Bulging Bottle Redesign
The Opportunity
Juicy Juice had an issue with bottles bulging on one of their four filling lines, which was preventing them from launching a new bottle design. Juicy Juice wanted to launch their 64oz package at a reduced bottle weight without purchasing new equipment, or making any other major changes to the filling lines.
The Innovation
PTI developed two alternative bottle designs and evaluated them virtually to discover a successful design. Once that was complete, a unique lab device was invented in order to simulate the filling line so that real world experiments could be conducted to validate the new design. This helped successfully launch the new design in the plant at the reduced target weight.
The Outcome
Juicy Juice acheived significant savings due to reduced downtime for line interruptions, material costs, and eliminated need for validation trials. In addition, this allowed the brand to launch a new, lightweight package without requiring expensive investment in new filling equipment.
