The launch of the first 100% recyclable cap for the famous squeezy ketchup bottle by Kraft Heinz Company demonstrates a collaborative achievement in sustainable packaging solutions, utilizing innovative design and manufacturing capabilities in the food and drink packaging industry.
Historically, Heinz sauce bottles used a flexible silicone valve for consistent portion delivery, but this was challenging to recycle. Together with Berry Global, Heinz has now switched to a mono-material cap, manufactured in PP, meeting requirements for recyclability.
The project has taken eight years, 45 prototypes, and over 185,000 hours in development to ensure an optimum balance between functionality and sustainability. Berry was involved in the design and production process, from concept to the creation of the series tools in Berry’s in-house tool shop, as well as the development of assembly equipment for industrial production.
Heinz followed a rigorous testing procedure to ensure the cap met the highest quality standards. An extended consumer survey confirmed that the new concept would be well received by the public, as it dispenses the same perfect amount of sauce every time without affecting the squeezability.
The new cap design helps consumers squeeze more ketchup out of the bottle when it is nearly empty – a testament to Berry’s ability to holistically improve the cap’s performance alongside its recyclability.
The concept won Rigid Pack of the Year for Kraft Heinz at the 2023 UK Packaging Awards.
Matthias Hammersen, Sales Director – Food Market at Berry Global, commented: “Heinz set us the kind of challenge that suits us and our development departments best: to reconstruct the design of the cap to make it 100% recyclable, without affecting the performance that millions of consumers know and love.”
The caps are being rolled out UK-wide on 400ml and bigger top-down bottles of Heinz Tomato Ketchup, including 50% Less Sugar and Salt varieties. In the future, the cap will also be rolled out across more of the Heinz sauces range in the U.K. and Europe.
Heinz claims the move to the recyclable cap will save a potential 300 million plastic lids from being sent to landfill every year globally.
Jojo de Noronha, President of Kraft Heinz Northern Europe, said: “We’re delighted to see our innovative, more sustainable caps on Heinz Tomato Ketchup bottles across the UK. Although a small change, this makes it easy for the millions of Heinz lovers to recycle their whole squeezy bottle at once – a small action with big potential for impact.”
Learn more about Berry Global’s range of plastic caps and closures suitable for various applications in food and drink sustainable packaging.
