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Inbuilt caps for plastic bottles

The idea eliminates the concept of having separate plastic caps for plastic bottles.

Photo of mitin anand
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The idea completely eliminates the need for having separate caps for plastic bottles. The bottle design consists of an extension and a blob at the end. The blob perfectly fits the mouth of the bottle. The beauty of the design is that the whole arrangement can be made in a single blow moulding process. There is no need for the bottle manufacturer to make separate plastic caps. The caps are inseparable from the bottle and also made of the same material as the bottle. Hence the concept not only reduces plastic waste but also reduces the manufacturing cost for bottle manufacturer. 

Idea Title

All is one, one is all


Malvika - Mitin -

Where are you / your team located?

Bangalore, India

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

The design of the bottle is such that the bottle caps are permanently attached to the bottle. Hence the caps cannot be throw away.

Which use cases does your Idea apply to?

Use case 2

In what geographical context or area does your Idea plan to operate / solve?


How do you envision scaling up your Idea?

The only challenge is that the manufacturer need to adapt to a new bottle design for their products. Since the new design would eventually reduce their manufacturing cost in the long run. I am pretty sure that they would go for the new bottle design. Also need to work on the new design of the bottle to make it more user friendly.

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.

The funding would help us to refine the concept further to a manufacturing stage. As designers we intend to make multiple prototypes and perform user testing until we come up with an appropriate design.

Please describe from where your Idea emerged

The idea evolved from a brainstorming session

Tell us about your work experience

Malvika- product designer, worked with a variety of products & systems : research-concept-market Mitin- product designer, mechanical engineer & design and development consultant for start-ups

Please describe, in detail, your business model and how you intend to test and iterate this model.

We could approach companies like Nestle and urge them to use the new environment friendly and cost effective bottle design for disaster struck victims. It could be a situation for them. Firstly they can supply more bottles to victims since the cost per bottle is less. Secondly it would help them to validate the new design and employ it for their upcoming products.

Please explain how your innovation will work within, potentially improve, and provide benefit to the plastics system.

The new design is such that the cap is made of the same material as the bottle and it is inseperable. So the same machinery can recycle the bottle and the cap together. Also the users cannot throw away the cap since it is inseperable from bottle. Hence the bottle and the cap comes as one unit to the recycling unit.

Please describe, in depth, how your solution will reduce the overall environmental footprint of packaging.

PP has been proved to be one of the safer plastics and its is 100% recyclable. In the existing scenario caps are manufactured separately and transported to the bottle site. The new design dosent call for such need . Hence it reduces the resource for manufacturing and transportation of caps. At the recycling plant caps are generally sorted and separated. The new design doesn't require the need for sorting caps. Hence making the whole process more efficient.

Please outline how your design, material, and delivery choices will influence price, and how you intend to address the price increase that may result from this solution.

PP containers appear to offer major cost advantages over PET. The cost of PP resin is lesser compared to PET. Furthermore, PP has a 44% density advantage over PET. Hence a bottle made of PP will always be cheaper that the bottle made of PET.

Please explain how your solution will impact user behavior, and what design considerations you've included to ensure easy and intuitive interactions with your Idea. 

1. Easy to open the bottle : The cap is easy to open and close since it is a push fit kind of arrangement. Hence only a thumb is required to open the bottle. 2. Need not worry about caps : Since the cap is attached to the bottle using a live hinge the user need not worry about the cap once the bottle is open. Also, the cap is attached to the bottle using a live butterfly hinge hence it doesn't come in the way while drinking from the bottle.

Please describe how you intend to use the prize funding, if selected as a Top Idea. Be specific.

Before approaching major brands we would like have a fully functional prototype ready for manufacturing. The prize money would help us to refine the concept to manufacturing stage.


Join the conversation:

Photo of Lisa

Hi Mitin,
Has any of this come to fruition and if so have you encountered any challenges since implementing the idea?

Photo of Lauren Ito

Hi mitin anand !

As Refinement Phase quickly comes to a close in LESS THAN 7 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.

If you have any questions, please email

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

Photo of Kate Rushton

Hi Mitin!

Welcome to the refinement phase!

What material do you plan to use for the bottles?

How does the design impact filling and other unit operations at a beverage plant?

Is there a way for the cap to be tucked away when opened so that it doesn't get in the way.

I look forward to seeing a prototype of your bottle. Are you able to produce an early stage prototype?

There are a few ideas that you might want to check out as a source of inspiration for prototyping and gathering user feedback:

Friendly ATM - - a top idea from our financial longevity challenge has a great example of rapid, low budget prototyping and gathering feedback from customers. The use of video to demonstrate the prototyping/testing session is really good.

InLid - another idea in refinement - - has a really good example of using video to demonstrate rapid prototyping and getting feedback from the users

If you have any questions, feel free to reach out to me by tagging me here (@ followed by my name) or send me an email -

I just want to remind you that the deadline to complete the Refinement Questions via the online submission form is August 31 at 11:30 p.m. Pacific Time.

Photo of mitin anand

Hi Kate,

Sorry for the delayed response.
Thank you so much for your inputs.

Yes we have made an early stage prototype for testing the concept. Will definitely share it in the final phase. Our final design is most suited for PP material. However with some changes in the design it could fit for PET as well.

We have worked on the refilling and other usability aspect. Will update the results and share it in the refinement post. Since we feel it would be more appropriate to explain it thru renders and sketches.

Photo of Kate Rushton

Hi Mitin!

There are 7 days left in the refinement phase.

If there is key information in the comments on your idea submission, I recommend that you move them to the main body of your idea submission before the cut-off time.

I just want to remind you that the deadline to complete the Refinement Questions via the online submission form is August 31 at 11:30 p.m. Pacific Time.

Photo of Kate Rushton

Hi Mitin!

It is great to have you in the challenge. I would recommend that you check out Nepenthes by Marilu Valente 

Have you been able to get feedback from manufacturing facilities on your design?

Photo of mitin anand

Hi Kate,

We are in discussion with some blow moulding experts and we have received positive feedback on the manufacturing aspect. A bit more refinement is required before taking it to the manufacturing stage. But it is definitely manufacturable.