Plastic Packaging

Plastic packaging spans a wide range of formats, including bottles, jars, tubes, closures, sprayers, pumps, droppers, and airless systems, as well as more specialized formats like cartridges, solid sticks, and refillable packaging. The right format depends on your product's dispensing requirements, shelf positioning, and end-use application. Evergreen supplies all major plastic packaging formats across personal care, home care, food and beverage, and industrial applications.

The most common plastic materials used in packaging are PET, HDPE, PP, and LDPE, each selected based on factors like chemical compatibility, clarity, flexibility, and end-use requirements. PET is widely used for bottles requiring clarity and strength, while HDPE and PP are preferred for their chemical resistance and durability. Evergreen supplies all major resin types and works with brands to match material selection to product performance and sustainability goals.

Both stock and custom plastic packaging options are available, with the right choice depending on volume requirements, budget, timeline, and the level of brand differentiation needed. Stock formats offer faster lead times and lower upfront costs, while custom tooling enables unique shapes, embedded logos, and proprietary structures that stock components cannot offer. Evergreen supports both approaches and helps brands evaluate the tradeoffs based on their specific commercial and brand requirements.

Custom plastic packaging tooling typically takes between 35 and 70 days for production molds, depending on part complexity and the molding process required. Pilot molds can be completed in as few as 10 days, and 3D-printed prototypes are available in as little as 48 hours for early-stage design validation. Evergreen provides a clear development timeline at the start of every project, covering tooling, sampling, approvals, and delivery. To learn more, visit our Custom Tooling Page.

Plastic packaging supports a broad range of decoration techniques, including silkscreen printing, offset printing, hot stamping, embossing, debossing, metallization, and soft-touch coatings. The right decoration method depends on the complexity of the design, and the desired finish. Evergreen's decoration capabilities are integrated with tooling development, so design intent and manufacturing feasibility are aligned from the start of each project. To learn more, visit our Advanced Decorations Page.

PCR (post-consumer recycled) packaging is made using plastic resin recovered and reprocessed from post-consumer waste, such as used bottles and containers, rather than virgin petroleum-derived plastic. It performs comparably to virgin resin in most applications but carries a lower environmental footprint and supports brands' recycled content commitments. Evergreen offers PCR resin options across most plastic packaging formats, with inclusion ranging from 30-100%, depending on the component type.

Dispensing packaging is any packaging system designed to control how a product is released or applied, rather than requiring the user to pour or scoop directly from the container. It encompasses a broad range of formats, including pumps, trigger sprayers, fine mist sprayers, airless bottles, and dispensing closures. The right dispensing packaging improves user experience, reduces product waste, and protects formula integrity between uses.

Quality in plastic packaging production is managed through dimensional checks, material verification, visual inspection, and functional testing at key stages of the manufacturing process. Issues caught during production — rather than at the point of delivery — reduce the risk of defects reaching the customer and avoid costly rework or delays. Evergreen QC engineers are onsite at all productions globally, and every facility in our network is audited across 165 quality management metrics.