A Design Perspective: Berry Global’s Robust Packaging Solution for Vamoosh Plug Hole Unblocker
At Cosanostra Design, we’re always inspired by packaging innovations that combine technical finesse with aesthetic clarity. One particularly impressive case is Berry Global’s customised packaging for Vamoosh’s Plug Hole Unblocker. We found their solution both functionally robust and elegantly responsive to brand needs—and a great example of innovation in action. Read the original article here: [Berry Global Supports Vamoosh with Robust Packaging Solution for Plug Unblocker](https://spnews.com/berry-vamoosh/) ([Sustainable Packaging News][1]).
The Challenge: Ordinary Materials Were Simply Not Enough
Vamoosh needed a packaging solution that could withstand the powerful chemicals within its Plug Hole Unblocker. Standard bottle materials like PET and HDPE failed to deliver the durability required. Berry Global’s systematic research and testing quickly confirmed this limitation—and set the course for a stronger alternative. ([Sustainable Packaging News][1])
Engineering the Answer: ESCR Meets Thickness
To tackle the chemical load, Berry enhanced their 600 ml Alpha bottle through two strategic adjustments:
They introduced an Environmental Stress Crack Resistant (ESCR) additive, boosting the material’s capacity to resist stress and crack propagation.
They increased the wall thickness, which ultimately culminated in a bottle weight of 52g—a weight choice informed by rigorous testing. ([Sustainable Packaging News][1])
Fast-Track Development: Visualisation and Trials
Berry Global’s streamlined workflow ensured that the project advanced at pace:
Within two days, Berry delivered 3D-rendered graphics and branding visuals—giving Vamoosh a near-final look before even producing the bottle. ([Sustainable Packaging News][1])
They sent three bottle weight samples to Vamoosh for real-world trials. This hands-on evaluation empowered an informed decision and helped avoid unnecessary tooling or cost overruns. ([Sustainable Packaging News][1])
Compliance Made Simple
Regulatory expectations were met simply and effectively: the bottle’s **neck was adapted to accept a standard child-resistant closure (CRC)**—no extra fuss, just smart design. ([Sustainable Packaging News][1])
Local Production, Global Efficiency
Berry kept the entire manufacturing process tight and efficient by using their UK facilities:
Beccles, for bottle production
Norwich, for cap manufacturing
This proximity ensured seamless integration and rapid delivery—a strategic advantage for accelerated market launch. ([Sustainable Packaging News][1])
Client Feedback: Speed and Substance
Dave Toms, Director of Cares Laboratory Ltd. (the creator of Vamoosh), summed it up well:
> “Our collaboration with Berry Global has been pivotal in developing a packaging solution that meets our performance criteria. Berry’s swift turnaround and comprehensive service capabilities allowed us to bring our product to market quickly and efficiently.” ([Sustainable Packaging News][1])
What Makes This Stand Out (From a Design Eye)
Material & Wall Design | Combining ESCR additives with increased thickness created a resilient packaging core.
Rapid Visuals | Early-stage 3D renderings accelerated decisions—minimising revisions and time.
Iterative Trials | Sampling multiple prototypes ensured fit-for-purpose outcomes before tooling.
Regulatory Readiness | Pre-emptive CRC integration avoided post-design rework.
Streamlined Production | Localised manufacturing offered speed, cost-efficiency, and consistent quality.
Why This Resonates with Cosanostra Design
While Berry handled the structural engineering, the design opportunity was equally compelling—and in fact, deeply complementary. Translating a technically robust bottle into an eye-catching yet clear label design involves:
• Understanding the vessel’s form and surface texture
• Building a visual hierarchy that highlights brand, ingredients, and instructions
• Working within regulatory and material constraints
• Designing with production feasibility in mind
This project offers a perfect case study: an engineered container ready for a designer’s touch, with alignment across teams to get to market fast and well.
Final Thoughts
Berry Global’s approach to Vamoosh’s Plug Hole Unblocker packaging is a standout example of innovation, collaboration, and execution. At Cosanostra Design, we’re excited by propositions like this—where form and function coalesce to create products that truly work.
Curious about how we translate structural packaging into compelling brand experiences? Get in touch with us, and let’s make your product pack more than just a container—but a statement.
We hope you enjoyed this design-oriented look at a packaging success story. You can read the original post here: [Berry Global Supports Vamoosh with Robust Packaging Solution for Plug Unblocker](https://spnews.com/berry-vamoosh/) ([Sustainable Packaging News][1])
