Polyplastics, Colgate-Palmolive, and Plastic Technologies Inc. (PTI) have introduced an innovative method for manufacturing high-density polyethylene (HDPE) bottles, representing a major advancement in lightweight packaging technology.
The new approach was presented at The Packaging Conference held in Austin, Texas.
The technology adapts the injection stretch blow molding (ISBM) process—commonly used to produce PET water and soft drink bottles—to manufacture thin, attractive, and hot-fillable HDPE containers. Traditionally, most HDPE bottles are produced using extrusion blow molding (EBM), a method that generally involves longer production cycles and often results in heavier containers, particularly at the base.
The newly developed process addresses these limitations by incorporating a second component into HDPE. This material, an ethylene copolymer known as TOPAS® COC (cyclic olefin copolymer), significantly expands the processing window for HDPE. By enabling the use of ISBM technology, it helps produce lighter bottles while maintaining recyclability. Demonstrations of the process have shown weight and cycle-time reductions of more than 25%.
TOPAS® COC is widely used in the packaging industry in combination with polyethylene (PE) to enhance material properties, and it is also used in medical applications where extremely high purity is required.
Colgate-Palmolive is currently evaluating the use of COC to enable cost-effective, high-performance packaging solutions that meet increasing regulatory requirements for lighter weight. Early results have been encouraging, and the company plans to continue advancing the technology toward commercialization.
Extensive testing has been conducted by Polyplastics at PTI’s development facility in Holland, Ohio. PTI has also confirmed the hot-fill capabilities of the new technology.
Looking ahead, PTI plans to collaborate with several brands to support the commercial launch of ISBM HDPE bottles for a wide range of applications, including cosmetics, food, medical products, household goods, industrial products, and general packaging.