Silgan on eco-mission with airless beauty dispenser

16 Nov 2021 --- Silgan Dispensing’s latest launch, Pearl 2, aims to provide the benefits of airless packaging - namely formula protection, 360-degree application and a high-evacuation rate - to help consumers get the last drop of product out and avoid frustration. In addition, John Ferro, Vice President of Marketing and Innovation at Silgan explains: “Pearl 2 is made with materials designed for recyclability and has a better technical performance.”

Unlike previous airless packaging systems, Pearl 2 uses Silgan Dispensing’s LifeCycle technology to deliver a more sustainable dispensing solution. “Our LifeCycle technology is a revolutionary, patented plastic spring that enables the removal of non-recyclable materials and metal,” says Ferro. Detailing how this technology impacted the overall finished packaging product, Ferro adds: “This technology led to the dispenser being made almost entirely from a single polyolefin.” A versatile and common plastic used in today’s manufacturing, polyolefins are a collection of polyethylene and polypropylene thermoplastics.

As a result of the design and materials chosen, Ferro says that RecyClass, a certification system for plastic packaging recyclability, “determined that Pearl 2 did not have a negative impact on recycling streams, based on third-party laboratory testing”. To ascertain this, RecyClass used its Recyclability Evaluation Protocol for HDPE containers. RecyClass recognition applies to an undecorated clear or white jar and overcap and requires the applied printing technology to be compatible with recycling.

Click to EnlargeA patented plastic spring lies behind the Pearl 2. Source: Silgan Dispensing.

Pearl 2 has also passed third-party e-commerce testing protocols as a result of its design and overcap. The pump can withstand changes in air pressure, which means it won’t leak during transport or air travel.

As well as its enhanced sustainability credentials through the elimination of non-recyclable materials, Silgan Dispensing also confirms that Pearl 2 has high compatibility across formulations and viscosities. The product has an approximately 95% evacuation rate; offers “superior” protection against oxidation, enabling preservative-free natural ingredients; and has been vacuum tested. 

Pearl 2’s development centered on improved performance, both technically and for the consumer. On the technical side, the system has consistency of performance across a variety of formulas and viscosity levels. A longer stroke length, for example, strives to maximize dosing control in an ergonomic, one-handed dispenser.

Innovating to meet demands

Silgan Dispensing’s focus when developing the product was on three key areas: sustainability, e-commerce, and improved performance.

Creating Pearl 2 after recognizing the dispensing market was missing packaging for today’s personal care consumer, Ferro shares: “We understand that sustainability continues to be a top expectation when it comes to packaging, but so is dispensing performance and the e-commerce channel. When developing Pearl 2, we sought to address all three while also capitalizing on Silgan Dispensing’s global reach, excellent customer service and expansive decoration network.”

Click to EnlargeSilgan has developed a range of dispensers with recyclability in mind. Source: Silgan Dispensing.The technical aspects of creating an airless system that met targets relating to sustainability, e-commerce and improved performance required innovation. “Creating a patented plastic spring that can replace metal but still deliver excellent performance took a global team of engineers and material experts years to perfect,” Ferro outlines. 

Silgan Dispensing developed and tested hundreds of designs and materials to ensure that it could deliver on the demanding specifications of airless systems while meeting consumer use expectations. The company’s new-to-the-world plastic spring technology is the result of the work, ability and persistence of the company’s engineering and development team, Ferro relays.

“We want to support our customers and their goals around sustainability,” expresses Ferro. With Pearl 2, Ferro explains: “Silgan Dispensing has been able to demonstrate that an airless system can provide enhanced sustainability while providing all the performance features consumers have come to expect: convenience, safety and cleanliness.” 

With its latest product, the company strives to bring value to the dispensing market where going metal-free is a challenge. Pearl 2 is the next iteration in the company’s line of more sustainable product offerings, including a full range of post-consumer recycled options. 

“Sustainability continues to be a top expectation when it comes to packaging and was our first priority,” says Guillaume de Demandolx, Vice President of Fragrance and Beauty for Silgan Dispensing. “Finding solutions that do not disrupt today’s recycling streams, without sacrificing quality and performance, is often elusive. Today’s recycling infrastructure has challenges in sorting the small round packages typical in beauty products, so we focused on designing Pearl 2 with the right mix of materials compatible with the recycling stream.”

One of the company’s goals with Pearl 2 was to produce a package that was e-commerce certified. Ferro notes: “E-commerce has become an increasingly important channel for brand owners to reach their consumers, especially during the pandemic. Broken or leaking packaging during transport can obviously tarnish that brand’s reputation with consumers.”

Looking ahead, Ferro says: “Our goal is to continue to develop further eco-friendly packaging to respect our sustainability commitment, be a sustainable partner for our customers and respect the environment.” 

By Natasha Spencer-Jolliffe, BPC Insights Senior Journalist