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Portola Packaging, Inc: Plug-seal closure for hot-fill, aseptic beverage packaging

The GreenLyte one-piece closure line from Portola Packaging is a new line of plug-seal, high-density polyethylene (HDPE) 38 mm closures for single and multiserve, hot-fill, and aseptic beverage packaging applications.

GreenLyte closures are a cost-effective, alternative to traditional two-piece (closure plus liner) polypropylene (PP) types typically used for juices, ready-to-drink teas, isotonics, enhanced waters, low-acid nutraceuticals, and high-end, aseptic-filled beverage products.

The one-piece plug design reduces costs for brand owners due to shell lightweighting, liner elimination, and material choice. Because the GreenLyte line is made from high-density polyethylene, resin is less expensive than pricing volatility-prone polypropylene, which is the material from which most two-piece closures are made. 

GreenLyte’s plug construction eliminates the need for a liner, eliminating the difficulty some consumers have opening two-piece closures, which do use a liner that can make opening difficult. 

GreenLyte closures also offer multiple production line efficiencies. Unlike two-piece closures, which usually require that the TPE liner be steamed in order to achieve proper application, this step is not necessary with the linerless GreenLyte line. Additionally, the seal design and low coefficient of friction facilitates application over a wide range of capper settings.

In addition to the cost, production, and performance benefits, the GreenLyte launch provides a conversion opportunity for those hot-fill beverage product manufacturers still using 43mm finishes. Instead of converting from a 43mm two-piece to a traditional 38 mm two-piece closure,  producers can now go straight into a 38mm one-piece plug closure improving their cost and environmental profile.


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