CG Roxane has recently changed its Alpine Spring Water bottle lids from detachable screw closures to EZ-Caps (tethered caps). Coca-Cola, The Absolut Company, and Coverpla make similar changes to their caps.
What’s driving these changes?
The three main reasons are sustainability goals, consumer preference, and updated government regulations, including EU directive 2019/904 and California’s AB 793.
But why is the focus on something as small as a bottle cap?
Bottlecaps are often ignored in sustainability discussions, yet they are among the top five pollutants in our oceans. Governments like the EU, the US, and Nigeria are working to address this issue. They aim to phase out loose caps from plastic drinking bottles.
They are also mandating plastic bottles to contain at least 25% recycled materials by 2025 and upto 90% by 2029, including the caps.
Hence, companies are now trying different solutions to make caps sustainable with user-friendly designs.
This article discusses 5 trends that the bottle caps and closures will see in 2025 or beyond.
Curious about what more is changing in bottle cap materials and designs? How are brands staying ahead with minor tweaks to their caps? And what do consumers think about these changes?
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Bottle Caps and Closures Trends
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1. Biodegradable Materials
Polyhydroxyalkanoate (PHA) caps that degrade within six months
Unlike traditional plastics, PHA caps do not contribute to long-term plastic pollution. Many companies are adopting PHA caps to meet sustainability goals and comply with stricter regulations on single-use plastics.
Danimer Scientific, a Georgia-based company, expanded its Winchester, Kentucky plant to boost PHA bioplastic production. This expansion positions Danimer as one of the world’s largest PHA producers.
In Mar 2024, Beyond Plastic introduced the first fully biodegradable plastic bottle cap from PHA. This cap mirrors the appearance and functionality of conventional petroleum-based caps but offers significant environmental benefits.
Source: Beyond Plastic
PHA caps make bottles fully recyclable. However, manufacturing challenges exist. Their melting points and molding processes differ from conventional plastics, requiring costly machinery adjustments and downtime.
Variability in biological feedstocks used to make PHA caps impacts the cap quality. This means more quality checks are needed, increasing costs. Producing PHA on a large scale requires a lot of money, special machines, and skilled workers. This makes it costly and not very profitable for many companies.
Companies are recognizing these hurdles and collaborating to find solutions. One example is Beyond Plastic’s partnership with CJ Biomaterials and Tech-Long International. CJ Biomaterials provided high-quality PHA, solving issues with scalability and consistency. Tech-Long International customized machinery to integrate PHA processing into current production lines. This collaboration enabled large-scale sustainable bottle cap production.
PHA caps are undoubtedly a good option for replacing plastic caps. This is especially true when considering end-of-life (EOL) decomposition.
Waterless Fiber-based caps
Fiber-based caps are made from renewable cellulose or wood fibers. They are fully recyclable and biodegradable in paper waste streams, making them an efficient, sustainable, and eco-friendly alternative to plastic caps.
PulPac and PA Consulting are collaboratively using an innovative dry-molded fiber technology. The process converts plant fibers into sustainable packaging products using minimal (almost no) water. The method forms plant-based fibers, such as wood pulp or other agricultural by-products, into a molded shape like caps.
Source: Packaging Europe
The Bottle Collective, which includes companies such as Diageo, Logoplaste, Haleon, and Sanofi, is testing these dry-molded fiber caps. The goal is to create complete dry-molded fiber bottles and closures with 95% fiber-based content.
Find more about PulPac’s latest technologies and other industry advancements with Slate – an expert AI Research tool. Continue this conversation here:
Another similar recent collaboration was of Blue Ocean Closures and Paboco. They are creating a recyclable, market-ready paper bottle and fiber-based cap combination that weighs 16 grams (HDPE barrier<2 grams).
Ola Tönnberg, CCO at BlueOcean Closures, states: “We see that the fiber-based closure is a new standard category, applicable to a range of different bottle materials. Expanding the possibilities to reduce plastics, we are very excited to launch it on fiber bottles through our collaboration with Paboco.”
2. Design Changes in Bottle Caps
Bottle caps are among the top items found in marine debris. To solve the problem of bottle caps getting missed to add marine waste, the European Union rolled out a Single-Use Plastics Directive. Companies must ensure that caps stay attached to single-use plastic bottles. This makes collection and disposal easier.
To comply, companies like CG Roxane and Coca-Cola changed their bottle caps. Now, they remain permanently attached to the bottle using a tether rather than fully detachable.
Packaging solutions companies like Retal are developing patented, market-acceptable tethered cap designs, as these changes are not easy to implement and are not widely accepted by consumers.
However, consumers and their drinking habits are not taking these sudden changes very well. Some value the environmental benefits, while others find them annoying and rank them as the second-worst innovation in Europe.
Social media is critiquing the EU for passing this legislation. Usability issues are being raised. Users have trouble reattaching parts, which can cause leaks or spills.
Another debate surrounding these caps is whether they reduce plastic waste and are recyclable. The reasons behind these doubts are simple yet well-researched.
Tethered caps stay with the bottle during recycling. This way, both the bottle and the cap get processed together. However, unlike PET or rPET bottles, manufacturers make these caps from different materials, such as HDPE and PP.
Moreover, manufacturers make bottles transparent and uncolored while they color the caps. Usually, colored caps or plastic are categorized as recycling contaminants. This means machines need to take them out for recycling. You can’t recycle mixed plastics together. However, the whole process is resource-intensive.
A simple solution is to create transparent caps and bottles from the same materials, like PET. This helps promote a circular economy for tethered caps.
Origin Materials is tackling the issue of cap recyclability. They have designed and made tethered PET caps using the same PET material as the attached bottles.
Another company, Aptar, provides four different single-material transparent closures for sports and dispensers. These caps are non-detachable and tamper-evident.
3. Smart caps that track your habits
Smart caps integrate advanced technology, such as built-in sensors, Bluetooth connectivity, or other intelligent features, to track product usage and monitor freshness. These sensors and connected apps can provide real-time data to consumers or manufacturers.
For instance, these caps remind users to stay hydrated, track the amount of liquid consumed, or alert them when the product is nearing expiration. They provide convenience and sustainability. Combined with improved consumer engagement, smart caps are a popular choice in the F&B, healthcare, and wellness industries.
For instance, Danone collaborated with an Israeli startup, Water.io (now impacX), to introduce its Smart Cap for its Font Vella Spanish mineral water bottles. This innovative cap uses Bluetooth technology to sync with the Coach2O app. It tracks users’ hydration levels and offers personalized reminders, tips, and facts.
Water.io’s smart cap provides a blinking light reminder if hydration is insufficient, per user goals. It has a clip-on design to fit over water bottle caps to minimize water damage and can be removed easily after use. This will help maintain sustainability and reusability for these caps.
Another example of technology integration using caps is Ambev embedding unique QR codes inside the caps of its Brahma beer bottles. For now, in Brazil only, consumers can scan these codes using the Zé Delivery app to participate in a loyalty program and earn rewards with each purchase.
Brasilata developed the caps that preserve the beer’s flavor while offering digital functionality. Integrating QR codes and smart packaging is helping Ambev improve customer interaction, product usage tracking, and supply chain transparency.
Malibu Rum’s incorporation is another alcoholic beverage company that has changed its regular bottle caps into smart caps with near-field communication (NFC) technology.
These caps provide customers with interactive experiences, including drink recipes, competitions/events, and product information, such as ingredients. The company is using these caps for customer engagement and quality control. These technology-integrated caps also make shipment tracking and product recall processes easier.
Berry Global Inc. patented one such smart closure, combining child-resistant features with electronic tracking systems. The closure comprises two layers: an outer cap and an inner cap. When the user presses down to open the cap, the electronic switch moves from a non-contact position to direct contact with the inner cap.
This motion activates the electronic system, allowing data collection and triggering alerts if needed. This system provides real-time data tracking and enhances security by integrating an electronic monitoring mechanism within a child-resistant closure system.
The embedded electronic system records each time the cap is opened, tracking when and how often the medicine container is accessed. This data can then be transmitted to a connected device or app, allowing users to monitor medication habits in real time. For security, the system ensures that the container cannot be opened unless a specific downward and rotational force is applied, making it difficult for children to access.
Additionally, if the cap is not closed correctly, the system can trigger alerts or notifications, preventing accidental overdoses or improper medication storage. This is especially beneficial for households with children, ensuring that harmful medications remain secure.
Moreover, the recorded opening history allows users to verify whether they or their caregivers took the correct dosage at the right time. Caregivers or family members can also remotely track whether elderly individuals or patients with cognitive conditions, such as dementia, adhere to their medication schedules.
The system can integrate with mobile applications to provide reminders and notifications based on tracked data. These features make the system highly useful for medication tracking, parental control, pharmaceutical security, and elderly care, ensuring safe and monitored medication usage.
4. Child Resistant Caps with Improvisation for Special Persons
In 2023, the National Capital Poison Center reported over 2.1 million calls to 55 U.S. centers. Infants and toddlers (0-2 years) and young children (3-5 years), related incidents accounted for 40% of these calls.
Most of these incidents are unintentional, with cleaning materials and pain medications leading to the list of substances implicated in pediatric exposures.
Using child-resistant packaging for over-the-counter drugs, prescription medications, and household cleaners can significantly lower these incident risks.
Regulations like the Poison Prevention Packaging Act (PPPA) mandate that most prescription drugs be packaged in child-resistant containers.
However, CR packaging can pose significant challenges for individuals with physical disabilities or limited dexterity.
The primary design of child-resistant caps typically relies on push-and-turn or squeeze-to-release mechanisms. Opening these caps requires specific strength and coordination (dexterity).
For people with conditions such as arthritis, Parkinson’s disease, multiple sclerosis, or stroke, opening these packages can be difficult or impossible without assistance. These people need the medication most, and CR caps can hinder their access to the medicine.
This issue has led to the development of adaptive packaging solutions that balance safety for children and ease of use for people with disabilities.
One such innovation is the patented Snapslide CR caps, which feature a no-torque and ergonomic design. The caps’ sliding, two-step opening mechanism requires less force and dexterity than traditional push-and-turn closures.
This allows users to open and close the cap using one hand for metered doses. It provides convenience for those with arthritis, Parkinson’s disease, or other conditions that affect fine motor skills. Made from lightweight, durable materials, SnapSlide Caps are 27% lighter than conventional child-resistant caps. They also focus on reducing plastic usage and improving sustainability.
SnapSlide Caps are ideal for over-the-counter (OTC) products and prescription medications. They are available for both plastic and glass bottles.
Our research experts at GreyB helped a leading pharmaceutical company develop an innovative child-resistant packaging solution that meets clients’ recyclability goals and makes minimum adjustments to current production processes.
In this case study, we discuss how we helped develop child-resistant packaging that enhances safety and compliance for pharmaceutical products.
5. Universal Design
As consumer preferences evolve, the design of bottle caps is increasingly influenced by the need for universal accessibility. A key driver of this change is the growing demand for easier packaging that is accessible to everyone, regardless of age, physical ability, or dexterity.
Take patented SnapSlide caps, for example. These caps have emerged as an innovation designed for individuals with limited hand strength or dexterity. They offer a sliding two-step mechanism that can be operated with one hand and requires less force than traditional push-and-turn caps.
Another change is the shift toward larger, ergonomic caps that are easier to grip. These caps help those with arthritis or limited mobility open bottles without struggling.
Conclusion
According to a 2023 UK beach survey, bottle caps are the third most common type of litter, while a Dutch coastline survey found up to 128 caps per kilometer of beach. Their buoyant design enables them to travel far in the ocean and poses a significant threat to marine life, which often mistakes them for food. This highlights that the issue with caps is more severe than it appears.
Amidst growing environmental awareness, consumers increasingly make purchase decisions that reflect their concerns. Nielsen’s 2023 market research indicates that 92% of shoppers prefer brands with sustainable products. This shift in consumer behavior is particularly influential in shaping the market for small yet impactful items like bottle caps.
The packaging industry changes as sustainability pressures grow, regulations tighten, and consumer preferences shift.
One of the challenges in the EU’s PPW Regulations is that they cause headaches for many industries, especially packaging. Since caps and closures are part of the packaging, they are also affected.
Navigating the regulations is a priority for manufacturers and organizations.
GreyB specializes in helping businesses navigate similar complexities of innovation and intellectual property.
To see how we’ve helped other companies thrive, visit our case studies page.
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Authored by: Naveen Kumar, Marketing.
Edited by: Ridhima Mahajan, Marketing.
