Usana Health Sciences recently released to market its newly branded One World supplement line featuring a custom molded cap by Mold-Rite. The new cap and bottle combo was a huge group undertaking that seamlessly combined both custom and stock packaging. Mold-Rite's hand in creating the One World cap made the brand come to life, adding texture and dimension by embossing the company's circular human wellness logo onto the closure.

The project began back in December of 2011 when Usana sought out Berlin Packaging and presented the idea with a tight schedule, hoping to have the to complete solution ready within a half year's time. Usana needed to depict the essence of its company in this rebrand - freedom from pain and illness. The new packaging also had to represent the various supplement types (heart health, brain and nerve, etc.) and offer different product capacities.

Alpha Packaging was chosen to supply superior stock bottles, however, the cap presented challenges requiring customization. This is where Mold-Rite jumped in, tasked with creating a visually captivating closure with highly advanced sealing, and the ability to be manufactured along with a standard bottle for time and cost saving advantages.

Mold-rite specializes in custom molding and has its own in-house tool-building capabilities. Such an advantage allowed the company to meet manufacturing specifications, like the design of horizontal lines on the side of the closure so that it would release properly from the mold during the injection-molding process. Also, by keeping the depth of the closure to 0.05 in Berlin and Mold-Rite were able to create cavities over existing cores to keep costs down while still creating a very customized look and feel.

Thanks to the hard work and collaborative efforts of many, Mold-Rite was able to supply these custom molded and embossed closures with a rapid turnaround of only 10 weeks - nearly half of the time usually required for such a project. The closure was created in five different sizes to match the various bottle capacities ranging from 75 to 400 cc. The solution was also made to work with Usana's pre-existing capping equipment.

"Overall, the response from our distributors has been very good. Customers are happy with the new look and have embraced the new identity... Everything just came together for this project; the team that was organized was well thought out. The people who came together made this happen. It was a culmination of several different entities, including Usana and their marketing team in Australia, three different divisions of Berlin, and Mold-Rite. The project came off flawlessly, it really did," says Jon Jeffery, District Manager for Berlin Packaging.

Weatherchem, Stull Technologies and Mold-Rite Plastics are now united providing an expanded product portfolio, multiple manufacturing locations, in-house tooling, outstanding innovation, unmatched flexibility and responsiveness. The company's complete line of products offers a single source for the broadest range of closures ideal for a wide variety of markets. Among product offerings are: A vast CT Closure selection, Child Resistant Closures, Dispensing Closures including: Back and top-hinged disc tops, Turret-style, Twist-open, Strap caps, Jars, and Vials and Fitments.

Mold-Rite Plastics is a leading manufacturer of rigid plastic packaging products, serving a wide variety of markets across the globe. Founded in 1976, Mold-Rite has grown from a handful of injection molding machines into a full service manufacturer with capabilities in molding, lining and decorating of products.