The Coca-Cola Company’s Sicily-based bottler, Sibeg, will install a complete aseptic PET line with the help of Sidel – enabling the company to package sensitive products in-house while reducing plastic and energy consumption.
At Sibeg’s site in Catania, the company oversees the production, bottling, distribution, and development of products from the Coca-Cola, Monster Energy, and Acqua di Tepelene portfolios. The new 18,000 bph PET line will allow Sibeg to handle production that was previously tasked to external companies through co-packing.
The line combines Sidel’s Aseptic Combi Predis, EvoFilm Stretch, and PalKombi machines, alongside digital solutions. The first of the machines undertakes sterilization, blow moulding, filling, and capping in a single process; it is designed for easy and economic use by operators without the need for extensive training.
In particular, the Aseptic Combi Predis uses a hydrogen peroxide mist for its dry preform decontamination. This is believed to cut down on water and chemical consumption, as well as ensure product safety without relying on preservatives; it is said to have passed the aseptic validation protocol on its first attempt.
This machine is hoped to ensure the product’s integrity and extend the shelf life of sensitive beverages. It also aims to minimize downtime and unlock ‘exceptional’ flexibility, with Sibeg able to swap between ten different product formats – all without sacrificing food safety or productivity.
Meanwhile, the EvoFilm Stretch packer operates at an ambient temperature, unlike traditional shrink-wrapping. This is set to avoid the need for energy-heavy shrink tunnels, reportedly lowering plastic use by up to 60% and energy consumption by up to 90%.
“Using high pre-stretch LLDPE with a thickness of 10 to 23 microns, EvoFilm Stretch allows automatic sealing and flexible wrapping options,” says Gianluca Tornatore, operations director at Sibeg.
“It lowers plastic use from 26 grams to 6 grams per pack and [its] energy use is only 10 kWh, leading to a 90% savings compared to traditional shrink-wrapping solutions.
“Without shrink tunnels or conveyors, it also minimizes machine footprint, making packaging lines more compact and cost-effective.”
Additionally, Sidel’s Evo-ON Flex app is an intelligent software set to streamline the changeover process for bottles. Operators are guided through each action step-by-step, and the app offers a real-time overview of all scheduled changeovers for the current work shift, keeping downtime at a minimum.
The line is expected to achieve ‘substantial’ savings for water, energy, chemicals, and plastic, with ‘100% rPET’ production expected to minimize waste and contribute to a circular economy. Sibeg also aims for zero Scope 1 and Scope 2 emissions by 2030, and complete carbon neutrality by 2032.
“Sidel and Sibeg share a long-standing partnership, with a complete line previously supplied for CSD (carbonated soft drinks) packaging,” says Sibeg CEO Luca Busi. “Once again, Sibeg places its trust in Sidel, this time for aseptic production, relying on its well-known expertise to ensure the highest levels of product safety.
“The complete aseptic PET line will enable us to diversify into energy drinks and tea production.”
Explaining that Sidel was selected as the only vendor for the entire supply, Tornatore continues: “We felt safe relying, especially from a technical point of view, on a partner who is widely renowned for mastering the PET aseptic packaging production.
“Moreover, the collaboration with Tetra Pak for the processing part enabled us to cover the entire production process, from beverage preparation to the packaging line with a single contact point, bringing a strong increase in efficiency during execution.
“The Sidel team were deeply committed to meeting our needs and timelines at every stage, from line design to ramp-up, while navigating the challenges of meeting Coca-Cola’s stringent safety standards,” adds Tornatore. “Their dedication ensured a smooth process without compromising on quality or compliance.”
The development comes after Sidel helped PepsiCo’s exclusive bottler in Mexico, Grupo GEPP, install expanded bottling lines for returnable PET and glass. The move is anticipated to help the bottler achieve a 10% increase in returnable packaging solutions by 2030.
In other news, Coca-Cola is trialling a new multipack that replaces plastic film with glue dots and a recyclable cardboard handle – a solution expected to reduce plastic waste and improve recyclability.
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