SLMG Beverages, the largest Coca-Cola bottler in India, has expanded production capacity at its Chhata plant in the state of Uttar Pradesh by 35% with the installation of a new PET bottling line from KHS. The upgrade comes just in time for the peak season in a region where extreme summer temperatures and a growing consumer base are driving strong demand for carbonated soft drinks. With Uttar Pradesh alone counting more than 240 million inhabitants and the recent addition of the neighboring state of Bihar, SLMG Beverages is set to supply around 350 million people with beverages.
Until about 15 years ago, carbonated soft drinks in India were primarily consumed by higher income groups. Over time, improved affordability and access have opened this segment to all social strata, despite significant logistical challenges across the country. In this context, SLMG Beverages plays a key role in the Coca-Cola system in northern India. The company is a consolidation of four bottlers owned and operated by members of the Ladhani family, who have been working with Coca-Cola in Uttar Pradesh and adjoining regions for more than three decades. Through the takeover of an additional bottler, SLMG Beverages has also secured the license for Bihar, further expanding its geographic coverage.
One of the group’s eight associated filling facilities is located in Chhata, near the city of Agra. This site now operates six beverage lines, the newest of which was supplied and installed by KHS. The Chhata plant focuses heavily on PET packaging for carbonated soft drinks, particularly in smaller, single-serve formats during the hot season from March to July, when local temperatures can reach up to 50°C. For consumers in the region, reliable access to packaged beverages is closely linked to everyday resilience in these extreme climatic conditions.
TriBlock as a growth driver
The core of the new PET line in Chhata is the InnoPET TriBlock from KHS. The modular block system combines a stretch blow molder, a roll-fed labeler and a filler in a compact layout that requires comparatively little floor space. The line is designed to process up to 48,000 non-returnable PET bottles per hour in sizes ranging from 250 milliliters to 2 liters. During the high season, the line is geared toward small single-serve formats, which dominate demand in the region.
According to Sriharsha Chilukuri, senior general manager of the Chhata plant, the new installation has had a measurable impact on output and packaging mix. He states that in 2023 production volume at the facility increased by almost 35% compared with the previous year, followed by a further 25% rise in 2024. Around 60% of the plant’s soft drinks are now filled in PET bottles on the new line. In total, the bottling plant fills approximately 15.4 million containers per year on this TriBlock-based system.
The choice of the InnoPET TriBlock was influenced by several technical and operational criteria. KHS positions this machine concept as a solution with low media and energy consumption, and SLMG Beverages also focused on efficiency and the integrated roll-fed station for hot-melt, wrap-around label application. The ability to install a space-saving block that integrates key process steps into one unit was an additional factor in the line design for the Chhata facility.
Rapid implementation and line performance
SLMG Beverages and KHS have a long-standing relationship. Chilukuri notes that the bottler has been procuring equipment from KHS since it began filling beverages for Coca-Cola. Two of the more recent additions prior to the TriBlock line were Plasmax coating machines, which apply an ultra-thin glass layer to the inner surface of PET bottles. This barrier coating is designed to protect the beverage from oxygen ingress and carbon dioxide loss, helping to preserve taste and extend shelf life.
The InnoPET TriBlock represents the first complete line project jointly implemented by KHS and SLMG Beverages. The contract decision was influenced not only by machine efficiency and functionality but also by the project schedule. For the bottler, the timing of commissioning was critical, as approximately 80% of its annual turnover is generated during the few peak months of the hot season. KHS committed to a short implementation window for delivery, installation and start-up of the new line.
According to the parties involved, the agreed schedule was met. Only 40 days passed from the delivery of the machines to the installation and validation of the first marketable bottle. Chilukuri highlights this implementation speed as an important success factor for the project. The local KHS team at the company’s Indian production site in Ahmedabad played a central role. In addition to manufacturing and supplying conveyors and palletizers on site, they were responsible for installation and commissioning of the entire line at Chhata.
The acceptance test results were also noteworthy. Dharmesh Baria, project manager for after sales and service at KHS, reports that during acceptance the line ran for ten hours without disruption. This corresponds to a measured performance of 99.96%. For a high-speed PET bottling line operating at up to 48,000 bottles per hour, this level of stability is significant in terms of actual usable capacity and scheduling reliability in peak demand periods.
The InnoPET TriBlock, that processes up to 48,000 non-returnable PET bottles an hour, consists of a stretch blow molder, a roll-fed labeler and a filler (from right to left).
Local presence and long-term expansion plans
Beyond machine performance, SLMG Beverages emphasizes the importance of close cooperation with its equipment suppliers. Chilukuri describes the relationship between the bottler and KHS as extending beyond a standard original equipment manufacturer and customer setup. In his view, both parties act as business partners on an equal footing and as a team working toward shared operational targets.
An important factor in this cooperation is KHS’ local presence in India. Technical experts are available to SLMG Beverages on site, which, according to Chilukuri, ensures that the company can obtain the specific support it needs with limited delay. For a bottler whose volumes are highly seasonal and whose markets are both large and logistically demanding, rapid technical assistance can directly impact line availability and sales in peak periods.
SLMG Beverages has outlined ambitious growth plans for the coming years. The company reports total investments of nearly €400 million in advanced plant engineering over recent years. Historically, the bottler has achieved annual growth rates in the range of 20% to 25%. On this basis, SLMG Beverages is targeting turnover of more than one billion euros in 2025. This growth objective is supported by its recent expansion into Bihar and the associated increase in its licensed territory within the Coca-Cola system.
Given India’s status as the most populous country in the world and the large consumer base in northern states such as Uttar Pradesh and Bihar, SLMG Beverages’ network of eight filling facilities and modern PET bottling lines is expected to play a central role in Coca-Cola’s regional sales volumes. The new InnoPET TriBlock line in Chhata strengthens the bottler’s ability to respond to seasonal demand peaks and underscores the strategic importance of reliable, high-performance PET packaging technology in the Indian soft drinks market.
