Success Story: Enhancing rPET Efficiency While Cutting Costs

Client Overview

A food and beverage company was relying on a costly additive in its rPET preforms, an approach originally adopted as a safeguard to minimize risk to packaging and product integrity. Over time, however, the additive became a significant recurring expense.

The Challenge

The optimization effort required a careful balance between cost reduction and risk mitigation:

  • The additive had been used as a built-in safety buffer, and reducing it required proving that performance would remain stable.

  • Suppliers needed to test multiple levels of additive removal, which demanded coordination and rigorous validation.

  • Any change had the potential to impact critical performance attributes, requiring robust data analysis.

  • A long-term monitoring plan was necessary to ensure that reduction efforts would not introduce quality issues over time.

These challenges made it essential to rely on thorough testing, data-driven decision-making, and ongoing performance verification.

Our Approach

Adept executed a structured, controlled process to validate and optimize additive reduction:

  • Worked directly with suppliers to test the removal of the rPET additive at various levels

  • Completed detailed data analysis to identify the maximum allowable additive reduction without impacting packaging performance or specification limits

  • Monitored supplier quality data for six months post-change, ensuring material performance remained stable and fully within spec

  • Identified opportunities for additional savings through future rPET transition projects already in progress

The Impact

The additive optimization delivered significant measurable benefits:

  • $800K annual savings

  • Potential for additional future savings embedded within other concurrent rPET initiatives

  • Reduced complexity for suppliers, improving consistency and simplifying production

This isn't just a fix. It’s a transformation.

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