Amcor has partnered with Insymmetry to develop a 2oz (60ml) retort bottle, which it says will address the growing demand for durable, shelf-stable packaging.
Designed to meet the needs of brands seeking high-performance packaging for low-acid, shelf-stable products like coffee and dairy-based beverages, this packaging solution is the first to leverage Amcor Rigid Packaging’s (ARP) proprietary StormPanel technology.
The bottle is designed to withstand high-pressure retort sterilisation processes while maintaining product integrity and market-ready aesthetics, the bottle provides manufacturers with a reliable and scalable alternative to aseptic processing.
Stellify, a beverage brand owned by Insymmetry, is the first company to take advantage of the StormPanel technology with its energy nootropic Dulce de Leche Energy and Espresso Energy wellness beverage shots, which will be spotlighted at Natural Products Expo West 2025.
Filling industry needs
The StormPanel bottle responds directly to evolving market demands for durable, shelf-stable packaging solutions that meet stringent performance requirements for nutrition standards, including the Real California Milk seal.
According to the company, this 2oz product not only caters to the health-conscious consumer but also provides a convenient option for on-the-go lifestyles.
“At Amcor, we are committed to driving innovation that addresses the evolving needs of the food and beverage industry,” said Greg Rosati, vice-president of Strategy and Marketing at ARP.
“Our innovative StormPanel packaging allows beverage brands to elevate shelf-stable, low-acid products in a compact, ready-to-use bottle.”
According to Amcor, while it is an ideal product for the end-user, the retort process also offers a more cost-effective and time-efficient solution for manufacturers compared to aseptic processing, as it reduces upfront equipment investment and streamlining production timelines, while maintaining product integrity.
“Amcor’s expertise in packaging innovation enabled us to develop a solution that meets our unique needs,” said Josh Cua, chief innovations officer of Insymmetry.
“By leveraging their advanced manufacturing technology and material science capabilities, we were able to create a bottle that not only performs exceptionally in the retort environment, but also aligns with growing consumer demand for preservative-free nutritional shots.”
Revolutionising retort packaging
Engineered with StormPanel technology, the bottle maintains shape and structural integrity under the extreme heat and pressure fluctuations of retort sterilisation, ensuring reliable protection and an extended 12-month shelf-life with no refrigeration.
The design incorporates features that preserve the round shape, while other areas are specifically designed to flex.
“This collaboration is a testament to Amcor’s ability to combine deep industry expertise with advanced engineering to address complex challenges,” said Mikey Tom, business development manager at ARP.
“We are proud to deliver a solution that provides manufacturers and consumers with uncompromising quality and functionality.”
A collaborative approach to innovation
ARP’s close collaboration with Insymmetry was key to developing the innovative retort polypropylene bottle.
Utilising finite element analysis (FEA) and ARP’s VR capabilities to streamline the process, the teams refined the StormPanel design to maintain structural integrity during the retort sterilisation.
By selecting a co-polymer resin and optimising a one-step moulding system, they ensured efficiency and scalability.
Also, the project’s proximity to Insymmetry’s California operations enabled rapid prototyping and promises of accelerated commercialisation.
“As a smaller company, we are truly grateful for Amcor’s trust, time and confidence in us. Partnering with a global leader like Amcor has been invaluable, and we greatly appreciate the dedication of the entire team for making the impossible possible,” Cua concluded.
