One bottle mold, infinite possibilities: PET Engineering unveils interchangeable inserts solution for maximum brand differentiation

24 Apr 2019 --- Polyethylene terephthalate (PET) packaging specialist PET Engineering has launched a new bottling solution that allows manufacturers to produce multiple formats and aesthetic differentiations without the need for a new mold. Instead, the ITM solution makes use of inserts to provide endless customization possibilities. Heineken Russia is set to launch two new PET bottles using the ITM solution.

The new bottle shapes for Heineken Russia’s 3 Medvedya, one of the most well-known Russian brands, and Okhota & Okckoe, are described as “simple and equally eye-catching.” The ITM solution provides excellent format and decorative flexibility because the bottles can be easily modified using interchangeable inserts. This means it is always possible to apply new decorations, to move and resize the label area and, last but not least, to alter the capacity of the bottle, which is a very important aspect for future possible downsizing to 1.3l and 1.25l formats.

“One of the main advantages of the ITM solution is that it is very simple,” a PET Engineering representative tells PackagingInsights. “We have a single mold that, thanks to different inserts, can give birth to different bottle shapes and decoration, with slightly different sizes (from 5 up to 10 percent depending on the design), and different label positions.”

PET Engineering's ITM solution opens up a wealth of format and decorative differentiation for bottlers.“In this way, our bottlers can easily update their packaging, for example by revamping or changing imagery, creating a whole new branding and issuing limited edition bottles, all with minimal investment as they only have to change the inserts, not the mold,” they explain.

The ability to create infinite variants from a single mold shape is particularly useful for companies wishing to introduce new Stock Keeping Units (SKUs) to their portfolios. The ITM solution also ensures it can be achieved with low implementation costs.

“In fact, Heineken Russia will no longer have to buy new mold sets should it want to revamp the image of its products – it can instead just use simple inserts, which ensures significant savings,” the representative notes.Heineken Russia’s new launches.

Furthermore, despite the alterations to the bottle’s general appearance, expensive interventions to format changes on the production line will no longer be necessary.

The 115 sets of molds were supplied (1 set = 1 mold + 2 inserts) to seven Russian factories. They were equipped with lighter, lub-free composite components and treated for a greater durability with the application of the ceramic coating to ensure high wear resistance combined with a low coefficient of friction, bigger resistance to corrosion and an antibacterial and self-cleaning action.

“In addition to Heineken Russia, ITM has already been sold to another Russian bottler, who cannot be named for competitive reasons, and we are working on more two more projects. The ITM solution is appreciated in Russia for its cost-saving benefits,” the representative says.