Resource Efficient Innovations Database (REID)

Innovative bottle production

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Innovative bottle production
New “Roll ‘n’ Blow” method of producing thermoformed bottles saves materials and energy
In Use – The system was launched at Interpack in 2011. As yet, no commercial installations have been cited by the manufacturers.

Packaging Reduction, Resource efficiency (e.g. filling line efficiency), Storage and Transport efficiency

Product Categories
Drinks, Food

Relevant Materials
Plastic – rigid

Relevant Packaging Formats
Bottles and jars

Supply Chain Phase
Filling, Production


A new technology has been developed which allows bottles to be manufactured from plastic sheets at a cost and material weight lower than that achieved by conventional thermoforming methods. It is based on an innovative technology of tubular thermoforming from a plastic sheet in a reel. The technology allows high and round shapes to be produced, for volumes in the range of 100-500ml.
The technology targets the fresh dairy products industry, in particular drinking yoghurts and fruit juices.
The raw material comes in the form of plastic sheeting. Each plastic sheet is then cut into strips, and each strip is shaped into a tube around a blow pipe. Each strip is then welded lengthwise and the resulting plastic tube is heated and blown into a mould in order to create the bottle. The process is compatible with many types of polymers, including PS, PP, PET and PLA.  Where multilayer materials are required there are further cost benefits, as films are extruded flat at high speed which improves the economics of production.
Using reels of plastic sheeting as the base material also reduces transport and storage costs, as well as costs associated with the handling of bottles or empty preforms, before they are blown up. Where traditionally 25 lorries would be required to supply bottles and five required for supplying preforms, only one is needed for supplying the reels of plastic sheeting to feed a hole in the wall roll ‘n’ blow operation.
Consumables costs are also reduced across the board as there are fewer accessories required for production. The plastic blowing is carried out at a low pressure (less than six bars) and at a low temperature (under 150°C). There is no need for a high-pressure compressor. Subsequently less electricity is required, as compared to traditional preform blowing.
The Roll N Blow thermoforming machine is produced by Agami, a start-up partially owned by Serac. The machine can produce up to 7,000 bottles per hour.
The content in this entry has been obtained from publicly available information sources only (e.g. press releases, website and trade press articles) and is subject to completion of a validation process with the technology supplier.

Potential Benefits

The technology providers identify a number of environmental benefits arising from the use of the roll ‘ n’ blow technology compared to traditional bottle manufacturing processes, including: lighter weight bottles; lower energy requirements during production; and improved transport efficiency during the distribution of materials in sheet form as opposed to preforms

Intellectual Property

Roll N Blow, has been developed by the start-up Agami and is distributed by Serac worldwide.

Consultant View

Readers interested in this technology should search for other technologies in the REID database which enable light-weighting of beverage containers. Try combinations of search filters and key word searches using terms such as “beverages” and “light-weighting”.

Contacts and Further Information

Stylianos Eleftheriou
11 rue Val D’Izé
35 500 VITRE
Tel      : +33 (0)2 99 96 10 19

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