Flexible production solutions

Fully recyclable, biodegradable, made of 100% recycled material, produced from organic raw materials – today, packaging sustainability is promoted in many ways. All those involved are clearly responding to the high expectations of consumers in the B2C market. But what exactly do the specific references to the packaging’s properties really mean? Is biodegradable plastic film better than conventional film? How does the eco-balance of fibre-based composites compare to that of pure plastic packaging? And won’t everything be incinerated in the end?

Whilst natural cosmetics were more of a niche product some years ago, they can now be found in almost every drugstore and, of course, online. Consumers are now not only concerned about natural ingredients, but they are also very attentive to the sustainability of cosmetic packaging. When shopping, many are uncertain as to which options will keep their ecological footprint as low as possible. They are not alone in this – many manufacturers and users of packaging feel the same way. Packaging 
that may be well-intentioned but is more harmful to the environment than beneficial, continues to enter the market.

Ultimately, it is the waste management companies that bear the brunt: anything that cannot be separated well or that only accounts for a small share of recyclable material collection cannot be recycled. The recyclers then miss out on the material and their margins. For non-recyclable materials, the only option is thermal recycling – a euphemism for waste incineration.

Challenge of packaging trends

For economic reasons, and because the industry expects politicians to impose even stricter recycling quotas in the foreseeable future, several recyclers and dual systems have now developed their own certifications to assess the recyclability of packaging. Points are deducted, for example, for material composites that cannot be separated or are difficult to separate, such as PE bottles with PVC sleeves; mono-material, on the other hand, is rewarded.

In the cosmetics sector, too, the use of mono-material packaging and 
paper packaging is increasing. For example, deodorants and shampoos, which are sold in plastic bottles, 
are available in versions with almost no plastic. They are often packed 
in thin cardboard boxes for drug-store shelves.

In recent times, there has also been an increasing focus on refillable products. Thanks to high-quality packaging, empty powder compacts or shampoo bottles, for example, can be given a second life – with refills. All these trends are prompting cosmetics manufacturers to rethink: Where can plastic be dispensed with? Of course, plastic needs to be reduced, but how can you protect more lightweight shampoo and shower gel bottles from damage?

Changing demands

Meeting consumer demands in terms of packaging is only one of the challenges currently facing cosmetics manufacturers. As a rule, they also have a constantly changing product range. Whether to suit the upcoming 
season or a new emerging trend: product novelties, re-launches and new developments are intrinsic to the industry.

Online purchases of cosmetics and drugstore products are on the rise, and more and more consumers are also taking advantage of the possibility their creams and shampoos can be customised. This all implies that production needs to be continuously adapted for larger and smaller batches. In practical terms, this means that the packaging machines need to be flexibly adapted to changing packaging formats, new product packaging and new materials. Not all materials, however, can be processed easily on a single machine.

Flexibility and recycling

Bottles, jars, or tubes, small or large batch sizes – when developing new lines, for the developer it is important to pay great attention to flexible application options to address trends such as the demand for alternative packaging materials.

At the same time, customers’ packaging should be carefully checked. Can savings be made on packaging material? Can a more sustainable material be used? Finally, ‘design for recycling’ should not be seen as a hurdle, but as an integral part of the development process.

Of course, you always must be realistic. For cosmetics producers, sustainability is one aspect among many. Especially in the cosmetics sector, competition is extremely fierce. And visibility at POS plays a vital role. The challenge is to consider all needs equally to find an ideal final solution that involves as few compromises as possible.

Since product changes and modifications are far from uncommon in the cosmetics sector, this also means that the packaging machines must be adapted with the right format parts. The use of 3D printing results in 
significant advantages in tool production. A high-quality 3D printer designed specifically for this purpose can support the manufacturer’s agility by producing its own interchangeable parts.

Flexibility is imperative

Flexible, modular lines are paramount for the cosmetics industry with its constantly changing trends and product ranges. Smaller order quantities, limited editions, personalised products – natural cosmetics manufacturer agility involves fast format changes, a high variety of formats and low format costs, as well as the rapid implementation of future formats to further reduce time-to-market. The foundation for this also lies in 3D printing. Except for the magazine plate, all interchangeable parts can be 3D printed on appropriate systems. This allows costs to be significantly minimised as well as format changeover times.

With a keen eye on sustainability, there is an increasing demand for openness to technology in many industrial sectors. With flexible systems on the market since the mid-1980s, and in combination with robotics and 3D printing, a wide range of packaging formats and materials opens up. The freedom to modify existing packaging within flexible lines also ensures that brands can future-proof their investments. From a business perspective, this is also a reflection of sustainability. 

Most sustainable

Plastic or paper, metal or glass, compo-sites or indeed a material that is un-known today – no single packaging can cover all needs equally and al-ways offer the highest level of sustain-ability. Expertise and technological skill are required to find the best possi-ble solution for a given application. High-performance, flexible systems and application-oriented development capabilities enables companies to  meet environmental and business de-mands in equal measure. The most sus-tainable solution can only be achieved when both work in harmony.