Resource Efficient Innovations Database (REID)

Innovative preform manufacturing technology supports PET bottle light-weighting

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Innovative preform manufacturing technology supports PET bottle light-weighting
Innovative preblow process during demoulding allows greater influence to be exterted over container wall thickness and material build-up.
In Use – Previewed during 2012 and now commercially available.

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

Product Categories

Relevant Materials
Plastic – rigid

Relevant Packaging Formats
Bottles and jars

Supply Chain Phase


A machinery and production systems supplier has further developed their innovative cooling system that supports preform cooling through internal pressure in the preform. Using the system, PET performs are intensively post-cooled without interruption after demoulding. The latest innovation to the system further extends this cooling phase with a blow-out process in the base area.

During this blow out process, the base contour and, thus, the surface area can be changed for the first time. By increasing the size of the base contour through the blowing process, a thinner wall in the critical base area is obtained, resulting in a lighter weight container. The process allows more influence to be exerted on container thickness and material build-up and these can then be improved significantly.
During the subsequent blowing process, with a larger surface area, the UV lamps in the blowing machine have to heat a thinner wall resulting in lower process energy requirements and shorter cycle times.
The resulting containers produced by this process have been dubbed LightBase. The PREBLOW process builds on Nestal’s  proven PET-LINE Calitec© System.
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

This technology offers valuable light-weighting opportunities for PET containers. During an initial test with 1-litre juice bottles, a weight reduction of more than 1 g was attained. Subsequently, at the Chinaplas exhibition in April 2012, Netstal presented a system which produced a preform weighing 15.8g for non-carbonated water. Although the bottle quality remained identical, material consumption was reduced by at least 0.5 g material. Calculated over the year, this corresponds to significant material savings for beverage fillers.

Intellectual Property

This technology is the subject of a patent application.

Consultant View

The REID database features many entries describing technologies which aim to reduce the environmental impact of beverage packaging. For further examples, try searching the database using the search terms “Drinks” or “Beverages”.

Contacts and Further Information

Thomas Anderegg, Vice President Sales at Netstal.
Netstal-Maschinen AG
CH-8752 Näfels/Switzerland
Tel: +41 (0) 55 618 61 11
CH-8752 Näfels/Switzerland
Phone +41 (0) 55 618 61 11

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