Extrusion blow molded container and method

A multi-layer extrusion blow molded plastic container, comprising:

• a sidewall portion;
• a base portion comprising an outer base portion including a support surface, and an inner base portion including a pushup portion;
• an inner polymer layer comprising virgin material with little or no added colorant;
• an outer polymer layer;
• a middle polymer layer disposed between the inner polymer layer and an outer polymer layer, the middle polymer layer comprising up to 50% post-consumer recycled (PCR) content;
• and
• at least one adhesive layer disposed between adjacent polymer layers;
• wherein the inner polymer layer, the middle polymer layer, and the outer polymer layer respectively comprise 10% or less, at least 50%, and 30% or less of a total weight of the plastic container when unlabeled and unfilled;
• wherein a wall thickness at a sidewall portion within a label panel area is about 0.032 inches or less;
• and
• wherein a wall thickness at a central portion of the pushup portion is about 0.024 inches or less.

A method of forming a lightweight extrusion blow molded plastic container with controlled material distribution, comprising:

• extruding a multi-layer parison comprising at least an outer layer, a middle layer, and an inner layer, with at least one adhesive layer disposed between adjacent layers, wherein parison wall thickness is controlled such that a wall thickness of the formed container at a sidewall portion within a label panel area is 0.032 inches or less and a wall thickness at a central portion of a pushup portion of a base of the formed container is 0.024 inches or less;
• inflating the parison within a blow mold using compressed air to form the plastic container such that the inner layer comprises virgin polymer material with little or no added colorant, the middle layer comprises up to 50% post-consumer recycled content, and the inner layer, middle layer, and outer layer respectively comprise 10% or less, at least 50%, and 30% or less of a total weight of the formed container when unlabeled and unfilled;
• and
• cooling the formed container to solidify the layers;
• wherein the formed container has a capacity of at least 150 fluid ounces and an unlabeled and unfilled weight of 172 grams or less.