GEPP expands returnable packaging with Sidel to cut virgin plastic use and boost

MEXICO – Grupo GEPP, PepsiCo’s exclusive bottler in Mexico, has expanded its returnable packaging operations through the installation of advanced PET and glass bottling lines supplied by Sidel, aiming to significantly reduce the use of virgin plastic and strengthen circular packaging practices.

The new returnable lines, installed across several GEPP production sites, are a major step toward the company’s goal of doubling the share of returnable packaging from 10% to 20% by 2030, part of PepsiCo’s global environmental strategy.

These returnable PET and glass solutions help GEPP cut raw material usage, lower emissions, and increase the share of recycled content in its packaging.

Sidel’s technology includes the EvoFILL Glass, a highly hygienic level probe filler that provides superior flexibility across formats, and the Hydra bottle washer, designed to optimize washing efficiency while reducing water and chemical consumption, ultimately lowering the total cost of ownership.

The partnership began in 2018 when Sidel installed a partial returnable glass bottle (RGB) line at GEPP’s Puebla plant.

Successive projects followed: a combined returnable PET and glass line in Apodaca (2019), a full PET returnable line in Guadalajara (2020), and both PET and glass returnable lines in Merida (2021).

These lines are designed for flexibility, with capabilities to handle multiple sizes, such as 2L, 2.5L, and 3L bottles, and future integration with additional formats.

This continued collaboration with Sidel has allowed GEPP to capture nearly 30% of incremental PET volume through returnable formats, avoiding significant amounts of virgin plastic.

From 2018 to 2023, GEPP increased the volume of returnable packaging in PET and glass by 73.3%, rising from a baseline index of 100 to 173.3.

The returnable packaging expansion is part of GEPP’s broader sustainability efforts. In partnership with ECOCE, a local non-profit promoting recycling, GEPP helps recover six out of every ten bottles produced in Mexico, one of the highest recovery rates globally.

This has enabled the company to increase its recycled PET (rPET) content to 26% by the end of 2023.

In 2018, GEPP also introduced a universal returnable glass bottle to streamline production and cut material waste.

With support from Sidel’s reliable engineering and sustainability-focused solutions, GEPP continues to lead in developing a circular plastic economy in Mexico while meeting rising consumer demand for eco-friendly packaging.

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