According to Statista, more than 75% of U.S. consumers “placed some level of importance on sustainably packaged cosmetic products in 2023,” with the largest cohort stating that sustainable cosmetic packaging was at least somewhat important in their skin care and makeup selection processa.
At the same time, Spateb has noted a 34.6% year-over-year uptick in searches for upcycled products; simultaneously, searches for chemical recycling, particularly chemical recycling centers, has also increased.
Taken together, consumer awareness of the sustainability issues associated with cosmetic packaging continues to grow. It’s no surprise, then, that so many packaging suppliers have upped their game with a wide array of sustainable, high-performance packaging solutions.
Sustainable Leak-proof Packaging
Product leakage, particularly in e-commerce-related shipping is a perennial issue facing beauty brands. Two new solutions address these concerns.
The disc-top closure features an integrated, concealed mechanism that requires more force to be applied upon initial opening, but thereafter operates as a standard disc top closure, per Aptar.Aptar
It also allows brands to bypass shipping preparation fees imposed by major online retailers when additional protective packaging is required.
The E-Disc Top, manufactured in the United States, is currently being produced and is available in a 24-410 flat neck finish. It is suitable for medium to thick viscosities.
It features a crab claw seal and fits 0.166- and 0.310-inch orifice sizes.
The top is Amazon ISTA-6 compliant and is therefore able to withstand harsh shipping conditions.
This keeps the product secure and prevents cracks, leaks and breaks, thereby diminishing customer complaints and returns.
The disc-top closure features an integrated, concealed mechanism that requires more force to be applied upon initial opening, but thereafter operates as a standard disc top closure, per Aptar.
The PP closure is fully recyclable and available in post-consumer recycled (PCR) content.
Two more disc top dispensing solutions will be launched by Aptar this year, per the company.
Meanwhile, Epopack’s leak-proof PET screw-on cap with dual seal function is designed to ensure products ship without incident.
Designed to address common leakage issues associated with oil-based products, the AV series screw-on caps, paired with PET heavy wall bottles, provide leakage prevention for products such as oils, makeup removers and toners—all with a monomaterial solution.
Epopack’s leak-proof PET screw-on cap with dual seal function is designed to ensure products ship without incident.Epopack
First up is a stopper in the center of the cap that can be plugged into the reducer’s opening.
Second is a seal ring round the cap, which is designed to press on the surface of the reducer to create a second seal.
Combined, the design elements are intended to keep products secured during transport and storage.
Meanwhile, the heavy-wall bottles provide additional sturdiness and durability, as well as a weighty, premium feel.
The AV series is available in 30 ml, 60 ml, 120 ml and 150 ml variants and can be customized with various decoration options.
Finally, Aptar’s new hoodless Maya aerosol actuator features a twist-to-lock feature for easy on-the-go use and product security while in transit.
Maya’s top surface is 100% customizable, per Aptar, allowing for the application of sensorial actuation features, finishes and logos. Also, because the actuator is molded in two parts, brands have wide flexibility on color combinations.
Maya can be used for the dispensing of high powder, with a smooth flow path for solid powder formulations that reduces clogging.
The actuator is production-ready in North America.
Refillable Designs
Monomaterial Lipsticks
Albéa Cosmetics & Fragrance’s Pure Kiss lipstick pack cuts the environmental impact of lip products with a monomaterial PET design that is readily recyclable.Albéa
The square-shaped lipstick comprises Albéa's Unigreen PET mechanism, which features three pieces.
Unigreen's gentle swivel torque offers brands an elegant gesture, per the company, and supports easy and secure refills.
Notably, the unguided mechanism is not usable if not snapped into the lipstick base.
The pack is compatible with various types of lip formulas and can be customized.
Laëtitia Beavogui, marketing manager at Albéa Cosmetics & Fragrance, says, “Our objective for 2025 is to offer beauty brands a standard range of refillable lipsticks made of environmentally friendly materials that drive packaging recycling.”
Refillable Jars
Lumson’s new Re Place refillable glass jars are designed to marry aesthetics with sustainability.Lumson
• 50 ml (DeLuxe, Unique and Slim)
• 50 ml and 15 ml (Japa)
• 50 ml with thick and conical base (Infinity)
The jars’ plastic inner cups are rendered in PP that can be readily recycled, per Lumson, and paired with a protective cover. The jar, inner cup and cover can be customized with inner lacquering, various colors and other deco options.
Airless Refillables
Quadpack’s Regula Airless Refill is now reportedly manufactured in the United States.Quadpack
The airless designs are produced in 15 ml, 30 ml and 50 ml variants that offer formula protection, a high restitution rate, precision dosage and 360-degree usage, per the supplier.
The Regula Airless Refill features a metal-free pump and a refillable mechanism that allows easy removal and insertion of refill cartridges. It is available in PET or with post-consumer recycled (PCR) PET, according to Quadpack.
Post-consumer Waste Folding Board
Neeneh recently launched folding boards offering a variety of effects for sustainable and/or premium brands.Neeneh
Separately, the company has launched pearlized single colors for premium beauty and holiday packaging. White pearl, available in 18 pt thickness, is bright, blue-white, while the silver pearl, also available in 18 pt thickness, offers a neutral on-trend shade that can be applied to holiday concepts.
Finally, Neeneh’s black pearl, available in 18 pt thickness and 30% PCW, offers a “unique and sophisticated” shade of black for upscale brands.
Versatile Atmospheric Aluminum
Lumson’s Essential atmospheric aluminum collection features minimalist designs with bottles available in 50 ml, 75 ml, 100 ml and 150 ml variants that can be paired with cream and spray pumps, depending on dosage.Lumson
The Essential collection is therefore appropriate for sun, hair, body and skin care applications, per Lumson.
The aluminum designs can be customized with decorations and finishes up to six colors.
The Essential collection can be manufactured in 100% PCR aluminum and combined with dispensing systems in PP/PCR PP/aluminum overshell.
Lumson also offers the TAL airless system with an aluminum container in 50 ml, 75 ml and 100 ml sizes. TAL has been designed to allow the consumer to separate the aluminum components from the plastic one, allowing each to be properly recycled after use.
PCR Fragrance Pump
Aptar Beauty's new Color Code PCR is reportedly the first fragrance pump available with as much as 67% mechanical PCR Plus resin content without compromising on customization options and aesthetics.
The pump's PCR content (100% PCR Plus cap, 95% PCR Plus collar and 50% PCR Plus actuator and fixture) reportedly cuts its CO2 emissions by up to 39% compared to a pump featuring conventional content.Aptar
The pump's PCR content (100% PCR Plus cap, 95% PCR Plus collar and 50% PCR Plus actuator and fixture) reportedly cuts its CO2 emissions by up to 39% compared to a pump featuring conventional content.
This was confirmed via a life cycle analysis using Aptar's Eco Design tool, the company noted.
This reduction in emissions allows brand clients to reduce their Scope 3 carbon output, while leveraging a PCR content claim.
The pump could also help brands avoid some plastic packaging taxes in certain regions.
The design follow's Aptar's endorsement of the New Plastics Economy Global Commitment to address plastic waste in part by rendering products more recyclable and longer-lasting.
“Color Code PCR is a stylish step towards sustainability: it is our very first plastic fragrance pump integrating PCR," says Giuseppe Barletta, regional platform manager EMEA for fragrance lifestyle, Aptar Beauty. "This pump not only adds a touch of color and differentiation to fragrance launches but can also help brands achieve their sustainability goals by committing to packaging circularity."
Versatile Dip-ins
Quadpack has launched a range of dip-in packs with matching applicators.Quadpack
Featuring thick-wall bottles made of recyclable materials, the packs can be mixed and matched with various applicators.
Applicator options include standard and novel options for makeup and skin care.
Convenient Formula Protection Solutions
SeaCliff Beauty’s BeautiLock SPF Cushion Compact design features the company’s patented BeautiLock closure technology that limits product weight loss at less than 1%.SeaCliff
The compact concept formula is easy to apply (and reapply), while the packaging is convenient for on-the-go use.
The formulation can be easily applied over makeup while featuring makeup-setting and mattifying effects.
Better Beauty Dispensing
Precision Dosing
Aptar Beauty's new NeoDropper delivers precise dispensation of "demanding concentrated" skin care, as well as foundations. The concept aligns with the rise in prestige and clinical skin care.
When the NeoDropper's bulb is pressed, the formula within rises in the dip tube and fills the short applicator. The dose can then be dispensed with a new press of the bulb.
Aptar Beauty's new NeoDropper delivers precise dispensation of "demanding concentrated" skin care, as well as foundations.Aptar
In fact, in an Aptar consumer study featuring 17 female skin care serum users, participants reported that NeoDropper's "primary benefit identified was the improved dosage facilitated by the new short applicator, which was perceived as easier to handle and aiding in using the correct amount of product."
Furthermore, the design reportedly ensures that the applicator does not come into direct contact with the formula in the bottle, which in turn ensures product integrity by preventing retro-contamination by bacteria.
The NeoDropper's design also prevents product from spilling, even if the bottle is overturned, per Aptar.
The upper and lower collars of the NeoDropper are fully customizable with anodizing colors, double anodization, brushed effects, silk-screening, lacquering and branding on metal.
The bulb's color and finish (including metallization) can also be customized.
NeoDropper can be paired with current dropper bottles in the market, per Aptar, though the bottle selected for the launch is Heinz Glas' Oslo II, which is reportedly generally compatible with glass recycling streams.
According to Aptar, after using the NeoDropper pack daily for two weeks, 15 of 17 respondents declared that they preferred NeoDropper over their current packaging and would be willing to pay €5-15 more for it.
NeoDropper Classic samples are now available, with production expected in November 2024.
“We have created NeoDropper after a thorough study of consumers needs and desires in the face care experience," says Xavier Joseph, vice president global marketing and innovation, Aptar Beauty. "We look forward to partnering with premium and prestige skin care brands in order to have consumers enjoying this innovation."
Plug-and-play Tottles
FusionPKG’s Revo Tottle is designed for controlled liquid dispensing of low-viscosity and lightweight formulas, particularly serums, primers and foundations.FusionPKG
Its SimpliSqueeze valve technology supports pinpoint application for an easy, mess-free experience, per the company.
The Boston round tottle is produced with advanced blow molding techniques and offers brands a practical plug and play system, reportedly allowing brands to tailor the package’s shape and aesthetics without the added tooling costs.
The tottles can be produced in recycle-ready PP or PE/EVOH, with PCR possibilities for all PP components.
Customizable Tottles
Allstar Packaging Corp. offers squeezable HDPE tottles with PP caps and PE dropper tips that can be customized in various shapes and sizes, while the bottle and cap can be produced with customized color.Allstar Packaging Corp.
Ideal for low-viscosity formulations, the designs’ components can be separated for recycling, per the company. Furthermore, the tottle bottle and cap can be made in PCR.
New Deco Opportunities
Inoac offers shrink sleeves featuring a variety of deco processes and textures in the same label.Inoac
The stamping can be applied to PE containers, which have traditionally not been able to accept hot stamping. Furthermore, the cold foil stamping can be applied to textured surfaces.
The company also offers shrink sleeves featuring a variety of deco processes and textures in the same label. The sleeves feature a virtually invisible seam and can be removed for packaging recycling.
Beyond these capabilities, Inoac offers extrusion blow molding services for squeezable designs available in PE, PET and PP. Featuring lower tooling costs compared to other processes, the production method allows for various deco options.
Inoac has launched new decoration techniques, including cold foil stamping, which offers the look and feel of hot stamping without the risk of deformation on thin, lightweight containers.Inoac
Labeling Excellence
Premium Label & Packaging Solutions (PLPS) has won a Gold in the "Best Use of Cold Foil (Label or Carton)" category at the Foil & Specialty Effects Association's (FSEA) 31st Annual Gold Leaf Awards.
The winning shrink sleeve label was produced for OL Products for its Infatuated Tanning Lotion and was printed at Overnight Labels, the company’s Deer Park, New York plant.
Premium Label & Packaging Solutions (PLPS) has won a Gold in the "Best Use of Cold Foil (Label or Carton)" category at the Foil & Specialty Effects Association's (FSEA) 31st Annual Gold Leaf Awards.PLPS
PLPS used multiple processes to achieve the look, beginning by laying down the black and red ink.
Once that was completed, PLPS applied a holographic Pillars of Light cold foil and a second coat of black and white ink.
In the final step, the web was turned to apply a silk screen UV to the red triangles to boost its dimensionality.
"We are always driven to maintain a level of excellence in everything we print, particularly when a job demands intricate details," says Leslie Gurland, VP of sales and marketing at PLPS. "This win is a testament to our unwavering commitment to quality and the artistry of label printing.”
“We had a record number of entries in our 31st annual FSEA Gold Leaf Awards, which highlighted a variety of print embellishment technologies,” says FSEA executive director Jeff Peterson. “The creativity and new uses for labels, cartons, direct mail, and other applications continue to amaze me.”
Packaging Problem Solving
Meanwhile, R.R. Donnelley & Sons Company recently highlighted its paperboard packaging and folding cartons, labels for shipping and decor needs, and supply chain solutions at Luxe Pack New York.
R.R. Donnelley & Sons Company recently highlighted its paperboard packaging and folding cartons, labels for shipping and decor needs, and supply chain solutions at Luxe Pack New York.
For one client, RRD introduced a clean beauty brand to a customized hemp stock comprising hemp, straw and recycled cotton fiber to reduce the amount of trees needed to produce packaging.
At the same time, the stock’s surface texture offered smooth printing with flood coats, ensuring the desired aesthetic effect. In addition, the stock reportedly did not crack when it was scored.
For another client, a skin care brand experiencing inconsistent packaging due to multiple sources of paper stock and presses for folded cartons, RRD standardized paper stocks, among other process upgrades.
Finally, for a cosmetics client, RRD was able to reduce label and packaging costs by running print trials to lower the expense of hot stamping, varnishing and pearl labeling. It also replaced films and liners with thinner variants. Finally, RRD near-shored carton production.
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