Amcor’s 1.9g weight drop reinvents ketchup caps without the squeeze on performance

GLOBAL – Amcor has launched a new 55mm Flava flip-top closure weighing just 8.5 grams, an 18.7 percent reduction from its predecessor, designed for mayonnaise, ketchup, and sweet sauces while maintaining clean dispensing and recycle-readiness.

The 38/400 neck finish format has been developed with circularity in mind as brand owners face mounting pressure to meet sustainability targets.

The redesign cuts the cap’s weight by 1.9 grams in absolute terms, taking it to 8.5 grams—a relative reduction of 18.7 percent compared with the previous 55mm flip-top closure.

The cap is made from a single material and comes in different orifice sizes and circular valve options, described as “recyclable-ready” when used with PET, HDPE, and PP bottles where suitable recycling systems exist.

Small Grams, Big Impact

For a single cap, 1.9 grams sounds trivial. Multiply by millions of units annually across a brand’s product portfolio, and the math becomes compelling.

A mid-sized condiment brand producing 50 million bottles per year would save 95 tonnes of plastic annually from this redesign alone—equivalent to eliminating approximately 95,000 kilograms of material from entering the waste stream.

When scaled across the entire industry, the cumulative material reduction runs into thousands of tonnes.

The Flava closure is produced in several colours and can be used with a selection of PET and HDPE bottles in Amcor’s range.

Among the bottle formats listed as compatible are the HDPE Eurosqueeze range, the 520ml Mercury PET, and the 400ml Force Oval PET.

This cross-compatibility allows brand owners to standardize closures across multiple product lines, simplifying inventory management and reducing the risk of production line errors.

Performance Without Compromise

Peter Briggs, Amcor’s UK food and beverage sales director, explained that the new Flava flip-top closure will help customers reach their carbon reduction targets thanks to its lighter design.

He noted that while weight saving is critical for reducing the carbon impact of the closure, it does not compromise performance.

Getting this balance right is crucial for consumers, who can be reassured that the product can be dispensed cleanly and easily.

He added that this lightweight design combines functionality, customer convenience, and recycle-readiness, supporting the circular economy while providing improved usability for a wide range of applications.

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