Reinventing Packaging Under Pressure with Lactogal

Working in partnership with FORDS, the project evolved into a complete packaging and line integration programme, delivering a lighter, more efficient format and full compliance ahead of the deadline.

New EU regulations requiring tethered caps meant Lactogal’s existing screw cap format was no longer viable. With a fixed compliance deadline in place, continuing production in its current form was simply not an option.

The challenge was not only to meet regulatory requirements, but to do so without disrupting production across multiple high-speed filling lines – all within a tightly defined timeframe.

Rather than simply replacing the existing closure, FORDS worked with Lactogal to rethink the packaging approach entirely.

By removing the screw thread and transitioning to a foil-sealed format, the team unlocked a number of advantages:

• A simpler, more efficient pack design
• Less material usage
• Overall weight saving of 2.5g per unit (25%)
• Lower component complexity
• A controlled, easy-peel opening experience designed with children in mind

What began as a compliance requirement became an opportunity to improve both the packaging and the production process.

To support the new format, FORDS designed and delivered a fully integrated system across three existing production lines – each operating at different speeds and with limited available space.

Rather than requiring significant reconfiguration of the lines, the solution was engineered to fit within the existing footprint, allowing Lactogal to upgrade their packaging format without major disruption to their production environment.

The three lines operate at 14,000 bottles per hour, 14,000 bottles per hour, and 25,000 bottles per hour, each presenting different handling and synchronisation requirements. FORDS developed a tailored solution for each line, while maintaining a high degree of commonality across the systems.

This included:

• 3 x Hermes XO Capping Systems
• 2 x Linear Induction Belt Sealers
• 1 x Custom Dual Linear Belt Sealer

While each system was configured to match the specific speed and behaviour of its line, they were engineered to operate with consistent logic, controls, and core components. This approach reduced the need for multiple unique spare parts, simplified operator training, and ensured a more efficient long-term maintenance strategy.

To further optimise integration, FORDS developed a synchronised transfer system, allowing containers to be passed directly from the filler into the capping and sealing process. This innovation improved line control and ensured stable, repeatable container handling at multiple production speeds.

On the highest-speed line, maintaining sufficient dwell time under induction sealing conditions was critical. At increased throughput, containers spend less time within the induction field which can impact seal integrity if not addressed.

To overcome this, FORDS developed a custom Dual Linear Belt Sealer, effectively extending the length of the induction tunnel to increase exposure time without reducing line speed. This ensured each container received the required sealing energy, maintaining consistent hermetic performance even at elevated production rates.

The combined system, running at 833cpm, supports an output of approximately 220 million units per year.

Alongside equipment delivery, FORDS supported the development of the new packaging format to ensure it performed reliably in production.

This included:

• Advising on bottle redesign and geometry
• Guiding foil structure selection and validation
• Developing an easy-peel seal with consistent performance
• Designing a pull-tab feature to deliver a controlled, accessible opening experience

This combined packaging and process development approach ensured the final solution was not only compliant, but commercially viable at scale – and within the necessary timeframe.

With the EU tethered cap regulation deadline approaching, Lactogal faced a hard stop. Without a compliant packaging format in place, production would not be able to continue beyond the enforcement date.

From the point of initial engagement in August 2023, there was less than a year to design, develop, manufacture, and commission a complete packaging and sealing solution across multiple high-speed lines.

This required a parallel, fast-moving approach. Systems were designed and built concurrently, with the first machines delivered while later units were still in production. Installation and commissioning were carried out in carefully planned stages, ensuring progress without interrupting ongoing production.

Every phase – from packaging development through to final line integration – had to align with the same immovable deadline.

All systems were installed, commissioned, and production-ready one week ahead of the 3^rd July 2024 compliance date.

Crucially, the machines were capping and hermetically sealing at full speed from day one. There was no ramp-up period required. Performance was delivered immediately, ensuring the deadline was met without disruption to production.

As with any new packaging format, achieving consistent performance at production speed required careful control of both the container and the sealing interface.

Working with first mould bottle production, early trials focused on understanding and accommodating variation in bottle geometry – including rim height, sealing surface consistency and bore concentricity. These factors directly influence how sealing pressure is applied and how the foil behaves during opening, and were actively managed as part of the development process.

To support a stable and reliable market launch, initial sealing parameters were intentionally configured to prioritise robust hermetic seal integrity across the full range of expected container variation. This ensured consistent sealing performance at production speed from day one, enabling Lactogal to introduce the new format to market with confidence while establishing a strong baseline for future refinement.

With the product successfully launched and performing reliably in production, the next phase of development focused on optimisation. Real-world consumer feedback and ongoing evaluation confirmed opportunities to further refine the opening experience, particularly for younger users within the target demographic.

FORDS subsequently worked closely with Lactogal and the bottle supplier to further optimise the sealing system. Bottle geometry at the sealing interface was refined, while sealing parameters were carefully adjusted to reduce the force required to initiate the peel without compromising seal integrity.

Alongside this, the foil structure itself was re-evaluated. Rather than relying solely on standard supplier recommendations, FORDS assessed alternative materials to identify a foil better suited to the application – one capable of delivering an easier peel experience while maintaining the required hermetic performance.

Through this structured, phased development approach – from first mould trials through to in-market optimisation – the system was progressively refined to balance production robustness, seal integrity and consumer usability.

The result was a reliable, repeatable sealing process at production speed, combined with a package that performs consistently on the line while delivering a noticeably improved opening experience for the end user.

Lactogal successfully transitioned to a compliant packaging format without disruption to production.

The final solution delivered:

• Full compliance with EU tethered cap regulations
• A simplified, lightweight bottle design – no screw caps or threads
• Reliable, hermetic sealing performance
• A seamless, easy-peel opening experience
• A consistent, integrated system across multiple production lines
• An approximate output of 220 million units per year
• 550 tonnes in packaging weight saved annually

The result is a packaging and production solution designed not just for compliance, but for long-term efficiency, performance, and sustainability.

“Working with FORDS allowed us to navigate a complex regulatory change within a fixed and demanding timeframe. Their packaging and engineering expertise enabled us to introduce a new, streamlined format that performs reliably in production and delivers a more enjoyable experience for our consumers.

Throughout the project, FORDS provided clear technical guidance at every stage – from early development through to full-scale production — ensuring a smooth transition across multiple lines without compromising output or performance”

José Filipe Mesquita, Technological Development Director, Lactogal