Most spirit bottles are made from flint (clear) glass, which showcases the liquid's color and clarity. Premium brands often specify extra-flint glass for its higher brilliance and near-colorless appearance, while amber, green, and blue glass are used selectively for visual differentiation. Evergreen produces spirit bottles in flint, extra-flint, and custom-colored glass to match a brand's positioning.

Glass spirit bottles range from small miniature formats up to large-format bottles, with 700ml and 750ml the standard for most distilled spirits at retail. Smaller sizes suit gifting and tastings, while 1L and above serve duty-free and premium presentation. Evergreen manufactures spirit bottles from 10ml to 3,000ml (3oz–100oz), with custom sizes available through dedicated tooling.

The difference between 700ml and 750ml spirit bottles is the market each serves: 700ml is the global and EU standard, while 750ml has been the traditional U.S. size. Since late 2020, the U.S. TTB has also permitted 700ml bottles, letting brands run a single format across domestic and export markets. Evergreen supplies both to support multi-market launches.

The most common spirit bottle shapes are round (cylindrical), square, rectangular, decanter-style, and tall slim profiles. Round bottles are the versatile default for whiskey, vodka, and rum; decanter shapes with broad shoulders signal premium cognac and brandy; tall slim bottles suit vodka and gin. Evergreen builds custom molds for brands wanting a distinctive proprietary shape.

Spirit bottles typically use cork or bar-top closures, screw caps, or ROPP options depending on the product and price point. Bar-top corks offer a tactile, premium unsealing ritual, while screw caps and ROPP closures provide tamper-evidence and reliable resealing. Each closure must be matched precisely to the bottle's neck finish, which Evergreen coordinates as part of bottle development.

Glass spirit bottles can be decorated with silkscreen printing, embossing and debossing, PS/ACL decals, frosting (acid etching), color spray, heat transfer, electroplating, and sandblasting, in addition to labeling. Embossing tooled into the mold adds permanent brand detail at no per-unit cost once the mold exists, while frosting and soft-touch color spray create a distinctive tactile finish. Evergreen offers all of these decoration methods in-house.

Creating a custom spirit bottle starts with translating a design concept into a glass mold through custom tooling. The process moves from design and feasibility review to mold fabrication, sampling, and approval before full production — with shape, weight, and neck finish all defined at the tooling stage. Evergreen manages custom tooling from initial ideation through full-scale production.

Spirit bottles are tested for dimensional accuracy, wall thickness, capacity, and visual defects such as inclusions or stress points, along with closure fit and seal integrity. Glass is also checked for annealing quality and thermal-shock resistance to withstand filling and handling. At Evergreen, QC engineers are onsite at every production, inspecting against 165 quality management metrics per facility.