Sidel has introduced an online Packaging Optimisation Tool aimed at helping packaging producers evaluate material efficiency, cost savings, and emissions reductions in PET bottle design and production. The tool enables users to simulate packaging design changes and assess their impact on primary packaging performance and sustainability.
Available on the company’s website, the platform allows adjustments across key packaging parameters, including bottle neck, body, and base configurations, as well as the adoption of partial labelling and recycled PET content. These variables are central to packaging development, where material reduction must be balanced with structural integrity, shelf performance, and processing efficiency.
The tool provides comparative outputs between existing packaging formats and optimised designs, offering estimated annual savings in both PET consumption and greenhouse gas (GHG) emissions. This reflects ongoing efforts within the packaging sector to reduce material intensity while maintaining functionality and compliance with product requirements.
“Rising and dynamic costs of PET are a significant challenge for customers, and every opportunity to optimise the package weight helps, both for their bottom line, and their sustainability goals,” said Vincent Le Guen, Vice-President for Packaging, Moulds and Line Solutions at Sidel.
According to the company, packaging lightweighting can achieve reductions of up to 40% in bottle neck weight, 35% in body weight, and 20% in base weight, depending on application. These design changes are supported by validation processes to ensure packaging performance across filling, handling, and distribution.
Sidel also pointed to packaging line technologies that contribute to further material reduction. Its EvoBLOW Laser system enables additional lightweighting, while roll-fed partial labelling reduces label material usage. Secondary packaging solutions such as EvoFilm Stretch are designed to lower plastic film consumption.
“This new online calculator is flexible, interactive, easy to use, and freely available, helping create awareness of what is possible for cost savings and advancing sustainable packaging,” said Jerome Neveu, Packaging and Moulds Product Manager at Sidel.