No Tip, No Slip: Vacuum Conveyors Keep Lightweight Bottles in Line
June 26, 2025
Consumer packaged goods (CPG) manufacturers are using more recycled content in their packaging, according to a new study released by AMERIPEN (American Institute for Packaging and the Environment). The average post-consumer recycled content (PCR) in plastic packaging doubled between 2019 and 2023, increasing from 5.3% to 10.7%. Consumer preferences for recyclable packaging and increasing U.S. and global regulations are just two of the driving factors in this shift. While AMERIPEN reports that many companies will not meet their 2025 goals for increasing PCR, there’s no question about which direction this trend is heading.
43% of U.S. consumers will pay more for a product with sustainable packaging
10 U.S. states have enacted sustainable packaging laws since 2020
Lightweighting Can Affect Production Efficiency
Using less plastic per packing unit has key business advantages, from reducing material and transportation costs to helping manufacturers meet sustainability goals. However, when empty, PET or HDPE bottles are lightweight, which makes them more unstable on the production line. Traditional conveying methods often struggle to handle lightweight bottles and jugs without them tipping. One effective solution is the use of vacuum conveyors. These conveyors gently stabilize products during transport using air pressure.
Advantages of a Nercon Vacuum Conveyor System
Nercon vacuum conveyor systems work by introducing negative air pressure—or vacuum—through a specially designed belt. This creates an artificial weight on lightweight products, helping them stay firmly positioned as they move through the production line.
The conveyor typically incorporates a deeper frame to house a plenum, or air chamber, which distributes the vacuum evenly. Design of the vacuum holes in the belt is customized based on the product’s size, weight, and base profile. The suction strength can also be fine-tuned using adjustable components like removable blast gates.
Here’s why Nercon vacuum conveyors are a smart move for modern CPG lines:
- Greater reliability in handling lightweight bottles and containers
- Enhanced line efficiency by reducing product jams and downtime
- Supports high-speed operations
- Flexibility in types of blowers used and located on the conveyor in order to match both the application and available facility space
- Quiet operation with noise reduction features that support safety on the plant floor
Meeting the Needs of Modern Production Lines
Nercon’s engineering team brings deep expertise to every vacuum conveyor system. From blower sizing to plenum design and vacuum hole placement, we ensure each component is precisely matched to the product being handled to maintain optimal suction and stability. This customized approach results in reliable performance for lightweight or uniquely shaped containers moving at high speeds.
Like to see how we’re helping CPG manufacturers stay ahead with vacuum conveyor systems? Connect with our team at 844-293-2814 or complete our online form to speak with a Nercon conveyor applications expert today.
1Shorr 2025 Sustainable Packaging Consumer Report
2Tracking US state packaging policies, Packaging Dive, June 25, 2025
