Sidel has unveiled its latest innovation, the StarLiteR, a bottle base crafted entirely from 100% recycled PET (rPET). This development is aimed at assisting carbonated soft drink (CSD) packaging producers in embracing circularity in their materials.

The StarLiteR offers a seamless transition for CSD producers looking to shift to rPET bottle production without compromising product quality or packaging integrity. Laurent Naveau, Sidel's Packaging Innovator Leader, highlighted some of the challenges posed by rPET resin in the packaging industry. These challenges include fluctuating consumption patterns affecting product categories throughout the year, as well as regional variations in PET collection models, leading to variations in post-consumer PET material bales.

Naveau noted, "The recycling process and equipment used will also influence PET resin. These factors can introduce new challenges for manufacturers aiming to create bottles containing rPET material.

In addition to the typical challenges associated with manufacturing CSD bottles, such as stress cracking, roll-out, and bursting during the blowing process, rPET processing requires higher temperatures. This elevated temperature can sometimes lead to reduced control over rPET material stretching and distribution within the bottle-making process. Traditionally, greater variability in rPET resin results in a narrower process window and lower bottle quality.

However, Sidel's innovative StarLiteR base addresses these concerns by enhancing production efficiency, thus restoring a broader process window. This is achieved through the design of the mould base profile and the advanced stretch rod end design.

The optimised mould base profile is engineered to facilitate ideal material distribution through advanced stretching, providing a high base clearance for maximum stability. Simultaneously, the advanced stretch rod end design enhances the stretching of the preform end-cap material and ensures precise injection gate centering on the bottle.

The StarLiteR solution also incorporates both external and internal cooling for the bottle base. Externally, a mould base cooling circuit is employed, which concentrates on the warmer areas of the bottle base. Internally, a hollow-stretch rod is used, eliminating the need for additional air supply.

One of the standout features of StarLiteR is its versatility. It can be effortlessly integrated into existing production lines and adapted to suit current bottle designs. Furthermore, the solution is compatible with Sidel's renowned blow molders, including EvoBlow, Universal, and Series 2, making it suitable for high-speed production environments.

By introducing the StarLiteR, Sidel aims to simplify the adoption of rPET materials in the production of CSD bottles, promoting sustainability and circularity within the packaging industry.