“Faktor 101” – the Next Generation of the PET Bottle -- interpack 2026

Together with Husky Technologies, the KHS Group from Dortmund, Germany, has launched a new generation of PET bottles for still beverages! Weighing just 5.89 grams with a volume of 591 milliliters, it is among the lightest PET containers in the world – yet it remains stable, reliable, and brand-ready.

More Sustainability Through Less Material

The trend toward so-called "lightweighting" is not new – but KHS and the Canada-based technology provider and service company Husky are taking it to the next level with this innovation under the name "Faktor 101". By consistently reducing material usage by 30%, both plastic consumption is lowered and the carbon footprint across the entire supply chain is significantly reduced.

On the right is the bottle design based on the “Faktor 101” concept, next to its predecessor “Faktor 100”.

The predecessor Faktor 100 (left) was successfully further developed into the Faktor 101 concept.
Image: Jörg Schwalfenberg

“With such extreme lightweighting, the so-called topload is particularly important. This value indicates how much vertical load the bottle can withstand. It determines whether the container can be stacked and transported without damage,” says KHS packaging developer Fabian Osterhold.

Fabian Osterhold, Packaging Developer, KHS
Image: Jörg Schwalfenberg

Production of new PET bottles

An industry-standard topload threshold is 200 newtons, while “Faktor 101” reaches 220 newtons. Achieving this high value required not only a suitable preform and optimal stretch ratios from preform to bottle, but also a well-designed container shape. The core of the development, which took just four months, is the sophisticated bottle design: a modified shoulder area with functional ribs and an innovative base with a pop-in effect ensure high structural stability. As a result, the beverage bottle retains its shape even under high internal pressure and mechanical stress – ideal for modern filling and logistics processes.

Shown is the shoulder section of the beverage bottle with vertical ribs.

To stabilize the extremely lightweight bottle, its shoulder was reinforced with vertical ribs, among other features.
Image: Jörg Schwalfenberg

“The main challenge was ensuring line performance at high speeds of up to 90,000 bottles per hour,” explains Osterhold. “Key focus areas were transport, labeling, and secondary packaging. In the shrink tunnel, for example, special attention had to be paid to the bottle’s shoulder area, and during transport, the container naturally needed to remain upright.”

Use of rPET

The “Faktor 101” concept also scores economically: lower material consumption means reduced production costs. At the same time, it is compatible with existing filling lines – a clear advantage for brand manufacturers looking to combine efficiency and sustainability, as the bottle can be made from up to 100 percent recycled PET. Target markets include the United States, the Middle East, and South America. Initial projects are already in preparation.

More information:

www.khs.com