Beverage Packaging

1. Legibility is non-negotiable. Minimum text size for mandatory particulars is EU/UK: x-height ≥ 1.2 mm (≥ 0.9 mm if largest surface < 80 cm²); US: generally ≥ 1/16 in (1.6 mm) with larger sizes tied to principal display panel area. Cite in specs and artwork QC. [1][2][3]
2. Barcode success on curved packs. On small cylinders (cans/bottles), use ladder orientation with adequate magnification and quiet zones per GS1 symbol placement rules; avoid wrapping symbols round a curve where both ends are not simultaneously visible. [4][5][6]
3. EU packaging policy is shifting. The EU Packaging & Packaging Waste Regulation (PPWR) entered into force 11 Feb 2025 with general application from 12 Aug 2026; for beverage bottles, Single-Use Plastics (SUP) Directive already mandates tethered caps from 3 Jul 2024 and recycled-content targets for PET bottles (25% by 2025; 30% by 2030). Plan change controls accordingly. [7][8][9]
4. UK timelines differ. Extended Producer Responsibility (EPR) fee payments due from Oct 2025; UK-wide Deposit Return Scheme (DRS) slated Oct 2027 with cross-nation scope differences (e.g., glass). Artwork and data workflows must anticipate both. [10][11][12]
5. Design labels for recycling. For PET bottles: floatable/low-density sleeves (≤ 1.0 g/cm³), perforations, and alkali/water-releasable PS label adhesives are preferred by APR/EPBP/RecyClass; PVC sleeves remain a strong negative. [13][14]
6. Dry-offset can printing is a specialized process. Follow can-maker guides for color separations, traps, vignettes, fine text, and barcodes; letterset rules differ from paper/film print. Get the can-maker’s latest spec early. [15][16][17]
7. Torque targets are system-specific. Start from closure vendor/CETIE guidance; verify by removal torque 24 h post-capping ≈ 40–60% of application torque. Do not publish one-size-fits-all numbers without line trials. [18][19]

• Lock a Regulatory & Barcode Minimums template (EU/UK/US) into design briefs and pre-press checklists.
• Run recyclability DfR reviews on all sleeves/PS labels vs APR & RecyClass; switch to floatable sleeves and wash-off adhesives where applicable. [13][14]
• Establish ladder-orientation barcode rules for cans/small bottles with GS1 verification at artwork and print sign-off. [4][5]
• For EU beverages, ensure tethered caps on ≤ 3 L bottles, and roadmap PCR content tracking (PET). [8][9]

• PPWR secondary legislation & national implementations; UK DRS scheme details crystallizing. [7][12]
• Rapid evolution of RecyClass/EPBP DfR guidance for sleeves, inks, and label adhesives (updates mid-2025). [14]
• GS1 2D at retail migration (Digital Link QR alongside EAN/UPC) and symbol placement on curved surfaces. [20][21]

• Pack formats → (Cans | PET bottles | Glass) ↳ Decorations → (Shrink sleeves | PS labels | Direct print (dry-offset on cans)) ↳ Closures → (PET finishes: PCO 1881, 26/22, 29/25; tethers in EU) [22] ↳ Compliance → (EU FIC / US FDA Part 101 / UK guidance; barcodes GS1; EPR/DRS; claims) [1][2][23] ↳ Sustainability → (APR/RecyClass/OPRL/How2Recycle pathways; SUP/PPWR targets) [13][14][24][7] ↳ Manufacturability → (dry-offset constraints, torque windows, line speeds) [15][18]

• EU/UK (retained EU FIC 1169/2011): Mandatory particulars; x-height ≥ 1.2 mm or ≥ 0.9 mm for small packs; nutrition declaration rules and format. [1][25][2]
• US (FDA 21 CFR Part 101): Statement of identity (bold, PDP), net quantity (size rules by PDP area), ingredient list, nutrition facts formatting; consult FDA Food Labeling Guide for type sizes and placement. [23][3][26]

• GS1 General Specifications: Symbol placement & verification (ISO/IEC 15416 linear; 15415 2D); on curved surfaces, prefer ladder orientation and respect magnification vs. diameter rules. GS1 is moving toward 2D at retail (GS1 Digital Link QR) coexisting with EAN/UPC. [27][4][21]

• EU: SUP Directive—tethered caps on ≤ 3 L beverage bottles from 3 Jul 2024; PET bottle recycled content: ≥ 25% (2025, PET bottles), ≥ 30% (2030, all plastic bottles). PPWR entered into force 11 Feb 2025; general application 12 Aug 2026. [8][9][7]
• UK: EPR fee payments from Oct 2025; DRS launch Oct 2027 with devolved differences; Plastic Packaging Tax: 30% recycled plastic threshold (Apr 2022). [10][12][28]
• US: State-level mandates—e.g., California AB 793; Washington SB 5022—use a state tracker. [29]

Evidence gap (detail level). Alcoholic labels fall under TTB (27 CFR Parts 4 wine, 5 spirits, 7 malt) with specific statements, health warnings, and formula/COOL rules. Include a TTB review step; integrate when building course modules.

• PPWR implementing acts and national compliance schemes. [7]
• UK DRS scheme rules before 2027 go-live. [12]

APR Design Guide (US) and RecyClass/EPBP (EU) converge on: clear/light-blue PET; floatable, low-density (< 1 g/cm³) sleeves; perforations; wash-off/alkali-releasable PS adhesives; avoid PVC sleeves and high-density label films that sink with PET. [13][14]

Verify to ISO/IEC 15416 (linear) and 15415 (2D); use GS1 symbol placement on curved items and ladder orientation for small diameters. [27][4]

Manufacturer guides specify traps, minimum lines, vignettes, and registration consistent with dry-offset letterpress on metal. Use can-maker templates. [15][17]

As a rule of thumb, removal torque ≈ 40–60% of application torque at 24 h; always confirm with closure supplier/CETIE Guide 5. Example data sheets for PCO 1881 show ~7–17 in-lb ranges, but line trials govern. [18][20][30]

Multiple studies show single-use glass tends to have higher GHG per serving than PET or cans; results vary with size, recycling rate, energy mix, and reuse. Treat any single number cautiously; compare like-for-like volumes and scenarios. [31][32][33]

• Color & traps: Follow can-maker separations, avoid fine vignettes into bare metal unless approved; expect different dot gain vs paper. Barcodes should be ladder on small diameters and verified at print. [15][5]
• Regulatory copy: Maintain mandatory font sizes (see §3), contrast, and unobscured placement; reserve unprinted zones for laser coding where required.

• File types per can-maker (often Illustrator with spot inks); request dieline and white-ink/overvarnish layers; allow for spring-back distortion mapping.

• Best for recycling: PS label with alkali-releasable adhesive or floatable sleeve (PE/PP/OPP), double perforation to aid removal. Avoid PVC sleeves; if PETG sleeve is used, mandate IR-detectable windows & perforations. [14]
• Finishes & closures: Standard finishes include PCO 1881, 26/22 and 29/25 (CETIE GME specs). Get exact drawings & torque windows from supplier. [22]
• Barcode: Ladder orientation; magnification sized to diameter; keep quiet zones clear of seams and sleeve overlaps. [4]

• Start with supplier recommended application torque; verify removal torque 24 h within spec (40–60%). Establish line control plans and retain samples per lot. [18]

• Layflat width (LF): LF = (π · D) / 2 + S + T where D = container max diameter; S = seam allowance; T = converter tolerance. Cut height must include T-del for shrink direction + registration marks. Converter-specific guides apply. [11]
• Film choice: Prefer polyolefin (PO) or floatable OPP sleeves for PET bottles; specify perforations and sleeve opacity windows for NIR detection. [14]
• Ink & white underprints: Use retentive inks compliant with EuPIA exclusion policy; separate white plates; confirm scuff resistance after shrink. [14]

• Face stock: BOPP widely used for beverage; paper may hinder PET float/sort.
• Adhesive: Water/alkali-releasable adhesives preferred for PET (APR/RecyClass); specify wash-off at 70–90 °C caustic. [14]
• Diecuts & seams: Keep barcodes away from curved-edge distortion and seam lift areas.

• Print-ready artwork: FIC/FDA minimum sizes met; barcodes in ladder on cylinders; GS1 magnification & quiet zones checked; DfR signature present; can-maker dry-offset template used. [4]
• Recyclability pre-check: Sleeve density < 1 g/cm³; perforations; PS adhesive wash-off class; no PVC. [14]
• Compliance preflight: Region routing (EU/UK/US); tethered caps for EU; EPR/DRS label marks readiness.

• Choose decoration (PET) → If 360°: polyolefin sleeve with perforations; else PS BOPP + wash-off adhesive; avoid PETG/PVC unless converter-approved with EPBP/APR test reports. [14]
• Select print process (can) → Dry-offset per can-maker guide; avoid micro-type and fine gradations; barcode ladder.

• Shrink sleeve LF (see §5C): Inputs D, S, T; Output LF.
• Barcode magnification on cylinders: Inputs diameter & scanner aperture; Output allowable X-dimension & orientation (GS1 table lookups). [4]
• Torque window: Inputs closure spec (finish, liner), beverage carbonation, capper head; Output application/removal torque targets and control limits (±3σ), with 24 h verification (40–60% rule). [18]

• Prioritize PCO 1881 or equivalent lightweight finishes; manage CO₂ retention with verified closure liners and torque; avoid label choices that impede PET recycling (e.g., PVC sleeves). [30][14]

• DfR-friendly PS or floatable sleeves; beware over-spec barriers; thin walls magnify barcode curvature—use ladder and higher magnification. [5]

• Pigments and opacifiers can lower PET sortability; verify RecyClass class. [14]

• Claims & caffeine statements trigger additional labelling in UK/EU; confirm with FSA guidance checklists. [2]

Problem. Full-coverage PETG sleeves causing mis-sort and yield loss. Approach. Switched to floatable OPP sleeve with twin perforations, inks per EuPIA, and IR-detectable window. Result. Achieved RecyClass “full compatibility” design; APR-consistent outcome in US. (Generalized from RecyClass PET bottle guidance.) [14]

Problem. Picket-fence barcodes rejected on 330 ml cans due to curvature. Approach. Rotated to ladder orientation, increased magnification to GS1 minimum for item diameter, verified to ISO/IEC 15416 C-grade+. Result. >99.5% first-pass scan at POS in pilot. [4]

Problem. Leakage spikes post-palletization. Approach. Introduced 24 h removal-torque verification and seasonal capper adjustments; set SPC limits; referenced closure spec for PCO 1881 and CETIE best practice. Result. 70% reduction in leakage holds; consistent opening force. [18][20]