Cristalia’s New BottleOne PET Bottle is “Súper Unico”

Have you seen the buzz around Cristalia’s new product launch? It’s Súper Unico! Cristalia replaced their HDPE gallon jug filling line with a BottleOne blow-to-fill PET line. They managed the turnaround in an amazing six months. Out with the old HDPE jug and in with the new PET bottle – complemented by many accolades and impressive success.
 
Cristalia moved into the BottleOne package to reduce costs through improved operations, enhanced shelf impact, and to increase market share. Research showed that a crystal-clear 120oz. PET bottle with an integrated handle and new 3D labeling would help Cristalia meet these objectives. And, it did!

6 Benefits to Cristalia’s New BottleOne PET Bottle:
(none of which would be possible with HDPE)

1. COST SAVINGS

When Cristalia moved from purchasing HDPE bottles to manufacturing their own blow-to-fill BottleOne PET bottles, they realized their greatest cost savings.

By standardizing with 100% PET (compared to HDPE or PET with an applied handle), Cristalia simplified their operations.

Packaging and processing efficiencies include reductions in power, repairs, scrap, and poly bags. By moving to the BottleOne PET bottle, they eliminated corrugate boxes by 100% and reduced corrugate handling, recycling, and storage by 90%. They have also reduced the required warehouse space by 30%.

This is only possible due to the strength of each PET bottle. No boxes, crates, or trays are required for product distribution in BottleOne.

Independent top load strength tests demonstrated PET was far superior (>7x) to HDPE bottles in a side-by-side evaluation of half gallon bottles. (source: Exordium Engineering 2023)

InterTech was instrumental in providing a thorough, independent, and private feasibility study with an ROI of approximately 2 years.

InterTech also designed and installed Cristalia’s new blow-to-fill line.

This new process also provides significant labor savings with reductions in bottle handling and production.

Cristalia also benefits from a reduction of incoming trucks from 10 for empty bottles to 1 for preforms. Damage is almost nil due to increased bottle strength and durability.

2. ENVIRONMENTAL IMPACT

BottleOne was carefully designed to be 100% recyclable. By incorporating the PET handle into the PET bottle preform, BottleOne provides a large format bottle with a handle made of mono-material PET which is single stream, bottle-to-bottle recyclable, and 50% PCR capable.

This large format bottle with an integrated handle is 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 recycled material. Cristalia is committed to incorporating 25% PCR PET by 2025.

3. INNOVATION

Cristalia’s BottleOne PET bottle is a result of many innovative ideas coming together from a team of over 20 individuals who worked to design, create, patent, and process this new technology.

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 the filler).

This patented design runs on a blow-to-fill production line, improves production processes, reduces waste, and optimizes true bottle-to-bottle recyclability.

The Cristalia design is the first BottleOne PET bottle to fully incorporate a 100% PET handled preform that is being run on a blow-to-fill line at constant production speeds.

It has been launched at retail in over 20 locations.

4. MARKETING

This BottleOne package reflects important new marketing strategies. The crystal-clear bottle provides the perfect substrate for the appearance of a three-dimensional label, which elevates the Cristalia brand to the “Súper Unico” status of their branding campaign.

This campaign targets retail consumers through traditional and social media channels to bring awareness to the many benefits of their “Súper Unico” BottleOne PET bottle.

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), and the enhanced recyclability of the bottle.

Incorporating an overnight go-to-market strategy, Cristalia coordinated replacing all of their HDPE gallon bottles at 18 Walmart locations, in a single evening.

By filling their shelf space with these “Súper Unico” bottles, promoting them heavily, and ensuring availability, we have seen evidence that Cristalia has caused not one, but two MAJOR brands to reduce their prices by more than 5% in this region.

This is a sign of market share instability. Good job, Cristalia. We love it when the underdog comes out shining.

Incorporating a PET handle into a PET bottle preform and then blowing it into an incredibly durable bottle is the first major development in large format bottle production in 50 years.

5. PACKAGE PERFORMANCE

BottleOne is easily filled, opened, dispensed, reclosed, and stored without any spillage or mess – even while laying down in refrigerators or coolers.

The blow-to-fill equipment provides production efficiencies, and for Cristalia, a desirable 2-year ROI.

BottleOne can also be run on existing downstream packaging machinery with minimal adaptations.

BottleOne is easily integrated into the existing distribution system using standard pallets and standard heights. The elimination or minimization of secondary and tertiary packaging saves space while reducing waste and inventory inefficiency. And at the same time, improving merchandising options and costs.

6. PRODUCT PROTECTION

PET’s excellent barrier properties, and its neck and cap seal, improve product protection. It seals air-tight and water-tight, eliminating leaks that are common in current HDPE packaging.

This seal reduces messes in production and in consumers’ homes. It also provides a longer shelf life for the product.

This extended shelf life gives Pac Tech more flexibility to produce and store water for the busier times of the year.

CONCLUSION

Congratulations, Cristalia. Thank you for your vision, and for demonstrating what is possible in this industry. We wish you continued success on your path to incorporating 25% PCR PET by 2025.

If you are inspired by Cristalia’s story and would like to consider BottleOne’s package for your own products, contact us. We would be happy to help.