Berry Global develops custom plastic packaging solution for Vamoosh’s Plug Hole Unblocker

UK – Packaging leader Berry Global has unveiled a tailored plastic packaging solution for Vamoosh’s Plug Hole Unblocker, addressing the complex challenges presented by the product’s unique chemical formulation.

Developed through in-depth research and testing, the solution ensures durability, compliance, and market-readiness.

Traditional packaging materials such as polyethylene terephthalate (PET) and high-density polyethylene (HDPE) proved unsuitable due to the unblocker’s specialist chemical composition.

In response, Berry Global enhanced its 600ml Alpha bottle with an environmental stress crack-resistant additive and increased its wall thickness. After testing various weights, a 52g bottle was selected for optimal strength and performance.

Dave Toms, Director of Cares Laboratory, the inventor of Vamoosh, praised the collaboration, “Our partnership with Berry Global has been pivotal in developing a packaging solution that meets our performance criteria.

“Berry’s swift turnaround and comprehensive service allowed us to bring our product to market quickly and efficiently.”

The development process included rapid 3D-rendered graphics for branding visualization and trials using bottles of three different weights. This helped Vamoosh finalize a cost-effective tooling template, accelerating the product’s time-to-market.

Berry Global also modified the bottle’s neck to fit a standard child-resistant closure cap, ensuring regulatory compliance.

Berry’s Beccles facility produced the product, and the closure was manufactured at its Norwich factory in the UK.

Berry’s Sales and Marketing Director, Joe Horton, highlighted the company’s strategic approach: “We were committed to delivering a fit-for-purpose pack and a fast-to-market launch for Vamoosh.

“This solution meets stringent performance standards and demonstrates how our global network and design capabilities deliver high-quality, integrated results.”

Expanding sustainable packaging for global brands

This project aligns with Berry Global’s broader commitment to innovation and sustainability. The company recently partnered with Mars, Inc. to roll out 100% recycled plastic pantry jars for brands such as M&M’s, SKITTLES, and STARBURST.

Building on their 2022 launch of jars with 15% recycled content, the new jars now use mechanically recycled post-consumer resin (PCR) and are available in 60, 81, and 87-ounce sizes.

This initiative is expected to eliminate more than 1,300 metric tons of virgin plastic annually—equivalent to the weight of 238 African elephants.

The easy-grip square jars are manufactured using food-grade PCR sourced from curbside recycling, further contributing to a circular economy. Consumers are encouraged to recycle jars and lids to support ongoing sustainability goals.

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