Plastic Bottle Sizes & Volumes Explained
Bottle sizes sound simple until a "500 ml" bottle turns out to hold more — or less — than you expect. This guide explains fill volume, headspace and how to match a size to your product.
Fill volume vs brim-full capacity
Every bottle has two numbers: the fill volume (the amount it is designed to hold in use) and the brim-full capacity (the absolute maximum, filled right to the top). A "500 ml" bottle is sized around its fill volume; the brim-full capacity is usually a little higher. Always order by fill volume, not by the number stamped on the mould.
Leave headspace
Never fill to the brim. The gap above the liquid — the headspace — lets you seat the cap, absorbs expansion, and stops overflow when the bottle is squeezed or handled. Leave more headspace if you are:
- Hot-filling — the liquid contracts as it cools.
- Carbonating — pressure needs somewhere to go.
- Shipping in warm conditions or at altitude.
A common rule is 5–10% headspace, and more for the cases above.
ml to litre quick reference
| Millilitres | Litres |
|---|---|
| 100 ml | 0.1 L |
| 250 ml | 0.25 L |
| 500 ml | 0.5 L |
| 750 ml | 0.75 L |
| 1000 ml | 1 L |
| 5000 ml | 5 L |
Matching size to use case
- Samples & testers — 30–100 ml.
- Retail cosmetics & food — 100–500 ml.
- Household & refills — 500 ml–1 L.
- Bulk & professional — 1 L and above.
Buying in bulk
FUMERO bottles are sold in bulk with the cap bundled, priced ex-VAT in EUR, with quantity-break discounts that fall as your volume rises (a €50 minimum order applies). Mixing a couple of sizes across a range is often more efficient than forcing one size to do everything.
Ready to size your order? Browse our bottles, or read How to choose the right plastic bottle for material, neck and closure guidance.