Renowned PepsiCo bottler, MenaBev, has successfully introduced seven new bottle formats across two PET lines with the assistance of Sidel, a leading provider of packaging solutions. Sidel collaborated closely with MenaBev to convert two Combi PET lines at the expansive MEGA Plant in Jeddah within a remarkable one-week timeframe. This swift, efficient, and sustainable transition resulted in enhanced line performance and included the development of a new lightweight design for the iconic Aquafina brand.
MenaBev, the foremost bottling operator in the Middle East and North Africa (MENA) region, operates the MEGA Plant, which stands as one of PepsiCo’s largest bottling facilities globally, spanning 300,000 square meters. This plant effectively meets the production demands of millions of consumers in the region, supported by a local distribution center.
Benefitting from Sidel’s extensive experience of over 40 years in designing and implementing customized complete PET line solutions, MenaBev successfully met its product release dates with efficient support from Sidel. Both projects involved a comprehensive scope of work to ensure that one of the Combi PET line adaptations accommodated three new variations of the Aquafina bottle, while the other line could produce four new formats for the Carolina brand.
The collaboration between Sidel and MenaBev spanned over three years, fostering a strong partnership with streamlined project management. Moreover, MenaBev sought Sidel’s expertise to introduce new Carolina bottle formats in response to increased sugar taxes impacting the Saudi market. Despite facing challenges due to component shortages across the market, the two-line conversion projects were executed smoothly, with the necessary parts delivered swiftly. Both Combi PET lines were successfully adapted within one week. Additionally, Sidel’s engineers optimized production performance, enabling the Aquafina line to achieve a production capacity of up to 60,000 bottles per hour (bph) compared to its previous capacity of 54,000 bph. The Carolina line maintained its optimized speed of 48,000 bph.
A key focus during the design process for Aquafina was supporting MenaBev’s sustainability goals by delivering a lightweight and high-performance bottle for this iconic brand. Sidel conducted a thorough technical development of the new design, which included a comprehensive feasibility study, laboratory checks, and performance tests on the stretch blow-molding process. This meticulous approach was applied to the 330ml, 500ml, and 1.5L Aquafina bottles to ensure superior performance. The new Aquafina design resulted in a lighter-weight 330ml bottle, benefiting from a 10% reduction in raw materials while optimizing industrial performance and providing an exceptional consumer experience.
Karim Abdel Wahed, Service Manager at Sidel, highlighted the company’s ability to adapt and convert existing Sidel lines, enabling customers like MenaBev to respond swiftly to global changes and market demands. Wahed expressed pride in Sidel’s expertise in packaging design, which facilitated the creation of a new bottle for the iconic Aquafina brand, ensuring its continued high performance and delivering an enjoyable experience for consumers. This collaboration also bolsters MenaBev’s commitment to sustainability.
In conclusion, MenaBev’s collaboration with Sidel has resulted in the successful introduction of new bottle formats, improved line performance, and the development of a lightweight and sustainable design for the Aquafina brand. The partnership between these two industry leaders exemplifies the ability to adapt to market needs while maintaining a strong focus on sustainability.