As beverage manufacturers face increasing pressure to improve production efficiency, reduce energy consumption and optimise capital investments, equipment manufacturers must deliver advanced technologies at commercially viable prices. This challenge is particularly relevant in India, where manufacturers seek globally proven technology without compromising operational reliability or investment returns.

For Synergy Machinery, the approach combines European technology with local manufacturing, engineering capabilities and market-specific design modifications. With Sidel having completed 25 years in India, Synergy is strengthening its portfolio with solutions that address the evolving requirements of beverage manufacturers.

At Drinktec India 2026, Synergy Machinery and Sidel India showcased developments in blow moulding, preform heating, energy efficiency and mould manufacturing. A key highlight was Synergy's patented Low Blowing Pressure Kit, an add-on solution designed primarily for non-carbonated beverage applications to reduce blowing pressure and compressed air consumption.

Speaking during the exhibition, Mr Ashish Deshpande, Managing Director, Synergy Machinery and Sidel India, discussed the company's journey, technology strategy and plans for growth in India and international markets.

Localising European technology for the Indian market

Synergy began its journey in India approximately 25 years ago with the objective of making European technology accessible through local manufacturing.

"We started our journey with Synergy in India approximately 25 years ago. The initial objective was to bring the same technology available in Europe to India, manufacture it locally and supply it from India. We have introduced several technologies that we have localised, and we are now also making design modifications to ensure they meet the price expectations of the market," said Mr Deshpande.

He identified price sensitivity as one of the industry's persistent challenges. While manufacturers recognise the importance of advanced technology, investment decisions must also reflect commercial realities.

"One of the biggest pain points for the industry has been price. While everybody wants to invest in technology, India is a very price-conscious market. The challenge was essentially how to manufacture or supply the same technology, or a similar technology, at the price point the market demands. That is where Synergy was born," he explained.

The company leverages Sidel technology, localising and modifying designs to suit Indian requirements while maintaining equipment quality and reliability.

"We bring technology from Europe while maintaining the same reliability and quality, but at a price point suitable for Indian customers," Deshpande added.

Low Blowing Pressure Kit: Improving production economics

One of the key technologies showcased at the exhibition was Synergy's patented Low Blowing Pressure Kit. Developed primarily for water and other non-carbonated, non-viscous beverages, the add-on module reduces the pressure required during bottle blowing, helping lower compressed air consumption and associated energy costs.

Importantly, the kit can be integrated into existing machines, allowing manufacturers to upgrade their equipment rather than replace an entire production system.

"The Low Blowing Pressure Kit is an add-on module that can be fitted onto existing machines. The objective is to reduce bottle-blowing pressure by approximately 40% compared with conventional requirements. This results in substantial operational savings over the lifetime of the machine. It also means that customers can opt for a compressor with a lower capacity," said Deshpande.

Conventional machines generally operate at blowing pressures of around 30–35 bar. The kit is designed to reduce this requirement by around 40%. Its customised design incorporates modifications to the bottle mould, including its gate configuration, to reduce resistance during the blowing process.

"The technology reduces the pressure required to blow the bottle through its specific mould design and gate configuration. This, in turn, reduces air consumption," he explained.

The resulting benefits extend to both capital expenditure (CAPEX) and operational expenditure (OPEX). A lower compressor capacity requirement can reduce initial investment, while lower compressed air and energy consumption can generate savings throughout the machine's operating life.

Measurable savings and retrofit potential

For manufacturers assessing the technology, Synergy has developed a business case based on measurable consumption reductions. Customers can use flow meters to monitor compressed air consumption and independently evaluate the savings.

"The technology offers a 40% reduction in consumption, which we have also translated into actual monetary savings. These are tangible and measurable benefits, and customers can independently measure their air consumption using a flow meter," Mr Deshpande said.

Depending on operating hours and usage, the typical return on investment is approximately one to one-and-a-half years.

The solution currently focuses on water and other non-carbonated, non-viscous beverages, with the company looking to extend its application to carbonated soft drinks in the future.

Its retrofit capability is a significant commercial advantage, particularly for manufacturers seeking efficiency improvements without major equipment replacement.

"Since it is an add-on kit, customers can install it as an upgrade to their existing machines without having to replace the machine itself. They simply need to add the kit, along with the required mould modifications, and they can start realising the benefits," Mr Deshpande said.

Laser Oven and production line developments

Sidel India's showcase also featured the Laser Oven, which uses lasers instead of conventional halogen lamps for preform heating. The technology enables targeted heating and greater control over the process, supporting preform lightweighting and more uniform bottle blowing and stretching.

According to Mr Deshpande, it offers potential material savings of approximately four grams per preform—a significant opportunity for high-volume PET bottle manufacturers.

"Instead of using conventional halogen lamps for preform heating, the technology uses lasers. This enables targeted heating of the preform and also helps achieve uniform blowing and stretching of the bottle," he explained.

Synergy's exhibition focus included the Low Blowing Pressure Kit, plans to launch a complete 18K water line and range extensions for its existing linear portfolio. These developments reflect the company's focus on expanding its equipment offering in line with beverage manufacturers' production requirements.

In-house mould manufacturing expands capabilities

Synergy's in-house mould manufacturing facility in Pune is another important part of its integrated offering. Its capabilities span packaging development, bottle design and mould engineering, enabling the company to support customers from preform and bottle development through to packaging and the finished product.

"The biggest advantage Synergy has is its in-house mould shop in Pune. Our expertise covers both packaging and bottle design. When a customer undertakes a greenfield project or plans a new production line, we can support them right from the bottle design stage to packaging design. Essentially, we offer a complete solution, starting from the preform stage through to the finished product," said Mr Deshpande.

The facility also manufactures moulds for machines from competing brands, extending its reach beyond Synergy and Sidel equipment. These solutions are supplied under Competek, a brand that is growing in India.

"We do not manufacture moulds exclusively for Synergy machines. We also manufacture moulds for competing machine brands. This helps us leverage our mould shop capacity not just for Synergy or Sidel machines but also for machines from competing manufacturers," he explained.

A customer-partnership approach and international ambitions

Mr Deshpande emphasised that understanding customers' operational challenges is central to Synergy's approach. Rather than functioning simply as an equipment supplier, the company aims to work alongside manufacturers to identify requirements and develop appropriate solutions.

Reflecting on the response at Drinktec India, he said, "We had excellent footfall. Customers believe in the Sidel brand and the Synergy brand. They trust the brands, the quality of the machines and their reliability. Price remains a challenge, but that is something we are also working on."

He added, "Where Sidel and Synergy excel is in working collaboratively with customers as partners rather than simply as suppliers. We try to understand their pain points and then work specifically towards addressing those challenges."

Building on its established Indian presence, Synergy is looking to expand its reach across South Asia, Southeast Asia, Africa and the Middle East.

"Synergy's future plans are centred on leveraging this particular brand not just for India but also for the world. We are focusing not only on India but also on South Asia, Southeast Asia, Africa and the Middle East," Mr Deshpande said.

The company's journey is reflected in its installed base of more than 1,000 machines in India alone, excluding installations outside the country.

Concluding with a message to beverage manufacturers, Mr Deshpande underlined the importance of reliability and production continuity.

"We understand that customers are running production lines, and downtime is never really an option for them. When customers are looking for a high-performance machine that offers reliability and quality, I would say Synergy is the way to go," he concluded.