Glass bottle redesigned with confidence using clear SLA 3D printing

Orora earns client buy-in on new beer bottle design using colour-matched 3D printed appearance models with identical heft and hue of glass.

Packaging redesigns are a serious undertaking. On the marketing side, changes are visual and emotional; on the manufacturing side, changes cost money. Before making the investment to overhaul its glass bottle tooling systems, the maker of Australia’s James Boag’s Premium Lager needed to know an update to its bottle would not be change for change’s sake. It needed to be sure the new bottle would look good and be well received by customers. Ideally, this confidence would come before spending major time and capital on the project.

As the supplier of Boag’s bottles, Orora had skin in the game to validate the design quickly and accurately. Orora’s Innovation & Design team put wheels into motion by contacting 3D Systems On Demand Manufacturing, a long-time partner, to develop a state-of-the-art 3D printed prototype. Keeping Boag’s existing supply chain processes top of mind, a new-look bottle was designed to comply with the manufacturing infrastructure already in place to help avoid expensive and time-consuming changes.

3D printing a lookalike for glass

To get Boag’s buy-in on the new design, a credible appearance model was needed for evaluation. To be convincing, the 3D printed models needed to have the same clarity and hue as glass as well as the same in-hand heft. 3D Systems’ On Demand Manufacturing experts accounted for weight disparities by adjusting the interior wall thickness of the design file based on the density of the selected stereolithography (SLA) resin, and then got to work on color-matching to achieve the iconic green of the classic Boag bottle.

Using 3D Systems’ leading SLA 3D printing technology and VisiJet® SL Clear resin, 3D Systems’ On Demand Manufacturing experts printed four SLA prototypes. “Successful lab testing of 3D Systems’ clear materials verify they are the best solution for transparent 3D prints,” said Dr. Don Titterington, Vice President of Materials R&D, 3D Systems. “Used in a variety of demanding applications, clear materials deliver high-performing, cost-effective choices for functional, transparent prototypes.”

Once printed, the bottles were put through an in-house finishing protocol to bring them to final product quality. This included wet and dry sanding, applying a surface tint, and a final clear coat to deliver a glass-like sheen. With just a few simple steps, clear SLA prints can be transformed with incredible results. According to 3D Systems’ Tracy Beard, general manager for On Demand Manufacturing’s facility in Lawrenceburg, TN, thousands of clear parts are produced each week in the Lawrenceburg facility alone. “The materials are versatile enough to be quickly finished and tinted for perfect prototypes,” Beard says.

Fast feedback for fast progress

The appearance models were ready within a week, allowing Orora and Boag to quickly transition the new design to customer trials and gauge the public’s reaction. They filled the 3D printed bottles with liquid, outfitted them with a label and cap, and put them in a shop for monitoring. Feedback from these in-store trials indicated that the new design was a hit, clearing the new design for production.

“The new James Boag’s Lager bottle has set a standard within Orora for the way packaging design and 3D prototyping can come together seamlessly with short notice,” said Orora’s Innovation & Design team. “It’s the sort of technology innovation that’s giving us a critical edge when it comes to developing best-practice bottling design and manufacturing solutions for our customers.”

New jobs at Orora bottle manufacturing plant in Adelaide

International packaging firm Orora Limited has completed a $42 million expansion of its glass bottle manufacturing plant, boosting its 317-strong employee numbers by 26 and creating 85 construction jobs in northern Adelaide.

Minister for Investment and Trade Martin Hamilton-Smith today congratulated the company, located near Gawler, on delivering the project on time and on-budget. The State Government, through Regions SA and Investment Attraction South Australia collaborated to provide $2.4 million in funding to support the expansion.

Managing Director and CEO of Orora Limited, Nigel Garrard said the expansion project at Gawler represents one of Orora’s single largest capital investments in Australia.

“Orora’s Gawler plant is already one of the largest glass manufacturing facilities in the Southern Hemisphere and the $42 million investment enables us to meet the increasing demand for high quality glass bottles,” he said.

The investment has substantially grown the scale of the Gawler operation, increasing capacity by around 60 million bottles, which will directly support the local wine industry.

The expanded facility is expected to result in more than $10 million a year being spent within the South Australian supply chain through raw materials, energy, maintenance and labour costs. Local suppliers have also benefited through the expansion process with a good proportion of the contracts going to South Australian companies.

“This project is another example that South Australia’s manufacturing sector can deliver on a global scale and provide the efficiencies which international markets expect,” said Minister for Investment and Trade Martin Hamilton-Smith.

“With more locally manufactured bottles and forming lines leading to further supply chain advantages, this is a great result for South Australia’s wine sector and a great demonstration of an import replacement investment.”

The South Australian Centre for Economic Studies has calculated the gross employment impact of the project to be 180 FTE (100 ongoing, 80 from capital works) and real GSP impact of $30.3 million.



Result Group finds a new way to advertise on bottles

Australia’s largest label manufacturer worked in conjunction with one of Australasia’s largest food and beverage companies to find an innovative way to advertise on bottles.

To assist The Daily Drinks Company in advertising a promotional message, Labelmakers (in partnership with Lion) used the HERMA 400 to create a simplified adhesive neck tag for the company’s bottles.

According to Result Group, this type of promotional information usually hangs loosely over the bottle neck. However, this form of advertisement does not offer much content space and there is no guarantee that the neck tags will stay on the bottles up to the point of purchase.

Result Group believe that the adhesive neck tag will be successful, as it uses standard pressure sensitive materials and is easy for the production site to process with limited changes to the existing process.

Global Packaging Trends Report shows modest growth in 2015

The recent Global Packaging Trends Report for 2015, which was sponsored by Australian Packaging & Processing Machinery Association (APPMA), shows three influencers making a mark in every region: growing consumer awareness of health and wellness, stronger influence of recycling and environmental issues, and increasing disposable income and purchasing power. 

Other important regional trends include urbanisation, convenience, smaller pack sizes, branding strategies, Internet retailing, and premiumisation. 

Globally, flexible plastic remains the dominant pack type with PET Bottles in second place. Pack types such as brick liquid cartons and PET bottles will register the highest growth rates.
"These trends are affecting packaging because they're driving consumers' purchasing choices," says Mark Dingley, Chairman, APPMA. 

"Recyclability and reusability of packaging are dominant trends and the report is predicting that this will continue as PET and glass bottle usage increases."

Packaging markets in the Middle East and Africa are anticipating 5.3 per cent CAGR growth in volume, but forecasts for Western Europe and North America land at the other end of the spectrum, with 0.4 per cent and 0.5 per cent, respectively.

The expansion in the Middle East and Africa is the result of increasing exposure to modern lifestyles, and is manifesting in growth opportunities available for packaging of carbonates, biscuits, and yogurt and sour milk products. 

In Asia Pacific, forecast for 4.3 per cent CAGR increases in volume, the increasing demand for PET bottles, particularly in the bottled water category, supports health and wellness concerns.

North America, on the other hand, is a mature market, but consumers are developing growing interest in several categories. These include healthy categories such as bottled water, and areas of innovation, such as confectionery.

Globally, the report notes flexible plastic remains the dominant pack type, accounting for 29 per cent of the market, while PET bottles (12 per cent of the market) will be among the fastest growing, with 4.7 per cent CAGR. Bottled water is expected to add 135 billion units through 2019, accounting for 54 per cent of the absolute volume growth in PET bottle use. While beverage packaging drives growth in PET and glass, categories such as confectionery and biscuits prop up flexible packaging use.

To access a copy of the Executive Summary please email the APPMA on

Mextrade joins Sesión as exclusive distribution partner

Sesión tequila is joining forces with the distributor of Mexican tequila and mezcal, Mextrade. 

The partnership means Sesión's genuine 100 per cent Blue Agave tequila is now available in all the top bars and restaurants across the country, delivering a unique chance to savour the complex flavours of an artisinal, small batch tequila made using traditional techniques.  

Founded by local Mexican entrepreneurs with a passion for hospitality and the best Agave-based spirits, Mextrade sources only from family-owned brands who have been working in the field for generations. 

Today, Mextrade is the premier distributor of 100 per cent Agave Tequila and Mezcal in Australia and works exclusively with some of the best known brands of Agave distillates across the globe. 

Cheeky Rascal steals win at the Australian Cider Awards

Boutique cider house Rebello has taken out best in class in the inaugural ‘cider with fruit’ category of this year’s Australian Cider Awards with its ‘Passionfruit Pink Lady’.

Made with Victorian grown pink lady apples and real passionfruit, Passionfruit Pink Lady was created as a limited edition range to the Cheeky Rascal Cider family, but proved was so popular, it’s now part of the core range.

As with all of Cheeky Rascal Ciders it’s made using 100% real fresh fruit, without concentrates and flavourings by third generation entrepreneurs of the Sunny Ridge Strawberry Farm, Matt and Ruth Gallace.

There were 155 entries across 18 classes in the annual awards, but this was the first time a category was created for cider or perry with real fruit.

Judges described it as a “well-made, clean, bright, crisp cider with grippy passionfruit character”.

Cider Australia President Sam Reid says the addition of the new class for ciders, made with the addition of natural fruits other than apple and pear, was to ensure the awards reflect the diversity of cider styles available to and enjoyed by Australian consumers.

"Our goal is to drive and reward innovation in cider making, and it's great to be seeing some solid results in these new classes."

Rebello CEO Ruth Gallace says it’s humbling to take out the inaugural award at what is the largest cider awards in the country.

“Having a category to recognise the work which goes into blending real fruit with cider is not only validation for cider makers like ourselves who have invested heavily for many years to produce a quality real fruit cider alternative, but it also provides credibility and clarity for the customer.”

Passionfruit Pink Lady was created on the back of requests by Cheeky Rascal’s loyal followers who it canvassed asking them to identify fruits they’d like to see blended with cider.

Alcohol warning labels a bit blurry says new study

 Australia’s current alcohol warning labels are failing to effectively convey health messages to the public, according to a new study from Deakin University.
Researchers with Deakin’s School of Psychology examined awareness of the voluntary warning labels and the ‘Get the facts’ logo that directs consumers to the industry-led informational website DrinkWise, and whether alcohol consumers visited this site.
The study found that recall of the current, voluntary warning labels on Australian alcohol products was non-existent, overall awareness was low, and few people reported visiting the DrinkWise website. 
“These findings demonstrate that the current approach of industry self-regulation is a straightforward case of regulatory failure,” said one of the report authors Peter Miller, Associate Professor of Psychology at Deakin.

The voluntary consumer messages on alcohol products were put in place in 2011 by DrinkWise – a ‘social aspects/public relations’ organisation, which is funded and governed by the alcohol industry – in response to a recommendation by an independent government review that all alcohol product labels depict a health warning.
The most recent audit showed that these labels are only depicted on around one third of alcohol products.
“Given that the majority of the Australian public support the introduction of mandatory health warning labels for alcohol products, and the success seen from strong, research-based tobacco labelling, it is time for the government to put in place mandatory, highly visible, black and white warning labels on the front of all alcohol products,” Associate Professor Miller said.
“We cannot continue to rely on voluntary industry-led measures where these important messages are being obscurely placed and take up less than five per cent of the product label.”

The study included 561 participants aged between 18-45 years, who completed an online survey to assess their alcohol consumption patterns, awareness of the ‘Get the facts’ messages, and their use of the DrinkWise website. Participants were asked about the series of DrinkWise warning labels, including ‘It is safest not to drink while pregnant’, an image of a silhouette of a pregnant woman with a strike through, ‘Is your drinking harming yourself or others?’, and ‘Kids and alcohol don’t mix’.
The results showed that no participants could spontaneously recall the ‘Get the facts’ logo. Around 16 per cent of participants could recall warning labels on alcohol products when prompted with images, 25 per cent recognised the logo and 13-38 per cent recognised the warnings. Overall, only 7.3 per cent of participants had visited the website.

Awareness of the ‘Get the facts’ logo and warning labels was also found to be positively associated with younger drinkers, increased frequency of binge drinking, consuming alcohol straight from the bottle or can, and being a supporter of warning labels.
“Our study demonstrated a low awareness of Australian alcohol warning labels, and a lack of consumer use of the industry-funded website. This highlights that while the DrinkWise brand might be a very successful marketing ploy by the alcohol industry, it doesn’t translate effectively into consumer knowledge or behaviour,” Associate Professor Miller said.
“Further research is now needed to evaluate the effectiveness of a consumer targeted alcohol control website.
“Information presented on an alcohol consumer information site needs to be evidence-based, useful and provide practical health advice. Currently, the DrinkWise website is used to create an impression of corporate social responsibility, but it does not promote evidence-based interventions and alcohol-harm reduction strategies.”


Smaller is bigger for Coca-Cola

Smaller cans and bottles driving overall transaction growth in Australia

Coca-Cola South Pacific has revealed the success of its new smaller sized packs, which are now growing faster than larger alternatives. 

250ml small cans were launched in August last year and have seen a rapid expansion in market share to 12 per cent of total single serve sales. It now has the highest transaction growth rate versus all other single serve options. 

Responding to consumer demand for smaller package sizes, the sales success has been important in driving up overall transaction growth for the company, with the 250ml can now available in 30 per cent of all retail outlets around Australia and 50 per cent of grocery outlets. 200mls multipacks are also now available in 95 per cent of grocery channels. 

Coca-Cola South Pacific says it is continuing its commitment to smaller portion sizes, with the 450ml bottle downsizing to 390mls. 

Lisa Winn, Marketing Director, Coca-Cola South Pacific, said: "More people are now drinking our products, in smaller quantities. It is fantastic to see that small packages are helping drive our overall transaction growth. Right now it is clear that smaller packages are offering the perfect treat size refreshment."

Asahi super dry shows off its new six pack

Asahi Super Dry has launched new packaging for its bottled 330ml product six pack baskets and cartons throughout Australia.

The new packaging was designed in Japan with the intention of creating a more premium feel to replicate the Asahi Super Dry brand positioning.

The Asahi Super Dry product itself remains completely unchanged offering exactly the same award winning beer with a fresh new exterior carton and six pack design. 

The bottle design remains unchanged. Michael Vousden, Beer and Cider Marketing Manager for Asahi Premium Beverages states: “The new Asahi Super  Dry packaging is sleek and  sophisticated,  mirroring  the qualities of the beer, in  line with our consumer base.” 

The revamped look is a refreshing update for the brand aesthetic and we look forward to getting it out into the market.”

”The new six pack and carton packaging is predominately black and showcases a  more simplistic  design, featuring the Asahi Super Dry logo and an image of the  bottle surrounded by crisp, ice cold vapour.  In comparison, previous packaging featured vibrant images and a red and white colour scheme.”

The minimalist and sophisticated new black and silver look complements the same great Asahi Super Dry product, offering a rich, full-flavoured beer with a refreshing after taste. “