Case studiesDairy · Lightweighting
A lighter four-pint, without losing a gram of strength.
Lightweighting plus 30% recycled HDPE on a flagship four-pint format, rolled out across the whole range.
- SectorDairy
- ServiceLightweighting
- Material30% rHDPE
- FormatFour-pint
The challenge
A flagship four-pint milk bottle needed to hit recycled-content and material-reduction targets without compromising top-load, handling or shelf-life. The pack was already considered optimised, so any further saving had to be engineered, not guessed.
What we did
- 1Modelled material reduction per SKU against top-load and drop-test data.
- 2Introduced 30% recycled HDPE into the blend.
- 3Verified strength and stacking before tooling and rollout.
- 4Phased the new spec across the range to manage supply.
“They took weight out of a bottle we thought was already optimised, and it still performs.”
The result
A lighter four-pint with 30% recycled content, rolled out across the full range with no loss of strength or shelf-life. Less plastic per pack, less weight in transit, and a measurable cut in material across millions of bottles.
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