Lighter but stronger packaging via laser heating
EvoBLOW Laser system delivers precision heating with up to 36 zones, instant restarts and improved lightweighting capabilities
At drinktec, Sidel presented the EvoBLOW Laser, described by the company as the first industrialised laser-powered solution for PET bottle blowing. The system is designed to improve line efficiency and expand possibilities for lightweight packaging. The company positions the development as a response to growing demand for higher performance and more sustainable packaging solutions.
Halogen technology has long been the standard for PET bottle production, with continuous improvements and widespread success but without a widely adopted alternative. Sidel presents the EvoBLOW Laser as a new approach intended to address some of the limitations of halogen-based heating.
The introduction comes at a time when producers face increasing pressure to lower costs, improve sustainability, and operate with greater flexibility. According to Sidel, the new system is designed to support these objectives.
Lighter but stronger packaging
One feature of laser-based heating is its higher level of precision compared with conventional halogen systems. In traditional solutions, preforms are heated in eight broad zones, whereas the EvoBLOW Laser uses up to 36 heating lines. This allows more detailed control of material distribution along the container.
According to Sidel, this control enables further lightweighting, including for premium bottles. The process creates small, thicker “power rings” in specific areas of the bottle wall. These reinforcements, which are not visible to consumers, are intended to increase strength while reducing overall material use. Unlike conventional geometrical ribs, they also allow more flexibility in bottle design. Lightweighting can also be applied in areas that have been difficult to optimise previously, such as just beneath the bottle neck.
Process stability with laser heating
Halogen-based systems can be sensitive to environmental conditions and often require frequent adjustments to maintain consistent results. These adaptations take time and rely on operator expertise, which can affect production time.
Sidel reports that the laser-based system is less influenced by ambient conditions. Each heating line requires only a single process setting for intensity, which is intended to provide a stable thermal profile for every preform throughout production. The company states that this consistency helps ensure uniform results independent of temperature fluctuations in the production environment.
Line efficiency features
According to Sidel, the EvoBLOW Laser contributes to line efficiency through its cold start capability. Unlike halogen systems, which require warm-up and cool-down periods, the laser-based oven can be restarted without stand-by heating, reducing downtime during stops and starts.
Efficiency is also supported by live speed modulation, which allows the blower to automatically adjust its speed in real time to adapt to changing line conditions. In addition, the system is designed to handle a wider range of bottle formats and shapes from the same preform, which Sidel states can simplify logistics.
Knowing that the EvoBLOW Laser can restart instantly with consistent quality reduces the stress of unplanned stops. The cold oven technology also allows fast access to the oven without waiting for cooling, with zero risk of burns.
When adjustments or changes are needed, an intuitive ‘touch and shape’ interface supports simple and quick settings. Maintenance is also claimed to be easier due to the absence of ventilation fans and filters, and the longevity of laser diodes.
Sustainability and rPET use
The company states that the solution supports increased use of rPET, as the system is less sensitive to material variations than conventional heating technologies. Adjustments to accommodate different rPET properties can be made immediately. The development is claimed to enable faster heating and a higher achievable preform temperature which supports optimal stretching.
Sidel also states that the technology reduces preform waste compared with its halogen-based solutions and operates with a smaller oven footprint. The company quantifies the reduction in preform waste at around 50 per cent.
Field testing with Refresco
The EvoBLOW Laser has been tested in cooperation with Refresco, which Sidel describes as the world’s largest independent beverage solutions provider. Coert Michielsen, Chief Supply Chain Officer at Refresco, said the company sees laser oven technology as a significant change in PET packaging production and expects it to play an important role in the future.