SHERIDAN, WYOMING – Feb. 4, 2025 - Coca-Cola Installs InnoPET Blomax at Its Knetzgau Plant
With the help of latest-generation KHS stretch blow molding technology, Coca-Cola Europacific Partners (CCEP) is elevating energy savings in its PET bottle manufacturing operations. The company has replaced two older machines with the InnoPET Blomax, exceeding performance expectations. Central to this achievement is KHS’s innovative Double Gate (DoGa) heating concept, setting a new industry benchmark for sustainability and efficiency.
Coca-Cola Knetzgau: A Hub of Sustainable Innovation
Nestled in the Lower Franconian town of Knetzgau, Germany, Coca-Cola’s sprawling 200,000-square-meter production facility stands as one of the company’s largest in the country. Employing approximately 500 personnel, the site produces iconic beverages like Coca-Cola, Fanta, Sprite, and Mezzo Mix. As part of its commitment to a sustainable future, CCEP has prioritized reducing energy, water, and material consumption—a strategy that benefits both the environment and operational costs. The recent installation of KHS’s InnoPET Blomax V underscores this mission, delivering unprecedented energy efficiency through cutting-edge technology.
Near Infrared and Double Gate: Revolutionizing Energy Efficiency
The InnoPET Blomax V distinguishes itself through two groundbreaking features: near infrared (NIR) radiation and the Double Gate heating concept. Unlike conventional infrared heaters, NIR technology optimizes energy transfer, heating PET preforms more efficiently. Meanwhile, the Double Gate system eliminates the need for primary reflectors, channeling energy through dual lanes on either side of the lamps. This design not only slashes energy consumption but also reduces the machine’s physical footprint.
For Ralph Sauter, project manager at Coca-Cola Knetzgau, these innovations were pivotal in selecting the KHS system. “Saving energy is critical to our sustainability goals. The Double Gate technology’s potential savings made KHS the clear choice,” he explains. Since installation, the plant anticipates annual energy savings of up to 560,000 kWh—a vital advantage amid rising energy costs. Sauter adds, “While all suppliers emphasize efficiency, the KHS setup outperforms competitors significantly.”
Performance Meets Precision: Overcoming Design Challenges
Beyond energy savings, the InnoPET Blomax V impressed CCEP with its operational prowess. The machine processes 20,000 2.0-liter and 30,000 1.5-liter containers per hour, seamlessly integrating into existing production lines. However, the installation posed unique challenges. “Adapting the bottle air conveyor to serve a single machine instead of two required meticulous alignment,” Sauter notes. The fixed position of the conveyor demanded centimeter-level precision during installation—a feat achieved through close collaboration with KHS.
Marc Harald Eysel, KHS’s PET Technology Sales Manager, reflects on the project: “Aligning the system with the existing infrastructure was complex but routine for our team. We aim to exceed expectations not just through technology, but by tailoring solutions to our clients’ needs.”
A Growing Demand for Sustainable Solutions
The success in Knetzgau mirrors a broader industry trend. As companies prioritize sustainability, demand for energy-efficient technologies like the Double Gate continues to surge. Eysel highlights, “Compared to systems from the late 2010s, the InnoPET Blomax V reduces energy use by up to 30%. This positions KHS as a leader in sustainable manufacturing innovation.”
Conclusion: Pioneering a Greener Future
Coca-Cola Knetzgau’s investment in the InnoPET Blomax V exemplifies how strategic partnerships and advanced technology can drive sustainability. By leveraging KHS’s expertise, CCEP not only enhances operational efficiency but also reinforces its commitment to environmental stewardship. As energy prices climb and sustainability mandates tighten, such innovations will remain vital to maintaining competitive and eco-conscious production practices.
For more information on KHS’s energy-efficient solutions, visit www.khs.com.
Images courtesy of Frank Reinhold.