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Portola Packaging launches GreenLyte™ plug-seal closure line

Portola Packaging, Inc. are introducing GreenLyte™, a new line of plug-seal, high-density polyethylene (HDPE) 38 mm closures for single and multiservice, hot-fill and aseptic beverage packaging applications. 

GreenLyte™ one-piece closures represent a cost-effective, performance-driven alternative to traditional two-piece (closure plus liner) polypropylene (PP) types typically used for juices, ready-to-drink teas, isotonic,enhanced waters, low-acid nutraceuticals, and high-end, aseptic-filled beverage products.

“Our internal tests show that GreenLyte™ closures equal or exceed performance attributes offered by traditional two-piece closures. Additionally, the one-piece plug design reduces costs for brand owners due to shell light weighting, liner elimination and material choice. We believe that this launch will be of significant interest for beverage brand owners looking for ways maintain or improve performance, while reducing costs,”

Because the GreenLyte™ line is made from high-density polyethylene, resin is less expensive than pricing volatility-prone polypropylene, which is the material from which most two-piece closures are made. 

“Two-piece closures have also been known to be difficult for consumers to open.  The thermoplastic elastomer (TPE) liner material tends to drag across the top of the finish requiring a significant amount of torque to access the contents.  Because the GreenLyte’s plug construction eliminates the need for a liner, opening issues are mostly eliminated.

GreenLyte™ plug-seal closures also offer multiple production line efficiencies. Unlike two-piece closures which usually require that the TPE liner be steamed in order to achieve proper application, this step is not necessary with Portola’s liner less GreenLyte™ line. Additionally, the seal design and low coefficient of friction facilitates application over a wide range of capper settings.


Portola Packaging is one of the first North American manufacturers to commercially produce liner less closures that can meet the rigorous demands of hot-fill, extended shelf life and aseptic applications.