Materials / Cans & bottles / Rigid Containers / Sustainable Packaging

New plastics technology improves sustainability spice packaging

Specialized plastics manufacturer, Meredith-Springfield Associates, Inc., provides innovative approach to save on costs and environmental impact of household brands

July 10, 2014
Trans

Classic spice brand, Mrs. Dash is using pioneering technology from. Meredith-Springfield Associates, Inc. (meredithspfld.com), a world-class plastics manufacturer specializing in extrusion blow molding and injection stretch blow molding.

“An analysis of the Mrs. Dash packaging process revealed the need to create a more sustainable bottle,” says president and chief executive officer of Meredith-Springfield, Mel O’Leary, Jr. While sustainable packaging has become a point of interest for manufacturers with regards to environmental benefits, significant cost-savings can also be realized. “Sustainable package innovation offered by advanced plastic molding technology minimizes packaging costs – which in turn reduces warehousing and transportation costs, as well” says O’Leary.  

Meredith-Springfield constructed pilot molds and conducted design experiments with the objective to reduce the amount of PET (polyethylene terephthalate) used in the creation of Mrs. Dash packaging. “Manufacturers seeking more sustainable plastic packaging should look for innovative ways to reduce PET,” says O’Leary. “For Mrs. Dash, we are using the most advanced plastic molding technology to alter the amount of plastic and place PET only where it most impacts package performance.” By adjusting the weight bearing performance of the packaging, Meredith-Springfield was able to reduce the weight of a Mrs. Dash bottle by more than 25%. The more sustainable packaging saves B&G Foods an excess of 200,000 pounds of PET resin per year and reduces related costs of optimizing other aspects of the molding and delivery process. “In reducing the weight, we carefully engineered the placement of remaining mass of plastic to go into the areas of the bottle which would maximize top-loading ability,” says O’Leary. The entire re-design resulted in a significant cost-savings for B&G Foods, but required in-depth research and development.

“We never single source,” says director of global procurement of B&G Foods, Marty Schoch. “We always look at our alternatives and benchmark our current suppliers. Meredith-Springfield’s customer service, exceptionally low defect level and willingness to conduct research and development set them apart from the competition.” Schoch also identified Meredith-Springfield’s competitive pricing for a niche market and consistent, timely delivery as valued components to the working relationship. “The new packaging process for Mrs. Dash was able to save B&G Foods a double-digit profit percentage without impacting the brand ID,” says Schoch. “Despite a complete packaging overhaul, the bottle is not noticeably different to the consumer.”

The new extrusion blow molding machine produces more than 100,000 Mrs. Dash bottles in each 24-hour production period and is capable of delivering more than 35 million units per year. “This process is a major volume addition to our evolving PET business,” says O’Leary. “It provides economies of scale with resin, packaging and transportation purchases so it helps lower all costs and adds to our critical mass on both extrusion blow molding and stretch blow molding capabilities.”

The machine is a one-step process for making specialty PET bottles versus a two-step process used to make carbonated beverage bottles. Beverage bottles require multiple steps; first, a “perform” is molded in an injection molding machine and then transferred to a reheat-stretch machine. “Our technology is the most energy-efficient method available,” says O’Leary. “It goes from plastic pellets to finished bottles on one machine.”

 In addition to cost-savings, the new Mrs. Dash bottles also save the environment; 100% of the PET used in the bottle is recyclable through curbside collection. “The plastic from these bottles may find their way into new plastic bottles or may also be used to make other things like polyester-based clothing, carpets or automotive interior components,” says O’Leary. 

Did you enjoy this article? Click here to subscribe to Food and Beverage Packaging

You must login or register in order to post a comment.

Multimedia

Videos

Image Galleries

2014 Beverage Breakthroughs of the Year

Beverage packaging innovations huff, puff and blow traditional packaging down.

Food and Beverage Packaging

FBP October 2014 cover

2014 October

Check out the October 2014 issue of Food & Beverage Packaging, with a special PACK EXPO preview, and much more!

Table Of Contents Subscribe

Packaging Innovation

Which segment do you see the most innovation in packaging?
View Results Poll Archive

The Food and Beverage Packaging Store

M:\General Shared\__AEC Store Katie Z\AEC Store\Images\FBP\modified-atmosphere.gif
Modified Atmosphere and Active Packaging Technologies

Many factors are relevant in making the proper choice of food packaging material, including those related to shelf life and biodegradability.

More Products

FBP Buyer's Guide

2013 FBP Buyers Guide

 

 

Food and Beverage Packaging's Buyer's Guide provides a list of suppliers of food and beverage packaging solutions. 

STAY CONNECTED

 Facebook iconTwitter iconYoutube icon LinkedIn icong+icon

Clear Seas Research

CS-OflRGBhomepage.jpgWith access to over one million professionals and more than 60 industry-specific publications, Clear Seas Research offers relevant insights from those who know your industry best. Let us customize a market research solution that exceeds your marketing goals.