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.