Sidel presents EvoDECO® Next, its new next-generation reel-fed labelling solution, which combines high production performance with greater design freedom and significantly lower material consumption. The use of partial labels on a reel platform enables beverage producers to consume less material and show more of the container, achieving a premium and distinctive brand expression without compromising the robustness required for industrial production.
“With EvoDECO Next, we have reimagined reel-fed labelling. Today, manufacturers no longer have to choose between industrial efficiency, reduced material consumption and the use of high-impact decorations. By introducing partial labels on a simplified reel architecture, we help our customers use less material and create new branding opportunities, while always maintaining the level of performance required by production lines,” explains Anne Philippe Lafon, Sidel Labelling Product Manager.
A response to the evolution of PET packaging
PET packaging continues to move towards greater efficiency and material circularity, while brands seek to differentiate themselves more effectively on the shelves. Most of the industry’s innovations in lightweighting have focused on the bottle as a whole, from the neck to the body and down to the base. EvoDECO Next, on the other hand, extends this concept to decoration as well, treating the label as an additional optimisable component of the packaging.
Traditionally associated with wrap-around decoration, reel-fed labelling can now also be used with smaller partial labels thanks to EvoDECO Next. By revealing a larger area of the bottle, manufacturers can integrate the shape of the container, the transparent PET and the liquid into the product’s visual identity. The result is a premium aesthetic that also involves using less material to create the label.
Less material, more brand impact
Depending on the type of decoration selected, Sidel helps manufacturers reduce the surface area of the label, achieving a reduction of up to 75% compared to traditional wrap-around labels. This result is possible with the 90-degree configuration shown, while the 180-degree configuration reduces the label area by 50%.
For companies that produce large volumes, partial labelling translates into significant savings. In the example calculated by Sidel, switching from a full wrap-around label to a partial 90-degree label reduced the consumption of biaxially oriented polypropylene (BOPP) by 208.4 tonnes per year, cut the associated CO₂ emissions by 346 tonnes and generated annual savings of approximately €723,000 on raw materials1.
This approach also supports Sidel’s JUST label concept, which combines sustainability, branding and reduced Total Cost of Ownership with simpler technology. By making the uncovered part of the bottle an intentional design choice, manufacturers can reduce material consumption while maintaining an appealing shelf presence.
Integrated technology to streamline production performance
EvoDECO Next was designed as an integrated platform rather than a simple reel-fed labeller adapted for shorter labels. Its architecture integrates Cutter 2.0, Smart Buffer, and Smart Camera innovations with high-speed format changeovers, ensuring that feeding, cutting, transfer, and control operations work in perfect synergy.
At the heart of this new partial labelling concept is the new cutting system, located directly on the transfer drum. The rotary cutting device handles shorter labels using two blades that cut more rapidly at high speeds.
The Smart Buffer is designed to accommodate reel changes without altering production speed. Its streamlined configuration requires no extra footprint or changes to the standard film path, allowing splicing operations to be performed at nominal speed and helping to safeguard overall production efficiency.
Meanwhile, the Smart Camera enables label handling without reference marks. Eliminating these marks and the traditional clear zone increases flexibility regarding raw materials and label design, creating further opportunities for material savings. Dedicated software enables self-correction, improves auto-homing, and enhances diagnostics.
New high-speed format changeover parts further boost machine autonomy and process reliability. An optimized sliding surface and air-knife system minimize glue cross-contamination and label stress, helping to extend machine runtime fivefold and reduce unplanned downtime.
Simplified operations from reel to label
EvoDECO Next can also be paired with Sidel’s CoboREEL® automated reel handling solution, which reduces operator intervention, offers an integrated traceability system, and enables autonomous production for up to 18 reels.
Within the labeling station, Sidel has also streamlined key elements to facilitate faster format changeovers, easier maintenance, and consistent productivity.
Leveraging Sidel’s more than 50 years of experience in labeling—along with over 330 EvoDECO machines sold since launch and more than 5,000 Sidel labelers installed worldwide—EvoDECO Next extends packaging optimization beyond PET bottles. It helps producers maximize the value of every single label through reduced material consumption, greater design freedom, and streamlined production.
- Hypothetical data used for the calculation: a production line with a speed of 61,000 bph, producing approximately 459 million bottles per year. Label surface area reduced from 20,160 mm² to 5,040 mm² per bottle by switching from a full wrap-around label to a partial label with a 90-degree configuration. Cost and CO₂ savings are based on Sidel’s model assumptions and may vary depending on product type, material specifications, and operating conditions. ↩︎
