A Refill Duo That Shares One Closure Family
A 500 ml refill and a 100 ml travel companion. The engineering goal was that the same pump fits both, so the customer stocks one closure.
| Item | Specification |
|---|---|
| Capacity | 500 ml + 100 ml |
| Material | PET, clear |
| Neck | 24/410 on both |
| Closures | One lotion pump family, two dip-tube lengths |
| Tooling | 2 moulds, 24 days |
One Neck, Two Bottles
Fixing both bottles on 24/410 meant one closure purchase, one torque setting and one spare part. The cost was the 100 ml body: a 24/410 neck at that volume looks large, so the shoulder was raised to keep the proportion.
The Dip Tube Is the Only Difference
Same pump, two tube lengths. That is a stocking decision as much as an engineering one: the customer holds one pump SKU and two tubes instead of two complete closure SKUs.
What Went Wrong Once
The 100 ml tube was initially cut for the 500 ml bottle and touched the base, which made the pump feel stiff. Trimming 6 mm fixed it. In a two-size range, the tube length is the part that gets copied by mistake.
Planning a Range?
Send the sizes and the closure you want to standardise on.