CREATING A CLEAR DIFFERENCE
It’s just beautiful
BottleOne is an affordable large capacity, standard grade PET bottle with an integrated PET handle
You can find us in several markets and locations:
Summerville Tea
Cristalia Water
La Cucina Olive Oil
Walmart
Menards
Dollar General
Rochester
SuperMax
Costco
What makes it so special
How this technology will impact your bottom line
Production
- Corrugated Savings
- Corrugated Storage Savings
- Potential Resin Savings
- Increased Production Efficiency
- Faster Run Times
- Produce More in the Same Footprint
- On Demand Manufacturing
- Accurate Fill Height
- Reduced Bottle Leaks
- Reduced Mess
- Reduced Production Sanitation
Distribution
- Better Distribution Efficiency
- Increased Bottle Durability
- Reduced Warehouse Space
- Faster Truck Loading
- Dock Door Efficiency
- Optimizes Fleet Efficiency
- Reduced Shipments/Emissions
- Reduced Bottle Leaks
- Reduced Mess
Consumption
- Improved Consumer Perception
- Bottle Clarity
- Improved Taste
- Retained Nutrition
- Reduced Product Degradation
- Increased Retail Efficiency
- Reduced Bottle Leaks
- Increased Bottle Durability
- Reduced Corrugate Handling
- Reduced Corrugate Recycling
- Reduced Corrugate Storage
IMPROVE OPERATING EFFICIENCY, REDUCE COSTS, AND DELIGHT CUSTOMERS WHILE LOWERING YOUR CARBON FOOTPRINT
Environmental
By incorporating the PET handle into the PET bottle preform, this package provides the first large format bottle with a handle made of mono-material PET – which is single stream, bottle-to-bottle recyclable, and 50% PCR capable.
Additionally, PET is the only FDA approved food grade recycled plastic material.
BottleOne containers are so strong and durable that they can be stacked on top of each other without the need for cardboard boxes or crates.
Some BottleOne users have found:
- Gallon HDPE jugs that require corrugated boxes to ship pallets with 4 layers have been replaced by BottleOne gallon jugs in bundles that can be palletized with 5 layers, and those 5-high pallets can be stacked 2 high.
- Corrugated usage is reduced by more than 30-60%.
- Climate controlled warehousing space can be cut by 30%.
- Trucks that were maxed out on floor space with 4-high pallets can now be maxed out on weight which means 25% more product can be shipped per truck vs. HDPE bottles, eliminating 25% of current emissions.
Endlessly Sustainable
BottleOne’s processes and equipment can handle up to 50% PCR. BottleOne containers are designed to be caseless, and will enable elimination of most secondary packaging due to their inherent strength and durability. If PCR content negatively affects strength and durability, we will adapt our designs and processes to mitigate them in order to keep secondary packaging minimized. The door to circularity swings only one way, opening to the future, and will not permit a return to the past. PCR is here to stay.
MANUFACTURED WITH UP TO 50% RECYCLED PET (PCR)
No Leaks, No Contamination
BottleOne’s excellent barrier properties, and its neck and cap seal, improve product security. It seals hermetically, eliminating leaks that are endemic to current HDPE packaging. This reduces the mess in production, in the dairy case and in the consumer’s home. It also expands sales and geographic distribution limits currently placed upon many production facilities, as they can ship farther without product loss or damage. Now that large capacity bottles don’t leak, they can easily be included in last-mile deliveries, whether through a personal service or drone delivery.
Improved
Taste Profile
We already know that multiple variables can influence product quality, including microorganisms, light, oxygen and temperature. PET barrier solutions improve product safety with good oxygen barrier properties – 50 times higher than HDPE (high density polyethylene). Studies have demonstrated that products taste better when they are packaged in PET.
Retains more
nutrition
The same variables that ensure your products taste better also help them retain better nutrition than regular HDPE jugs. A Virginia Tech Study proves that 2% milk, packaged in PET, retains more nutrition and tastes better than products packaged in standard HDPE bottles. Many other beverage products, particularly plant-based beverages like tea and juice contain the same vitamins and nutrients that are found in milk, and it is logical to believe that the flavor and nutrition benefits gained by milk in PET will impact those products in similar ways.
Balancing economic, social and environmental sustainability factors in equal harmony
Just one (of many) BottleOne savings opportunities
Here is a fraction of the total sustainability savings available to you.
By converting one million corrugated boxes to tray pack, you will save:
TONS OF PAPER
4,855.2
TREES
GALLONS OF WATER
KWH OF ELECTRICITY
GALLONS OF OIL
By changing your bottle…
We can introduce you to a much more efficient operating model
Manufacturing
A revolutionary blow molding processBottleOne Technology builds on the principles of injection and reheat stretch blow molding to create PET containers of extraordinary strength and durability. Using a preform with an integrated PET handle, BottleOne technology uses established manufacturing platforms to create large capacity handled containers at industry competitive speeds and economics.
Unique Technology Benefits
Food Grade PCR
BottleOne has developed a PET dairy container that not only meets but exceeds the PCR content levels mandated by various states. Our PET containers can incorporate 25% recycled content from the onset in 2024, with the potential to increase this percentage significantly over time.
Retain Nutrition and Flavor
We know that multiple variables can influence product quality, including microorganisms, light, oxygen and temperature. PET’s excellent barrier properties, and its neck and cap seal, improve product security.
It seals air-tight and water-tight, eliminating leaks that are endemic to current HDPE packaging. This seal reduces any mess in production or in a consumer’s home and also provides a longer shelf life for the product.
“Compared to HDPE bottles, PET bottles retained significantly higher riboflavin level in reduced fat (2%) fluid milk, regardless of light intensity during lighted, refrigerated storage.” – Department of Food Science & Technology, Virginia Tech
Air-Tight, Water-Tight
There is exciting growth happening in e-commerce. Participating in that growth requires a package with the toughness of BottleOne. Most HDPE bottles do not have the performance characteristics to shine in the e-commerce industry, as even a small leak will contaminate other products, other shipments, and the delivery vehicle itself.
Large HDPE bottles leak everywhere – in production, in transportation, in the dairy case, in consumers’ cars, homes, and refrigerators. Customers expect more, and deserve more.
BottleOne Technology provides a seal that is air-tight and water-tight.
Elevate Your Brand
With BottleOne Technology, you get crystal clear PET showing your product and adding value at retail, producing maximum shelf impact!
Lower Operational Costs
BottleOne Technology is designed for in-line, on-demand production. BottleOne PET containers can be made faster than HDPE to match filler speeds, with significant savings from space utilization, labor content, energy, waste, and work-in-process. Most customers find a favorable payback when adapting their production line to incorporate BottleOne containers.
Made to be Remade
100% PET is set to lead the way as the circular economy becomes a promising solution for our planet. PET is the only FDA approved food-grade post-consumer recycled material.
The packaging required to get HDPE bottles to retail is extensive: crates, cardboard boxes, stretch wrap, etc. Purchasing, handling, warehousing and disposing of these materials is all very costly, and they take a toll on the environment. BottleOne eliminates the need for any crates or corrugate boxes.
Significant savings are also found from space utilization, labor content, energy, waste, and work-in-process. Most customers find a strong payback when adapting their production line to incorporate BottleOne containers.
100% PET, In-Mold Handle
The PET handle is molded directly into the PET preform. These preforms can then be blown on-demand into large format bottles at production speeds of 5,000 bottles per hour (which matches the speeds of many fillers).
BottleOne packaging is made-to-be-remade, bottle-to-bottle recyclable.
Packaging and processing efficiencies provide significant labor savings with reductions in bottle handling and production. Additional benefits include reducing incoming trucks from 10 for empty bottles to 1 for preforms. Damage is almost nil due to increased bottle strength and durability.
BottleOne Technology provides strength that eliminates the need for corrugate boxes by 100% and reduces corrugate handling, recycling, and storage by 90%. It also reduces the required warehouse space by 30%.
Consumers are drawn to the transparent visual quality, the shelf appeal, the air-tight and water-tight seal, the built-in handle (for toting or single hand pouring), the improved flavor and nutrition, and the enhanced recyclability of the bottle.
Patented Technology
Independent top load strength tests demonstrated BottleOne was far superior (>7x) to HDPE bottles in a side-by-side evaluation of one gallon bottles. Virginia Tech has validated BottleOne to have a higher retention of riboflavin (flavor), vitamins, and dissolved oxygen (potential for longer primary shelf life).
17 US PATENTS AND 1 US PATENT PENDING
THE INITIAL PATENT HAS BEEN APPROVED IN 30 COUNTRIES
OVER 44 ADDITIONAL INTERNATIONAL PATENTS HAVE BEEN GRANTED
Making a BottleOne PET bottle
Preforms
- BottleOne is your source for preforms that take advantage of the BottleOne technology.
- BottleOne offers volume pricing, continuous technological improvements, and the ability to quickly and easily adopt this innovative operating model.
- Preforms can be manufactured with up to 100% recycled PET.
- A variety of stock and custom sizes are available.
- All BottleOne product is 100% recyclable.
Blow molding
BottleOne containers are manufactured utilizing a reheat stretch blow molding process on industry standard blow molding equipment modified for the technology. No ancillary equipment is required to apply or attach the handle.
Blow molding process
Industrial design services
We provide industrial design services, including product testing, engineering design, and industrial design consultations for consumer plastic containers.
Incredible partnership
InterTech has been engaged as our exclusive engineering integrator, for design, installation and project management of all production line conversions to BottleOne.
InterTech has helped hundreds of food and beverage plants implement a variety of manufacturing projects for over 35 years. InterTech helps manufacturing companies reduce their operating cost for a single line or for multi-plant operations. They model plant operations and provide feasibility analyses of project ideas.
InterTech also develops Requests for Information (RFIs) or Requests for Proposals (RFPs) for major equipment to determine and secure the best value for its clients. InterTech can forecast operational costs for the long-term and establish budgets for plants that have not previously been self-manufacturing their bottles.
InterTech’s clients include Coca Cola and Pepsi Cola (and their respective bottlers), Cargill, ADM, Refresco, and many others. We invite you to view a more complete list of InterTech’s esteemed past and current clients.
Meet some of the experts
With decades of relevant experience in PET bottle manufacturing, we’re collaboratively solving all potential roadblocks to implement BottleOne technology.
Bill Duelge
Chief Technology Officer
Brian Lynch
Chief Financial Officer
Gregory A. Kershner
Chief Executive Officer
Mike Cunningham
Business Development
John Hagreen
Business Development
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