Orkla boosts ketchup production with support from Sidel

The challenge

Within the sauces and dressings category, there has been an increase in consumer demands for convenient, sustainable, and healthier products. In response to these market needs, Orkla Foods, part of the wider Nordic Orkla Group, required a PET packaging solution to increase its production capacity and cost efficiency while reducing its environmental impact. The ketchup manufacturer turned to Sidel for support in reaching its overarching goals of health, modernity, and productivity.

The solution

Orkla Foods utilised Sidel’s preferential heating technology, which optimises PET distribution while allowing the asymmetrical stretching needed to blow flat and shaped containers, to redesign its packaging range from cylindrical PP (polypropylene) bottles to more modern, flat rectangular designs. Additionally, Orkla replaced its outdated technology, by moving away from hot filling processes to ensure product stability and hygienic production. Sidel provided ultra-clean ambient filling technology within an integrated combi solution combining the blowing and capping functionalities.

The outcome

By moving to a new PET packaging design and in-house blowing with Sidel’s integrated blow-fill-cap solution,Orkla has ensured its original taste profile while delivering a product that is healthier and more eco-friendly. Its new easy-to-use rPET bottle shapes are up to 30 percent lighter than previous designs and allow users to completely empty the bottle and ensure that there is not unnecessary food wastage. The new set up allows for ambient filling with less preservatives and a reduction in waste and changeovers on Orkla’s operators. This global solution has allowed a production capacity increase, from six tons per hour to nine preservative-free tons per hour. With production volumes being achieved in less time, Orkla benefited from the ability to introduce and expand new formats and recipes onto its line. 

"Switching to a more modern and sustainable PET bottle to revitalise our ketchup brands has been positively received by consumers, resulting in an increase in sales and market shares."

Per Samuelsson

Project and Process Developer of Orkla

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