Conversion of Retort to Aseptic Filling
The client came to PTI to help with the conversion of a retort filling process to an aseptic filling process for one of their nutritional beverages. The desired change provided the perfect opportunity for the company to also develop a container that was more aesthetically pleasing. It also was important to start the project with a clean slate – the only stipulations were to keep the current finish and a high-barrier material.
To kick off the project, PTI was invited to participate in a brainstorming session that included the client and an external design firm. At the end of the three-day session, three designs were taken forward to prototype bottle samples that were used for focus group testing. The client then selected one of the prototypes and moved ahead with a custom preform. As a part of the design process, PTI performed qualification trials for the machines and their associated molds as well as studied various barrier options to determine recyclability.
The end result was a monolayer PET bottle with an appropriate oxygen barrier. A printed full sleeve label is used to help minimize the amount of light that penetrates through the side wall. A design patent was awarded for the bottle.