In the world of beauty and cosmetics packaging, the concept of airless packaging has evolved into a game-changer. As a packaging engineer with years of experience in the industry, I’ve seen first-hand how the shift towards airless packaging has benefited brands, formulators, and ultimately, consumers. However, while its advantages are clear, there are significant engineering challenges to overcome to ensure that these systems function as intended. Let’s dive into the intricacies of airless packaging, exploring the benefits and the hurdles we face during its development.
Airless packaging isn't just a trend—it’s a revolution that is reshaping how we think about product preservation, sustainability, and consumer experience. The essence of airless technology lies in its ability to protect formulas from air exposure, which can cause oxidation, degradation, and contamination. This is particularly vital for beauty and skincare products that often contain sensitive active ingredients like Vitamin C, retinoids, and natural extracts.
Here are some of the key benefits:
1. Enhanced Product Shelf Life
Traditional packaging systems, such as jars or standard pumps, allow air to enter every time they are opened, compromising the formula over time. Airless packaging utilizes a sealed chamber that prevents air from coming into contact with the product. This leads to prolonged shelf life and helps maintain the potency of active ingredients.
2. Minimal Product Waste
From an engineering standpoint, airless packaging systems are designed to dispense nearly every last drop of the product. The mechanism works through a piston or collapsible bag that moves upward as the product is dispensed. This design results in minimal product wastage, addressing consumer concerns about value for money and supporting sustainability goals.
3. Precise Dosing and Hygiene
For high-end or sensitive formulations, airless systems offer a precise, controlled dose with each pump. This is particularly beneficial for serums, creams, and other products where a specific amount is needed. Additionally, since the product is dispensed without opening the packaging, it reduces the risk of contamination, ensuring a more hygienic experience for the user.
4. Sustainability Considerations
While sustainability might not be the first thing that comes to mind with airless packaging, the latest designs can be made from recyclable materials, and some are even refillable such as APC Packaging’s Airless Refillable System. By extending product shelf life and reducing waste, airless systems align with the industry’s growing focus on sustainability.
While the benefits are clear, the journey to develop and engineer airless packaging systems is far from straightforward. There are several technical hurdles that need to be addressed to meet both the expectations of brands and the demands of consumers.
1. Precision in Tolerances and Sealing
The effectiveness of airless systems relies on precise engineering. The internal components, such as the piston or the collapsible bag, must be meticulously designed to ensure a perfect seal. Any slight deviation in manufacturing tolerances can result in air leaks, reducing the effectiveness of the airless system. The sealing process is especially challenging when using eco-friendly materials, which may have different barrier properties than conventional plastics.
2. Material Compatibility
When selecting materials for airless packaging, we must ensure that they are compatible with the formulation inside. Certain ingredients can interact with the packaging material, leading to changes in the formula or the breakdown of the packaging itself. The challenge here is to balance the need for a strong barrier with the use of sustainable, recyclable materials.
3. Pump Efficiency and Consistency
Airless pumps need to work seamlessly with varying product viscosities. For lightweight serums, the pump mechanism must be gentle enough to dispense without spitting. For thick creams, it should be strong enough to dispense without clogging. Engineering these pumps to deliver consistent doses across different formulations requires extensive testing and optimization.
4. Sustainability vs. Functionality
As the industry moves towards more sustainable solutions, using PCR (post-consumer recycled) plastics or biodegradable materials is becoming a priority. However, these materials often come with trade-offs in terms of mechanical properties. For example, PCR materials may not provide the same level of airtight sealing as virgin plastics, which can impact the performance of airless systems. As engineers, we need to innovate to bridge this gap between sustainability and functionality.
5. Scalability and Cost
Developing an airless packaging solution that is both high-quality and cost-effective is no easy feat. While brands are increasingly interested in airless systems, especially as consumer awareness grows, the challenge is to produce these systems at scale without significantly increasing costs. This requires close collaboration between the engineering, supply chain, and manufacturing teams to streamline processes and optimize material usage.
As a packaging engineer, I see tremendous potential in the continued evolution of airless technology. The current push towards sustainability is driving innovation in materials, such as bio-based plastics, glass airless systems, and refillable cartridges. At APC Packaging, we are constantly exploring ways to refine our airless packaging solutions, ensuring that they meet the highest standards of performance while aligning with our sustainability goals.
The future of airless packaging will likely involve smart packaging features, such as sensors that can detect product levels or even track the remaining shelf life. Additionally, the integration of more sustainable materials will continue to be a major focus, as consumers demand both eco-friendly and high-performance solutions.
The journey of developing airless packaging is one of balancing form and function. It’s about creating a product that not only looks good on the shelf but also preserves the integrity of the formulation and aligns with evolving market expectations. As engineers, we are not just problem-solvers—we are innovators, constantly pushing the boundaries of what’s possible in the world of beauty packaging. Reach out to APC Packaging to talk about your next airless project at apcpackaging.com/contact/.