The container weight has become increasingly important in today’s context, where sustainability, efficiency, and cost reduction are top priorities across production and logistics chains.
Weight optimisation not only implies economic advantages but also contributes to a lower environmental impact — a key concern for many environmentally conscious companies and consumers.
We invite you to learn much more in the following article!
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Talking about container weight means understanding the total mass of a packaging unit, whose role now goes far beyond simply holding a product.
It must protect, ensure product stability, and withstand mechanical stress during storage and transportation—making the distribution process more efficient across diverse sectors such as food, chemicals, or pharmaceuticals.
However, container weight is not a simple figure. It involves multiple variables that influence its final value and affect how the industry perceives sustainability and operational efficiency—while never compromising on safety.
It is essential for industrial companies to consider the factors that influence container weight in order to make smart decisions and make the best choice around their products and budget.
Let’s see what the main variables are:
Get to know more about us: Alcion Packaging Solutions: 80 years of innovation and leadership in the plastic packaging industry
Container weight is not only a reflection of material costs, but also has a direct impact on operational and logistical efficiency—two critical factors for the competitiveness of any industrial company.
Transportation is one of the most expensive and polluting phases of the supply chain.
Reducing container weight improves payload efficiency by optimizing load capacity and reducing travel distances.
This results in lower fuel costs, a reduced carbon footprint, and a more efficient and sustainable logistics management.
Lighter containers also simplify the manufacturing process, as they require less energy for filling, sealing, and handling.
Additionally, reducing container weight helps decrease machinery wear and makes production lines more efficient, enabling higher speeds and lower energy consumption.
Reducing the container weight also leads to a decrease in raw material consumption, resulting in less waste generated throughout the product’s life cycle.
Sustainable containers are easier to recycle, which extends their lifespan and supports a circular economy. Minimizing industrial waste helps meet environmental goals and lowers costs associated with waste management.
Keep learning: Mechanical recycling: What is it and how does it enhance the circularity of packaging?
Reducing the container weight improves operational aspects of production and logistics, while also providing competitive advantages and aligning with global regulations and trends in efficiency and sustainability.
In fact, lowering the net content of containers brings significant benefits for companies.
Today, innovation in materials and design makes it possible to create lightweight yet strong and functional containers that help reduce the environmental footprint of production.
This enhances sustainability while ensuring resistant and functional packaging solutions.
Lower container weight means less material consumption, reducing raw material and production costs.
It also lowers expenses related to transportation and storage, improving the overall profitability of the supply chain.
More and more countries and global organizations are establishing strict regulations on the use of plastics, waste, and emissions.
Reducing container weight helps meet these requirements while positioning companies as responsible and committed to sustainability, enhancing their brand image and facilitating access to increasingly regulated markets.
At APS, we offer a wide range of solutions that meet any plastic packaging needs across the most demanding industrial sectors. Our industrial packaging for chemical products is continuously analyzed to achieve optimisation, always keeping safety at the forefront, as it is essential in this sector.
We provide tailored solutions for each company, delivering packaging adapted to specific requirements, backed by all the guarantees of an approved product and our efficient production capabilities with tight lead times.
At Alcion Packaging Solutions, we address any technical and aesthetic demand, and tackling container weight is no minor detail. Controlling and reducing the weight of packaging is not only feasible but necessary in today’s context, where cost efficiency, regulatory pressure, and environmental responsibility are key drivers.
Let us work with you to find the perfect balance of safety, functionality, and sustainability in your projects.
Alcion Packaging Solutions has long stood as a hallmark of transformation and innovation within the plastic industry.
Celebrating 80 years in operation is a remarkable achivement - one attained by only a select number of enterprises. Established in 1945, ALCION began as a modest Bakelite processing workshop and has since evolved into a globally recognised manufacturer of rigid plastic packaging. This journey has been underscored by a commitment to forward-thinking innovation, continuous investment in technology, and an enduring dedication to quality and sustainability.
The company’s progress is underpinned by a highly capable and committed workforce - comprising machine operators, engineers specialising in in R&D and industrial processes, logistics professionals, human resources specialists, and commercial technicians. Each member of the Alcion team has brought expertise and professionalism to bear, ensuring our packaging consistently meets the most stringent standards. A culture of cross-functional collaboration and transparent communication has been pivotal in maintaining our position as a leader in the sector for eight decades.
As we mark this anniversary, we take great pride in our legacy, reaffirm our commitment to the present, and look to the future with confidence and ambition.
We warmly invite you to discover the spirit of innovation in the plastic industry that defines Alcion Packaging Solutions!
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ALCION’s continued success is rooted in its ability to embrace evolution, innovation, and provide solutions that enhance the functionality, safety, and environmental performance of plastic packaging. In the current climate — where sustainable innovation is more vital than ever — Alcion remains at the forefront.
Historically, the company has specialised in packaging solutions tailored to the industrial sector, with particular expertise in the chemical and agrochemical industries. This specialist knowledge has enabled us to design and manufacture high-performance packaging, safe and efficient solutions that adheres to the most rigorous international regulations.
As new regulatory frameworks drive a shift towards more sustainable materials, Alcion remains proactive — developing forward-looking packaging solutions aligned with environmental best practices.
Since our inception, we have prioritised innovation and responsiveness to both societal expectations and market trends, continuously designing packaging systems that shape the industry’s future.
Find out more information: Alcion Packaging Solutions: manufacture of custom plastic packaging
A cornerstone of Alcion’s sustainability strategy is the integration of recycled materials into our production processes, all of which are certified in accordance with UNE-EN 15343.
This approach significantly contributes to the reduction of our carbon footprint and supports the principles of a circular economy — where materials are reused and given new life. We have consistently invested in the development of techniques that enable the use of recycled content without compromising the structural integrity or performance of the final product.
Alcion is regarded as a leading manufacturer of sustainable barrier packaging solutions, which provide optimal protection against environmental factors such as light, humidity, oxygen, and temperature fluctuations.
Through advanced multi-layer coextrusion technologies and plasma barrier treatment, we produce packaging that effectively mitigates risks of degradation, leakage, or deformation — ensuring the safe and stable storage of sensitive products.
Creating packaging that provides practical and efficient solutions for storage and transportation is at the core of APS.
Our packaging is developed with ease of use, storage, and transport in mind — ultimately improving both operational efficiency and the user experience. This focus not only reduces waste and costs, but also contributes directly to our sustainability goals and supports our customers’ logistical and commercial needs.
Alcion’s sustained leadership in innovation in the plastic industry is largely attributable to our early and ongoing adoption of advanced, sustainable production technologies.
Our Aldaia production facility was established with blow moulding as its foundational technology. This enabled the manufacture of HDPE containers suitable for a range of markets — including cosmetics, personal care, household detergents, and certain chemical and agrochemical products — all while maintaining high recyclability standards.
This division, implemented alongside the blow extrusion section, is responsible for the production of closures and complementary components that optimise the performance of our packaging systems. The injection moulding process ensures precise fit, enhanced sealing, and overall product integrity.
The coextrusion process allows for the manufacture of multi-layer structure by extruding several polymers simultaneously. One or more of these layers may feature barrier properties, resulting in robust packaging suitable for hazardous materials and compliant with ADR certification. This process represents a significant technological advancement, improving resistance and barrier properties.
Keep learning: Keys and advances of sustainable plastic packaging
The introduction of plasma technology in the 21st century has marked a turning point in our manufacturing capabilities. This method enables the creation of single-layer HDPE packaging with enhanced barrier properties, while maintaining full recyclability. Plasma treatment accelerates the surface coating process, yielding high-performance packaging with a lower environmental impact.
Thanks to this innovation, ALCION was awarded the GOLDPACK Prize for Best Circular Economy Project in 2024, highlighting its leadership in implementing sustainable technologies in plastic barrier packaging manufacturing.
Alcion Packaging Solutions’ greatest commitment to achieving innovation in the plastic industry is prioritizing socio-environmental responsibility and sustainability.
Alcion is deeply committed to the continuous pursuit of a circular economy.
Our packaging is designed based on certain eco-design parameters, and its production is environmentally friendly, prioritizing recycling and optimized shipping services to reduce environmental impact.
Fully aware of its commitment to sustainable development and its contribution to the circular economy, Alcion has achieved and maintains important certifications in line with the highest international standards:
With 80 years of experience behind us, ALCION remains steadfast in its investment in research and development, always seeking to stay at the cutting edge of innovation and sustainability.
On this landmark anniversary, APS celebrates not only a distinguished past but a future filled with opportunity and progress. We reaffirm our role as a benchmark in the global plastic packaging industry and commit to continued excellence in innovation, quality, and environmental stewardship.
Alcion is your perfect partner in plastic packaging innovation - helping shape a more sustainable future, together
In the plastic packaging manufacturing industry, controlling specific technical parameters is key to ensuring functionality, efficiency in use, and the acceptance of the final product. One such parameter, often overlooked at first glance, is the ovality of cylindrical containers.
But what is ovality, and why is it so important?
In this article, we will explore the concept of ovality, its impact, and how it influences the design, production, and performance of cylindrical plastic containers throughout their lifespan.
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Ovality is defined as the deviation from a perfect cylindrical shape. In other words, it measures how close a cylindrical container is to being perfectly round. In the plastic industry, deviations in this parameter can arise from various factors, such as the manufacturing process, material behavior during processing, and even storage or transportation conditions.
Ovality is typically measured by calculating the difference between a containers’ maximum and minimum diameters. It is expressed as a percentage, obtained by dividing this difference by the nominal diameter. High ovality values indicate significant deformation, whereas low values signify a more uniform product. Each container has a defined tolerance limit based on its technical specifications.
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Excessive ovality can hinder the automatic filling processes, as containers may not fit correctly into the machine holders. Additionally, improper shape can cause sealing defects, leading to leaks and product contamination.
Containers with high ovality are less stable, particularly when stacked. This increases the risk of tipping over and sustaining damage during transportation and storage, ultimately affecting customer perception of quality.
In today’s highly competitive market, packaging appearance is crucial. Containers with visible deformations may be perceived as defective or of lower quality, negatively impacting brand image and consumer trust.
Controlling ovality allows for optimized wall thickness, reducing production costs and, consequently, minimising environmental impact by using only the necessary amount of material.
Ovality deviations beyond acceptable limits can hinder proper label application. Labels may wrinkle, shift, or fail to adhere uniformly, affecting product presentation and making critical information, such as ingredients, barcodes, or usage instructions, difficult to read.
Ensuring that ovality remains within acceptable limits requires several key considerations :
In summary, ovality is a critical factor that influences the functionality, aesthetics and efficiency of cylindrical rigid plastic containers. Proper control of this parameter enhances performance across packaging production and distribution processes while reinforcing consumers’ perception of quality. In a highly technical industry, attention to details like ovality can determine or failure a container.
You may be interested in: Sustainable plastic storage of chemicals: An approach to the circular economy and safety
It is essential to remember that a plastic container’s structural integrity is influenced throughout the whole production process, especially as it exists the blow molding station at high temperatures.
At APS, we maintain strict compliance with the ovality parameters defined in our production technical specifications, conducting in-lie checks to detect and correct any deviations. Contact us! Our team will help you find the perfect container for your product!
The GoldPack Awards are an initiative of the Packaging Innovation Cluster and specifically, the Award for the Best Circular Economy Project is proposed to recognize excellent projects in different areas of the business Circular Economy, such as the implementation of sustainable production practices that minimize waste generation and/or promote recycling, among several other aspects.
In its first edition 2024, the jury has recognized ALCION PACKAGING SOLUTIONS as deserving of this award for our Circular Economy Project based on the Implementation of a new technology: Chemical Generation of Barrier by Plasma. A disruptive technology that revolutionizes our field of barrier packaging in terms of recycling and environmental impact, which allows to go from a multi-layer multi-material structure to a mono-material with barrier properties, applying surface treatment using Plasma that provides the protective barrier to the packaging. This has materialized in a new line of plastic containers for the packaging of chemical products, manufactured using a disruptive and pioneering technology in Spain. 5 and 10l jerrycans for the industrial sector and approved for the transport of dangerous goods (UN marking), analysed in the design phase to optimise their behaviour and facilitate the circularity of the packaging.
Multilayer barrier packaging presents a significant challenge in terms of recycling. Although there are possibilities through Chemical Recycling, it involves the use of solvents and is a high-cost process, compared to mechanical recycling. The plasma technology that we have implemented at ALCION appears to solve the recyclability of these barrier containers as it allows them to be recycled 100% mechanically and provide greater environmental benefits, using highly efficient state-of-the-art electrical equipment that, in our facilities, consumes energy of 100% renewable origin. In addition, these containers facilitate a better use of the packaged product. The plasma produces a modification of the surface tension that allows a greater sliding and emptying of the packaged product, reducing the loss of residual product that remains in the container, thus achieving the Objective of offering a Barrier Container integrated into a closed recycling circuit (HDPE).
At ALCION PACKAGING SOLUTIONS we have been working for years to achieve plastic packaging that not only meets the needs of the market, but also contributes to a more sustainable future. This award is for us "a validation of these efforts and a reminder of the importance of continuing on this path", which is why we continue to work on other projects such as the incorporation of recycled materials certified UNE EN 15343:2008 to our packaging that will also be marketed with their corresponding approval for the transportation of dangerous goods (UN marking).
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The term post-industrial recycled plastic refers to plastic materials discarded in industrial processes that do not reach the market for final consumer sale. This includes production waste, cut-offs, or scraps from manufacturers using plastic in their production processes.
Post-industrial plastic is typically of fairly good quality and can be recycled and reused for the same production process or for the creation of new plastic products. By recycling this type of plastic and reintegrating it into the same transformation process, it prevents it from ending up in landfills and contributes to a more sustainable use of resources.
Examples of post-industrial plastic may include manufacturing waste from packaging such as bottles and jerrycans, pipe waste, electronic components, among others. These waste materials are collected, sorted, and processed by a waste manager to give them a new purpose, avoiding the use of virgin plastic and reducing environmental impact.
Post-consumer recycled plastic, or PCR, refers to plastic that has been collected, sorted, and processed to be reused after its life as a consumer product. This means the plastic has been used by consumers and then recycled for subsequent use in manufacturing new products. Using post-consumer recycled plastic to manufacture new products helps reduce the amount of plastic waste in landfills and conserves the natural resources used in virgin plastic production.
Keep reading: Challenges in Plastic packaging and the environment
Both post-industrial and post-consumer recycled plastic must be homologated for use in the manufacturing of new packaging. Homologating recycled plastic involves subjecting it to tests and analyses to ensure it meets the necessary quality and safety requirements for use in packaging.
This ensures that recycled plastic does not contain hazardous substances and has the proper mechanical properties to fulfill its function as packaging. Homologation is also crucial to guarantee the traceability of recycled materials and promote transparency in the recycling process.
There is no single global standard for homologating recycled plastic. Many countries have regulations and standards related to recycling and waste management, including post-consumer plastic. These standards may vary depending on the country and its environmental legislation.
The European standard specifying the necessary procedures for the traceability of recycled plastics is UNE-EN 15343. This standard provides the basis for calculating the recycled content of a product: "Recycled plastics. Traceability and assessment of conformity for recycled plastics and recycled content." It establishes requirements and test methods for recycled plastics from municipal solid waste and mechanical recycling of plastic packaging, enabling them to be used in the manufacturing of non-food products.
UNE-EN 15343 is a European standard that sets requirements and test methods for recycled plastics intended for use in manufactured products. Its goal is to ensure that recycled plastics have suitable properties for use in products, complying with quality and safety standards.
Keep learning: Sustainable plastic storage of chemicals: An approach to the circular economy and safety
The standard establishes criteria for classifying recycled plastics into different categories based on their origin, recycling processes, and technical characteristics. It also sets minimum quality requirements for these recycled plastics, including physical, mechanical, and thermal properties.
Additionally, it defines the testing methods that should be used to determine the properties of recycled plastics, including tests for strength, hardness, density, thermal stability, among others.
Its importance lies in standardizing the requirements and test methods for recycled plastic used in plastic products. It is crucial for promoting the use of recycled plastic as an alternative that supports sustainability, reduces the environmental impact of plastic waste, and fosters a circular economy.
The UNE-EN 15343 standard establishes quality and safety criteria to ensure that recycled plastic meets the technical and health requirements necessary for its use in plastic products. This is essential to ensure that products made with recycled plastic are safe for users and comply with established technical specifications.
In conclusion, the homologation of recycled plastic, whether post-industrial or post-consumer, plays a fundamental role in the transition to a circular and sustainable economy. The UNE-EN 15343 standard serves as an essential pillar by setting rigorous criteria for the quality and safety of recycled plastics used in the manufacturing of new products.
This standard not only contributes to reducing the environmental impact of plastic waste but also promotes environmental awareness and encourages the adoption of more responsible practices in plastic material management. Adhering to these standards promotes the creation of more sustainable packaging, mitigating the negative effects of plastic on the environment and moving towards a greener future.
Do you need help choosing the right plastic packaging for your product? Contact us!
“Paneling” in a plastic container is the phenomenon in which the walls of the container deform or collapse, generating visible ripples or wrinkles. Paneling is the deformation of the sides of the plastic container when it is subjected to external/internal pressure. This can happen during the storage, transportation, or handling of the products.
Paneling can have a negative impact on the appearance of the packaging and, in some cases, can affect the integrity of the packaged product and, of course, the image of the manufacturer brand of that packaged product.
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There are several reasons why a plastic container with chemical formulations inside could collapse.
Keep reading: How to ensure the preservation of the agrochemical
Some of the factors that can cause paneling are the following:
However, to avoid paneling a container, we recommend selecting the right plastic container. Use packaging with the optimal structural composition (monolayer or with co-extruded barrier layer or plasma fluorination) and weight, of quality and resistance, which is capable of withstanding the external forces to which it will be subjected during its shelf life, as well as internal pressures due to possible alterations and internal reactions of the packaged formulation.
In addition, correct handling must be carried out, ensuring that the containers are handled correctly, avoiding bumps, excessive stacking or irregular pressures, and using appropriate packaging or palletizing systems to protect the containers during transport and storage.
On our side, from the point of view of the construction and design of our plastic packaging, APS takes into account:
By following these measures, the likelihood of paneling on packaging can be minimized, ensuring product integrity and consumer satisfaction.
In short, a plastic container containing chemical formulations can collapse due to the internal pressure generated, the chemical reaction with the plastic, changes in temperature or external pressure, or damage to the structure of the container. It is important to use suitable and resistant packaging to store and transport these types of chemical formulations, which generally require approval according to ADR (European Agreement on the International Carriage of Dangerous Goods by Road) and marked with their respective identification number.
Carrying out packaging-product compatibility tests for packaging chemicals is important in order to ensure that the packaging and the chemical are compatible and that there are no negative interactions that could compromise the quality of the packaged product or the safety of the user.
From APS we recommend our customers to carry out the following steps to check the compatibility of the product with the packaging seen as a set (container + cap):
APS has a specific department that is responsible for supplying small series of its containers and/or caps duly identified so that our customers can carry out the relevant tests.
It is important to note that these packaging-product compatibility tests are only one part of the evaluation of the safety and quality of the packaging for the storage of chemicals. Other aspects, such as local regulations and labeling requirements, must also be taken into account to ensure the proper storage and handling of these chemicals. For this reason, we always recommend consulting the regulations and recommendations of the country where the product is going to be marketed beforehand.
In general, the transport and handling of these chemicals normally requires compliance with the ADR (European Agreement on the International Carriage of Dangerous Goods by Road). To determine if a plastic container complies with ADR and the legislation for the transport of dangerous goods, at APS we verify that it complies with characteristics such as:
In addition, we provide our customers with information on the materials used in their manufacture and their resistance to hazardous substances, as well as the temperature and pressure limits to which they may be subjected.
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Based on all the tests and parameters tested, the packaging will be certified according to ADR (UN mark) by an authorized body to ensure that it complies with the safety standards established by current legislation.
In case of doubt, it is advisable to consult the specific regulations of each country and, in the case of international transport, the ADR, for precise and up-to-date information on the requirements that plastic packaging must meet for the transport of dangerous goods.
The registration number of a plastic container certified according to ADR (European Agreement on the International Carriage of Dangerous Goods by Road) contains the following information:
An UN symbol followed by a nomenclature that indicates:
Marking example:
UN 3H1/Y1.4/140/23/E/J-10033/APS
This marking means the following, as explained:
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