The Benefits
of PET and rPET
Packaging decisions are often driven by shape, appearance and functionality. Alongside these considerations, another factor can play an important role throughout the supply chain: weight.
Every gram of packaging moves with the product through filling, handling, storage and distribution. For a single bottle, the difference between packaging materials may seem relatively small. Across thousands of bottles, cases and pallets, that difference becomes significant.
485 kg of Glass. 56.5 kg of PET
Consider a 250ml glass sauce bottle currently available on the market. At approximately 220g per bottle, with 2,205 bottles packed per pallet, the bottles alone account for around 485kg of packaging weight.
EMBACO’s 250ml PET Saucy Bottle weighs 24g, with 2,352 bottles packed per pallet. Despite fitting 147 more bottles onto the pallet, the bottles weigh approximately 56.5kg in total. That is around 428kg less packaging weight per pallet.
The benefits extend beyond the pallet itself. Lower packaging weight carries through handling, storage and transport, while PET’s high impact resistance reduces the risk of breakage associated with glass.
There is a financial consideration too. Based on the EPR figures used for this comparison, the glass bottles represent approximately £93.13 in EPR charges per pallet, compared with £23.43 for PET.
Weight and associated costs are important considerations, but changing packaging material involves more than the numbers alone.
Beyond Weight:
Packaging That Performs
Switching from glass to PET is not simply a question of weight. The packaging still needs to perform – protecting the product, working with the filling process and delivering the shelf life and shelf presence the brand requires.
For products sensitive to oxygen or UV light, PET can incorporate barriers, additives or colour depending on the requirements of the application. Hot-fill applications do not automatically rule out plastic either – materials such as PP can provide an alternative where higher filling temperatures are required.
Appearance is another important consideration. Glass is often associated with a premium look and feel, but choosing PET does not have to mean compromising on shelf presence. Shape, colour, tailored embossing, decoration and refined closures can all help create packaging that feels distinctive and considered.
The question is therefore not whether PET is universally better than glass. It is whether glass is still the right material for a particular product, supply chain and brand.
From Standard Formats to Custom Development
EMBACO offers 500+ standard products across an extensive range of packaging formats. Competitively priced custom tooling extends those possibilities, allowing EMBACO to develop dedicated moulds for bottle shapes designed specifically around a product and brand.
Custom development can include unique bottle shapes, embossing, colours and finishes, allowing specific design elements to be carried through into the final packaging. For brands considering a transition from glass, this provides greater scope to retain a distinctive format while benefiting from the lower weight of plastic packaging.
Material choice can be part of that development too. For brands looking to incorporate recycled material, rPET retains the low weight, clarity, strength and design flexibility associated with PET.
What Could the Difference Look Like for Your Packaging?
The 250ml sauce bottle example demonstrates how significantly packaging weight can change when moving from glass to PET. What that difference looks like for your packaging will depend on factors such as bottle size, weight and pallet configuration.
With 500+ standard products and custom development capabilities, EMBACO offers a wide range of PET and rPET options to meet different product and brand requirements.
Ready to explore what PET or rPET could do for your packaging? Contact EMBACO today to discuss your options. You can also request a sample to compare directly with your current bottle.
London Packaging Week 2026
Where: London Packaging Week, United Kingdom
When: September 16th to 17th, 2026
Stand No. F40
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