Hot Fill Lines

Sidel delivers a complete packaging approach, from preform and packaging design all the way through to production and ongoing packaging optimisation to achieve a high quality HR bottle:

• Optimised preforms: created with specific bi-orientation ratio and thickness
• Innovative bottles: combining customer specifications and proven Sidel technical features
• High PET crystallinity: precise preform heating process
• Perfect stretching: precise pre-blowing and rapid pressure rise
• Production consistency: efficient mould heating and reliable regulation

Staying ahead with innovative packaging

Sidel is continuously innovating its packaging and offering new opportunities beyond traditional bottle designs. Traditional HR PET bottles feature vacuum panels to absorb volume variations between hot and cold conditions. With Sidel, you can even create lightweight and heat-set HR PET bottles without panels, leading to significant cost savings.

The latest generation of Sidel heat-resistant blowers adds yet another dimension to the Sidel Hot Fill line. By using electricity instead of oil to heat the mould, the Sidel Matrix eHR blower increases bottle consistency and energy savings while enhancing operator safety, production flexibility and uptime.

The eHR process

• Four electrical resistances and one probe for temperature control and self-regulation in each half shell of the mould
• Consistent heat distribution on top, medium and lower bottle areas
• Temperature setting applied directly to each half shell using decentralised control units
• Thermal insulation ensures no direct contact between shell holder and mould

Benefits

• Top HR bottle quality
• Up to 45% energy savings
• Optimal production hygiene and operator safety
• Improved production performance and flexibility
• Simple and fast changeovers

Sidel fillers offer the highest standards of hygiene and operational reliability. The design of Sidel Matrix hot filler SF700 and its contactless filling valves optimise product safety throughout the packaging process.

The hot filling process

• The supply tank for the liquid beverage is located outside the filling carousel
• The liquid beverage is delivered by a pump to a product distributor ring on the top of the carousel
• The electronic filling valve is equipped with an individual flow-meter to determine filling volume
• Dual-speed filling avoids generation of any foam
• Low product recirculation maintains high beverage quality 

Benefits

• Accurate filling: Controlled flow rate and precise particle delivery
• Enhanced food safety: No contact between filling valve and bottleneck
• Excellent production flexibility: Accommodates different beverage types (teas, isotonics, juices, with or without pulps or particles) ,PET bottle sizes (200 ml to 3 litres) and production speeds (6,000 to 60,000 bottles per hour)

The Sidel Matrix Combi Hot Fill incorporates the very best of our modular Sidel Matrix eHR blower and SF700 filler with the advantages of the standard Combi configuration to produce hot filled beverages in PET bottles in one single enclosure.

Flexible and hygienic

• Extensive range of configurations
• Optimised line layout and efficiency with compact and ergonomic design
• Ensured hygiene and food safety with a controlled production environment
• Greater HR bottle shape freedom 

Efficient and cost-saving

• Up to 4% more efficient than standalone machines
• Cuts operating costs by up to 12%
• Reduces need for energy, labour, raw materials and spare parts
• Attractive lightweighting opportunities Faster format changeovers

Once the hot beverage is filled and capped, the head-space and cap are sterilised by tilting the bottle at a precise angle, temperature and contact time. The Sidel cap steriliser keeps all those parameters under control.

Tilting process

• Keeps inside bottle area in contact with the hot beverage
• Maintains contact between beverage and cap by rotating bottle up to 110 degrees
• Eliminates microorganisms and extends shelf life
• Removes air bubbles to ensure safety and consistency 

Benefits

• Controls contact time, angle and temperature parameters
• Flexible contact time ranges between 7 and 30 seconds
• Easily accommodates different plant sizes and line configurations

After cap sterilisation, bottles need to be effectively cooled down to ambient temperature through uniform water spraying. The Sidel cooling system reduces the liquid beverage's temperature while avoiding thermal stress and preserving organoleptic properties.

Benefits

• Handles different beverage viscosities and bottle sizes without changeovers
• Uses high density spraying for water flow optimisation 20% less footprint due to optimised efficiency and engineering
• Ergonomic design for easy operation and maintenance
• Modular and upgradable for production needs of tomorrow
• Easy integration with Tetra Pak processing with energy savings up to 45%

After the hot filling process, the beverage product moves onto one of its most defining features - the label. Whether you require roll-fed or sleeve labels for your hot filled beverages, our labellers can handle any label format and will make sure your product stands out from the crowd. 

Apply roll-fed labels with Sidel EvoDECO Roll-Fed labeller

Boasting four carousel sizes, up to three labelling stations and 24 configurations, the Roll-Fed can generate outputs of up to 72,000 containers per hour, when standalone, at an efficiency rate of 98%. It achieves outputs of up to 81,000 if integrated with Super Combi.

• Greater performance and ergonomics
• Boasted production uptime
• Sustainable and quality production

Apply sleeve or roll-fed labels with Sidel RollSLEEVE labeller

The unique RollSLEEVE labeller combines the simplicity of Sidel consolidated Roll-Fed technology with an innovative high-speed shrink sleeve process in one single machine.

In developing the Rollsleeve labeller, Sidel focused on the branding opportunities shrink-sleeve labels present. In addition to its potential for delivering reduced operating costs, the Rollsleeve labeller combines the simplicity of Sidel consolidated roll-fed technology with an innovative, high-speed shrink sleeve process in one single machine.

• A unique and patented label application
• Efficient and top quality labelling
• Quick payback
• Flexibility of containers, films and layout

Once hot filled beverage product has been filled and the bottle has been labelled, the primary package is transferred using Sidel conveyors to its secondary packaging process. The final result is the package the customer sees at the point of sale, so it needs to grab their attention. These packs ensure protection from elements such as weather, pressure and temperature changes.

Whether you choose shrink-printed film, nested packs or wraparound cartons, Sidel packers gently feed bottles to ensure durable and cost-effective packs.

Benefits

• Pack consistency and quality
• Gentle and precise infeed configuration
• Flexible handling of multiple SKUs
• Automatic pack and raw material changeovers
• Heat, glue, carton and film optimisation

Once your packaged product is ready to continue across the supply chain, efficiency during storage and transport is essential. As bottles and packs vary in format and size, it is important that conveying and palletising handles a variety of products, packs and layer patterns.

Benefits

• Conventional palletiser: easy operation, troubleshooting and maintenance; handles up to 3 SKUs simultaneously
• Robotic palletiser: compact fit with high production speeds and multiple patterns; handles up to 4 SKUs simultaneously

Once your Hot Fill line production and efficiency targets are reached, the goal is to maintain and even improve these levels for years to come. With our dedicated Sidel Services team and our tailored portfolio, you can lower costs and increase the value of your beverage production for long-term success.  

Maintain performance

• Access 24/7 Sidel support and ongoing on-site diagnostic visits
• Predict and resolve issues in advance
• Ensure line longevity with Sidel's global team of experts
• Monitor performance, pre-plan downtime and provide fast corrective maintenance 

Improve performance

• Original Sidel spare parts for increased uptime and reliability
• Access more than 500 options and upgrades for every step of production
• Upgrade with training in new methodologies and procedures
• Get training on-site, online or at any global Sidel Training Centre 

Adapt production to new demands

•  Continuously adjust for new products, recipes or packaging
• Use original Sidel moulds for line conversions
• Experience increased uptime, reduced costs and greater production flexibility