Method is first with 100% RPET detergent bottle

Method overcomes design and manufacturing challenges to create a 53-oz 100% RPET bottle with strong shelf appeal and environmental benefits for its new laundry detergent.

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Method Products has expanded its laundry care product line, introducing its new 4X Concentrated Laundry Detergent in a 53-oz PET bottle containing 100% post-consumer recycled PET resin from Amcor Rigid Plastics. The sleek, transparent custom container, which delivers strong shelf appeal, is the industry’s first liquid laundry bottle made of 100% PCR PET.

Well-known for its brightly colored handwash and all-purpose cleaning formulations showcased in clear PET bottles, Method has broken new ground in the liquid laundry detergent aisle, according to Joe Hunter, Director of Packaging for Method. “This new PET offering in the liquid laundry segment resonates with the rest of our brand portfolio in handwash and all-purpose cleaners,” he says. “This is an important achievement in a market that has previously been predominately limited to opaque high-density polyethylene containers.”

The new 4X concentrated liquid detergent complements Method’s existing portfolio of 8X Laundry Detergent, packaged in 10-, 20-, and 30-oz HDPE containers.

According to Amcor, until now, PET has struggled to enter the liquid laundry detergent market due to compatibility and color stability issues. Initially, Amcor provided product compatibility testing with Method’s liquid formula product to ensure package stability on the store shelf. Amcor did initial testing on preforms and further stability testing revealed no issues, according to Matt Lewis, Senior Development Engineer for Amcor Rigid Plastics.

Amcor’s design engineering team worked closely with Method’s industrial design team to create a bottle with Method’s unique look that could be stretch blow molded without a handle. The mold design created challenges due to the cross corner parting line split and the highly functional ergonomic handgrips molded on the back of the bottle. This was overcome by a variable radius parting line that allowed the part to release from the blow mold with no plastic entrapment.

The neck design also presented challenges due to the two-piece polypropylene pour spout and cup closure. The pour spout required orientation to the front of the bottle and once in that location could not be rotated by the removal of the pour cup. This was complicated because the PP closure was designed for an HDPE bottle. The lug design on the neck went through a series of design trials to find the best option. In addition, a small adjustment was made to the bottle’s shoulder height to accommodate the filling process.

The 53-oz container with 100% PCR PET enabled Method to gain major sustainability benefits. “Among our primary business priorities is reducing the environmental impact of all our products,” explains Hunter. Analysis using Amcor’s ASSET life-cycle assessment tool showed that by using 100% PCR resin, the package’s life-cycle energy consumption is reduced by 78%, and its carbon footprint is lowered by 35% versus a virgin PET alternative.”

Method’s new 4X Concentrated Laundry Detergent is available at Target stores and on the Method website in the U.S. The laundry product is available in four fragrances—Beach Sage, Fresh Clover, Spring Garden, and Ginger Mango—along with a fragrance- and dye-free option.

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