Refresco and Sidel redefine PET standards with EvoBLOW Laser

Refresco, the world’s largest independent beverage solutions provider, has set a new benchmark for PET production efficiency following a year of successful industrial operation with Sidel’s EvoBLOW Laser.

Marking a departure from nearly 50 years of traditional halogen-based heating, the installation in Bruchsal proves that laser technology is no longer a concept but a proven solution for high-volume, sustainable bottling.

Traditional blow moulding relies on halogen lamps that heat preforms in eight broad zones. In contrast, the Sidel EvoBLOW Laser utilises up to 36 precise heating lines. This granular control allows Refresco to manage material thickness with surgical accuracy, enabling a “paradox solved”: bottles that are significantly lighter yet structurally stronger.

Gabriele Luna, head of indirect procurement at Refresco, highlights the shift: “We’ve been able to lightweight the bottles while keeping them robust and strong. For us, the real value is the level of control and stability this technology brings to everyday production.”

By utilising invisible “power rings” — small bands of thicker material — the technology reinforces bottle integrity without the need for visible geometric ribs, offering greater design freedom while reducing material use by up to 15%.

For Refresco, the stability of the laser system is a game-changer for sustainability, particularly when working with recycled PET (rPET). Unlike halogen systems, which are sensitive to ambient temperature and material fluctuations, the laser remains unaffected by its surroundings.

Operational highlights include:

• Instant start-up: eliminates warm-up and cool-down times, allowing for “cold starts” that improve productivity.
• rPET optimisation: successfully tested with up to 100% rPET, producing consistent results across 50% and 70% rPET blends using the same blowing recipe.
• Scrap reduction: precision heating reduces preform waste by up to 50% compared to traditional solutions.

The success of the EvoBLOW Laser is the result of a deep technical partnership. Refresco’s 45+ plants worldwide provided a rigorous testing ground for Sidel’s innovation, moving the technology from the lab to a robust industrial environment.

“After 45 years of halogen technology, we are now entering a new era,” says Coert Michielsen, chief supply chain officer at Refresco. “I firmly believe that laser oven technology will become the new standard.”