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RightWeight – the sweet spot between resource savings and a great consumer experience

When you get the balance right between reducing a bottle’s weight while maintaining its strength, you save costs and ensure the consumer gets the best possible brand experience with no inadvertent ‘over squeeze’ effects. That’s the difference between rightweighting and lightweighting.

For many years lightweighting has been the goal of many beverage manufacturers around the world. The technique has enabled the industry to enjoy savings in resources, energy and transport costs by using less packaging for bottles. However, with so much of the protective packaging removed, certain challenges have arisen because lightweight bottles have not had the strength or rigidity to withstand the pressures of transportation or consumer use.

 

Lightweight design with heavyweight performance

Sidel has been acutely aware of the potential impact of lightweighting on brand value and the consumer experience. It has been working on an ambitious concept that achieves all of the lightweighting advantages but with none of the drawbacks. This concept is RightWeight™. The first proof of its success can be seen in the design of the RightWeight 0.5 litre concept bottle for still water. 

Weighing just 7.95 grams, this new bottle is around 34% lighter than the average commercial bottle, which allows manufacturers to capitalise on raw material cost savings of up to EUR 1.75 million per year, according to Sidel data. Furthermore, in spite of its light weight, it has an impressive top load performance. In tests the bottle achieved a top load performance of 33 kilograms - 32% more than the lightest commercial bottle. This means thatthe RightWeight bottle is far likelier to travel across the supply chain and arrive on the supermarket shelf in front of the consumer in the same condition as when it left the production line.

In many cases, other bottles can match the top-load performance of the RightWeight bottle, but they require the use of nitrogen. The RightWeight bottle achieves the required solidity without the use of nitrogen, ensuring further cost savings can be achieved.

 

Designed for success

The design of the RightWeight concept bottle was made possible by incorporating the recently launched Sidel StarLite™ bottle base. This innovative bottle base design leads to a lighter bottle weight, increased
resistance to extreme temperatures (hot and cold), and less blowing pressure during production.

 

Sidel RightWeight StarLiteIn addition to tests run on the StarLite base, the RightWeight concept was tested using numerous computer simulations. Once the design team was satisfied with the theoretical calculations, they put the design into practice and carried out real-world physical tests. The result is the perfect geometrical solution that hits the balance between a lightweight design and strong performance.

 

A key success enabler was the complete redesign and optimisation of the preform done internally by the Sidel team. They focused on lightening the neck of the preform and redesigned the standard 26/22 neck to save an extra 15% of weight, while maintaining compatibility with existing standard 26/22 caps.

 

Compatible with existing production lines

Starlite BottleThe fact that the RightWeight concept bottle is compatible with existing standard 26/22 caps makes it easy to adapt into existing production lines that use these formats. Many manufacturers have already realised the potential of rightweighting with Sidel line conversions that will allow them to put this concept into production.

The RightWeight bottle can be used with all Sidel PET packaging solutions and output speeds for still water, including the new Sidel Matrix™ system for liquid packaging. This popular system includes Sidel's unique Intelliblower™ technology that ensures more consistent quality.

Sidel RightWeight is more than just a concept bottle design. It's a holistic approach to creating the perfect packaging solution that reduces resource consumption, protects the integrity of the beverage and offers the consumer a premium experience. Each manufacturer has its own brand goals, supply chain conditions, industrial production capabilities and consumer expectations, so rightweighting design is a project that needs to be carried out for each individual production line.

 

Sidel Starlite for environmental sustainability

The Sidel StarLite base aids rightweighting by improving overall bottle rigidity even with lightweight bottles. Although it was only launched last year, this new innovative PET bottle base for water and other still drinks has already won awards for its contribution to resource savings. At the 2013 Global Bottled Water Awards, it won the title of "Best Environmental Sustainability Initiative", recognising its contribution to lightweighting and bottle design. 

Sidel RightWeight is more than just a concept bottle design. It's a holistic approach to creating the perfect packaging solution that reduces resource consumption, protects the integrity of the beverage and offers the consumer a premium experience.

Sidel has been acutely aware of the shortfalls of the lightweighting trend and has been working to develop a concept that achieves all of the lightweighting advantages but with none of the drawbacks. This concept is RightWeight.

 

Weighing in at a mere 7.95 grams, most people will never have drunk from a 0.5 litre bottle this light.

 

 

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