In the world of sustainable packaging, lightweighting is increasingly becoming a symbol of innovation. This is clearly demonstrated by Factor 101, the latest project by KHS, developed in collaboration with Husky Technologies, which has led to the creation of one of the lightest PET bottles for still beverages in the world: just 5.89 grams to hold 591 ml of product.
That’s a 30% material reduction compared to the current standard on the US market, achieved without compromising strength, stability, or high-speed production compatibility.
Lightweight meets intelligent design
It’s not just about using less plastic – the key lies in smart engineering: the bottle shoulder has been reinforced, the body strengthened with functional webbing, and the base features an innovative “pop-in” effect that increases internal pressure when loaded. The result? A top load resistance of 220 newtons, well above the industry average.
Technology and collaboration as success factors
The project brought together multiple technical teams and was completed in just four months. KHS focused on bottle geometry and blow moulding optimisation, while Husky designed a tailored preform, leveraging its global leadership in PET injection moulding systems.
Market-ready and designed for high-volume lines
Presented at NPE 2024 in Florida, the bottle has already attracted strong interest from high-cost-pressure markets such as the United States, the Middle East and South America.
In addition to being fully producible in rPET, it’s compatible with production speeds of up to 90,000 bottles per hour, having overcome key challenges like conveying, labelling and secondary packaging.
This project opens the door to a new generation of sustainable packaging, where efficiency meets circularity. It’s through solutions like this that packaging can truly lead the green transition.
