Berry Global has created a range of reusable bottles made entirely out of post-consumer recycled (PCR) plastic for leading UK ethical cleaning company The Bio-D Company.

The range includes 750ml, 1 litre and 5 litre sizes for a number of Bio-D’s liquid products including Laundry Liquid, Fabric Conditioner, Dishwasher Rinse Aid, Washing Up Liquid, and Home & Garden Cleaner.

Bio-D specialises in the production of cleaning products which offer 100% naturally derived alternatives to toxic chemicals for safe and efficient cleaning that does not harm people or the environment. This commitment to protect and preserve the planet extends to the company’s packaging, and for several of its liquid products, Bio-D’s own analysis has concluded that a 100% PCR bottle is the most suitable and environmentally responsible choice.

At the same time, it is essential that the bottles deliver a high level of performance, most notably in terms of their durability and longevity. In particular, their design facilitates reuse as they can be refilled multiple times at over 300 refill stores nationwide. Equally important, the bottles can finally be recycled at their end of life.

Bio-D has calculated that the CO2 emissions saved by using 100% PCR bottles compared to virgin plastic amount to 13 tonnes annually.

“Our customers are naturally very sustainability conscious, so it is vital that our packaging represents the same ethos,” said Heather Nixon, Bio-D’s Sustainability Manager.

“Reusable bottles made completely from PCR offer a more sustainable solution than alternatives such as pouches. Berry has worked hard to ensure that the bottle is tough and long-lasting while also offering convenience and ease of use for the consumer to deliver a solution that is fit for purpose while fully complementing our brand values.”

The various bottles are blow moulded in 100% PCR HDPE and incorporate an embossed Bio-D logo to maintain the brand’s presence throughout the life of the bottle. The design for the 1 litre Laundry Liquid and Fabric Conditioner bottles also features a handle for safe carrying and controlled pouring.

Berry’s technical and design expertise were critical to the successful production of the bottle.

“While we have been using recycled material in our containers for many years, the requirements for the Bio-D bottle set us additional challenges that required new material technology and processing requirements and an extensive new test regime,” explained Sally Halliwell, Sales Development Manager, Berry Global Blow Moulding Specialities.

“We are delighted to have partnered with Bio-D in a project that has enabled us to further refine and perfect our processes and which will inform the ongoing development of other products within the Berry BMS portfolio.

“This project also demonstrates why collaboration is so critical to supporting a circular economy. Our team is passionate about pushing the boundaries of what can be achieved with recycled plastics. Working closely with Bio-D, we have been able to deliver ‘More Together’ and show how recycled plastics can play a vital role in the development of packaging solutions that are both practical and sustainable.”

As part of the development process, Berry BMS was able to call on the processing experience of Berry’s specialist recycling business Berry Circular Polymers. In addition, the plastic closure for the bottle is produced by Berry Norwich, providing Bio-D with a complete single-source bottle and closure solution.

“As a B Corp certified business, which confirms that we meet the highest standards of social and environmental impact, it is vital that our packaging contributes towards making our products environmentally responsible,” concluded Heather Nixon.

“We have worked with Berry over a number of years and the company has always delivered excellent quality and service. Consumers love these bottles because they know each one has been manufactured from waste plastic and can be used time and time again.”