Current plastic beverage packaging presents limitations in shelf life, stability, and integrity throughout manufacturing and transportation. PepsiCo is looking for solutions for their beverage polyethylene terephthalate (PET) bottling needs.
With our commitment to sustainability, one of our focus areas is to introduce more sustainable packaging through innovation. Aligned with our strategy to minimize single-use plastic, switching to lightweight packaging represents a solution that has been explored. However, lightweight PET bottles are more susceptible to damage, especially during production and transport. Their thinner walls are less rigid, more prone to deformation under stress, vulnerable to pressure changes, and less able to withstand mechanical stresses and impacts.
Additionally, PET bottles that undergo the hot fill process - where the beverage is filled into the PET container at high temperatures (175 to 195°F) to ensure sterilization and preservation - often experience structural instability and top-load issues, failing to withstand vertical compressive forces during stacking and capping. These bottles frequently suffer dents throughout the production line and transportation, causing them to fail PepsiCo’s quality standards. As a result, they do not meet the desired freshness and quality shelf-life goals.
Existing market technologies, such as some coatings and resins, involve high capital costs and have not proven cost-effective nor efficient for our needs. Therefore, we are seeking more effective solutions in terms of both efficacy and cost. We are open to resin, preform and bottle technologies to lightweight our PET packaging.
Technologies capable of enhancing the structural stability of lightweight PET bottles, addressing both integrity and extended shelf life, would not only ensure the bottle can withstand the stresses of production, transportation, handling, and storage but also allow it to be filled to the maximum volume without compromising structure. This would lead to a more efficient use of packaging materials, reducing the amount of plastic needed per unit of beverage.
We are looking for cost-effective and scalable technology to enhance the structural stability and extend the shelf life of carbonated soft drinks in lightweight PET bottles, while maintaining recyclability. The solution should increase the top-load capacity of bottles and maximize the volume a bottle can hold, while minimizing dents during production and RQL (rejectable quality limits) failures. We need solutions for all bottle sizes (up to two liters), with a primary focus on 20 oz / 500 ml bottles.
- New cost-effective barrier coatings
- Novel additives for PET bottles
- Enhanced PET resin formulations
- Novel materials
- Advanced mold design techniques
- Solutions must extend the shelf life of carbonated soft drinks and/or enhance the structural stability of lightweight PET bottles. Current shelf life is between 7-12 weeks depending on bottle size.
- Solutions should demonstrate the potential to be cost-effective and scalable for large-scale production.
- Solutions that are FDA approved or in the process of approval to meet food-grade requirements.
- Solutions that aim to achieve cost efficiency with a payback period (breakeven) of 24 months or less.
- Solutions that negatively impact the recyclability of PET bottles.
- Established approaches to lightweight packaging that are already known and in use which require significant capital investment or have industry restrictive IP.
- Technologies that do not work with PET plastics.
- Technologies that require excessively high capital investment for implementation.
PepsiCo products are enjoyed by consumers more than one billion times a day in more than 200 countries and territories around the world. PepsiCo's product portfolio includes a wide range of enjoyable foods and beverages, including many iconic brands that generate more than $1 billion each in estimated annual retail sales.
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