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The Energy Drink Market: Growth and Packaging Trends

Energy drinks represent one of the fastest-growing segments in the global beverage industry, with the market valued at over $80 billion and projected to continue growing at 7-8% annually. Red Bull, Monster, Rockstar, and hundreds of private-label brands drive continuous demand for production capacity.

The dominant packaging format for energy drinks is the slim aluminium can (250ml), followed by standard cans (330ml, 500ml) and PET bottles. The slim can format has become iconic for the category and is almost exclusively used for premium energy drink brands.

For new brand entrants and contract packers, used energy drink production equipment offers the fastest route to market. New canning equipment lead times of 10-14 months can delay product launches significantly, while a used line can be operational within 2-4 months. The cost advantage of 40-60% compared to new equipment is equally compelling for a category where speed-to-market is critical.

Core Equipment for Energy Drink Production

Batch Preparation and Mixing: Energy drinks require precise blending of water, sugars/sweeteners, caffeine, taurine, B-vitamins, flavourings, and other functional ingredients. Batch mixing systems with temperature control and inline brix measurement ensure consistency. Used mixing systems from GEA, Krones, and Alfa Laval are suitable.

Carbonation: Most energy drinks are carbonated at moderate to high levels (3.0-4.5 volumes CO2). Standard beverage carbonation systems are used. Ensure the carbonator can achieve the required CO2 volume consistently.

Can Filler and Seamer: The core production unit. For slim cans (250ml), counter-pressure fillers from KHS (Innofill Can DVD), Krones (Modulfill Can), CFT, and Codi are standard. The seamer (Angelus, Ferrum, Pneumatic Scale) applies the can end with a critical double seam. For slim cans, verify that the filler and seamer are configured for the smaller 202/200 diameter.

Nitrogen Dosing: Many energy drinks use liquid nitrogen dosing to pressurise non-carbonated or lightly carbonated variants. A nitrogen doser adds a drop of liquid nitrogen before seaming, which expands to pressurise the can and provide structural rigidity.

Pasteurisation: Flash pasteurisation (typically 72-85°C for 15-30 seconds) is standard for energy drinks to ensure microbiological stability. Tunnel pasteurisers are also used for post-fill treatment. Evaluate heat exchanger condition and temperature control accuracy.

Slim Can Considerations and Format Flexibility

The 250ml slim can (diameter 53mm/202 end) is the signature format for energy drinks. When purchasing used equipment for this format, several specific considerations apply:

Filler compatibility: Not all can fillers handle slim cans. The smaller diameter requires specific can handling guides, pocket stars, and infeed/outfeed timing. Verify that the filler is configured for slim cans or that conversion kits are available and included.

Seamer tooling: Slim cans use 202-diameter ends (smaller than standard 206 ends). Seaming rolls and chucks must be specifically sized. Used seamers should include the correct tooling for slim cans, or budget €5,000-€15,000 for new tooling.

Can supply chain: Slim cans are widely available from major can manufacturers (Ball, Crown, Ardagh, Can-Pack). Verify that the filler can handle cans from multiple suppliers, as slight dimensional variations exist.

Multi-format capability: For producers who want to offer both slim (250ml) and standard (330ml, 500ml) cans, ensure the used line can accommodate format changes. Typical changeover time between can sizes is 2-4 hours for filler and seamer adjustment.

Speed considerations: High-speed slim can lines operate at 600-2,000+ cans per minute. For energy drink start-ups, lines in the 200-600 CPM range offer the best balance of capacity and investment.

Secondary Packaging for Energy Drinks

Energy drink secondary packaging is a critical brand touchpoint:

Shrink Multipacks: 4-packs and 6-packs in printed shrink film are the standard retail format. Used shrink wrappers from KHS (Innopack Kisters), Krones (Variopac), and SMI handle these configurations. Evaluate film tension, seal quality, and shrink tunnel temperature uniformity.

Tray Shrink: Cans on a corrugated tray with shrink overwrap. Common for club stores and wholesale channels.

Hi-Cone: Plastic ring carriers are being phased out in many markets due to environmental concerns. Consider future-proof alternatives.

Variety/Mixed Packs: Growing trend in energy drinks. Requires either manual packing or flexible automated systems that can combine different can variants.

Printed Shrink Film: High-quality graphics on shrink film multipacks serve as point-of-sale marketing. Ensure the shrink wrapper can handle the required film specifications and print registration.

Case Packing: For distribution, cans are typically packed in RSC (regular slotted container) cases. Case erectors, packers, and sealers from Pearson, Hartness, and SACMI are commonly available used.

Starting an Energy Drink Brand: Equipment Strategy

For entrepreneurs and brand owners entering the energy drink market, the equipment acquisition strategy should consider:

Contract packing vs own production: Many successful energy drink brands start with contract packing before investing in own equipment. However, own production provides control over quality, scheduling, and costs.

Minimum viable line: A complete used energy drink canning line (mixing, carbonation, filling, seaming, pasteurisation, shrink wrapping) capable of 200-400 CPM can be assembled for €300,000-€800,000 using quality used equipment.

Scalability: Choose used equipment that can grow with your brand. A mid-range canning line (400-800 CPM) provides room for growth without the capital intensity of high-speed equipment.

Regulatory compliance: Energy drink production facilities must meet food safety standards (HACCP, BRC/IFS). Used equipment should be evaluated for hygiene design and CIP capability.

Quality differentiation: In a crowded market, product quality and consistency are competitive advantages. Invest in quality mixing equipment and analytical instruments to ensure batch-to-batch consistency.

BottlingScout specialises in helping energy drink producers configure complete used production lines matched to their specific requirements, from start-up capacity to industrial scale.

Frequently asked questions

What speed canning line do I need for an energy drink brand?

For a start-up brand producing 1-5 million cans annually, a 200-400 CPM line is sufficient. For established brands producing 10-50 million cans, 600-1,200 CPM lines are appropriate. Larger brands may require 1,500+ CPM. Growth projections should guide your initial investment.

Can I use the same canning line for energy drinks and other beverages?

Yes, most canning lines can handle multiple beverage types. Energy drinks, soft drinks, beer, hard seltzers, and ready-to-drink cocktails can all be produced on the same equipment. CIP cleaning between products prevents cross-contamination and flavour carryover.

What is the shelf life of canned energy drinks?

Properly processed and sealed canned energy drinks typically have a shelf life of 18-24 months. Shelf life depends on pasteurisation effectiveness, dissolved oxygen levels, seam integrity, and ingredient stability. Quality used equipment with proper DO control achieves commercial shelf life requirements.

Do I need a pasteuriser for energy drinks?

Yes, pasteurisation is standard for commercial energy drink production to ensure microbiological stability. Flash pasteurisers are most common (lower thermal impact on flavours), but tunnel pasteurisers are also used. Some producers use chemical preservatives as an alternative or complement.

The Soft Drink Equipment Market

The global soft drink industry encompasses carbonated soft drinks (CSD), still beverages, juices, flavoured water, iced tea, sports drinks, and functional beverages. This diverse category requires equally diverse filling and packaging solutions, making the used equipment market for soft drink production one of the most varied and active.

Carbonated soft drinks remain the largest segment by volume, requiring specialised equipment for carbonation, counter-pressure filling, and pressure-resistant packaging. Still beverages and juices use simpler filling technology but may require thermal processing (pasteurisation or hot-fill) for shelf stability.

Used soft drink bottling lines frequently become available as major beverage companies consolidate production, upgrade to higher speeds, or shift between packaging formats (glass to PET, bottles to cans). This creates excellent opportunities for independent bottlers, contract packers, and emerging brands to acquire established production technology at accessible price points.

CSD Filling Technology and Carbonation Systems

Carbonation and Mixing Systems: Before filling, CSD products must be mixed and carbonated. Premix systems blend syrup and water before carbonation, while postmix systems add syrup after water is carbonated. Key manufacturers include KHS, Krones, Flottweg, and Alfa Laval.

When evaluating used mixing and carbonation equipment, verify CO2 injection efficiency, deaeration system performance, and brix (sugar concentration) control accuracy. The mixer-carbonator represents a critical quality control point.

Counter-Pressure Filling: CSD filling requires counter-pressure (isobaric) technology. The bottle or can is pressurised with CO2 before filling begins, preventing foaming and CO2 loss. Filling speeds for CSD are typically 10-15% lower than for still products due to the additional pre-pressurisation and post-fill snifting steps.

Hot-Fill Technology: An alternative for non-carbonated soft drinks. Products are heated to 85-92°C and filled hot, with the thermal energy providing pasteurisation. Hot-fill requires specially designed PET bottles with vacuum absorption panels. Used hot-fill lines from Krones, Sidel, and KHS are available for producers of juices, teas, and functional beverages.

Aseptic Cold-Fill: Premium technology for sensitive products. Provides ambient shelf stability without thermal degradation of flavours and vitamins. Used aseptic fillers (Sidel Predis, Krones Contipure, GEA) represent the highest-value segment of the used market.

Packaging Formats for Soft Drinks

Soft drink producers must choose between multiple packaging formats, each requiring different equipment configurations:

PET Bottles: The dominant format globally. Available in sizes from 200ml to 3 litres. PET CSD bottles require thicker walls and pressure-resistant designs compared to still water bottles. Used PET CSD lines typically include blow moulding, filling, capping, and labelling.

Aluminium Cans: The fastest-growing format. Standard sizes include 250ml slim, 330ml, and 500ml. Can CSD filling requires counter-pressure technology with seaming rather than capping. Used canning lines for CSD are in high demand.

Glass Bottles: Primarily used for premium and returnable-bottle markets. Glass CSD filling uses crown cap or screw cap closures. Returnable glass systems require additional equipment (washers, inspectors, decraters).

Carton and Pouch: Tetra Pak and similar formats for juice and still drinks. A niche segment in the used market with limited availability.

When planning a soft drink operation, consider multi-format capability. Some producers operate both PET and can lines to serve different market channels. Used equipment strategies can be particularly effective here, allowing investment in two formats for the price of one new line.

Secondary Processing and Quality Control

Pasteurisation: Tunnel pasteurisers are standard for CSD in glass and cans. Flash (plate) pasteurisers are used for hot-fill PET and inline treatment. Evaluate temperature zone accuracy, conveyor belt condition, and thermal treatment records.

Water Treatment: Soft drink production requires high-quality treated water. Reverse osmosis, UV treatment, and activated carbon filtration systems are essential. These auxiliary systems significantly impact final product quality and should be evaluated carefully.

Quality Lab Equipment: CO2 volume measurement, brix meters, pH monitoring, dissolved oxygen meters, and microbiological testing equipment. While not part of the filling line, these instruments are essential for production control.

Date Coding and Traceability: Laser coders, inkjet printers, and label printing systems for batch tracking and regulatory compliance.

Inspection Systems: Fill level detection (X-ray for cans, camera-based for PET), cap presence/torque verification, label inspection, and foreign object detection. HEUFT, Krones Checkmat, and Pressco are inspection equipment manufacturers whose products are widely available used.

Investment Strategy for Soft Drink Production

Starting or expanding a soft drink bottling operation with used equipment requires careful planning:

Production volume planning: Define your target annual volume and peak daily output. Size equipment at 120-130% of average requirement to accommodate seasonal peaks and preventive maintenance downtime.

Product range considerations: If bottling multiple products (cola, orange, lemon-lime, water), factor in changeover time between products. CIP (Clean-in-Place) cycles between flavours can take 30-60 minutes per changeover.

Typical investment ranges for used CSD lines:

• Small PET line (4,000-8,000 BPH): €200,000-€500,000
• Medium PET line (12,000-24,000 BPH): €500,000-€1,500,000
• Large PET/can line (36,000+ BPH): €1,500,000-€4,000,000+

Return on investment: Used CSD equipment typically delivers payback within 2-4 years for well-managed operations, compared to 5-8 years for new equipment. The lower initial capital requirement also reduces financial risk for new market entrants.

BottlingScout provides technical consultation for soft drink producers, helping match production requirements with available used equipment to create optimal line configurations.

Frequently asked questions

What equipment do I need to start a soft drink bottling operation?

A minimum CSD line includes: water treatment, syrup preparation, mixing and carbonation, filling and capping, labelling, and secondary packaging. For PET, add blow moulding. Auxiliary systems include CIP, compressed air, and CO2 storage. Used equipment can cover all these requirements.

Can a used CSD filler handle both carbonated and still products?

Some modern fillers offer dual-mode operation, but most counter-pressure fillers are optimised for carbonated products. A dedicated gravity or electronic filler is preferred for still beverages. When buying used, specify your product range to ensure equipment compatibility.

What is the difference between hot-fill and aseptic cold-fill?

Hot-fill heats the product to 85-92°C before filling, using thermal energy for pasteurisation but requiring heat-resistant PET bottles. Aseptic cold-fill sterilises the container and product separately, filling at ambient temperature. Aseptic preserves taste and nutrients better but equipment costs are significantly higher.

Brewery Packaging: A Critical Quality Control Point

Beer packaging is widely recognised as the most technically demanding application in the beverage filling industry. Unlike water or soft drinks, beer is a living product that is extremely sensitive to oxygen exposure, light, temperature, and microbiological contamination. Every component of the packaging line must be designed and maintained to protect beer quality throughout the filling process.

The brewing industry operates three primary packaging formats: glass bottles (returnable and one-way), aluminium cans, and PET bottles (primarily for emerging markets). Each format requires specific filling technology, and the choice impacts product shelf life, brand perception, and production costs.

Used brewery packaging lines represent significant value for craft breweries scaling up production, regional breweries expanding capacity, and international brewing groups establishing operations in new markets. The heavy-duty construction required for beer filling means that used brewery equipment often has decades of service life remaining when properly maintained.

Beer Filling Technology: Oxygen Is the Enemy

The primary technical challenge in beer filling is minimising dissolved oxygen (DO) pickup. Oxygen causes beer staling, producing unwanted cardboard-like flavours, darkening colour, and reducing shelf life. Modern beer fillers are designed to achieve total packaged oxygen (TPO) levels below 100 ppb, with higher-specification fillers achieving below 50 ppb.

Counter-pressure (isobaric) filling: Standard for all carbonated beer. The container is evacuated of air, purged with CO2 (often double or triple pre-evacuation), pressurised to filling pressure, and filled under isobaric conditions. After filling, the headspace is fobbed with a high-pressure water jet to create foam that expels residual air before capping.

Key beer filler manufacturers:

• Krones: Modulfill and Volumetic series — the global established manufacturer for brewery fillers
• KHS: Innofill Glass DRS and Innofill Can DVD — designed for low-oxygen filling performance
• GEA (Huppmann/Tuchenhagen): Specialised brewery filling technology with outstanding DO performance
• Bertolaso: Traditional Italian manufacturer with strong presence in wine and beer filling
• Simonazzi (now Sidel): Historical brewery filling installations, widely available in the used market

Fobbing devices: The high-pressure water injection device that creates controlled foam after filling. Critical for expelling headspace oxygen. Condition and alignment of fobbing nozzles significantly impact TPO results.

Under-lid gassing: CO2 injection under the crown cap or can lid immediately before closing. Displaces residual air in the headspace.

Brewery Line Equipment Beyond the Filler

Bottle Washers (returnable glass): Essential for markets using returnable glass systems. Krones Lavatec and KHS Innoclean are the benchmark machines. Evaluate caustic tank condition (wall thickness measurement), spray nozzle coverage, label removal efficiency, and energy consumption. A well-maintained bottle washer operates for 25-35+ years.

Pasteurisation: Tunnel pasteurisers apply precisely controlled heat treatment to filled and sealed containers. Standard for mainstream beer to ensure microbiological stability. Evaluate zone temperature accuracy, belt condition, and water circulation systems. Krones, KHS, and Sander Hansen are primary manufacturers.

Flash Pasteurisation: Inline heat treatment before filling. Increasingly popular for craft beer as it reduces thermal impact on flavour compared to tunnel pasteurisation. Used flash pasteurisers from Alfa Laval and GEA are available.

Bottle Inspectors: Empty bottle inspection (Krones Linatronic, HEUFT InLine IXS) is essential for returnable glass to detect residual liquid, foreign objects, and glass defects. Full bottle inspection (Krones Checkmat, HEUFT VX) verifies fill level, cap presence, and label position.

Crowners and Cappers: Crown cap applicators (Krones, KHS, Arol, Zalkin) for standard beer bottles. Screw cap adapters for craft beer long-neck formats. Verify cap chute and pocket star condition.

Cold Glue Labellers: Traditional paper label application using cold glue (starch-based adhesive). The dominant labelling technology for beer in many markets. Krones Solomatic and KHS Innoket are standards. Check label magazine, glue roller, and gripper cylinder condition.

Craft Brewery Packaging Solutions

The craft brewery revolution has created enormous demand for small to mid-range used packaging equipment:

Entry-level bottling (1,000-5,000 BPH): Semi-automatic or compact automatic lines. Used machines from smaller Italian manufacturers (MBF, GAI, IC Filling Systems) and reconditioned equipment from larger manufacturers. Budget: €50,000-€200,000 for a basic fill-cap-label line.

Growth-stage bottling (5,000-15,000 BPH): Fully automatic rotary lines. Used Krones, KHS, and Simonazzi fillers become accessible at this speed range. Budget: €200,000-€600,000 for a complete glass bottling line.

Craft canning (50-400 CPM): The fastest-growing segment in craft brewery packaging. Used canning lines from Wild Goose, Cask, Oktober, and CFT. Budget: €80,000-€400,000.

Mobile canning: Contract mobile canning services use truck-mounted canning lines that visit breweries for filling runs. Some used mobile canning systems appear in the market. An alternative to owning equipment for very small producers.

Key considerations for craft breweries: Flexibility for multiple formats (bottle sizes, can sizes), easy CIP cleaning between batches, manageable operator skill requirements, and compact footprint for typically space-limited craft brewery premises.

Market Analysis and Acquisition Strategy

Market supply drivers: The ongoing consolidation in the global brewing industry is the primary source of used brewery packaging equipment. When large brewing groups close or restructure production sites, complete lines become available.

Regional market patterns: European breweries (particularly Germany, Belgium, UK, and Czech Republic) are the richest source of used brewery equipment due to the continent's dense brewery landscape and tradition of investing in higher-specification equipment.

Price stability: Used brewery equipment maintains stable value due to the specialised nature of beer filling technology and the heavy-duty construction required. Lines from the 2005-2015 era offer the best value-to-performance ratio.

Complete line vs components: For breweries expanding into packaging from draft-only operations, complete used lines offer the simplest path. For established operations upgrading specific machines, individual components provide targeted improvements.

Due diligence checklist for brewery equipment:

1. Request TPO (Total Packaged Oxygen) measurement records

2. Verify pasteurisation unit (PU) delivery accuracy

3. Inspect CIP system thoroughly (chemical tanks, pumps, valves)

4. Test inspection equipment with known defect samples

5. Verify CO2 recovery system condition (if applicable)

6. Review maintenance records and spare parts consumption history

BottlingScout provides specialised expertise in brewery packaging equipment, helping breweries of all sizes find the right used equipment matched to their specific production requirements and quality standards.

Frequently asked questions

What dissolved oxygen level should a used beer filler achieve?

Modern beer fillers should achieve total packaged oxygen (TPO) below 100 ppb, with higher-specification machines below 50 ppb. When evaluating used fillers, request recent TPO measurement records. Higher oxygen levels may indicate valve wear, seal deterioration, or inadequate CO2 purging that requires remediation.

Is a tunnel pasteuriser necessary for craft beer?

Not always. Many craft breweries rely on proper sanitation and cold-chain distribution instead of pasteurisation. However, for shelf-stable products, export, or warm-climate markets, pasteurisation is essential. Flash pasteurisers offer lower thermal impact than tunnel systems.

What is the minimum investment for a used craft brewery bottling line?

A basic semi-automatic glass bottling line (fill, cap, label) capable of 1,000-2,000 BPH can be acquired used for €50,000-€100,000. Fully automatic lines start at approximately €150,000-€200,000 for 3,000-5,000 BPH capacity.

Can I fill both bottles and cans on the same line?

Generally no — bottle and can filling are separate operations requiring different equipment. However, some upstream (mixing, carbonation, pasteurisation) and downstream (case packing, palletising) equipment can be shared between bottle and can lines operating in the same facility.

Sidel: PET Packaging Equipment Overview

Sidel, part of the Sidel Group (Tetra Laval), is a major manufacturer of PET packaging solutions. Headquartered in Parma, Italy, with major operations in France, Sidel has been active in PET bottle technology development. The company's SBO stretch blow moulder series is the most widely installed PET blow moulding platform in the world.

Sidel's strength lies in its comprehensive approach to PET packaging: from preform design and blow moulding through filling, capping, and labelling. The company's Combi concept — integrating blow moulder, filler, and capper into a single machine block — is a widely used approach for compact, hygienic PET filling systems.

In the used equipment market, Sidel machines are widely present in the used market due to their global installed base and range of models covering every speed and application requirement. Used Sidel SBO blow moulders, in particular, are frequently available in the global secondary market.

Sidel SBO Blow Moulders: Model Overview

The Sidel SBO series has evolved through multiple generations, each improving on energy efficiency, speed, and bottle quality:

SBO 6 to SBO 40: Classic SBO models with 6 to 40 cavities. The SBO 10, SBO 14, SBO 16, and SBO 20 are the most commonly available in the used market. Production speeds range from approximately 9,000 to 72,000 BPH depending on cavity count and bottle size.

SBO Universal: Enhanced platform with improved preform heating (preferential heating capability for non-round bottles) and faster format changes. Popular mid-generation model.

SBO 2 (Second Generation): Introduced advanced features including improved oven design and enhanced stretch blow process control. Widely available in the used market.

SBO Matrix: Current-generation platform with EcoOven (near-infrared heating for 45% energy reduction), independent mould opening, and digital monitoring. Used Matrix machines are increasingly available as producers upgrade.

Evaluation priorities for used SBO machines: Oven lamp hours (target under 5,000 hours per lamp), oven reflector condition, mould locking mechanism, stretching rod assemblies, high-pressure valve system, and preform sorting/feeding system. Request the complete blow recipe library — developing new recipes from scratch is time-consuming and expensive.

Mould sets are a significant cost factor. Each bottle format requires dedicated moulds (€12,000-€30,000+ per set). Verify included mould sets and their condition.

Sidel Filling Technology

Sidel Eurotronica: Widely installed electronic filling platform for water and still beverages. Uses electromagnetic flowmeters for precise volumetric filling. Available in gravity and slight-pressure configurations. The Eurotronica is a widely installed still-water filling platform.

Sidel Predis (Aseptic): Dry preform sterilisation system for aseptic PET filling. Eliminates the need for clean rooms by sterilising preforms with hydrogen peroxide vapour before blow moulding. The Predis-Combi Aseptic system is Sidel's offering for juice, dairy, and sensitive product applications.

Sidel Isobaric Filler: For carbonated beverages. Counter-pressure filling technology maintaining CO2 levels during the filling process.

Sidel Master Line: Integrated solution combining multiple Sidel technologies for high-speed production. Complete Master Lines occasionally appear in the used market from major water bottlers and soft drink producers.

Key evaluation points: For Eurotronica fillers, check flowmeter calibration, valve gasket condition, and product contact surface quality. For aseptic systems, verify H2O2 dosing system condition and decontamination validation records. All Sidel fillers use proprietary control software — verify licence transferability.

Sidel Combi Systems and Integration

The Sidel Combi concept integrates blow moulding, filling, and capping into a single enclosed machine block, connected by a transfer starwheel rather than air conveyors. Benefits include:

• Smaller footprint than separate machines
• Reduced contamination risk (no exposed bottle transport)
• Higher efficiency (no bottle-in-line accumulation needed)
• Lower energy consumption

Sidel Combi Predis: Aseptic variant with integrated preform decontamination. The Sidel offering for sensitive products.

Sidel Combi SBO/CSD: Standard Combi for carbonated and still beverages. Available in speeds from 12,000 to 50,000+ BPH.

Used Combi considerations: When purchasing a used Combi system, the machines are typically not separable — they must be acquired and installed as a complete unit. This is both an advantage (guaranteed integration) and a limitation (no flexibility to mix with other equipment). Combi systems also require specialised service knowledge for the transfer interface between blow moulder and filler.

Complete used Sidel Combi systems are less frequently available than standalone SBO machines, but offer exceptional value when they appear in the market due to their turnkey nature.

Buying Used Sidel Equipment: Market Guide

Market availability: Sidel SBO blow moulders are the most readily available blow moulders in the used market. This is partly due to the enormous global installed base and partly because Sidel actively promotes equipment lifecycle management, including trade-in programmes that feed the secondary market.

Price positioning: Used Sidel equipment is typically priced competitively with KHS and below Krones for comparable specifications. SBO blow moulders from the 2008-2018 era offer outstanding value.

Regional considerations: Sidel has particularly strong installations in water bottling (Middle East, Africa, Asia) and dairy (Europe, Americas). Equipment from these regions regularly enters the used market.

Service infrastructure: Sidel provides global service through its Customer Service organisation. Parts availability is excellent for all currently supported models. Third-party service for Sidel equipment is also well-established.

Software and digital: Newer Sidel machines (Matrix generation) include digital monitoring and predictive maintenance features. Verify that digital service subscriptions are transferable or budget for new agreements.

Recommended acquisition strategy: For PET filling operations, a used Sidel SBO blow moulder paired with either a Sidel Eurotronica (for still products) or a compatible isobaric filler from any manufacturer provides a cost-effective and high-performance solution. BottlingScout can assist in configuring optimal mixed-manufacturer lines that include Sidel core equipment.

Frequently asked questions

What is the most popular used Sidel machine?

The Sidel SBO blow moulder is by far the most traded Sidel machine in the used market. Models from SBO 8 to SBO 20 are the most common, covering speeds from 12,000 to 36,000 BPH. Their reliability and wide installation base make them safe investments.

How does Sidel Combi differ from separate machines?

A Sidel Combi integrates blow moulding, filling, and capping in one machine block, eliminating air conveyors between processes. This reduces footprint, contamination risk, and energy consumption. However, Combi systems cannot be split into separate machines and require specialised service.

Is Sidel aseptic technology available in the used market?

Yes, used Sidel Predis aseptic systems occasionally appear in the market. These are premium acquisitions requiring careful evaluation of the decontamination system. Buyers should verify H2O2 system condition and request validation documentation.

Can Sidel SBO moulds be used on other blow moulders?

No, Sidel SBO moulds are proprietary and not interchangeable with other blow moulder brands. When purchasing a used SBO, the value of included mould sets should be carefully assessed as new moulds represent a significant additional investment.

Glass Bottling: The Premium Packaging Standard

Glass remains the gold standard for premium beverages including wine, spirits, craft beer, and specialty soft drinks. Its impermeability, chemical inertness, and perceived quality make it irreplaceable for many producers despite the growth of PET and aluminium alternatives.

Used glass bottling lines represent excellent value for producers who need reliable equipment without the 12-18 month lead times and premium prices of new installations. The secondary market for glass bottling equipment is well-established, with lines from European producers frequently becoming available as breweries and wineries upgrade capacity or modernise their facilities.

Glass bottling lines differ fundamentally from PET lines in several ways: they handle heavier containers, require bottle washing systems (for returnable glass), operate at generally lower speeds, and must accommodate the greater fragility of glass containers. Understanding these differences is essential when evaluating used equipment.

Returnable vs One-Way Glass Lines

Returnable glass systems are common in European beer markets (Germany, Belgium, Czech Republic) and require additional equipment: depalletisers, uncasers (decraters), bottle washers, and empty bottle inspectors. The bottle washer is often the most critical and expensive component, requiring careful evaluation of caustic tank condition, spray nozzle wear, and label removal efficiency.

Key manufacturers of bottle washers include Krones (Lavatec), KHS (Innoclean), and Barry-Wehmiller. A well-maintained washer can operate for 30+ years, making used units excellent investments.

One-way glass systems are simpler, requiring only depalletising, rinsing, filling, and downstream processing. They are standard for wine, spirits, and markets where returnable systems are not economically viable.

Inspection equipment is essential for both systems. Empty bottle inspectors (Krones Linatronic, HEUFT InLine) check for residual liquid, foreign objects, chipped finishes, and base cracks. These machines should be tested with known defect samples during evaluation.

Speed ranges for glass lines are typically lower than PET: 5,000-15,000 BPH for wine and spirits, 20,000-60,000 BPH for beer and soft drinks on high-speed lines.

Glass Line Filling Technologies

Glass filling technology varies by product type and requires specific expertise during evaluation:

Isobaric (Counter-Pressure) Filling: Standard for carbonated beverages in glass. The bottle is pressurised with CO2 before filling, maintaining carbonation levels. Krones Modulfill, KHS Innofill Glass, and Gruppo Bertolaso are established manufacturers. Check valve condition, CO2 recovery systems, and filling accuracy.

Vacuum Filling: Common for wine and still beverages. Creates a vacuum in the bottle before filling, providing clean and consistent fill levels. Bertolaso, GAI, and MBF are established manufacturers in this segment. Inspect vacuum pump condition and valve sealing.

Gravity Filling: Simplest technology for non-carbonated products. Suitable for water, still wine, and certain food products. Available from virtually all major filling equipment manufacturers.

Hot Fill: Used for products requiring pasteurisation during filling (juices, sauces). Requires temperature-resistant seals and specialised valve materials.

Level Filling: Provides consistent visual fill levels regardless of volume variations. Important for premium products where shelf appearance matters. Common in spirits and premium water bottling.

Downstream Equipment for Glass Lines

After filling and capping/crowning, glass lines require several downstream processing stages:

Pasteurisation: Tunnel pasteurisers are essential for beer and many soft drink applications. These large machines represent significant investments even in the used market. Evaluate spray nozzle condition, temperature zone accuracy, belt tracking, and steam/hot water system efficiency. Krones, KHS, and Sander Hansen are primary manufacturers.

Labelling: Glass bottle labelling options include cold glue (traditional paper labels), self-adhesive, and hot melt. Cold glue labellers from Krones and KHS are widely available on the used market for beer applications. Wine producers typically prefer self-adhesive labellers for front, back, and neck labels.

Case Packing and Palletising: Glass bottles require gentle handling during secondary packaging. Case packers must accommodate the weight of glass, and palletisers need appropriate layer patterns. Integrated systems from Krones, KHS, and SMI are commonly available.

Conveyor Systems: Glass lines use heavier-duty conveyors than PET lines. Slat-band and mat-top conveyors must be evaluated for wear, alignment, and guide rail condition. Accumulation capacity between machine centres is critical for overall line efficiency.

Investment Analysis and Market Trends

The used glass bottling equipment market is influenced by several trends:

Craft brewery growth has increased demand for smaller glass bottling lines (3,000-10,000 BPH), making mid-range used equipment particularly sought after.

Sustainability initiatives are driving renewed interest in returnable glass systems, especially in European markets where deposit schemes are expanding.

Consolidation in the brewing industry regularly releases used glass bottling lines as large groups optimise their production networks.

Typical investment ranges for used glass bottling lines:

• Small wine/spirits lines (1,500-5,000 BPH): €80,000-€300,000
• Medium beer/beverage lines (10,000-25,000 BPH): €500,000-€1,500,000
• Large brewery lines (30,000-60,000 BPH): €1,500,000-€4,000,000+

Glass bottling equipment from established manufacturers (Krones, KHS, Bertolaso) retains value exceptionally well due to heavy-duty construction and long service lives. Lines built in the 2000s-2010s often offer the best value-to-performance ratio in the current market.

Frequently asked questions

Is used glass bottling equipment reliable?

Yes, glass bottling equipment is built for extreme durability. Machines from manufacturers like Krones, KHS, and Bertolaso routinely operate for 20-30+ years. The heavy construction and quality materials used in glass line equipment make it ideal for the secondary market.

Can a glass bottling line be converted from beer to wine?

Partial conversion is possible. The filler typically needs replacement (isobaric to vacuum), and the capper changes from a crowner to a cork/screw cap machine. Labellers and downstream equipment often require only format changes rather than replacement.

What utilities does a glass bottling line require?

Glass lines require compressed air (6-8 bar), steam or hot water for washing and pasteurisation, CO2 for carbonated products, electrical power (typically 380-400V three-phase), and treated water. Utility requirements increase significantly with line speed.

How do I evaluate a used bottle washer?

Key inspection points include: caustic tank wall thickness, spray nozzle condition, label extraction screens, carrier pocket wear, chain tension, drive system condition, and heat exchanger efficiency. Request water and chemical consumption data to benchmark against manufacturer specifications.

KHS Group: Beverage Filling and Packaging Equipment

KHS Group, based in Dortmund, Germany, is a major manufacturer of filling and packaging equipment for the beverage, food, and non-food industries. With a history dating back to 1868 and approximately 5,000 employees worldwide, KHS is a subsidiary of Salzgitter AG and produces bottling equipment used across the beverage, food, and non-food industries.

KHS has earned particular recognition for its innovations in PET technology, including the InnoPET Blomax stretch blow moulder series and nature MultiPack — an adhesive-based multipack solution designed to reduce shrink film usage. The company's filling technology spans the complete range from water and CSD to beer, wine, spirits, and sensitive products.

In the used equipment market, KHS machines are present in many production facilities worldwide. Used KHS equipment is regularly available on the secondary market across various configurations and speed ranges.

KHS Filling Systems: Innofill Range

KHS Innofill Glass DRS: A widely used platform for glass bottle filling. Available in configurations for beer (counter-pressure), soft drinks (CSD), and still products. The DRS (Dual Ring System) separates filling and capping on independent carousels for maximum flexibility and speed. Used Innofill Glass DRS machines from 2008 onwards are available in the secondary market.

KHS Innofill PET DRV: Purpose-built for PET bottle filling. The DRV (Dynamic Ring Valve) technology provides precise volumetric filling with minimal product waste. Available for water, CSD, juice, and sensitive products.

KHS Innofill Can DVD: Counter-pressure filler specifically designed for aluminium can filling. Features KHS's proprietary Dynamic Vacuum Dosing technology for minimal oxygen pickup — critical for beer and sensitive beverages.

KHS Innofill DMG: An older but still widespread filling platform. Many Innofill DMG machines from the 2000s remain in active production worldwide. Established technology with extensive spare parts availability.

Evaluation priorities: For all KHS fillers, check valve gasket condition, product bowl condition, CIP connections, rotary union seals, and control system version. KHS machines typically use Siemens S7 PLCs with KHS application software.

KHS PET Technology: InnoPET Blomax

The KHS InnoPET Blomax series is a stretch blow moulding platform used in PET production.

InnoPET Blomax Series IV: Current generation with AirbackPlus air recycling for significantly reduced compressed air consumption. Available in configurations from 4 to 36 cavities (approximately 6,000 to 72,000 BPH).

InnoPET Blomax Series III: Previous generation, widely available in the used market. documented performance. The Series III is commonly available in the secondary market.

InnoPET Blomax 16 and Blomax 12: Among the most popular models in the used market for mid-range PET production (16,000-32,000 BPH depending on bottle size).

Key inspection points: Oven lamp hours and reflector condition, mould locking mechanism wear, stretching rod alignment, high-pressure valve condition, and preform distribution system. KHS machines feature user-friendly recipe management for quick format changes.

Energy efficiency: KHS blow moulders feature energy efficiency options, particularly models with AirbackPlus technology. This translates to lower operating costs for the end user.

KHS Labelling and Packaging Technology

KHS Innoket Neo: Current-generation modular labelling platform supporting roll-fed, self-adhesive, cold glue, and hot melt labelling technologies. Flexible configuration for multiple label types on a single machine.

KHS Innoket SE: Previous generation, commonly available in the used market. Available in Multifix (cold glue) and Rollfeed variants. Reliable and established in high-speed applications.

KHS Innopack Kisters: Secondary packaging technology. The Kisters brand (acquired by KHS) covers shrink wrapping and multipack solutions. Innopack Kisters SP, TSP, and CSP models are widely available in the used market.

KHS nature MultiPack: Adhesive-based multipack system that bonds cans or PET bottles together without shrink film or plastic rings. A growing presence in the used market as producers upgrade to newer models.

KHS Innopal: Palletising technology for layer-by-layer pallet building. Both conventional and robotic systems are available from KHS.

KHS Innoclean: Bottle washing technology for returnable glass lines. The Innoclean series is known for excellent cleaning performance and low water/chemical consumption.

Purchasing Used KHS Equipment: Strategic Considerations

Market positioning: KHS equipment typically offers excellent value in the used market. While Krones widely used market share, KHS machines are available in various configurations across the secondary market.

Service and support: KHS maintains a global service network with regional centres in Europe, Americas, and Asia-Pacific. Used machine buyers can access KHS service for technical support, spare parts, and commissioning assistance.

Complete line philosophy: KHS is strongest when entire lines are KHS-sourced, benefiting from unified control architecture. However, KHS machines integrate well with mixed-manufacturer lines through standard industrial protocols.

Spare parts availability: Excellent for machines built after 2005. Older equipment (pre-2005) may require longer lead times for specific components. KHS offers a comprehensive online spare parts portal.

Technology transfers: KHS equipment is widely installed across Africa, Middle East, and Asia, where many filling lines were originally sold as complete turnkey projects. This creates a steady supply of well-maintained used equipment in the secondary market.

Recommended evaluation approach: Visit the machine in its current installation whenever possible. Request production records, maintenance logs, and spare parts consumption history. KHS machines benefit from regular factory-recommended maintenance intervals — verify compliance.

Frequently asked questions

How does KHS compare to Krones in the used market?

KHS and Krones produce equipment of comparable quality. KHS typically offers 10-20% lower prices in the used market while delivering similar performance. The choice often comes down to specific model availability, existing line compatibility, and regional service support.

Are KHS spare parts readily available?

Yes, KHS maintains excellent spare parts availability through its global network and online portal. Parts for machines from 2005 onwards are generally available within days. Older equipment may require longer lead times for specific components.

What is KHS InnoPET Blomax known for?

The InnoPET Blomax series is designed for its energy efficiency (particularly with AirbackPlus technology), documented performance, user-friendly operation, and quick format changes. It competes directly with the Krones Contiform series.

Can KHS equipment be serviced by third parties?

While KHS provides official service, many independent service companies specialise in KHS equipment maintenance. Standard Siemens PLC platforms make software maintenance accessible. However, for complex issues, KHS factory support is recommended.

Krones AG: Bottling Equipment Overview

Krones AG, headquartered in Neutraubling, Germany, is a major manufacturer of bottling and packaging equipment. Founded in 1951, Krones employs over 17,000 people worldwide.

Krones equipment is found in virtually every major brewery, water bottler, and beverage producer worldwide. The company covers the entire bottling process from raw material handling through blow moulding, filling, labelling, inspection, packaging, and palletising.

In the used equipment market, Krones machines are widely present in the used equipment market. This guide provides an independent overview of key Krones product lines and what to evaluate when purchasing pre-owned Krones machinery. This guide provides an independent overview of key Krones product lines and what to evaluate when purchasing pre-owned Krones machinery.

Krones Filling Technology: Modulfill, Volumetic, and Craftmate

Krones Modulfill: The current-generation modular filling platform for all beverage types. Available in configurations for water, CSD, beer, juice, and sensitive products. The Modulfill system uses individual servo-driven filling valves for exceptional accuracy and flexibility. Used Modulfill machines from 2010 onwards are available in the secondary market.

Krones Volumetic: The predecessor to Modulfill, widely used in installations from the 1990s-2010s. Available in VF (volumetric flow) and VP (volumetric pressure) variants. these fillers remain suitable performers in the used market, with extensive spare parts availability.

Krones Craftmate: Designed specifically for craft breweries, handling smaller batch sizes with flexible format changes. A growing presence in the used market as craft producers upgrade.

Krones Modulfill HRS (Hot Fill): For hot-fill applications (juices, teas) at temperatures up to 95°C. Specialised valve design and aseptic-capable configurations.

Key evaluation points for used Krones fillers: Check valve gasket condition, flowmeter calibration, CIP circuit integrity, bearing wear on the rotary distributor, and software version. Krones fillers from 2005 onwards typically use Siemens S7 PLCs with Krones-specific software. Ensure the software licence is transferable.

Krones Blow Moulding: Contiform Series

The Krones Contiform is a widely installed PET stretch blow moulding platform. Key models in the used market include:

Contiform S (S8 to S36): Standard series with 8 to 36 blow stations. The S-series offers speeds from approximately 12,000 to 72,000 bottles per hour depending on bottle size. The Contiform S is characterised by its compact footprint and energy-efficient heating system.

Contiform 3 Pro: Third-generation platform with enhanced energy efficiency (AirbackPlus air recycling), improved preform heating (NitroShield), and faster format changes. Used Contiform 3 machines are available in the secondary market.

Contiform 3 Speed: Extended performance variant capable of up to 2,750 bottles per hour per cavity, in higher-speed configurations.

Evaluation priorities: Inspect oven condition (lamp hours, reflector quality), mould condition and available mould sets, stretching rod alignment, high-pressure air compressor integration, and the preform feeding system. Krones provides detailed maintenance schedules — request the service history log.

Blow mould sets are expensive (€15,000-€40,000+ per set), so verify which bottle formats are included with the machine and the condition of each mould set.

Krones Labelling and Inspection Technology

Krones Contiroll: Roll-fed labelling machine for wrap-around OPP labels. A commonly used labeller in high-speed beverage applications. Available in HS (high-speed) and standard variants. Check drum condition, cutting blade wear, and glue application quality.

Krones Topmodul: Modular labelling platform supporting multiple label types (roll-fed, self-adhesive, cold glue) on a single carousel. Extremely flexible for producers handling multiple products.

Krones Autocol: Self-adhesive labelling head, available as standalone or integrated into Topmodul platforms. Standard for premium product labelling.

Krones Sleevematic: Shrink sleeve application system. Growing in popularity for 360-degree decorated containers.

Krones Linatronic: Empty container inspection system. Uses multiple camera systems to detect finish damage, base cracks, residual liquid, and foreign objects. Essential for returnable glass lines. The Linatronic AI (with deep learning) is the latest generation.

Krones Checkmat: Full container inspection for fill level, cap presence/position, label position, date code verification, and foreign object detection. The Checkmat FM-A (fill monitoring) uses X-ray technology for precise level measurement.

Note on software: Krones inspection systems use proprietary software. Verify that all software licences, inspection recipes, and configuration files are included with any used purchase.

Buying Used Krones Equipment: Practical Recommendations

When purchasing used Krones equipment, consider the following:

Spare parts: Krones operates a global spare parts network. Parts for machines built after 2000 are generally readily available. For older equipment (pre-2000), check specific component availability before purchase. Krones also offers refurbished spare parts through their service division.

Service support: Krones provides worldwide service and technical support. Used machine buyers can access Krones service for installation, commissioning, and ongoing maintenance. This is a significant advantage over less established manufacturers.

Software and licences: Krones machines run on the Krones SitePilot automation platform (newer machines) or Siemens PLC with Krones application software (older machines). Verify that all software licences are properly transferred with the machine sale.

Complete lines vs individual machines: Krones equipment integrates most directly with other Krones machines due to consistent control architecture and communication protocols. However, Krones machines can be integrated into mixed-manufacturer lines with appropriate interface engineering.

Typical market availability: Used Krones fillers, labellers, and inspection systems are regularly available. Complete Krones lines are less common and sell quickly. Blow moulders (Contiform) are moderately available. Krones packaging equipment (Variopac, Modulpal) is widely available in the used market.

BottlingScout regularly lists used Krones equipment with technical specifications, production year and stated condition.

Frequently asked questions

Are Krones spare parts available for older machines?

Krones maintains spare parts for most machines built after 2000. For machines from the 1990s, some components may require longer lead times or aftermarket alternatives. Krones also offers refurbished parts and upgrade kits for older equipment.

What is the typical lifespan of a Krones filling machine?

Krones fillers routinely operate for 20-30 years with proper maintenance. The mechanical construction is extremely robust. Key wear items (valve gaskets, bearings, O-rings) are replaced during regular maintenance intervals. Many Krones Volumetic fillers from the 1990s remain in active production.

Can Krones equipment be integrated with other manufacturers?

Yes. While Krones-to-Krones integration is simplest, Krones machines use standard industrial communication protocols (Profinet, Profibus) and can be integrated with equipment from any manufacturer. Interface engineering may be required for mixed-line configurations.

What makes Krones equipment more expensive than competitors?

Used Krones equipment often lists at higher prices than smaller platforms, reflecting build specifications, extensive R&D investment, global service network, and spare-parts availability. In the used market, Krones equipment retains resale value on the used market.

The Canning Revolution: Why Aluminium Cans Are Booming

The aluminium can has experienced a remarkable renaissance in the beverage industry. Once primarily associated with mass-market beer and soft drinks, cans are now the fastest-growing packaging format across virtually every beverage category including craft beer, hard seltzers, ready-to-drink cocktails, energy drinks, cold brew coffee, and even wine.

This growth is driven by several factors: high recyclability (aluminium is recyclable with no quality loss), effective product protection (complete light and oxygen barrier), consumer convenience, and increasingly positive brand perception. The global canned beverage market is projected to continue growing at 5-6% annually through 2030.

For producers looking to enter the canned beverage market or expand existing capacity, used canning lines offer significant advantages. New canning equipment typically requires 8-14 months lead time, while used lines can be operational within 2-4 months of purchase. The cost savings compared to new equipment range from 40-65%, making market entry feasible for smaller producers.

Core Components of a Canning Line

Depalletiser: Receives bulk empty cans from pallets and feeds them to the line. High-level depalletisers (sweeping type) are standard for speeds above 20,000 CPH. Check sweep bar condition and can orientation systems.

Can Rinser/Ioniser: Cleans empty cans before filling using air, ionised air, or water rinse. Essential for product quality and safety.

Counter-Pressure Filler: The core of any canning line. Cans are purged with CO2, pressurised, filled from bottom up to minimise oxygen pickup. Key manufacturers include KHS (Innofill Can), Krones (Modulfill Can), CFT, Wild Goose, and Codi. Evaluate fill accuracy, valve condition, and CO2 consumption.

Seamer: Applies the can end (lid) using a double-seaming operation. Seamers from Angelus, Ferrum, Pneumatic Scale Angelus, and Oktober are standard. Seam quality is critical for product shelf life. Request recent seam teardown reports and check tooling wear.

Lid Dispenser and Applicator: Feeds can ends to the seamer. Check magazine capacity, feed reliability, and end handling for different lid sizes.

Pasteuriser (for beer and certain beverages): Tunnel pasteuriser or flash pasteuriser depending on product requirements. Evaluate temperature control accuracy and zone consistency.

Secondary Packaging: Hi-cone applicators, shrink wrappers, tray packers, or variety pack systems depending on market requirements.

Canning Line Speeds and Formats

Used canning lines are available across a wide speed range to suit different production requirements:

Micro/Craft Lines (50-200 CPM): Manual or semi-automatic systems from manufacturers like Wild Goose, Cask, and Oktober. Ideal for craft breweries producing 5,000-50,000 hectolitres annually. These compact systems handle standard 330ml and 500ml cans.

Mid-Range Lines (200-800 CPM): Fully automatic lines suitable for regional breweries and beverage producers. Equipment from CFT, KHS, and Krones handles multiple can sizes (200ml to 568ml) with reasonable changeover times. These represent the sweet spot in the used market.

High-Speed Lines (800-2,500+ CPM): Industrial-scale canning lines from KHS and Krones for major breweries and soft drink producers. These lines require significant infrastructure and are typically only cost-effective at production volumes exceeding 500,000 hectolitres annually.

Can Formats: Standard can sizes include 150ml (slim), 200ml, 250ml (slim and standard), 330ml, 355ml (US standard), 440ml, 473ml (US pint), 500ml, and 568ml (Imperial pint). When purchasing used equipment, verify which formats the line can accommodate and the cost of changeover parts for additional sizes.

Sleek and Slim Cans: The trend toward slim and sleek can formats (particularly for energy drinks and mixers) requires specific tooling. Verify format compatibility before purchase.

Quality Control and Seam Integrity

Seam quality is the single most critical factor in canned beverage production. A faulty seam can lead to product contamination, spoilage, and recall — making seamer evaluation the highest priority when purchasing used canning equipment.

Double Seam Parameters: The double seam is formed in two operations. First operation rolls the can end curl under the body flange. Second operation compresses the seam tight. Critical measurements include: seam height, seam thickness, body hook length, cover hook length, overlap percentage, and tightness rating.

Inspection Equipment: Every canning line should include seam inspection equipment. Manual seam teardown tools, seam projectors, and automated seam vision systems (from HEUFT, Pressco, or Applied Vision) ensure consistent quality.

Fill Level Detection: X-ray, gamma, or capacitive fill level inspection systems verify correct fill volumes. These systems also detect foreign objects in filled cans.

Pressure Testing: For carbonated products, can pressure testing systems verify adequate carbonation and detect leaking seams before packaging.

When evaluating used canning equipment, request recent QC records, seam measurement logs, and maintenance history for the seamer. A well-maintained seamer from an established manufacturer (Angelus, Ferrum) will produce millions of perfect seams over its lifetime.

Market Analysis and Investment Guide

The used canning equipment market has tightened significantly since 2020 due to the explosive growth of canned beverages. However, opportunities remain as larger producers upgrade to higher-speed equipment and release mid-range lines.

Current market pricing for used canning lines:

• Craft/micro lines (50-150 CPM): €80,000-€250,000
• Mid-range automatic lines (200-600 CPM): €400,000-€1,200,000
• High-speed industrial lines (800+ CPM): €1,500,000-€5,000,000+

Energy drinks, hard seltzers, and RTD cocktails have created enormous demand for canning capacity. Producers in these segments should act quickly when suitable used equipment becomes available.

Key evaluation priorities when purchasing a used canning line:

1. Seamer condition and seam quality history

2. Filler valve condition and fill accuracy

3. CO2 consumption efficiency

4. Can format flexibility

5. Control system age and spare part availability

6. Overall line OEE history

BottlingScout maintains a continuously updated inventory of used canning equipment worldwide.

Frequently asked questions

What is the minimum viable speed for a commercial canning line?

For craft producers, lines starting at 50-100 cans per minute (3,000-6,000 CPH) are commercially viable. For mainstream beverage production, minimum 400-600 CPM is recommended for acceptable unit economics. The ideal speed depends on your annual volume projections.

Can a used canning line handle both standard and slim cans?

Many modern fillers and seamers can accommodate multiple can diameters with changeover parts. However, this must be verified for each specific machine. Changeover kits for the seamer (seaming rolls and chucks) and filler (can handling components) typically cost €5,000-€20,000 per additional format.

How critical is dissolved oxygen control in canning?

Extremely critical. Dissolved oxygen (DO) levels should be below 50 ppb for beer and below 100 ppb for most carbonated beverages. The filler design, CO2 pre-purge quality, and under-lid gassing system all impact DO pickup. Request DO measurement data when evaluating used canning fillers.

What are the main differences between a canning line and a bottling line?

Canning lines use seamers instead of cappers, handle lighter containers, typically operate at higher speeds, and require different secondary packaging (hi-cone, shrink multipacks). The filling principle is similar (counter-pressure for CSD) but valve design and can handling differ significantly from bottle filling.

Why PET widely used the Beverage Industry

PET (Polyethylene Terephthalate) has become the most widely used packaging material in the global beverage industry. Its combination of lightweight construction, shatter resistance, recyclability, and cost efficiency has made it the default choice for water, soft drinks, juices, and increasingly for beer, wine, and dairy products.

The global PET bottle market continues to expand, driven by population growth, urbanisation, and the shift from glass and metal packaging in emerging markets. For producers entering new markets or expanding capacity, used PET filling lines offer a cost-effective alternative to new equipment, often at 40-60% of the original investment.

A complete PET filling line typically includes: preform storage and feeding, blow moulding (stretch blow moulding), air conveying, rinsing, filling, capping, labelling (sleeve or adhesive), date coding, shrink wrapping or case packing, and palletising. Each section must be evaluated independently when purchasing used equipment.

Key Components of a Used PET Filling Line

Blow Moulding Machines: The heart of any PET line. Rotary stretch blow moulders from manufacturers like Sidel (SBO series), KHS (InnoPET Blomax), Krones (Contiform), and SIPA handle high-speed production from 6,000 to 80,000+ bottles per hour. When evaluating used blow moulders, inspect oven lamp condition, mould wear, stretching rod alignment, and compressed air system efficiency.

Rinsers and Fillers: PET fillers operate primarily with isobaric (counter-pressure) technology for carbonated beverages or gravity/flow-meter technology for still products. Key manufacturers include Krones (Modulfill, Volumetic), KHS (Innofill), Sidel (Eurotronica), and GEA. Inspect valve seats, flowmeters, CIP connections, and filling accuracy across all heads.

Cappers: Screw cappers are standard for PET applications. Check torque consistency, chuck wear, and cap feeding systems. Arol, Zalkin, and Krones Checkmat are common brands in the used market.

Labellers: Depending on the product, PET lines may use roll-fed (OPP), self-adhesive, or sleeve labelling. Krones, Sidel, P.E. Labellers, and Sacmi are established manufacturers. Evaluate label positioning accuracy and changeover flexibility.

Evaluating Line Speed and Integration

One of the most critical factors when purchasing a used PET filling line is ensuring all components are speed-matched. A common mistake is acquiring a high-speed filler without verifying that upstream and downstream equipment can sustain the same throughput.

For example, a 24,000 BPH filler requires a blow moulder capable of at least 26,000-28,000 BPH to account for efficiency losses. Similarly, the labeller, packer, and palletiser must handle the output speed with adequate buffer capacity.

Conveyor integration is equally important. PET bottles are typically transported by air conveyors from the blow moulder to the filler, then by slat-band or mat-top conveyors through downstream equipment. Check conveyor condition, guide rail adjustability, and accumulation table capacity.

Control system compatibility must be verified. Older lines may run on Siemens S5 or S7-300 PLCs, while newer equipment uses S7-1500 or Allen-Bradley platforms. Ensure spare parts availability and the possibility of software updates or migration.

Always request production reports showing actual OEE (Overall Equipment Effectiveness) data rather than theoretical speeds.

PET Line Configurations by Product Type

Still Water: The simplest PET filling application. Gravity or electronic volumetric fillers operating at ambient temperature. Lines can achieve the highest speeds (up to 80,000 BPH on large rotary systems). Hot-fill is used for certain flavoured water products.

Carbonated Soft Drinks (CSD): Require isobaric (counter-pressure) filling to maintain CO2 levels. Pre-cooling and deaeration systems are essential. Counter-pressure fillers from Krones, KHS, and Sidel are the standard. CSD lines also require more robust capping to prevent gas loss.

Juice and Isotonic: Often filled using hot-fill technology (85-90°C) or aseptic filling. Hot-fill PET requires specially designed bottles with vacuum panels. Aseptic PET filling (e.g., Sidel Aseptic Combi) represents the premium end of the used market.

Beer in PET: Growing segment in Eastern Europe and emerging markets. Requires multi-layer PET bottles with oxygen barriers, counter-pressure filling, and often nitrogen dosing. Specialised equipment from KHS and Krones is available in the used market.

Oil and Liquid Foods: Volumetric or mass-flow filling technology. Higher viscosity products require positive displacement pumps and specialised valve configurations.

Cost Considerations and Market Availability

The used PET filling line market is one of the most active segments in the secondary equipment sector. Lines become available when producers upgrade capacity, change product formats, or consolidate production facilities.

Price ranges for used PET lines vary significantly based on speed, age, condition, and manufacturer:

• Entry-level lines (4,000-8,000 BPH): €150,000-€400,000
• Mid-range lines (12,000-24,000 BPH): €400,000-€1,200,000
• High-speed lines (36,000-60,000 BPH): €1,000,000-€3,000,000+

Additional costs to budget include: dismantling and transport (€30,000-€100,000 depending on distance), installation and commissioning (€50,000-€150,000), spare parts inventory, and potential refurbishment of wear components.

Working with a specialised dealer like BottlingScout gives access to equipment listed with technical specifications, photos and stated condition.

Frequently asked questions

What speed should I look for in a used PET filling line?

Speed depends on your production requirements. For small to medium producers, 6,000-12,000 BPH is typical. Medium operations target 18,000-36,000 BPH. Large-scale producers look for 40,000+ BPH. Always match blow moulder capacity to filler speed with a 10-15% buffer.

Can a used PET line be converted from one product to another?

Yes, many PET lines can be adapted. Converting from still water to CSD requires replacing the filler with an isobaric model and adding carbonation equipment. Bottle format changes require new blow moulds and conveyor adjustments. Label changes are usually the simplest modification.

What is the typical lifespan of a PET filling line?

Well-maintained PET filling lines can operate for 15-25 years. Key wear components (blow moulder lamps, filler valves, labeller components) require periodic replacement, but the mechanical structure and main drives have very long service lives. Lines from established manufacturers like Krones, Sidel, and KHS retain value particularly well.

How long does it take to install a used PET filling line?

Installation typically takes 4-8 weeks depending on line complexity, site preparation requirements, and whether utilities (compressed air, water, electricity) are already available. Commissioning and operator training add another 1-2 weeks.

Understanding Filling Machine Technologies

Filling machines are the central and most critical component of any bottling or canning operation. The choice of filling technology directly impacts product quality, production speed, operational efficiency, and total cost of ownership. Understanding the different filling principles is essential for making informed purchasing decisions in the used equipment market.

Filling machines can be categorised by several criteria: filling principle (gravity, pressure, vacuum, volumetric, mass flow), product type (still, carbonated, viscous, foaming), container type (glass, PET, can, pouch), and speed range (linear machines for low speed, rotary for medium to high speed).

The global used filling machine market is one of the most active segments in secondary processing equipment. Fillers become available when producers upgrade capacity, change product types, optimise line speeds, or consolidate operations. Quality used fillers from established manufacturers can deliver 15-25+ years of reliable service, making them outstanding investments.

Gravity and Low-Pressure Filling

Gravity filling is the simplest and most economical filling technology. Product flows from an elevated tank into the container by gravity alone. Used for non-carbonated, non-viscous products such as still water, wine, and thin liquid foods.

Advantages: Simple construction, easy maintenance, low operating costs, minimal product stress. Limitations: Slower than pressure-based systems, not suitable for carbonated or viscous products.

Slight pressure/Light depression filling: A variation where gentle air pressure assists filling from above, or slight vacuum from below accelerates fill speed. Bridges the gap between pure gravity and full isobaric systems.

Key manufacturers: GAI, MBF, CFT, Bertolaso, and budget-oriented Asian manufacturers. Premium gravity fillers from European manufacturers like Bertolaso and GAI are excellent used market acquisitions for wine and artisanal producers.

Evaluation priorities: Tank/bowl condition (welds, surface finish), valve gasket wear, level control system accuracy, and frame/carousel bearing condition.

Isobaric (Counter-Pressure) Filling

Isobaric filling is the standard technology for all carbonated beverages (beer, CSD, sparkling water, sparkling wine). The process involves: pressurising the container with CO2 to match the filling pressure, opening the liquid valve to allow product to flow under equal pressure, and finally releasing residual gas (snifting) before capping.

This technology prevents CO2 breakout and foaming during filling, maintaining product carbonation levels and ensuring clean, accurate fills.

Mechanical vs Electronic: Older isobaric fillers use mechanical (pneumatic) valve control with spring-loaded filling elements. Modern electronic fillers use individually controlled servo valves with electronic flowmeters for precise volumetric filling. Both types are widely available in the used market.

Key manufacturers and models:

• Krones: Modulfill, Volumetic VP
• KHS: Innofill Glass DRS, Innofill PET DRV, Innofill Can DVD
• Sidel: Various isobaric platforms
• GEA (Huppmann): For beer filling
• Bertolaso: Traditional beer and CSD fillers

Speed ranges: From 5,000 BPH (small rotary) to 80,000+ BPH (large rotary with 120+ filling valves). Linear isobaric fillers are available for very small operations (1,000-3,000 BPH).

Critical evaluation points: CO2 consumption rate, filling valve gasket condition, flowmeter calibration (electronic fillers), CIP circuit integrity, rotary union condition, and PLC/control system version.

Volumetric and Mass-Flow Filling

Electronic volumetric filling uses electromagnetic flowmeters to measure exact product volume dispensed into each container. This technology provides exceptional accuracy (±0.5% or better) and flexibility for multiple container sizes without mechanical adjustments.

Mass-flow filling uses Coriolis flowmeters to measure product mass rather than volume. High accuracy for products with varying densities or temperatures. Commonly used for high-value products.

Weight-based filling: Uses load cells under each filling station to fill by net weight. Excellent for viscous products, sauces, and high-value liquids where accuracy directly impacts profitability.

Piston filling: Positive displacement technology for viscous products (sauces, creams, pastes). Each stroke delivers a precise volume. Available from manufacturers like Serac, Bosch (now Syntegon), and Tetra Pak.

Time-pressure filling: Simplest electronic technology — fills for a set time at constant pressure. Adequate for non-critical applications but less accurate than volumetric methods.

Hot-fill systems: Specialised fillers operating at 85-95°C for products requiring thermal pasteurisation during filling. Require temperature-resistant valve materials and careful thermal management. Krones, Sidel, and KHS offer hot-fill configurations.

Evaluation note: For electronic fillers, verify that the control software version is current and that all filling recipes/programs are included. Sensor calibration records should be reviewed to ensure measurement accuracy.

Choosing the Right Used Filler: Decision Framework

Selecting the right used filling machine requires matching technology to your specific requirements. Consider the following framework:

Step 1 — Product type: Carbonated products require isobaric technology. Still products can use gravity, electronic volumetric, or vacuum. Viscous products need piston or mass-flow fillers. Sensitive products may require aseptic capability.

Step 2 — Container type: Glass bottles, PET bottles, cans, and pouches each require specific handling. Some fillers are dedicated to one container type; others can be adapted.

Step 3 — Speed requirement: Define your required output in containers per hour. Size the filler at 120% of average demand to account for efficiency losses and peak requirements.

Step 4 — Manufacturer preference: For integration with existing equipment, matching manufacturers is advantageous. For standalone installations, focus on the best available machine regardless of brand.

Step 5 — Budget allocation: Allocate 30-40% of total line budget to the filler, as it is the most critical component. Never compromise on filler quality to save costs elsewhere.

Price ranges for used fillers:

• Linear fillers (1,000-5,000 BPH): €20,000-€80,000
• Small rotary (5,000-15,000 BPH): €80,000-€250,000
• Medium rotary (15,000-36,000 BPH): €250,000-€600,000
• Large rotary (36,000-80,000+ BPH): €600,000-€2,000,000+

BottlingScout maintains the largest curated inventory of verified used filling machines, covering all technologies and speed ranges from the world's established manufacturer.

Frequently asked questions

What is the most versatile type of used filling machine?

Electronic volumetric fillers offer the greatest versatility. They handle multiple container sizes without mechanical changes, accommodate various still products, and provide excellent accuracy. For carbonated products, electronic isobaric fillers with flow meters provide similar flexibility.

How long do used filling machines last?

Quality filling machines from manufacturers like Krones, KHS, Sidel, and Bertolaso routinely operate for 20-30+ years. The mechanical frame and main structure are virtually indestructible. Regular replacement of wear parts (gaskets, O-rings, sensors) maintains performance throughout the machine lifecycle.

Can a used filler be retrofitted for different products?

Often yes, depending on the required change. Converting a gravity filler to isobaric requires significant modification. Converting between different still products typically requires only CIP cleaning and recipe adjustment. Consult the manufacturer or an experienced dealer for specific conversion feasibility.

What is the difference between mechanical and electronic filling valves?

Mechanical valves use springs and pneumatic actuators for fixed-volume fills. Electronic valves use servo motors and flowmeters for programmable fills. Electronic valves offer superior accuracy, flexibility, and data logging but are more complex. Both technologies are established.

Should I buy a monoblock or separate filler and capper?

Monoblocks (integrated filler-capper) save space and eliminate bottle transfer between machines. Separate machines offer more flexibility for maintenance and format changes. For speeds above 20,000 BPH, monoblocks are standard. For lower speeds, either configuration works well.