Berry Global equips UK cleaning products firm with recycled and reusable plastic bottles

19 Jul 2023 --- Berry Global has created a range of reusable bottles from post-consumer recycled (PCR) plastic for UK-based cleaning company The Bio-D Company. Bio-D has calculated that the CO2 emissions saved by using 100% PCR bottles are 13 metric tons annually, compared to virgin plastic.

The range includes 750 mL, 1 L and 5 L sizes for several of Bio-D’s liquid products, including Laundry Liquid, Fabric Conditioner, Dishwasher Rinse Aid, Washing Up Liquid and Home & Garden Cleaner. 

“Our customers are sustainability conscious, so it is vital that our packaging represents the same ethos,” says Heather Nixon, Bio-D’s sustainability manager. 

“Reusable bottles made completely from PCR offer a more [environmentally] sustainable solution than alternatives such as pouches. Berry has worked hard to ensure that the bottle is tough and long-lasting while offering convenience and ease of use for the consumer to deliver a solution that is fit for purpose while fully complementing our brand values.”

Slashing chemicals
Bio-D specializes in producing cleaning products that offer environmentally sustainable alternatives to toxic chemicals. Regarding packaging for liquid cleaning products, Bio-D’s analysis concluded that a 100% PCR bottle is “the most” suitable and environmentally responsible choice.

The bottles are blow molded in 100% PCR high-density PE.Berry explains that it is essential that the bottles deliver a high level of performance, most notably regarding durability and longevity. The new bottle’s design is said to facilitate reuse as it can be refilled multiple times at over 300 refill stores across the UK. Furthermore, the bottles can finally be recycled at their end of life.

The bottles are blow molded in 100% PCR high-density PE and incorporate an embossed Bio-D logo to maintain the brand’s presence throughout the bottle’s life. The 1 L Laundry Liquid and Fabric Conditioner bottle design also features a handle for safe carrying and controlled pouring.

Recycled plastic innovation 
Berry says its technical and design knowledge was critical to the successful production of the bottle.

“While we have been using recycled material in our containers for many years, the requirements for the Bio-D bottle set us additional challenges that required new material technology and processing requirements and an extensive new test regime,” explains Sally Halliwell, sales development manager at Berry Global Blow Moulding Specialities (BMS).

“This project demonstrates why collaboration is critical to supporting a circular economy. Working closely with Bio-D, we have been able to deliver ‘More Together’ and show how recycled plastics can play a vital role in the development of packaging solutions that are both practical and sustainable.”

As part of the development process, Berry BMS called on the processing experience of Berry’s specialist recycling business Berry Circular Polymers. In addition, the plastic closure for the bottle is produced by Berry Norwich, providing Bio-D with a single-source bottle and closure solution.

“As a B Corp-certified business, which confirms that we meet the highest standards of social and environmental impact, it is vital that our packaging contributes toward making our products environmentally responsible,” says Nixon.

“We have worked with Berry over a number of years, and the company has always delivered excellent quality and service. Consumers love these bottles because they know each one has been manufactured from waste plastic and can be used time and time again.”

Edited by Natalie Schwertheim