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RE-CAP _ reusable caps

A cap-less 100% PET bottle compatible with reusable caps

Photo of Andrea Mangone
16 10

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PET Bottles come with a cap of a different material, specifically HDPE or PP. This poses an important problem when the bottles are disposed since the two materials cannot be recycled together. Only few advanced recycling facilities have an automatised system to separate the bottles from the caps and recycle the two materials separately, while in most cases only PET bottles get recycled. 

My idea is to create a 100% PET bottle composed by a traditional blow moulded bottle and a PET film seal heat bonded to the bottle, on the production line, straight after filling.

Single bottles could be sold in this cap-less format in stores at a discounted price and consumers could be given the chance to purchase the caps separately or use their on caps. 

Bottles sold in 3-6 packs could instead come with a single, shared cap, or even no cap at all.

The reusable caps integrate a plastic blade moulded in the design that perforates the PET film seal when screwed to the bottle neck.

This way caps would no more have the function of maintaining the integrity of the liquid from manufacturing to consumption but would simply offer the convenience to open and close the bottle during use.

The reusable caps could come in different forms/materials and be as simple as a standard plastic cap or integrate additional features like a sport bottle spout, a loop for hanging it to a carabiner or integrate a flip lid for easy opening.

The idea could save manufacturers money while lowering the impact on the environment. Manufacturing a cap-less bottle, in fact, could be sensibly cheaper and at scale could have an important impact.

How does this Idea redesign unrecyclable small format plastic items that often end up as waste?

This idea eliminates the need of one-time-use plastic caps by introducing 100%PET bottles compatible with reusable caps. The PET bottles could be easily sorted and recycled at the end of life while the caps could be re-used and shared between different bottles.

Which use cases does your Idea apply to?

This concept supports use case 2 - bottle caps and tear offs. The idea targets those communities that do not have sophisticated facilities able to sort and recycle separately PET bottles and HDPE/PP caps. Probably most municipalities.

How do you envision scaling up your Idea?

After prototyping the idea I would pitch drinks manufacturers to prove that the idea could save them money while lowering the impact on the environment. Manufacturing a cap-less bottle, in fact, could be sensibly cheaper and at scale could have an important impact. Reusable caps could also introduce a new product category and be leveraged by brands to differentiate from competitors.

At what stage of development is your Idea?

  • Research & Early Testing: You are exploring an idea, gathering inspiration and information needed to test it with real users.

Please describe how becoming a Top Idea and working with the Think Beyond Plastics Accelerator Program will help to accelerate your solution.

Through the Accelerator, I would first of all be able to prototype and test the idea. I would also benefit from the support and guidance on finding the correct business model to bring the idea to market.

Please describe from where your Idea emerged

In the last few years I have been interested and involved in design for sustainability but this specific idea emerged in response to the Circular Design Challenge.

Tell us about your work experience

I am a multidisciplinary designer with a passion for sustainability and humanising technology.

Please describe your legal and organizational structure

Limited company


Join the conversation:

Photo of Lauren Ito

Hi Andrea Mangone 

As Refinement Phase quickly comes to a close in LESS THAN 8 HOURS, I want to remind you that the following must be submitted by tonight, August 31st at 11:30 p.m. Pacific Time.

1. Submit the Refinement Questions Form online that was sent again via email yesterday evening--we have not yet received this from you. These questions are mandatory for Top Ideas consideration, so this should be your first priority in the final stretch.

2. A secondary priority, which is optional, is to update your Refinement Phase post. I see you've already updated your concept on the platform. But please share any additional information, photos, and documentation of your progress throughout this Phase!

Looking forward to reviewing and celebrating the amazing work you've achieved this Refinement Phase!

Photo of Andrea Mangone

Hi Lauren.

Last night I uploaded my answers to the questions in time and provided additional material. However I wasn't able to update the public page above since apparently the editing feature was blocked.
Now I can see the edit feature again. I will make sure to update the post ASAP

Thank you

Photo of Lauren Ito

Hi Andrea Mangone ,

As specified in our materials and resources, August 31st at 11:30 p.m. Pacific Time was the final deadline for all submission materials. Your post on the platform is now locked for edits because it is past that deadline.

Thank you for participating in the Challenge and we look forward to reviewing your submission!



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