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The aim of this research work is to develop a highly efficient process environment for the production of PET bottles. The ingenious process design carried out includes optimization of both the preheating stage of the process and PET preform shape. The heating of the PET preform is conducted using microwave. Dielectric properties of the PET preform, measured in this work, are used for designing microwave applicators. Studies into heat transfer were conducted by measuring temperature rise and temperature distribution during heating. A remarkable achievement is presented showing that PET preforms can be heated at least 5 times faster and more efficiently by microwave power. The results indicate that the designed cylindrical cavity works perfectly and validates the microwave heating for uniform and efficient heating. Microwave heating and conventional heating are then compared based on mechanical strength and thickness distribution of the end product (bottle). Software are used for structural analysis and thickness distribution analysis respectively. The comparative study concludes that microwave heating is an appropriate replacement for infrared heating.