I can’t count how many times I’ve scratched my mouth on the spout of a hard plastic waterbottle that got rough and sharp from using my teeth to get it open. Not only that, but occasionally the caps would fall off or leak. Those bottles used to be the only option when I was heading out on a ride or a run. But I consider myself somewhat lucky; at least I had water.

Brendan Hemp, 47, an executive creative and business consultant in Denver, Colo., whose athletic accomplishments include 7 marathons, 4 Ironman triathlons and literally hundreds of other running, cycling, and triathlon events, remembers workouts without water. “When I was in college training for cross country, there were no on-the-go hydration options,” he said. “We headed out for a long two hour run and either hoped to make it back to drink or stopped at someone’s yard when we spotted a garden hose.”

Modeled after the round metal canteens used by soldiers in the military, the first plastic polypropylene waterbottles started appearing in the 1950s and 1960s. Harder plastic bottles, like Nalgenes, further evolved from the early plastic bottles and dominated the market in the 1990s and early 2000s. While great for hiking and camping, hard plastic and metal bottles aren’t squeezable, so they weren’t as convenient for athletes participating in moving activities. Waterbottles with push/pull caps originated in cycling because they fit on a bike frame and were easy to handle while riding.

As bottle designs changed, so did materials. “Manufacturers switched to low density polyethylene (LDPE) for squeezable bottles because it was softer and more taste-free than prior materials,” explained Andrew Day, product manager for Ultimate Direction. Some companies also used Lexan, a polycarbonate resin plastic, which was one material that brought to light the presence of Bisphenol A (BPA) — a chemical some studies has linked to breast cancer and early puberty. In response to public concerns, most manufacturers’ now make BPA-free products — brands including Nalgene and CamelBak use Tritan, a BPA-free copolyester material made by Eastman.

To solve the leakage and popping off problems associated with traditional push/pull waterbottles, companies honed in on caps and valves. “Newer materials like silicone have made hands-free bottles and valves easier to use and less messy,” noted Day. “Take our Kicker Valve. Leave it open and just squeeze to sip small or gulp big, without spilling. To close it, just push the valve to the side — all without using your hands.”

Now think back to the late 80s when hydration packs first hit the scene; most were basic one-size bladders with drinking hoses and a nylon outer covering with a small amount of storage room. These days, you can choose packs based on what sport you’re doing (mountain cross country or freeride, hiking, running, etc.) how long you’ll be out there, how much gear you need to carry, whether it’s summer or winter and whether or not you want a women’s specific design. “I actually worked on the CamelBak logo design back in ’88 or ’89 and I tried out the prototype,” said Hemp. “It was not good to run with but it was great for mountain biking.” Ultimate Direction was the first company to offer running-specific hydration packs in the 1980s. “Our early designs focused specifically on allowing runners to bring water on training runs without having to hold a bottle the whole time,” explained Day. “Later developments included higher-volume reservoirs and more storage room for supplies like food and a jacket.”

Athletes’ evolving sport habits also affect hydration product designs. At shorter events, people can rely on aid stations. At longer events, it can be hours before athletes can resupply. And more people are going those longer distances — think ultramarathons, Ironmans and multi-day adventure races. “Research in sports nutrition has also shown how important staying hydrated relates to performance, especially in ultra endurance events,” said Day. In response, manufacturers have continually improved existing and created new designs and products.

Day said the industry is now headed on an environmentally friendly push to get people to replace disposable waterbottles with reusable ones. A product called HydraPouch is a good example. Made from recyclable silicone rubber, the HydraPouch is light and reusable, and aims to inspire cup-free racing. At a race, you run with it in your hand and refill it via a special high-speed dispensing valve (HydraPour) attached to water coolers at aid stations. Of course, not all events yet offer the HydraPour and up for debate is whether runners will actually want to stop to refill. Time will tell.

What else is in the works? “Companies are designing products with multiple compartment reservoirs (one for water and one for a sports drink), filtration and insulation, but there’s still a lot of room for refinement,” said Day. We’ll be waiting.

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