27 Nov 2023 --- Kraft Heinz Company has launched its first 100% recyclable cap for its squeezy ketchup bottle in collaboration with Berry Global. Traditionally, Heinz bottles used a flexible silicone valve to deliver a consistent portion of sauce per squeeze, but this was often challenging to recycle. Berry Global has now provided the company with a monomaterial PP cap. 

According to Heinz, R&D for the project took eight years, 45 prototypes and more than 185,000 hours. Berry was involved in the design and production process, from concept to creation of the series of tools in Berry’s in-house tool shop and developing the assembly equipment for industrial production. 

Heinz claims the move to the recyclable cap will save a potential 300 million plastic lids from being sent to landfill every year globally.

The company followed a rigorous testing procedure to make sure the cap met the highest quality standards. 

An extended consumer survey confirmed that the public would receive the new concept, as it dispenses the same perfect amount of sauce every time without affecting the squeezability. 

“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,” says Matthias Hammersen, sales director — Food Market at Berry Global. “We’re delighted that the finished result exceeds our initial expectations and actually improves the consumer experience.”

The R&D led to a new cap design that helps consumers squeeze more ketchup out of the bottle when it is nearly empty — an achievement Berry says signifies its ability to look holistically at the overall solution to improve the cap’s performance alongside its recyclability.

UK roll-out
The caps are being rolled out UK-wide on 400 ml and bigger top-down bottles of Heinz Tomato Ketchup, including 50% Less Sugar and Salt varieties. In the future, the cap will also be rolled out across more of the Heinz sauces range in the UK and Europe.

“We know our consumers care about their impact on the environment, and so do we, which is why we’re delighted to see our innovative, more sustainable caps on Heinz Tomato Ketchup bottles across the UK,” says Jojo de Noronha, president of Kraft Heinz Northern Europe.

“Although a small change, this makes it easy for the millions of Heinz lovers across the country to recycle their whole squeezy bottle at once — a small action with big potential for impact.”