Top 7 Mistakes Businesses Make When Choosing Plastic Containers (and How to Avoid Them)

Choosing the right plastic container sounds simple, until a business ends up with leaking products, warped bottles, faulty caps, or packaging that fails long before it reaches the customer. Across South Africa, small start-ups and even large manufacturers often make the same costly mistakes when selecting plastic bottles, jars, tubs, buckets or jerry cans. These issues not only affect product performance but also impact brand reputation, customer satisfaction and long-term costs.

This guide breaks down the top 7 most common mistakes South African businesses make when choosing plastic containers South Africa, with practical advice on how to avoid them using PackNet’s reliable, industry-proven packaging solutions.

1. Choosing the Wrong Material (PET vs HDPE vs Recycled Content)

One of the biggest mistakes businesses make is selecting the wrong plastic material for their product. Each material performs differently, and using the wrong one can lead to container failure, leaks or product degradation.

Common Problems

• Packaging strong cleaning chemicals in a PET bottle that isn’t suited to aggressive formulas.
• Using HDPE when the brand actually needs clear packaging to showcase product colour or texture.
• Ignoring sustainability goals by defaulting to virgin plastic instead of recycled-content options.

How to Avoid This Mistake

Understand the strengths of each material PackNet supplies:

PET (Polyethylene Terephthalate)

Best for:

• Personal care & cosmetics
• Food & beverage
• Home fragrance and room sprays

Benefits:

• Premium clarity and gloss
• Excellent shelf appeal
• 100% recyclable in South Africa

HDPE (High-Density Polyethylene)

Best for:

• Homecare and cleaning products
• Industrial & chemical applications
• Automotive products

Benefits:

• Excellent chemical resistance
• Strong and impact-resistant
• Also fully recyclable

EarthCare Recycled HDPE

Best for brands wanting:

• Containers made from recycled plastic
• Stronger sustainability positioning
• Durable packaging that still supports circular economy goals

PackNet’s EarthCare range gives brands an easy way to move into recycled-content packaging without sacrificing performance.

2. Buying Containers Without Checking the Neck Size or Closure Compatibility

Another very common mistake is buying bottles, jars or jerry cans without checking the neck size or closure type, only to find that the caps and bottles are not compatible.

Typical Issues

• Ordering a 28mm cap for a 24mm neck bottle.
• Choosing a mist sprayer for a bottle designed for trigger heads.
• Buying closures that fit the thread but don’t seal correctly.

How to Avoid This Mistake

When buying from a plastic container supplier like PackNet, always confirm:

• Neck size (e.g. 24/410, 28/410, 38/400 etc.).
• Thread pattern and neck finish.
• Recommended caps, spray heads or dispensers listed on the product page.

PackNet’s website clearly shows compatible closures for most containers, helping you match bottles and caps correctly the first time.

3. Ignoring Chemical Compatibility

Not all plastics are suitable for all chemicals. Using the wrong container for certain formulations can cause swelling, softening, cracking or paneling (when the container walls suck inwards).

Products That Often Cause Problems

• Bleach-based cleaners and disinfectants.
• Automotive degreasers and detailing chemicals.
• Formulas containing high levels of solvents or essential oils.
• Alcohol-heavy sanitisers or surface sprays.

How to Avoid This Mistake

A simple rule-of-thumb:

• Use PET for many food, beverage and cosmetic liquids that are not overly aggressive.
• Use HDPE for most cleaning, industrial and automotive products that need chemical resistance.

When in doubt, ask PackNet’s team for guidance on which material is most suitable for your formula. This is especially important if you are buying packaging online and aren’t sure how your product might react with certain plastics.

4. Choosing the Wrong Closure for the Product Formula

The closure (cap, sprayer or pump) completely changes how a product is used. A great formula in the wrong closure often leads to poor reviews, leakage or returns.

Common Closure Mistakes

• Using a fine mist sprayer for a thick lotion or viscous liquid.
• Using a trigger sprayer when a flip-top or screw cap would be more practical.
• Choosing low-quality caps that loosen during shipping.
• Selecting closures without liners where a seal is necessary.

How to Avoid This Mistake

Think about the product experience first:

• Mist sprayers: ideal for hair mists, body sprays, room fragrances and light sanitiser sprays.
• Trigger sprayers: perfect for all-purpose cleaners, automotive sprays and industrial applications.
• Flip-tops & screw caps: best for lotions, creams, syrups, sauces and other pourable products.

PackNet’s closures & dispensers range is designed to work with its bottles and containers, making it easier to choose a closure that fits and functions correctly.

5. Focusing Only on Looks (Not Practical Performance)

It’s tempting to choose plastic packaging purely based on appearance, especially when you’re building a new brand. But if the container can’t handle real-world conditions, it doesn’t matter how good it looks on a shelf.

Typical Appearance-Over-Performance Issues

• Choosing a thin-walled, cheap bottle that collapses or dents during transport.
• Using a container shape that looks premium but is difficult to label or palletise.
• Picking a material that cannot handle stacking or weight in storage.

How to Avoid This Mistake

When evaluating plastic containers South Africa options, ask:

• Will the container survive transport, stacking and storage?
• Is there enough flat area for labelling and legal information?
• Does the shape work with your filling and capping process?

PackNet’s range is designed with both appearance and durability in mind, including options specifically made for homecare, food, industrial and automotive sectors.

6. Ordering the Wrong Size (Underestimating or Overestimating Volume)

Size mistakes can be surprisingly expensive. If you order containers that are too small or too large, your filling process, product costs and customer expectations can all be affected.

What Usually Goes Wrong

• Underestimating fill volume so the product overflows the container.
• Choosing a bottle that, when correctly filled, still looks “half empty” due to required headspace.
• Using a container that doesn’t match standard retail expectations for your category.

How to Avoid This Mistake

Understand the difference between nominal volume and functional fill:

• A “500ml” bottle typically needs some headspace, it may not be designed to be filled right up to the brim.
• Buckets, tubs, and jerry cans (such as PackNet’s 20L & 25L range) also have working volumes that should be respected.

If you’re unsure, order a small pack first, test your fill level and adjust your packaging choice accordingly.

7. Buying the Cheapest Containers Online Instead of Using a Trusted Supplier

It’s tempting to chase the lowest price when buying packaging online. But very cheap plastic containers can come with hidden costs.

Risks of Low-Quality Containers

• Inconsistent neck sizes that cause sealing issues.
• Brittle plastic that cracks under pressure.
• Warped containers that don’t stand straight or stack properly.
• Unknown material quality, making them unsuitable for food, cosmetics or chemicals.

When packaging fails, it’s not just the container you lose, you lose the product inside, the cost of transport, and the customer’s trust.

How to Avoid This Mistake

Work with an established plastic container supplier like PackNet that offers:

• Consistent, repeatable quality across bottles, jars, buckets, tubs and jerry cans.
• Recyclable materials (PET, HDPE, PP) used across the range.
• Options for both SMEs and large manufacturers, including packs of 50–100 units.
• Nationwide delivery plus a Johannesburg showroom where you can view packaging in person.

PackNet also offers dedicated pages for businesses buying packaging online, such as its Plastic Containers for Sale in South Africa and Plastic Containers Supplier Johannesburg guides.

Conclusion

Selecting the right plastic containers is one of the most important decisions a business can make, whether you’re producing cleaning detergents, beauty products, sauces, or industrial chemicals. By avoiding these seven common mistakes, you save time, reduce waste, limit returns and protect your brand’s reputation.

PackNet’s comprehensive range of PET bottles, HDPE containers, jars, buckets, tubs, jerry cans, closures and EarthCare recycled packaging makes it easier for South African businesses to choose reliable, cost-effective and sustainable plastic containers.

Suppose you’re ready to upgrade your packaging or need expert guidance on choosing the right container for your product. In that case, PackNet’s team is ready to help, with advice, samples and nationwide delivery.