Amcor’s partnership with Insymmetry has resulted in the creation of a groundbreaking 2oz retort bottle, effectively responding to the rising demand for durable, shelf-stable packaging within the food and beverage sector.
This innovative packaging solution is meticulously designed to cater to brands that require high-performance packaging for low-acid, shelf-stable products such as coffee and dairy-based beverages. Notably, it is the first to incorporate Amcor Rigid Packaging’s (ARP) exclusive StormPanel technology. This cutting-edge solution withstands high-pressure retort sterilization processes while ensuring product integrity and readiness for market.
Stellify, a beverage brand owned by Insymmetry, is the pioneer in utilizing this StormPanel technology for its energy nootropic products, Dulce de Leche Energy and Espresso Energy wellness beverage shots. These innovations will be highlighted at the Natural Products Expo West in 2025.
“At Amcor, we are committed to driving innovation that addresses the evolving needs of the food and beverage industry,” stated Greg Rosati, VP of strategy and marketing for ARP. “Our StormPanel innovative packaging enables beverage brands to enhance shelf-stable, low-acid products in a compact, ready-to-use bottle.”
Furthermore, while this product is ideal for end-users, the retort process also presents a more cost-effective and time-efficient alternative for manufacturers compared to traditional aseptic processing. This approach reduces initial equipment investment and streamlines production timelines, all while preserving product integrity.
“Amcor’s expertise in packaging innovation enabled us to develop a solution that meets our unique needs,” remarked Josh Cua, chief innovations officer of Insymmetry. “By leveraging their advanced manufacturing technology and material science capabilities, we created a bottle that not only excels in the retort environment but also aligns with the growing consumer demand for preservative-free nutritional shots.”
The bottle, engineered with StormPanel technology, maintains its shape and structural integrity under the intense heat and pressure fluctuations of retort sterilization. This guarantees reliable protection and an extended shelf life of 12 months without refrigeration. Additionally, the design includes elements that preserve the round shape, while specific areas are intentionally designed to flex.
“This collaboration is a testament to Amcor’s ability to combine deep industry expertise with advanced engineering to tackle complex challenges,” noted Mikey Tom, business development manager at ARP. “We are proud to deliver a solution that offers manufacturers and consumers uncompromising quality and functionality.”
ARP’s close collaboration with Insymmetry was pivotal in developing the innovative retort polypropylene bottle. By employing finite element analysis (FEA) and ARP’s virtual reality capabilities, the teams refined the StormPanel design to ensure structural integrity during retort sterilization. Additionally, by selecting a co-polymer resin and optimizing a one-step molding system, they ensured both efficiency and scalability. The project’s proximity to Insymmetry’s California operations facilitated rapid prototyping and promises accelerated commercialization.
“As a smaller company, we are truly grateful for Amcor’s trust, time, and confidence in us,” expressed Cua. “Partnering with a global leader like Amcor has been invaluable, and we greatly appreciate the dedication of the entire team for making the impossible possible.”
