With the Pepsi bottles now filled and sealed, they move to the labeling and packaging phase, where they are branded, coded for traceability, and packed for distribution. This step ensures that each bottle is visually appealing, meets branding standards, and is ready for shipment to markets worldwide.
6.1 Advanced Labeling Technology
Pepsi uses high-speed automatic labeling machines that apply labels with precision and consistency. The process varies based on the type of bottle and regional branding requirements.
Types of Labels Used in Pepsi Bottle Manufacturing
- Shrink Sleeve Labels (Common for PET bottles)
- Applied as a plastic film and shrunk to fit perfectly around the bottle using steam or heat tunnels.
- Provides 360-degree branding with vibrant colors and graphics.
- Pressure-Sensitive Labels
- Used for smaller bottle sizes and special edition Pepsi products.
- Stuck onto the bottle surface using industrial adhesive.
- Direct Printing (For glass bottles)
- Some Pepsi glass bottles have branding directly printed using UV ink.
- This method is durable and resistant to fading.
Once labeled, bottles pass through an optical scanner to ensure proper alignment, checking for wrinkles, air bubbles, or missing labels.
6.2 Barcoding & Expiry Date Printing
Each Pepsi bottle must be traceable from the factory to the store shelf. To achieve this, laser and inkjet coding systems print essential information onto each bottle.
- Batch Codes & Serial Numbers – Used for inventory tracking and quality control.
- Manufacturing Date & Expiry Date – Ensures product freshness and compliance with regulations.
- QR Codes & Digital Printing – Some Pepsi products now include QR codes for promotions, digital engagement, and sustainability info.
These markings are applied using high-speed UV laser coders, which permanently engrave the data without damaging the bottle.
6.3 Final Packaging & Palletizing
Now fully branded, the Pepsi bottles enter automated packaging lines, where they are grouped, packed, and prepared for shipment.
Types of Packaging Used in Pepsi Manufacturing
- Shrink-Wrapped Multipacks
- Bottles are arranged in packs of 6, 12, or 24 and wrapped in heat-sealed plastic for easy handling.
- Cardboard Cartons & Trays
- Common for bulk orders and large-scale distribution.
- Reusable Plastic Crates
- Used for glass bottle transportation in returnable systems.
Once packed, the cases are stacked onto automated palletizers, which organize them into neat, stable layers for shipping.
6.4 Quality Inspection & Final Shipment
Before leaving the factory, Pepsi products go through one last quality check to ensure packaging integrity.
- Weight Sensors check for missing bottles in multipacks.
- AI-Powered Vision Systems scan for damaged labels or misprints.
- Automated Pallet Wrapping ensures each stack is secure for transportation.
From here, Pepsi bottles are loaded onto refrigerated trucks and distributed worldwide, completing their journey from raw materials to a ready-to-drink refreshment on store shelves.
