PepsiCo bottler undertakes format changes

PepsiCo bottler MenaBev has used Sidel’s expertise to deliver seven bottle formats across two PET lines. At its vast MEGA Plant, two Combi PET lines were converted in just one week, resulting in improved line performance, with deliverables including a new lightweight design for the Aquafina brand.

MenaBev, based in Jeddah, is a leading bottler in the Middle East and North Africa (MENA) region. Its MEGA Plant is one of the largest PepsiCo bottling plants globally, covering 300,000 m², and is supported by a local distribution centre.

Sidel supported MenaBev in reaching its product release dates on the market, with both projects requiring a wide scope of work to ensure that one of the Combi PET line adaptations catered for three new-look Aquafina formats, while the other could run four new Carolina formats.

In response to increased sugar taxes impacting the Saudi market, MenaBev also called on Sidel’s expertise to deliver new formats of the Carolina bottle. Although challenged by market-wide component shortages, the line conversion projects resulted in an optimised workflow and the fast delivery of the parts required. The separate Combi PET lines were both adapted in just one week respectively. In addition, Sidel’s engineers were able to maximise production performance, with the Aquafina line now capable of running up to 60,000 bottles per hour (bph) compared to its previous figure of 54,000 bph, while the Carolina line has maintained its speed of 48,000 bph.

Sidel focused on supporting MenaBev’s sustainability goals as part of the design process for Aquafina, delivering a lightweight, high-performance bottle for the iconic brand. The development of the new design included a full feasibility study, laboratory checks and performance tests on the stretch blow-moulding process. This was applied to the 330 mL, 500 mL and 1.5 L Aquafina bottles. The Aquafina design has delivered a lighter weight 330 mL bottle, with a 10% reduction in raw materials.