US-based Kraft Heinz company has launched its first 100% recyclable cap for its famous squeezy ketchup bottle.
The new cap is made from mono-material polypropene (PP), which meets requirements for recyclability. Nonetheless, PP is currently one of the least recycled post-consumer plastics, at around only 1%. Heinz claims the move to the recyclable cap will save a potential 300 million plastic lids from being sent to landfill every year globally.
Heinz previously used flexible silicone valve to deliver a consistent portion of sauce per squeeze, which was often challenging to recycle. The switch was developed by Berry Global. It took eight years, 45 prototypes, and more than 185,000 hours in development to ensure the optimum balance between functionality and sustainability.
Heinz said in a statement that the new cap dispenses the same amount of ketchup without affecting squeezability, and moreover helps consumers squeeze more sauce out of the bottle when it is nearly empty. The holistic design won Rigid Pack of the Year for Kraft Heinz at the 2023 UK Packaging Awards.
“Heinz set us the kind of challenge that suits us and our development departments best: to reconstruct the design of the cap to make it 100% recyclable, without affecting the performance that millions of consumers know and love,” Matthias Hammersen, sales director – food market at Berry Global commented. “We’re delighted that the finished result exceeds our initial expectations and actually improves the consumer experience.”
The caps are being rolled out across the UK on 400 ml and bigger top-down bottles of Heinz Tomato Ketchup, including 50% less sugar and salt varieties. The brand plans to roll out the caps in more of its sauces range in the UK and Europe.
In 2022, Kraft Heinz pledged to cut use of virgin plastics in packaging after being pressured by a shareholders' advocacy group.