Innovative DecoFusion™ technology allows for 360°, uninterrupted artwork with improved consumer “bounce-back” experience and thinner sidewalls to reduce material

Global packaging leader Berry Global Group, Inc. announced a significant investment to expand and enhance the company’s tube manufacturing capabilities using its new, patented DecoFusion™ hybrid technology process. This innovative process produces a seamless construction tube with high-impact, high-resolution graphic decoration while maintaining a premium rebound and feel.

“This revolutionary tube delivers spectacular graphics, a better consumer experience, and sustainability benefits, all in one package,” said Brian Jacobi, Chief Commercial Officer for Closures, Bottles & Specialties at Berry Global. “DecoFusion helps brands stand out on the shelf to gain market share and consumer interest at the first moment of truth and improves sustainability by incorporating recycled content and creating a premium feel using less material.”

Built on a first-of-its-kind manufacturing cell, DecoFusion benefits from Berry’s fully integrated framework. The full process, from resin pellet to substrate, decoration, finished tube, and closure, is all within one supply chain. Ahead of the launch, Berry’s material science and innovation teams developed the optimal process for integrating materials and manufacturing soluti
ons.

The tube market innovation leader’s latest offering provides:

  • Photorealistic, label-quality print with flexography, silkscreen, and foils
  • 360° decoration for uninterrupted artwork
  • Over-the-shoulder printing for full graphic coverage
  • Easy integration into existing filling lines for a fast conversion
  • A variety of closures available that can be oriented to the decoration
  • Easy-to-use tube with minimal force needed to evacuate product
  • Barrier layer available to improve shelf life
  • All polyethylene construction 

Berry’s DecoFusion tube can incorporate up to 75% of post-consumer recycled content and offers up to 27% weight savings compared to standard tubes due to using less material in the package. This move to more sustainable packaging, compared to standard tubes with no PCR, is estimated to reduce around 167 metric tons of greenhouse emissions annually* – the equivalent of removing 39 gasoline-powered U.S. cars off the road for one year**.

Discover the future of sustainable packaging with Berry’s DecoFusion tube. Learn more at Berry DecoFusion Tube.

*Source: https://plasticsrecycling.org/images/library/APR-Recycled-vs-Virgin-May2020.pdf (based on 20 million units)
**Source: https://www.epa.gov/energy/greenhouse-gas-equivalencies-calculator