Who Was the Client and What Was the Challenge?
A major Italian nutraceutical company contacted us with a recurring operational problem: glass bottles containing fish oil were frequently damaged during shipment.
Their current packaging relied heavily on single-use plastic materials — primarily bubble wrap and plastic tape — placed inside a large 12-bottle cardboard base.
The consequences of a breakage were serious:
– oil leakage could contaminate the entire shipment
– customer experience was compromised
– additional shipping and replacement costs
– handling single-use plastic waste conflicted with their sustainability roadmap
The annual estimated volume is 12,000 shipments. For operational efficiency, they preferred packs of 3 or 4 bottles instead of one large bulk format.
What Were the Objectives and Constraints?
Objective:
Design compact, single-use-plastic-free and shock-resistant packaging to guarantee the integrity of each bottle during shipment — even in case of accidental breakage.
Constraints:
• Zero single-use plastic (no bubble wrap, no tape)
• Fast packing process (under 1 minute)
• Each bottle must be individually protected
• A broken bottle must not compromise the others
• Minimise cost per shipment
• Standard products with immediate availability
What Solution Did BOTTA EcoPackaging Provide?
After receiving the bottle samples, our team performed internal stress and drop tests.
We identified a dual-component solution, using only standard paper-based products:
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Eco-Sleeve Standard
– Replaces single-use bubble wrap entirely
– Higher version ensures full top protection
– Isolates each bottle and prevents contact damage
– Absorbs liquid in case of breakage -
Eco-Single Bottle Pinch Top Box
– No single-use plastic fillers required
– Bottles remain fully stable during transit
– Resistant to handling, impacts, stacking
– Eliminates the need for the triple layer of protection
Packing time: less than 1 minute
Materials used: 100% recyclable, zero single-use plastic
Availability: standard items, ready for immediate delivery
What Results Are Expected?
By eliminating bubble wrap and switching to 100% recyclable packaging, the client expects to achieve:
• Zero-oil contamination risk during shipment
• Reduction of packaging time and labor costs
• Higher customer satisfaction and fewer claims
• Immediate alignment with sustainability goals
• Lower overall packaging cost per shipment
• Better stock management thanks to standardised formats
Why This Approach Works
Sustainable packaging is not just about materials — it’s about function, logistics, and risk management.
By isolating each bottle and eliminating plastic, we transformed a fragile product into a controlled packaging system ready for frequent shipments.
For transparency reasons, the company name is not disclosed, but the solution is now being replicated in other industries such as:
– nutraceutical products
– cosmetics
– craft beverages
– premium e-commerce
Want to Test This Solution on Your Products?
We offer internal tests using real samples, plus a commercial proposal based on your estimated volumes.
Our consultancy includes EU eco-labelling expertise and practical guidance for plastic elimination.
