Schweppes Zimbabwe Limited (SZL) has made significant strides in boosting production efficiency and sustainability with the installation of an advanced non-returnable PET line from KHS. The upgrade, implemented at the company’s Harare facility, has tripled production capacity while significantly reducing resource consumption and operating costs.
The state-of-the-art line includes the InnoPET BloFill stretch blow molder/filler, capable of producing and filling up to 36,000 containers per hour, along with the Innoket Neo labeler, Innopack PSP Advanced shrink packer, and Innopal PB N palletizer. Continuous quality monitoring ensures only premium products leave the facility.
Efficiency and Sustainability Gains
Ropafadzo Gwanetsa, Corporate Affairs Executive at SZL, emphasized the benefits of the upgrade: “Production capacity has increased by 300%, and we now process various packaging formats more flexibly, from 400ml to 2 liters.” She noted that automated systems have minimized operator intervention, further enhancing production efficiency.
The new line has also cut overall costs by approximately 80%, with energy consumption reduced by 30% and significant savings in water, CO2 emissions, and labeling expenses. Gwanetsa highlighted the company’s commitment to sustainability: “We are adopting an ambitious sustainability strategy, targeting climate neutrality. Our KHS technology is helping us achieve these goals.”
Lightweighting and Longevity
KHS technology has enabled SZL to use up to 15% less raw material for PET containers, contributing to reduced plastic waste. The equipment’s long service life further minimizes environmental impact, with Gwanetsa noting the line is expected to operate for the next 20 years.
Adapting to Space Constraints
A key challenge in the project was the limited space at the Harare facility. KHS tailored the line’s design to fit into an L-shaped layout, completing installation in just six weeks. “The cooperation between our teams ensured a smooth transition, with saleable products running off the belt shortly after commissioning,” said Bradley Naicker, KHS Sales Manager for South Africa.
Customized Solutions and Ongoing Support
SZL’s unique requirements, such as non-standard pallet formats, were met through customized robot programming. Gwanetsa praised KHS’ support throughout the project, including training and remote diagnostics via the KHS ReDiS system.
Naicker concluded, “We’ve exceeded expectations in capacity, resource efficiency, and cost reduction. SZL is now bottling higher-quality beverages at a lower environmental cost.”