Innovation in Action

The Challenge

The objective was to create a recyclable dual-compartment cup that delivers high shelf impact, ergonomic handling, and structural integrity, while holding 4.5 oz of yogurt and a complementary mix-in.

For the design team, this meant several critical engineering hurdles. Manufacturing complexities included managing plastic flow, preventing cup telescoping, and ensuring consistent stackability.

 

As Ileana Irimia, the lead development engineer on this project, shared:

“What made this project exciting from the beginning was the unique non-round, asymmetrical shape and the incorporation of an angled living hinge, which posed both a design and manufacturing challenge.”

The angled living hinge between the two compartments was particularly complex—it needed to be both functional and durable. Achieving a durable living hinge required precise material selection to balance clarity, strength, and flexibility.

The Solution

The team began with iterative prototyping and in-depth material testing to optimize the design for consumer usability and manufacturability. Our team used 3D prototypes to assess spoonability and stackability, collaborating closely with the customer to fine-tune compartment volumes. Real-world testing with various particulates ensured adequate headspace for mixing, with multiple rounds of iteration validating the user experience and confirming full spoonability.

As for the challenge of the durable living hinge, Ileana stated,

“We used a specially selected polypropylene material that offered the right balance of flexibility and stiffness, allowing the hinge to bend smoothly without cracking while keeping the compartments securely connected”.

The cup was specifically designed for IML decoration, with a large front panel for bold branding, strong shelf impact, and clear product communication. The label seam was strategically hidden between compartments for a clean, seamless, premium look. In production, the team overcame challenges like plastic flow and cup telescoping by introducing flow leaders, adjusting stacking lugs, and using mold flow simulations to ensure reliable stackability.

The Result

The success of this project was driven by a highly collaborative effort between Polytainers and key stakeholders. Beginning with a design concept in February 2022, the team led a rigorous development process—refining multiple iterations with a sharp focus on functionality, performance, and manufacturability.

Following extensive testing and validation, the design advanced smoothly into full-scale production in early 2024. Close coordination with global partners ensured that the final solution could be produced efficiently at high volumes, without compromising on quality or performance.

“I am proud of the cross-company collaboration, uniting design, tooling, automation, and labeling teams to bring this innovative split cup to life”, Ileana proudly shared.

Polytainers won Best in Class for Technical Innovation Design at the 2025 PAC Global awards for the complex, yet functional and appealing design of this split cup.

Currently, this is the only dual-gated, multi-compartment container in the market, demonstrating Polytainers’ ability to turn complex challenges into commercial breakthroughs.

 
The Benefit

The brand owner has expressed strong satisfaction with the new products line performance, which continues to gain traction with consumers.

Polytainers was able to achieve a 9% reduction in virgin resin compared to our existing split cup design, all without compromising structural integrity.

This project is a true testament to what can be achieved when a proven development process meets a team of experts committed to solving challenges. It wasn’t just about creating a cup—it was about facing design challenges, pushing boundaries, and delivering something both innovative and meaningful for the consumer through our proven process.

Contact Us