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Tums packages sealed with a twist

SmithKline Beecham breaks new ground with an oval-shaped, induction-sealed foil membrane beneath a twist-off cap. Benefits include reduced downtime and less scrap.

The redesigned Tums package (left) features a snap-on/twist-off cap and an oval-shaped neck finish that is induction-sealed on a
The redesigned Tums package (left) features a snap-on/twist-off cap and an oval-shaped neck finish that is induction-sealed on a

Relief is now just a twist away for Tums users. SmithKline Beecham Consumer Healthcare, the Pittsburgh-based manufacturer of Tums®, Tums E•X® and Tums Ultra® Antacid/Calcium supplements, recently completed a packaging makeover on its popular products. Previously topped by a snap-on cap that was removed by prying up on one side, the new, more consumer-friendly package employs a twist-off cap. It removes easily to reveal an oval-shaped foil membrane that is induction-sealed on a machine from Enercon Industries (Menomonee Falls, WI).

In early 1998, consumer feedback and keen observation led SB’s marketing department to the conclusion that a new package was in order. To help implement the changes, SB turned to long-time partner Pretium Packaging (Hermann, MO), which has supplied the pharmaceutical company with bottles and caps for almost 25 years.

The design team, consisting of SB, Pretium, and moldmakers Swan Industries (St. Louis, MO) and R.J. Abramo Associates (Hollison, MA), went to work on prototype packages with several goals in mind. First, they wanted a familiar shape for continued brand recognition, but with a new opening method for the cap. Another consideration in the design was the addition of an induction seal, as the conduction-sealing machines previously used were large, cumbersome and difficult to service.

“Basically, there were no change parts available for the machines,” says Jim Pitassi, packaging engineer with SB. “Everything had to be made in-house in the machine shop in St. Louis (where the Tums products are packaged). The conduction units took up a lot of space, and they were hard to service. The maintenance guys had to crawl around them to make necessary changes.”

In his quest for an induction-sealing supplier, Pitassi decided to add Enercon to the team developing the new Tums package. “I liked its strong, in-house research and development team, unlike R&D consultants that I found with some of the competition,” he explained. “Enercon also provided the commitment to work with us through and beyond completion of the project. Also, the induction sealer is a solid, compact unit.”

Working with the various prototypes, the design team finally established that it had a winner for bottle shape and material. The almost-finished design replaced the previous bottle material, polystyrene, with injection blow-molded polypropylene, resulting in a lighter bottle while maintaining the predecessor’s familiar silhouette. The injection-molded, high-density polyethylene cap was contoured to match the shape of the bottle, snapping on and twisting off. Once the basic cap and bottle design were decided upon, the design team needed to work on the sealing aspect of the package.

Sealing challenges

The old Tums bottle had a rectangular opening that matched the bottle’s shape. That rectangular bottle shape was something the design team wanted to retain because consumers were familiar with it. However, the rectangular opening had to go, as induction sealing doesn’t usually work with squared-off corners. So the design team came up with an oval shape that mimics the rectangular shape of the Tums bottle. It’s an oval neck shape that tops the rectangular container.

Videos from Enercon Industries Corp.
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