Tethered Caps Breakthrough in the US Beverage Market

The European Union (EU) is ever one — or many — steps ahead of the U.S. regarding materials and processes that decrease human impact on the environment. In 2018, the EU announced a directive to reduce single-use plastics, which led to multiple sustainability initiatives including a ban on loose caps on bottles up to three liters as of July 3, 2024.

CG Roxane, the family-owned maker of Crystal Geyser Alpine Spring Water, determined to lead sustainability efforts in the U.S., has taken the initiative to replace loose caps in its own 8-ounce bottles, starting with those produced in its home state of California.

This decision is part of the company’s ‘Thirst for Progress’ campaign highlighting CG Roxane’s commitment to delivering high-quality products while keeping sustainability at the forefront. The campaign’s goal is to empower consumers to make informed choices in their hydration and bottled water purchases.

Packaging Digest sat down with Lionel Ferchaud, vice president of operations at CG Roxane to learn more about the new tethered cap design.

Does the tethered cap cost more? If so, does the company charge more for those bottles?

Ferchaud: CG Roxane has invested in new equipment to develop the EZ-Cap. However, the brand has chosen not to pass this cost on to its clients or end consumers. Consequently, Crystal Geyser does not differentiate between the price of a regular cap and the tethered cap. It is important to note that Crystal Geyser does not set the retail price of the product.

Is it a continuous-thread closure or a snap-on cap?

Ferchaud: The EZ- Cap’s compact design reduces plastic consumption compared to traditional screw caps. The snap-on cap provides effortless click-and-go functionality allowing consumers to know the cap is opened and closed securely for hassle-free hydration. It can be opened and closed with one hand.

A 2018 article noted that Crystal Geyser previously used tethered caps on 500-milliliter bottles. So is the packaging news that the tethered cap is being extended to the 8-oz size? 

Ferchaud: CG Roxane has launched the EZ-cap on all its Californian 8-oz, with intention to extend it to more formats, if possible, within the next few years, including reintroducing them into the 500-mL bottles. 

The 8-oz is the only current format for Crystal Geyser Alpine Spring Water with the tethered cap. We stopped using the tethered cap on our 500-mL formats in 2019. At that time, we had upgraded to a state-of-the-art production line for the 500-mL format. Due to the line’s high speeds and other factors, the tethered cap was no longer suited to the 500-mL format.

Do you think other beverage companies in the US will follow Europe’s lead and switch to tethered closures? And do you foresee similar US legislation any time soon?

Ferchaud: While CG Roxane cannot speak for the strategies of other beverage companies, we anticipate that the industry may increasingly embrace tethered closures, especially as similar mandates start to gain traction in the US. Much like our proactive approach with recycled polyethylene terephthalate (rPET), being nearly a decade ahead of California’s legislative requirements, we expect that the recent EU mandate requiring plastic caps on beverage bottles of 3 liters or less to remain attached starting July 2024 will influence trends in the US beverage sector. As sustainability becomes a growing priority, beverage manufacturers would be prudent to stay informed and adaptable to such emerging regulations.

Does the rPET the company produces at its two recycling facilities supply all the rPET it uses in all its packaging at 50%?

Ferchaud: Yes, that is correct, the rPET the company produces at its San Bernardino, CA, and its Benton, TN, rPET plants, allow it to produce packaging with a minimum of 50% rPET, excluding labels and caps.

Is the company using 50% post-consumer recycled material in all its bottles or just select brands/sizes?

Ferchaud: The company uses PCR to manufacture all of its Crystal Geyser Alpine Spring Water bottles with 50% rPET.

Is the tethered cap option on its 8-oz bottles only sold in California or throughout the US?

Ferchaud: The tethered cap is produced out of our Olancha, CA, plant allowing distribution of 8-oz Crystal Geyser Alpine Spring Water with CG Roxane’s EZ-cap within California and to neighboring states including Nevada, Arizona, Colorado, Utah, and Washington.

Some other sizes of your products use a blue flip-top dispensing closure. Is this tethered closure too? The blue cap uses more plastic than the EZ-Cap tethered closure on the 8-oz size, correct?

Ferchaud: The blue flip-top is not considered a tethered cap because the mechanism of this cap still allows you to unscrew it, unlike the EZ-cap. It has a different functionality than the tethered cap because it serves as a sport cap allowing for controlled flow without needing to remove the cap entirely. This mechanism does require more plastic.

Who is the tethered closure supplier?

Ferchaud: Due to confidentiality agreements, we do not disclose our supplier names.

How is the closure designed to click and stay in the opened position? Is there a schematic for that?

Ferchaud: Please refer to patent number US D784,808 S, for more detail on the functionality of the closure design.

The plastic-reducing EZ-Cap is more compact than traditional screw caps. Image: CG Roxane

Does the company have plans to incorporate recycled content in the closures at some point?

Ferchaud: CG Roxane is committed to advancing sustainability and recycling initiatives. We continuously assess our packaging materials to explore opportunities for incorporating more recycled content and reducing plastic usage. Our goal is to remain at the forefront of sustainable practices and integrate innovations that align with our environmental commitments.

Editor's note: Also read "Inside Story of First US Water Brand With Tethered Caps" by our sister media outlet, PlasticsToday, which separately interviewed Lionel Ferchaud.