The transition toward more sustainable packaging is already a reality across the packaging industry. An increasing number of manufacturers are incorporating recycled materials into their production lines as part of their commitment to the circular economy. However, this progress also introduces new technical challenges that require dedicated, high-performance solutions.
One of the key challenges arises when introducing rPET bottles (post-consumer recycled PET, also known as PCR) alongside virgin PET (vPET) bottles on high-speed production lines, particularly in critical stages such as container unscrambling and orientation.
The rPET challenge: handling mixed formats without losing efficiency
Bottles manufactured from rPET present physical and mechanical characteristics that differ from those of virgin PET. While these differences are positive from an environmental perspective, they can affect container behaviour along the production line:
- Variations in rigidity and surface texture
- Different behaviour during vibration and sliding
- Increased complexity in bottle feeding and orientation
- Higher risk of jams and unplanned downtime
For manufacturers operating at high throughput levels and with demanding OEE targets, these variabilities can compromise process stability and overall line efficiency.
The POSIMAT solution: technology adapted to a new sustainable standard.
In response to this scenario, the engineering team at POSIMAT developed an automatic bottle unscrambling solution specifically optimised to handle mixed rPET and vPET formats.
Leveraging its expertise in precision mechanics, dynamic control and automation, the solution delivers:
- Automatic adaptation to the type of bottle being processed
- Stable feeding despite material and surface variations
- A significant reduction in jams and rejected containers
- Seamless integration with the rest of the packaging line
This technology-driven approach enables manufacturers to move towards more sustainable packaging without sacrificing productivity or operational reliability.
Want to stay updated on the latest in the packaging sector? Subscribe to our newsletter!
Results: sustainability and performance can go hand in hand.
The implementation of POSIMAT’s advanced unscrambling and orientation solutions enabled the manufacturer to:
- Integrate rPET bottles into the line without disruptions.
- Maintain key performance indicators, including OEE.
- Avoid unplanned stoppages caused by container variability.
- Align production with environmental objectives.
This case demonstrates that, with the right technology, sustainability is not only compatible with industrial efficiency, but can also become a source of competitive advantage.
Sustainable innovation within the Barcelona Packaging Hub ecosystem
Within the Barcelona Packaging Hub, collaboration between machinery manufacturers and industrial brands is actively promoted to address the major challenges facing the sector. Adapting production lines to new recycled materials is one of these challenges, and solutions such as those developed by POSIMAT illustrate how applied engineering can accelerate this transition in a safe, efficient and industrially robust way.
If your company is addressing the integration of rPET bottles into its production lines, contact us and discover how our ecosystem can help you do so efficiently and reliably.