Manufacturers in the water bottling industry have been quick to appreciate the benefits of Sidel’s StarLite PET bottle base, which was launched last year. This award-winning, patented base design optimises the resistance and stability of the bottle while enabling further lightweighting.

"The carbonated soft drinks segment remains the second most popular after water with 220 billion litres consumed in 2013, representing 28% of the global non-alcoholic beverage market. Around 40% of this amount is packaged in PET. These huge figures help explain why we are constantly striving to help beverage producers worldwide unlock value from their CSD bottles," says Laurent Naveau, Packaging Care Manager.

"One way of doing this is to reduce bottle weight and therefore the costs of PET and the environmental footprint, while maintaining or improving bottle performance. With Sidel StarLite CSD, we can help beverage producers achieve exactly this for their carbonated soft drinks production," he continues.


  • Tested and proven

To create this innovative base, Sidel's packaging experts analysed different geometrical solutions to achieve optimum strength for the carbonated soft drink bottle base. These designs were run through computer simulations followed by real-world physical tests to create the final design. This design includes four key patents covering the slopes, ridges and truncations. Ten different Sidel customers have already trialled the StarLite CSD bottle base and achieved the following benefits:

 Sidel StarLite CSD bottle

  • Better protection against stress cracking

Under the rigorous International Society of Beverage Technologists (ISBT) stress-cracking test protocol, the StarLite CSD base lasted 30% longer for0.5 litrebottles, 50% longer for1.5 litrebottles and 60% longer for2.0 litrebottles.



  • Better base resistance

The base successfully completed the ISBT 24-hour creeping test under45°Cconditions, compared with38°Crequired under standard testing. This means the base is less likely to burst during production, or deform during transport, which can unbalance pallets.


  • Lightweighting opportunities

Base weight can be reduced by up to 20% for0.5 litrebottles (from5 gramsaverage base weight to4 grams), 19% for1.5 litre(from9 gramsto7.3 grams), and 17% for2 litres(from 12 to10 grams). This can lead to cost savings of up to EUR 331,000 per year for0.5 litrelines, EUR 563,000 per year for1.5 litrelines and EUR 662,000 per year for2 litrelines, based on Sidel data.*


  • Reduced energy use

Under controlled conditions the base can be blown using down to 16 bars of air pressure versus 25 bars average for0.5 litrebottles, 18 bars versus 26 bars average for1.5 litrebottles, and 20 bars versus 28-30 bars average for2 litrebottles, creating up to EUR 78,700 cost savings per year, based on Sidel data.**


  • Higher output

Due to its compatibility with the new Sidel Matrix™ system, the output rate for the base is up to 2,300 bottles per mould per hour for0.5 litrebottles, 2,250 bottles per mould per hour for1.5 litrebottles, and 2,000 bottles per mould per hour for2 litrebottles (depending on conditions and specifications).


  • Easy to blow

The new base is easier to blow than previous CSD bases because it can be done within a wider range of parameter settings on the blower, whilst still achieving desired blowing performance.


  • Easy to implement

The base can easily be incorporated into existing bottle designs by Sidel's packaging engineering team. It can also be retrofitted onto existing production lines and moulds, using Sidel's accompanying enhanced StarLite CSD mould bases and line conversion
services. The accompanying Sidel StarLite CSD mould features an enhanced venting design for optimized cooling capabilities, and was developed in tandem to reach the desired high StarLite CSD bottle base performance levels.

Sidel StarLite CSD topAvailable for all PET bottle sizes up to three litres, the Sidel StarLite CSD base can be used with all Sidel blowing platforms and output speeds, including the Sidel Matrix system for liquid packaging.


*Based on an SBO 20 Universal2 running at 6,000 hours of production per year, with an output of 2,000 bottles per hour with a PET cost of EUR 1,600 per ton.


**Based on an SBO 20 Universal2 Eco producing2 litrebottles with 6,000 hours of production per year with a reduction in air pressure of 10 bars, without the use of an air recovery system at a cost of 0.08€/kwh.


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