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Keywords of this article:  packaging 
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The whole Fanta bottle family and it is now available for 500ml, 1L, 1.5L and 2L formats.
The whole Fanta bottle family and it is now available for 500ml, 1L, 1.5L and 2L formats.

Innovative design always plays a crucial role in packaging, helping brands to bring the best user experience to consumers. Meanwhile, new designs need advanced processing technologies to bring them to real life.

As the popularity of the original Fanta Splash bottle shape waned, the Coca-Cola Company has redesign a new “spiral” polyethylene terephthalate (PET) bottle for the purpose of rejuvenating its Fanta brand.

Coca-Cola partnered with Drink Works and Sidel in the project in which Drink Works was responsible for the design while Sidel provided technology support needed.

Designed by Drink Works, the new Fanta bottle represents a “rule-breaker” in terms of bottle design for carbonated soft drinks (CSD). It features a spiral, inspired by the twisting of an orange to release its juice.

The design is based on a series of ribs decorated with small bubbles, including torsion in the bottom half. This spiral gives the Fanta bottle an unusual, asymmetric structure which presented a real challenge for developing a container able to withstand deformation and stability issues.

60 technical drawings and 15 pilot molds

The spiral shape has the accolade of being truly unique in the world of carbonated packaging designs for containers in PET. The Sidel Group, the Italian based PET packaging specialist was selected for industrial production of the new Fanta bottle.

It is definitively critical that all opposing sides of the bottle have the same developed length to avoid issues with perpendicularity,” explained Jérome Neveu, packaging expert at Sidel. “We optimized the grip profile and the angular base orientation to retain the bottle geometry once filled.”

Undoubtedly, the Spiral bottle required full design testing and refinement. It is said that more than 60 technical drawing iterations and Finite Element Analysis were used to test performance using computing analysis. Moreover, it involved production of 15 pilot molds and feasibility tests successfully managed to achieve validation of the final bottle design.

The final PET bottle design was fully tested, making sure the vertical growth under pressure is perfectly controlled. The physical strength of the new bottle is as good as the previous Fanta Splash bottle. Other line stability tests were also conducted by Sidel, achieving suitable results for high speed filling.

Coca-Cola required that the Fanta Splash bottle's label panel size and position must be aligned with its Sprite and Contour bottles. Drink Works achieved this without compromising the design, as the existing label panel was moved further up towards the neck of the bottle.

This technical solution generated tangible efficiency benefits for Coca-Cola bottling partners when producing various bottle types and handling label changeovers. The new position of the label panel also has the added advantage of better visibility as it is no longer subject to potential masking by the front panels of some shelves or by stacking units.

The new Spiral Fanta bottle in PET is sold in many European countries, and will be rolled out globally.

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