Plastic Technologies, Inc. creates its 10,000th package design

For Plastic Technologies, Inc. (PTI), innovation doesn't stop at 10,000.

PTI started a new numbering system in 1991 to keep track of its design iterations. Since that time, it has designed 10,000 packages or components. These include: 4350 bottles, 2820 preforms, 900 finishes, 550 bases and 1380 miscellaneous items. 

"We listen to our clients' short and long term requirements," Ron Puvak, director of marketing and new business development for PTI, told PlasticsToday. "Our broad experience allows us to present novel packaging solutions. We continuously track industry developments that allow us to apply the latest technology to meet our clients' objectives. We also have a very creative design and development team."

For the past three decades, the company has developed polyethylene terephthalate (PET) and other plastic-based packages. PTI typically works behind the scenes as a confidential package development partner for brand owners. 

When it comes to how the company approaches the design process, Puvak said that "holistically" is the best description.

"The ideal scenario is for us to be involved at the concept stage," he said. "Because of our significant package development expertise, we are typically able to improve the process, thereby minimizing costs. This also results in faster speed to commercialization."

Packages are designed for applications such as beverages (carbonated and non-carbonated, water, juice, hot-fill, aseptic, ready-to-drink teas, juice, etc.) food, personal care, household/industrial chemicals, pharmaceuticals, nutraceuticals, etc.

Puvak said the timeline of design is project dependent.

"For example, we have gone from 'napkin sketch' to on-the-shelf commercialized product in nine months, including consumer testing," he said. " On the other hand, development of new materials, complex designs and stringent packaging performance requirements can take more than two years."

Materials commonly used to create the packages include PET, high density polyethylene (HDPE), oriented polypropylene, polyethylene naphthalate, plus bioderived PET alternatives, most notably polylactic acid. PTI is also working with new bioderived alternatives as they become commercially viable.

Package sizes have ranged from 2-ounces for an energy shot beverage to a 55 gallon HDPE drum. The lightest preform design has been 5.9 grams, also for the energy shot beverage. The heaviest weighed in at 650 grams and was designed for a beer keg application. Non-package designs include items such as bezels for auto interiors and instrumentation.

Puvak said that since the company has confidentiality agreements with all of its clients, they can't discuss specific projects.

"However, what we can say is that design is frequently driven by improved functionality," he said. "Brand owners are constantly seeking ways to improve the customer experience and provide better package interaction."

Going forward, Puvak said some of the key packaging trends include "the use biobased materials will grow which will impact plastics packaging for a long time to come; the ongoing trend to provide the very best consumer/package experience with the package; and lastly, we never forget that the primary role of the package is the protection of the product."

"As an independent package development consultant, we've have to earn brand owner trust one project at a time," he said. "To be able to say that we have created 10,000 different package designs means that major brand owners around the world have significant confidence in our ability to produce results."