Expanding Returnable PET and Glass Bottling Lines to Strengthen Sustainability Goals
Sidel supported Grupo GEPP, PepsiCo’s exclusive bottler in Mexico, to install expanded returnable PET and glass bottling lines to meet growing consumer demand and sustainability goals.
Grupo GEPP operates 44 production facilities dedicated to the manufacturing and distribution of renowned international brands, including Gatorade, Lipton, Pepsi, and 7Up and owns the brands Epura and Garci-Crespo. With a workforce exceeding 46,000 employees, Grupo GEPP stands as one of the largest private sector employers in Mexico. In 2014 and 2021, PepsiCo awarded GEPP the global ‘Bottler of the Year’ award.
In line with its strong commitment to sustainability, GEPP adopted PepsiCo’s strategy in 2018 to reduce the use of virgin plastics.
Reusability plays a key role in supporting PepsiCo’s broader environmental goals, including reducing first-use plastic per serving by 50%, increasing returnable packages from 10% to 20% by 2030 and achieving net zero emissions by 2040.
Returnable PET and glass lines – delivering greater flexibility and eco-friendly solutions
GEPP chose to partner with Sidel, recognising the company’s proven expertise in implementing returnable bottling solutions and the performance advantages of integrated technologies.
In 2018, Sidel supported with the installation of a partial returnable glass bottle (RGB) line at GEPP’s Puebla facility. Building on this success, a combined returnable PET and glass line was commissioned in Apodaca in 2019. In 2020, Sidel delivered a complete returnable PET line in Guadalajara, designed to handle 2L, 2.5L, and 3L formats, with built-in capability to accommodate RGB in the future. And 2021, Sidel also delivered a new returnable PET line and glass line in Merida.
The returnable PET and glass lines feature the innovative EvoFILL Glass, an advanced level probe filler that combines optimal hygienic conditions with greater flexibility, and the Hydra bottle washer, which enhances washing effectiveness while reducing chemical and water consumption, as well as the total cost of ownership (TCO).
“This ongoing collaboration exemplifies how long-term partnerships—grounded in reliability, service excellence, and technical knowledge-sharing—can enhance operational efficiency, support sustainable business practices, and help customers successfully navigate the evolving demands of the beverage industry,” comments Ascención Sánchez, Sidel’s Account Manager.
Prioritising sustainability
GEPP has been a pioneer and a key player in the creation of a true circular plastic economy in Mexico. Through ECOCE, a non-profit association that promotes packaging recycling, GEPP has contributed to collecting and recovering 6 out of every 10 bottles produced by the industry.
This recovery rate – currently the third highest in the world – has enabled GEPP to significantly increase the incorporation of recycled PET (rPET) used within its packaging, reaching 26% by the end of 2023, while dramatically reducing the use of PET resin.
The reduction in the use of raw materials is also driven by the growth of GEPP’s returnable bottle portfolio. The company has continued expanding its capabilities to offer consumers beverage options in returnable glass bottles and plastic returnable bottles.
Through its partnership with Sidel to strengthen its returnable packaging operations, this has enabled GEPP to capture nearly 30% of the incremental PET volume achieved by the business, thereby avoiding the use of virgin resin.
Between 2018 and 2023, GEPP achieved a 73.3% increase in the volume of returnable packaging in PET and glass, growing from a baseline of 100% in 2018 to 173.3% in 2023[1]. This growth reflects the company’s continued investment in sustainable packaging alternatives and its commitment to reducing the use of raw materials.
In 2018, GEPP launched the universal returnable glass bottle that makes beverage production more efficient and agile, while also contributing to the reduction and recycling of materials, mitigating the impact on the environment.
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