The development of a new Tropicana orange juice container is one example of how creativity, persistence and teamwork led to increased customer satisfaction and improved juice sales.<\/p>\n\n\n\n
In 2007, Tropicana wanted to change the way their orange juice products were packaged to meet consumer preferences for clear containers.\u00a0 At the time, Tropicana containers with handles were made of opaque, white plastic.<\/p>\n\n\n\n
Tropicana turned to the team at PepsiCo Advanced Research in Hawthorne, N.Y. to identify the materials and processes needed to produce a new 89-ounce juice container with a handle that was both clear and recyclable.<\/p>\n\n\n\n
The resin commercially available in 2007 did not meet PepsiCo\u2019s requirements. They lacked the melt strength necessary for extrusion blow molding large containers, a process used to make plastic containers with handles and were not recyclable.<\/p>\n\n\n\n
\n\tExtrusion Blow Molding<\/p>\n\t
Tropicana 89 ounce containers are produced with an extrusion blow molding process, where molten resin is formed into a hollow tube and inflated inside a mold. Cooling within the mold helps the package take its final shape as a strikingly clear beverage container with an integrated handle.<\/p>\n<\/blockquote>\n\n\n\n
When Clarence Sequeira, a material scientist at PepsiCo Advanced Research, asked a major resin supplier when a resin meeting PepsiCo\u2019s performance and sustainability requirements would be available, he was told five to seven years.<\/p>\n\n\n\n
So Sequeira and his team went to work to develop one that was recyclable and capable of high-speed production.\u00a0 After extensive research and experimentation, they produced a compounded resin that had the right properties and met PepsiCo\u2019s requirements.<\/p>\n\n\n\n
While pursuing a partner that could mass produce the PepsiCo resin, the team identified a supplier with a resin that was nearing commercial readiness and was similar to the PepsiCo resin. The supplier\u2019s resin was tested and, with modifications based on PepsiCo\u2019s research and development efforts, was made suitable for the production of the Tropicana containers.<\/p>\n\n\n\n
Next, Sequeira worked with a wheel blow molding equipment manufacturer to pilot test a high-speed production process by modifying existing hardware to melt, process and blow mold containers from the newly formulated resin.<\/p>\n\n\n\n
The pilot tests were successful and helped move the development of the 89 ounce container to the validation phase.\u00a0 At a Tropicana plant in Bradenton, Fla., Sequeira worked with Tropicana and equipment vendors to create a new, full-scale production unit using lessons from the pilot test.<\/p>\n\n\n\n
Sequeira and Ed Socci, director with PepsiCo Advanced Research, equipped a mobile test laboratory adjacent to the Bradenton plant to provide rapid analytical feedback during the validation process.\u00a0 The team used sophisticated equipment to evaluate the containers coming off the production line. Working long hours over several months, the team measured resin moisture content, container thickness and clarity.<\/p>\n\n\n\n
\u201cThis was a truly open and collaborative process,\u201d said Sequeira.\u00a0 \u201cWe had the full commitment of all partners, including vendors. Everyone was there to address problems, identify solutions and make the project a success.\u201d<\/p>\n\n\n\n
Also present was Nicole Green, the project leader for the overall packaging qualification project, who had the important job of commercializing the research and development team\u2019s work.<\/p>\n\n\n\n
Green worked with brand design teams to come up with a package that included not only the shape of the new bottle, but outstanding functionality.<\/p>\n\n\n\n
\u201cWe wanted something that looked elegant, that people felt comfortable putting on the kitchen table or using during Sunday brunch,\u201d said Green.\u00a0 \u201cWe wanted it to look premium to reflect the high quality of our juice.\u201d<\/p>\n\n\n\n
Green and her team developed a flip-top cap design and worked with equipment suppliers to overcome cap production challenges. They tested handles for size, feel and \u201cpositioning with respect to the package\u2019s center of gravity.\u201d<\/p>\n\n\n\n
They tested containers for strength and durability. And they tried various design concepts to ensure that the orange juice poured smoothly from the very first pour.<\/p>\n\n\n\n
Success was not guaranteed said Green.\u00a0 \u201cWe learned a lot and made modifications to the custom equipment specifically for the project,\u201d she said.\u00a0 \u201cOnce we were able to fine tune the process and get the data we needed from our tests, we were able to tell the business we felt comfortable going forward.\u201d<\/p>\n\n\n\n
Green also worked with suppliers to ensure that their systems were modified and scaled, both upstream and down, to support PepsiCo\u2019s new materials, equipment and processes.<\/p>\n\n\n\n
Today, thanks to the hard work and dedication of PepsiCo employees and the company\u2019s commitment to improving its products through research and development, clear, elegant and recyclable Tropicana 89 ounce orange juice containers can be found on supermarket shelves.<\/p>\n\n\n\n
Consumer reaction to the new 89 ounce package has been overwhelmingly positive. The added functionality of the easy-to-open lid, easy-to-pour handle, and clear container that allows consumers to see the juice have worked together to drive consumer excitement for the package, and the in-market results prove it.<\/p>\n\n\n\n
In the year of its launch, dollar sales of this package grew 40 percent. Tropicana\u2019s dollar share of 89 ounce orange juice grew 7 percentage points while Simply Orange\u2019s decreased 5 percentage points. Repeat on the Tropicana 89 ounce package has also improved from 56 percent of buyers to 57 percent, signaling that consumers are happy with the package after they use it.<\/p>\n\n\n\n
\n\tFor their efforts, Sequeira, Green and Neil Enciso were presented the 2013 PepsiCo Academy of Sciences Award in the science and technology category.\u00a0 The team was also awarded in 2013 a silver Visionary Award in the packaging development and design category sponsored by Packaging Digest, and Pharmaceutical and Medical Packaging News.<\/p>\n<\/blockquote>\n\n\n\n
\u201cThis was a four-year journey for me as well as the rest of my team,\u201d said Green. \u201cAnd Clarence and Ed were already working on the resin before I joined.<\/p>\n\n\n\n
\u201cIt was quite an effort,\u201d she said.\u00a0 \u201cIt\u2019s definitely one of those projects where you\u2019re going to look back and say we did really well, and we should be proud of the work.\u201d<\/p>","protected":false},"excerpt":{"rendered":"
PepsiCo innovators develop a recyclable Tropicana container to meet consumer preferences. Developing innovative products takes the time and talents of amazing\u00a0PepsiCo\u00a0\ufeffassociates who work hard to deliver consumers around the world […]<\/p>\n","protected":false},"featured_media":0,"template":"","fdoc_news_item_category":[100],"fdoc_citrus_type":[107,108,109],"fdoc_health_category":[],"class_list":["post-4075","fdoc-news-item","type-fdoc-news-item","status-publish","hentry","fdoc_news_item_category-industry","fdoc_citrus_type-orange","fdoc_citrus_type-orange-juice","fdoc_citrus_type-tangerine"],"acf":[],"aioseo_notices":[],"_links":{"self":[{"href":"https:\/\/www.floridacitrus.org\/grower\/fr\/wp-json\/wp\/v2\/fdoc-news-item\/4075","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.floridacitrus.org\/grower\/fr\/wp-json\/wp\/v2\/fdoc-news-item"}],"about":[{"href":"https:\/\/www.floridacitrus.org\/grower\/fr\/wp-json\/wp\/v2\/types\/fdoc-news-item"}],"wp:attachment":[{"href":"https:\/\/www.floridacitrus.org\/grower\/fr\/wp-json\/wp\/v2\/media?parent=4075"}],"wp:term":[{"taxonomy":"fdoc_news_item_category","embeddable":true,"href":"https:\/\/www.floridacitrus.org\/grower\/fr\/wp-json\/wp\/v2\/fdoc_news_item_category?post=4075"},{"taxonomy":"fdoc_citrus_type","embeddable":true,"href":"https:\/\/www.floridacitrus.org\/grower\/fr\/wp-json\/wp\/v2\/fdoc_citrus_type?post=4075"},{"taxonomy":"fdoc_health_category","embeddable":true,"href":"https:\/\/www.floridacitrus.org\/grower\/fr\/wp-json\/wp\/v2\/fdoc_health_category?post=4075"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}