Caps from two internationally well-known household detergent brands were chosen for a very successful trial of an exciting new technology which uses foaming additives to produce a lighter interior core to the component.

Given the world-wide footprint of this brand, involving multiple filling sites, it was vital to achieve the desired raw material reduction without compromising a reliable, universal fit. Any issue with colour, size or function would have truly global implications, so extensive rapid trialling was carried out and the target weight was achieved without any change in geometry or appearance.

The result – high quality caps offering complete consistency across the range and with a superb weight saving of approximately 1gm per unit, giving an annual reduction of 475 tons of raw materials and all achieved with zero tooling modification.