Creators of breakthrough, reusable bottle system sought a “true partner” to create an integrated, multi-part, leak-proof bottle destined to “streamline the refill experience”...
Innovation-driven Replenish Bottling, creators of a bold new format for plastic spray bottles and containers – truly reusable bottles designed for consumer mixing – turned to R&D/Leverage for its injection mold building expertise when it was time to scale up from initial pilot molds.
According to California-based Jason Foster, Founder and “Chief Reuser” of Replenish, his team met the R&D/Leverage team at a trade show in Florida, and the rest, as they say, is history. “At that point, we had made some tools, but nothing had been scaled up,” Foster said. “From the inception of our partnership with R&D/Leverage, it was clear that they recognized and were excited about the potential of our new category, and that their expertise is second-to-none. Together, we are changing what a bottle can be.”
The challenge to the R&D team, however, was formidable. The Replenish team required injection molds designed for high-speed automation to produce six different parts used in an integrated, leak-proof bottle-interior reservoir design that would appeal to makers of a wide range of packaged goods.
THE REPLENISH SYSTEM: DISPOSABLE BOTTLES AS “TOOLS FOR GOOD”
The patented Replenish design relegates the prosaic disposable bottle-refill paradigm to the dustbins of history. But it is one that requires cutting edge molds / molding. It features an internal mixing cup that easily allows consumers to add the right amount of concentrate into the bottle, which is then quickly mixed with household tap water. “Just turn the bottle upside-down, squeeze concentrate from the refill pod into the built-in measuring cup, and add water,” Foster explained. “The cost of creating and shipping water-based formulations is thus reduced. Plus, the Replenish System is hassle-free and fun to use.”
R&D/Leverage’s Project Manager Dave Taylor noted the immediate chemistry between the two teams. “We can handle everything from unit tools to 144-cavity production molds” he said, “and, in this case, we wanted to pioneer a new packaging category with Replenish. We were totally up for the challenge and were ready to partner with them to help commercialize their breakthrough vision.”
Added Account Manager Larry Schumacher, “we are a privately-owned company and have been since 1976. R&D/Leverage is here for the long-haul, which in this day and age (here today and gone tomorrow) means a lot to companies like Replenish. Further, our reputation for handling the toughest assignments, on-time and on-budget, is without peer in the industry,” he said. “Our tool design group has more than three decades of experience. We know how to build and refurbish molds. Our engineering and processing capabilities are first rate.”
Concluded Larry, “We have the in-house capability to deliver the best part possible, fast, and at the best value, with the added benefit that everything is made here in the United States. We have nine presses in our mold qualification lab with dedicated QA capabilities. We can assure our customer receives a quality product.”
THE REPLENISH MISSION TODAY
Replenish, through its partnership with R&D/Leverage USA, today continues its mission to eliminate waste and save money. The company’s goals, which include the marketing of its efficient, affordable and scalable refill system across brands and product categories, are being reached. “Most products we buy are 90 percent water [95-99% actually, but that’s neither here nor there], with only a small amount of active ingredients,” said Replenish’s Foster. “Our reusable bottling platform, created thanks to our true partnership with R&D/Leverage, helps us reach brand owners from household products to consumer beverages. It is a win for us, brand owners, retailers and consumers – and the planet.”
Photo: R&D/Leverage
