Reformulate the product to remove ingredients with which oxygen is reacting.Since oxygen comprises about 16 percent of the volume of air, reducing its concentration can significantly reduce the bottle's internal pressure, leading to bottle paneling. Oxygen may also be reacting with one or more of the product’s ingredients. It is possible that oxygen in the headspace of the bottle is being absorbed in the bottle’s contents, depending on the nature of the product. The design change adds structural integrity by replacing flat areas with a more rigid surface that can resist the pressure. One of the most effective solutions to combat panel sink is to improve the structural integrity of the bottle by slightly changing the shape, from a cylinder to an oval for example. Design the bottles so that paneling will result in the entire label being intentionally “sucked” into a flat, aesthetically appealing surface.Ensure your bottle is of proper gram weight and consistent wall thickness to combat paneling.Reduce the headspace in the bottle by increasing the fill level.Increase the structural integrity of the bottle walls through design mechanics means such as ribbing or vacuum panels - think Gatorade bottle.Allow the hot filled bottle to cool before sealing it.This negative pressure can cause the side panels to suck in to compensate for the loss of product volume. As the product cools, the contents and/or the air in the headspace contract, creating a negative pressure within the bottle. This is most noticeable in the case of bottles that are hot filled and sealed before cooling.
Conversely, when air inside a closed container is cooled, it contracts, reducing the internal pressure and triggering the conditions that can cause paneling. Here are five common causes and their cures: Cause #1 - Temperature / Pressure Change Fortunately, the causes of paneling are easy to identify and just as easy to avoid.
The result is an aesthetically unappealing product package with a distorted shape and badly puckered or wrinkled labels.Research has shown that a consumer’s first reaction to a bottle affected by paneling is often, “There must be something wrong with it.” potentially leading to a loss of business and damage to the brand. Paneling occurs when the pressure inside a plastic bottle becomes less than the ambient air pressure outside, causing the walls of the bottle to partially collapse inward.
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