Introducing the SIDEL STARLITE™ bottle base

Lighter, more resistant and more stable

A PET bottle base that increases resistance, lowers package weight and energy consumption, and maintains product safety, all at the same time, is no longer just a dream. Thanks to the dedication of Sidel packaging experts, the new Sidel StarLite bottle base utilises a unique shape that significantly increases base resistance and stability. This means it can improve bottle rigidity, while enabling a lower package weight and reduced energy consumption during production. The end result is a PET bottle that can cost less to produce, yet offers better pallet stability and higher bottle integrity throughout the supply chain, without compromising on the safety standards of the beverage inside. The base is especially suited for water and juices, and under certain conditions can also be used for other still beverages.


"Our customers are increasingly looking for ways to save costs, remain competitive and achieve their sustainability goals. One way of doing this is to lightweight the bottle, but to do this you need to ensure packaging integrity is not affected and the bottle remains attractive. The StarLite base enables producers to reduce package weight and blowing pressure, and increase base resistance to deformation," says vincent Le Guen, vice President, Packaging & Tooling.


Patented design

The Sidel StarLite bottle base uses two proprietary PET design innovations: the Edge Beam™ and the Smart Disc™. The Edge Beam is a specific groove structure that improves base stiffness while the Smart Disc reinforces the base to prevent deformation. Both innovations have been designed and tested by Sidel's packaging experts using bottle-validation technology to increase rigidity in the base and reduce plastic use.


The base can be adapted to all Sidel blowing platforms, including the new Sidel Matrix™ system for liquid packaging, and applied to existing production lines using Sidel's StarLite mould bases. It works with regular, ultra clean and aseptic filling solutions, and can also be used with nitrogen drop technology.


Proven value

Sidel's packaging experts analysed different base designs to achieve optimum strength. They then carried out numerous computer simulations followed by real-world physical tests. In those tests the StarLite design resulted in:


More bottle-base stability and resistance: An increase in top-load dent resistance of up to 30% when the bottle is on a pallet, and up to a 55% increase in side-load resistance when the bottle is on a conveyor or in a vending machine, for example. Overall pallet integrity also increased by up to 50% during transportation.


More resistance to extreme temperatures (hot and cold): Up to 25 days without bottle deformation in 50°C conditions, and up to a 50% decrease in base rollout under frozen conditions, making it especially useful for storage in harsh conditions.

More lightweighting possibilities: PET savings of up to 1 gram for a 0.5 litre bottle (equivalent to EUR 350,000 cost savings per year*), and up to 2 grams for a 1.5 litre bottle (equivalent to EUR 700,000 cost savings per year*).

More energy savings: For 0.5-1.0 litre bottles, only 16-20 bars of pressure were required for blowing, versus up to 25 bars previously. This means a reduction of up to 25% in air pressure, which can result in a cost saving of up to EUR 90,000 per year**.

More design flexibility: The StarLite base is also compatible with nitrogen drop technology, meaning that lightweighting can be pushed further. Furthermore, if the bottle pressure generated by the nitrogen dosing is 0.8 bar or under, StarLite can replace the traditional mini-petaloide base, usually associated with carbonated soft drinks in the minds of consumers.


Click here to find out more about Sidel StarLite.

Download the article as pdf

Download the whole Inline 6