Blow Moulding Technologies (BMT), a strategic partner to the global packaging industry, has announced the development of a precise-forming simulation methodology designed to help beverage manufacturers accurately predict the wall thickness and performance of PET and recycled PET (rPET) bottles. The newly developed approach integrates advanced material characterisation with a simulation-driven modelling process, enabling manufacturers to virtually assess the performance of bottles under real-world conditions. By delivering highly accurate insights during the design phase, the methodology is expected to reduce reliance on physical prototyping while accelerating product development timelines.
David McKelvey, Head of Product at BMT, highlighted the benefits of the technology, noting that it enables accurate prediction of key performance parameters such as top load strength and burst pressure. This allows manufacturers to optimise bottle designs for both durability and lightweighting, supporting cost efficiency and sustainability goals. He added that improving predictive accuracy early in development helps companies make better-informed design decisions and shorten time-to-market.
At the core of the methodology is detailed material characterisation, which examines how PET resin behaves during heating, stretching, and forming. This process includes biaxial tensile testing, where the material is stretched in two directions under controlled conditions to measure deformation patterns, stiffness variations, and stretch ratios. These insights capture how processing history influences the material’s mechanical properties, providing critical data inputs for simulation.
Using this data, BMT’s simulation models replicate the full bottle-forming process. Unlike conventional methods that assume uniform wall thickness or consistent material properties, BMT’s approach predicts how the material stretches in both axial and circumferential directions during blow moulding. This results in a highly accurate representation of thickness distribution and stiffness across the finished bottle.
The company also conducts virtual performance testing, including top load and burst pressure simulations, to evaluate how bottles will behave under real-world conditions. In a recent validation study, simulation models based on variable material properties achieved results within approximately 1 percent of physical testing outcomes. In contrast, traditional models using constant properties overestimated performance by up to 63 percent, underscoring the limitations of simplified assumptions.
This level of precision allows manufacturers to identify potential design issues earlier in the development cycle, assess the impact of design modifications, and make confident decisions before committing to tooling and production. The result is a more efficient, data-driven design process that reduces material waste and improves overall product performance.
BMT’s integrated workflow combines material characterisation and simulation into a unified process, ensuring seamless alignment between measured material behaviour and predicted bottle performance. This approach supports the company’s broader mission to enable sustainable packaging solutions by reducing material usage, improving design efficiency, and minimising environmental impact.
Headquartered in Belfast, BMT provides innovative stretch blow moulding technologies to packaging manufacturers worldwide. Its portfolio includes advanced inspection and sensing tools that help improve product quality and operational efficiency.
Through its combination of digital modelling, hardware solutions, and expert consultancy, the company continues to support the industry’s transition toward more sustainable and resource-efficient packaging. With this latest innovation, BMT reinforces its commitment to engineering solutions that bridge the gap between virtual design and real-world performance, empowering manufacturers to achieve both strength and sustainability in PET bottle production.
