The price tag on packaging, particularly PET preforms, can get pricey. The most important question is whether there are ways you can save on PET packaging while maintaining quality and not experiencing all of the issues associated with higher defects later due to lower-quality PET preforms. The answer for smart brands throughout India is “absolutely.”

Whether you are a bottled water manufacturer, an edible oil supplier or a pharmaceutical company, there are opportunities to reduce waste, avoid over-designed products and create better purchasing decisions.

No, this doesn’t mean sacrificing clarity or dealing with warped necks, but rather finding a way to save money while also eliminating common problems such as incorrect heating temperatures of PET preforms, poor-form thread profiles or causing producers to struggle with lack of blowability.

It’s also worth mentioning that the resin type, neck design/type, how much you invest into your moulds and handling of your logistics all play critical roles in reducing production costs more than they may appear on the surface, and we will provide a reputable preform manufacturer in India whom many of the top brands around the world trust to provide them with affordable preforms without sacrificing quality.

1. Switching Resin Types: How to Choose the Right Material at the Right Price

Examine the choice of resin as one of the fastest ways to reduce your PET preform cost.  

In India, most brands use virgin PET resin, which typically comes from major manufacturers such as Reliance and IOCL. While these materials offer superior clarity and strength, they come at a premium cost. However, not all applications need virgin resin. For many applications, such as non-food or multi-layer, changing to imported generic resin or rPET (recycled PET) can save you approximately 10-15% of your costs per kilogram.  

Before making a change, be sure to verify that your application is compliant with BIS or FSSAI regulations. As of 2023, India allows the use of rPET for food contact under strict guidelines (BIS 17883:2022), but clarification may still vary somewhat.  

You must also be careful when selecting low-quality resin, as inferior quality resin may lead to defects in the PET preform, such as:  

• Surface haziness.  
• Flow lines or streaks in the preform.  
• Poor reheat performance due to uneven IV values, etc.

Ultimately, we make a balance when selecting the correct type of resin for our preforms. When selecting an appropriate resin, we recommend that you consult a reliable plastic preform manufacturer in India, who will be able to help you navigate the various resin options available, in terms of both your budget and regulatory compliance.

2. Go Lean with Design: Reducing Preform Weight the Smart Way

Weight reduction is a viable method for companies to lower their production costs promptly by lowering the overall weight of their PET preforms without sacrificing performance.

For example, switching from a 12g preform to a 10g preform on a 1L water bottle could result in a cost savings of between ₹0.15 and ₹0.30 per unit, depending on current resin prices. In an example of a monthly production volume of 500,000 bottles, that could be a cost savings of over ₹1,00,000 per month.

However, if companies cut back too much without considering structural integrity and planning there are a few risks associated with such practices:

• Bottles will blowout when they are being formed
• Bottles will have thread deformation caused by the torque applied to the threads
• Bottles will have an uneven base because of improper heating of preforms

Companies need to collaborate with manufacturers to create custom mould designs, validate heating & cooling, and test blowability to experience successful lightweighting.

Leading brands are increasingly turning to custom how or modified mould designs to ensure there are even distribution of material around the neck and base. The neck & base of a bottle are the areas that experience the most stress during use, and therefore determine the strength of the finished product.

When conducted correctly, lightweighting reduces costs, supports sustainability efforts, reduces the weight of logistics, and minimizes a company’s carbon footprint.

3. Bulk Isn’t Always Better: Negotiating MOQs That Actually Work

The phrase “buy more, save more” does not always hold when dealing with PET plastic preforms, particularly when considering factors such as warehouse space constraints, resin volatility, and shelf-life limitations.

Although many brands overbuy simply to satisfy the Minimum Order Quantity (MOQ) requirements set by their suppliers, as a result, they are left with:

• Stock that becomes old
• An increased cost of storage
• Defects in the PET preforms caused by being exposed to heat and/or humidity for an extended period of time

Wise purchasers will turn the tables on their suppliers by negotiating for flexibility regarding the MOQ based upon:

• Seasonal supplier downtime
• Scheduled consolidated deliveries
• A commitment to reorder at specific intervals

By using this strategy, wise purchasers are able to preserve their working capital and avoid inventory bottlenecks. If you are a mid-sized company producing between 50,000 and 100,000 bottles per month, make sure to negotiate an MOQ that aligns with your actual needs. If you’re a mid-sized player producing 50,000 to 100,000 bottles/month, insist on MOQ alignment with your actual need.

4. Work Direct with Manufacturers: Eliminate the Middlemen Markup

There is a significant number of PET preform buyers in India that are spending more than necessary in the procurement process. The reason for this is that the majority of buyers source from middlemen, brokers, or via third-party aggregators who mark up their prices by 10%-20%.

What does this markup do for you? Absolutely nothing! The only outcome of going through a middleman is a communication gap that results in:

• Delayed Shipments
• Neck Dimensions Do Not Match
• No Support For Defects or Fixing Defects In PET Preforms

On the other hand, sourcing directly from a Preform Manufacturer in India provides the following benefits:

• Pricing Direct From Factory
• Customisation Availability
• Test Data, Batch Reports, and Quality Control (QC) Protocols
• Support For Heating Parameters and Process Optimization

The best manufacturers will provide complete transparency from the resin source to the conditions used in the moulding of their products and will even advise clients on how to set their heating temperatures to optimize the performance of their machines when using their PET Preforms.

If you are a serious buyer looking to grow your business, sourcing directly from the manufacturer is a no-brainer. It is not only less expensive but smarter!

5. Optimise Neck Design: Match Preforms with the Right Caps & Products

Selecting a neck design compatible with the bottle and closure can prevent costly production issues & help reduce costs. Many times, companies will go with a standard approach for their product without assessing its compatibility with performance or its downstream effects.

If your neck design doesn’t match up with your product, you may experience higher levels of PET preform defects such as:

• Leaks due to improper alignment of the cap’s threads.
• Caps are being overtightened during capping.
• Misalignment of caps in automated high-speed filling lines.

The type of neck will impact resin usage, blowability, and your cap sourcing costs. For example:

• An Alaska neck will work well for still bottled waters, but it’s not a good fit for carbonated products.
• PCO 1810 and 1881 neck designs are designed for pressurized products, such as soda and other fizzy drinks.
• Using a short neck can save material costs, but requires compatible closures to ensure that they can withstand the required amount of torque.

It is advisable to determine what type of neck design you will use when aligning with the cap and bottle application early in the design process. As an example, DRJ Plasttech has a comprehensive neck design consultation service that assists brand owners in selecting the most cost-effective option to meet their product requirements and reduce costs associated with compatibility problems and pre-formed production failures.

Minor changes to your neck design can generate anywhere from 2-4% savings on your total packaging costs when you produce in the millions.

Invest in a Mould, Save in the Long Run: Is Customisation Worth It?

Owning a custom PET preform mould provides significant advantages to brands with a considerable desire to increase operational efficiencies and cut down on their packaging expenditure. While the upfront capital investment will be substantial (on average, 2 to 5 lakh rupees), companies should expect to receive a quick return on this investment. 

When a brand operates with a custom mould, the brand’s operational costs are reduced because:

1. The weight distribution of the mould is maximized, therefore less resin is used per preform.

2. The neck and thread profiles are custom-designed to ensure that the rate of rejections (for capping) is minimized.

3. The blowability of the preform is maximized, and the amount of heating (and, therefore, energy) required is minimized.

4. More importantly, custom moulds allow the client to control variations that often cause defects (i.e., off-centre necks, walls of varying thickness, and warping during heating).

The good news is that many reputable manufacturers will offer shared or co-funded mould development to long-term clients. This means that the client will have partial ownership of or exclusive use of the mould at a significantly reduced cost compared to purchasing a mould outright.

In an environment where each rupee saved per unit can be critical to protecting your profit margins and ensuring the consistency of your products, owning your mould is one of the best things a client can do.

Logistics Planning: Reduce Freight Costs with Smart Scheduling

The cost of transport is not just a percentage of the total price of PET preforms; in addition, a considerable amount will come from freight charges incurred while transporting merchandise from one location to another. The amount of freight charge incurred will vary based on both the distance and the amount of product shipped. Freight charges can range from ₹0.10 to ₹0.30 per unit, depending on the size of your order and how far it needs to travel.

The logistics of soda logistics, like any other aspect of business, must be well-planned in addition to negotiating pricing. There are many methods brands can take to reduce shipping costs:

• Aggregate orders from different customers within your local geographical region.
• Coordinate their deliveries with the availability of backhaul freight.
• Use suppliers that are located closer to major ports or highways.

Because of its proximity to such major transportation hubs as Hazira and Mundra, Gujarat has established itself as the hub of India for the PET preform industry by creating multiple industrial clusters near these transportation hubs.

Major suppliers of PET preforms in India, such as DRJ Plasttech, provide various shipping options (FOB, CIF, or Door) based on the size and frequency of shipments. Aligning the delivery schedules of your order to your production schedule will save your company thousands of rupees in shipping costs every month for large volume orders.

Compare Before You Commit: What to Ask Before Finalizing a Deal

It’s important to note that selecting a PET Preform Supplier should not just be based on pricing alone; further investigation must be done so that you can inquire further regarding the long-term dependability and savings of the supplier.

To assist you in locating the best supplier for you, here are some recommended questions to ask the supplier before signing your contract:

• Could you please provide me with a current blow testing report? 

Provides you with the necessary information to determine if your blow moulding setup will be compatible with the preforms you receive and assist in minimizing preform defect occurrences.

• What weight tolerance do you typically use?

Inconsistencies in gram weight from order-to-order could adversely affect your calculations of product costs.

• Will you provide heating requirements for the preform based on your machine? 

Depending on the type of resin and the type of mould used, each preform has a specific heating temperature; the manufacturer should provide heating guidelines to help eliminate trial-and-error heating techniques.

• Would it be possible to receive a sample before a pre-shipment?

Testing preforms is always required before placing large orders.

• Do you use virgin resin or blended material? 

Transparency regarding virgin resin and blended resin use is critical for regulatory compliance, especially in food and pharmaceuticals.

Selecting a manufacturer who provides complete transparency about materials used in making their products protects both your brand and your bottom line.ine.

Conclusion: Cost-Saving Is a Strategy, Not a Shortcut

The process of selecting the right PET preform to help you achieve your cost-reduction goals involves more than just finding the least expensive option available on the market. Rather, it requires an understanding of how to optimize your PET preform purchasing strategy as well as where to allocate your investments for maximum benefit. By selecting the best resin grade and lightweight design, negotiating minimum order quantities (MOQs), aligning the neck specifications of your product, and seeking out one of the few manufacturers that is able to produce your desired preform further enhances your cost effectiveness.

Successful companies operating within the Indian marketplace demonstrate an ability to balance cost reductions while ensuring that consistency is maintained throughout the production process. By partnering with suppliers that place a high value on their commitment to quality control and the unique characteristics of heating temperature as it relates to PET preforms, you can mitigate the potential for defects.

In addition, if you are seeking to implement the cost-saving measures outlined above without compromising product performance, you should consider working with DRJ Plasttech Private Limited. DRJ combines an affordable pricing model with the technical requirements necessary for your business’s growth without exceeding your financial means. And if you want to know more about plastic preforms, here we are.

Your Packaging Process Has The Potential To Be Less Expensive While At The Same Time Creating More Value. All You Need Is A Straightforward Approach And A Reliable Supplier.