No Divider before the packaging section – less headaches and investment
Easier handling of conveyors
Lower risk of jams

Did you choose to go with shaped bottle anyway? Consider a 5-10% CAPEX increase (based on a 10.000bph line)

When to invest in a Blow Moulder?

Usually, the investment is worth it over the 8 millions of bottles produced in a year. But what to do without it?

Over around 3.000bph, include an unscrambler in your production line
Locate a supplier of bottles nearby your facility to improve the logistics efficiency
Choose whether to purchase moulds for your specific design or source STD bottles

Going with in-house blow moulding? Don’t forget a 40 bar compressor (and power!). Prepare for a booster in power supply. HP compressor, chiller & blow moulder can easily require 200kW for a 10.000bph line

Which Filling Technology?

Volumetric or by Level?

Level Filler is frequently cheaper than volumetric
Volumetric filler is the mos modern solution, with faster change formats and increased hygiene
Choose based on budget availabilty, level of automation required & product type

Did you choose level filler? Consider a 10-30% CAPEX saving on the filler price – but with old vibes and more work

How About the Label?

Sleeve or PSL are fancy, but…

Sleeve label is more expensive from a raw material point of view, but also from an operational one
PSL goes better with glass or shaped bottles, if you cylindrical, go for ROLLFED WRAPAROUND!
With sleeve, remember you will need some steam or some kW to run the retraction tunnel

Marketing going with sleeve? Expect a higher label price (and power!)

Time to Package

Film? Tray? Carton?

Only film is the cheapest option
when to add a Tray? when package is heavy (6×4, etc..)
And the carton? wrap-around or american, makes sense with high-value products (Oil, natural things, ..)

Should you go with only film? It’s a low capex choice, but make sure the pack holds!

Loading on Pallet

Automatic or Manual?

How many packs per minute at the packer outlet?
is the pack heavy? No one like lifting heavy packs. If you go manual expect low efficiency
Collect all the data before taking a decision: workforce cost, packs per minute to manage, packs weight, and find your break even point

Can i change my mind? Installing a palletizer later is always an option, but keep the space in the layout!

And The Conveyors?

Don’t see them only as a cost. Accumulation is good!

How many packs per minute at the packer outlet?
is the pack heavy? No one like lifting heavy packs. If you go manual expect low efficiency
Collect all the data before taking a decision: workforce cost, packs per minute to manage, packs weight, and find your break even point

What if i don’t have space? Go for synchro block! or accept some traffic