Nutrition company Xango has replaced the glass bottles of its mangosteen beverage Xango Juice with 750ml polyethylene terephthalate (Pet) bottles.

The PET bottles are manufactured by Berry Plastics using a two-stage reheat-and-blow process on equipment from Swiss-based Sidel.

According to the US-based Xango, the material change required a switch to aseptic filling from the pasteurisation and hot-fill process used for the bottles.

The process was completed by a contract packager with the help of filling and capping equipment manufactured by Fogg Filler, the US provider of bottle filling systems.

Decorated with two pressure-sensitive labels and a shrink band, the bottles were distributed by Berlin Packaging, while specialty packaging company Zion Flex Pack provided the shrink sleeve.

The move to PET is said to have brought about a host of environmental and economic advantages to the company, including savings of more than $1m annually in the cost of goods, freight, secondary packaging and breakage; 85% reduction in bottle weight and associated packaging/shipping requirements.

The switch also helped the company to achieve a 34%, 64% reduction in energy use and greenhouse gas emissions, respectively; significant waste reductions with no bottle breakage and less secondary packaging; 5.7 million lb savings in annual materials; and 2,039mt savings in annual CO2 emissions.

Xango said that it will continue to explore various packaging options and the initiative would apply to all of its products, going forward.
Xango technical director Rex said the move provided an opportunity to the company to improve in many areas while retaining the brand image and product quality.

"The changes in secondary packaging, such as eliminating the EPS inserts used to protect the glass bottles contributed significantly to the reduction in the overall package size," said Rex.