Joanna Cosgrove, Contributing Editor10.17.24
America, we have a recycling problem. The U.S. generates more than 40 million tons of municipal plastic waste, and at least 80% is likely sent to landfill sites (Statista, 2023). In short, the U.S. plastic recycling rate is practically stagnant.
While the packaging industry alone can’t fix the problem, creating packages made entirely out of one type of plastic—known as mono-material packages—can help improve the likelihood that consumers will recycle since there’s no need to disassemble and separate components before tossing the package in a recycling bin. Not only is the consumer convenience factor appealing to beauty brands, using mono-materials is also a responsible win-win that helps satisfy corporate sustainability business targets and strategies.
Additionally, mono-material packaging plays a part in helping to reduce contamination in the recycling stream, comments Melanie Gaudun, Business Development and Marketing Manager, Viva Healthcare Packaging (Canada) Ltd. “With fewer materials involved, mono-material packaging can lead to lower energy consumption during production and recycling,” she says. “Using a single material simplifies sourcing and inventory management, which can reduce lead times and improve supply chain efficiency.”
Viva specializes in injection-molded mono-material packaging, offering a range of sustainable options like mono-material polypropylene tubes (tube + closure + applicator + in-mold label) and mono-material polypropylene deodorant sticks (barrel + cap + internal components + in-mold labels), as well as a polypropylene jar and closure and a refillable heavy wall jar system featuring a polyethylene jar, closure, and inner refill pod. The company’s latest design is a mono-material polypropylene roller-ball tube.
Dr. Squatch opted to enhance the sustainability and shelf appeal of its deodorant stick packaging by using Viva’s mono-material wide deodorant stick and Viva’s D48.5 mono-material round oval tube for its line of Ball Barrier Dry Lotions, which Gaudun says creates a cohesive, eco-friendly packaging set. “Both products feature a mono-material polypropylene structure and a high percentage of PCR, reinforcing Dr. Squatch’s commitment to sustainability, while ensuring their products stand out on the shelf,” she says.
The brand’s custom-colored wide deodorant stick is 2.65 oz., and is comprised of 100% recycled PP barrel, cap, and inner mechanisms, with an in-mold labeled cap and barrel and custom debossed logo in the top of the cap. Its 3.4 fl. oz. is Viva’s D48.5 round oval tube, which is comprised of a custom-colored 35% recycled PP sleeve, 100% recycled PP shoulders, and 100% recycled PP molded matte flip-top cap. The tube also features 360° shoulder to crimp in-mold label decoration.
“The wide deodorant stick and D48.5 round oval tube were ideal for Dr. Squatch because they significantly enhanced the brand’s shelf presence, offering a larger canvas for high-definition artwork and branding through in-mold label decoration,” Gaudun explains. “Additionally, the mono-material polypropylene structure with a high percentage of PCR not only aligned with the brand’s sustainability goals, but also provided a cohesive and visually impactful packaging solution across different product categories, making it a perfect match for their products.”
The company boosted the recyclability of its multi-tasking Porescreen Mineral Sunscreen SPF 40 with a pump airless system tube from Wistadts, a company that’s also committed to sustainability and understands the challenges of developing multifunctional products.
Related: Harnessing The Advantages of Airless Packaging
The product, which not only provides sun protection, but also improves pores and tone with a radiant tint, incorporates a microencapsulated and challenging SPF formula that requires a high-quality airless system to protect the product integrity, preserve the microcapsules so that they do not break until they meet the skin, and ensure the SPF formula will pass through without clogging.
“To meet the demands of this innovative formula, our team created a sustainable packaging solution that ensures functionality, performance, and a premium product experience,” says Elizabete Gomes, Marketing and Business Manager, Wistadts, who notes that the packaging earned an award at this year’s Paris Packaging Week. “This is a mono-material packaging, made 100% in PE and 100% recyclable without rejectable waste, which is suitable for the method of collection, separation, and recycling, generating a high-quality PCR that can be easily reinserted into the circular economy for the manufacture of new packaging.”
Wistadts launched its first mono-material airless system made entirely of PE in 2018. The company has also introduced a complete range of PE mono-material airless systems focused on the skincare market, in compliance with the upcoming European demands for sustainability and to address environmental concerns related to the challenges of recycling packaging made from different resins. “Our choice of PE resin isn’t just for its well-known benefits—it’s about providing mono-material airless systems suitable for flexible tubes as well, thereby generating high-quality PCR (post-consumer resin) that recyclers can rely on,” Gomes says, adding that the company is also producing mono-material items in PP.
“Our customers and partners are increasingly aware of the importance of sustainability, especially with the new European Union regulations mandating the use of truly recyclable packaging and contributing to the circular economy by 2030 through high-quality PCR (Post-Consumer Recycled) materials,” she says. “However, the issue of packaging waste is real, and…it’s a growing concern for everyone, including consumers, who are making more conscious and sustainable choices.”
The sustainably focused airless and atmospheric packaging produced by FusionPKG adheres to guidelines aligned with progressive industry standards sought by retailers like Sephora, Ulta, and Credo. The company provides more than 175 mono-material package options integrated with APR-certified Airless-One and Atmos-One 100% polyolefin pump engines in a range of outputs from 0.09- to 1.0ml that are engineered with end-of-life in mind to promote a lower environmental impact with a lighter overall weight to reduce costs and environmental impact during transport.
The company’s Brady Bacchus, Marketing Manager, says FusionPKG is also placing emphasis on polypropylene in its full package stock selection, offering to provide 100% PCR possibilities. “We now offer an assortment of recycle-ready packaging including mono-material options with 100% PCR possibilities by eliminating harmful materials like acrylic, metal, POM, and more, while also doubling our recycled resin usage to reduce raw material consumption while increasing demand for post-consumer recycled resins,” she says.
And to help overcome the branding limitations presented by metallization decoration, which can curb recycling processes, FusionPKG’s assortment of mix-and-match packaging options can be decorated with silkscreen, hot stamping, and color injection for upscale customization.
Earlier this year FusionPKG collaborated with emerging brand Minu on its newest Brightening Sunscreen Minerals launch at Credo. The company chose FusionPKG’s mono-material 50ml Lift Airless bottle featuring 100% PCR in all PP parts and the Airless-One pump engine technology and customized the look with silkscreened branding. Bacchus says the final product is a recycle-ready, high-performance airless solution “to help promote a circular economy and a happier planet.”
UKPACK offers skincare product-friendly PP plastic for its mono-material airless pump packaging solutions. The company’s airless pump bottles come in a variety of capacities ranging from 15- to 200ml with a dosage of 1.0cc.
Allen Chen, UKPACK’s Marketing Manager, says the company also provides mono-material lotion pumps with neck finishes of 24/410 and 28/410. “For these lotion pumps, we offer PP plastic bottles in sizes of 200-, 230-, 300-, and 500ml, with a dosage of 1.5cc,” he says. “These are perfect for personal care and mother-and-baby products such as creams, body lotions, hand creams, and liquid soaps.”
UKPACK is also currently developing mono-material lotion pumps with a larger dosage capacity.
“It’s a solution that simplifies recycling because once the product is finished, all the components can be disposed of into the same recycling chain [and] the mono-material cover takes sustainability to a higher level for those brands seeking ‘ethics and aesthetics’,” says Matteo Carraro, Lumson’s Product Sustainability and Business Analyst Manager.
Prior to their disposal in the recycling chain, these types of mono-material packages have functional advantages for brands, too. “In this case,” Carraro says, “using mono-material packaging can be helpful in terms of decoration yield [because] the components [are] made of the same polymer [and have] the same surface tension. For example, the Eco-dropper’s components can be all easily [decorated] in the same color…to get a fully customized [look].”
Traditional cosmetic packaging is evolving, too. Every component of the mascara containers from Pibiplast can be molded entirely in PP or PET. Chiara Pani, the company’s Strategic Marketing Director, says beyond the bottle, the real challenge was in finessing cap and rod molding techniques. “The expertise we have gained has enabled us to develop larger caps and rods, such as those used for lip gloss and all-over products, where the dimensions are larger, thus presenting a greater challenge,” she says.
Related: What's New in Sustainable Packaging?
Pibiplast’s Essentia mono-material packaging range was created with the aim of developing dedicated molds to replace materials such as ABS and POM (which are typically used for caps and rods) in favor of 100% PET or PP. “In PP, we offer packaging specifically for mascara, while in PET, our range is broader, including not only mascara components but also bottles suitable for products such as lip gloss, liquid lipstick, concealer, or eyeshadow,” says Pani.
The company’s most recent mono-material launch is the Jumbo Flaconette. With a capacity of 15ml, it’s an ideal solution for multi-use formulas like foundation/concealer, highlighter, or bronzer, while its larger flocked applicator delivers easy and comfortable application for all areas of the face. The Jumbo Flaconette is available in both virgin and recycled mono-material, ensuring high recyclability at the end of the product’s life cycle.
One of the newest mono-material solutions offered by APC Packaging is the double-walled PWTJ jar, which can be easily recycled as a single unit. “Its innovative double-wall feature provides flexibility for a range of decorative possibilities, allowing the outer jar to be either opaque or translucent, thereby enabling a clear view of the inner jar,” says Rick Ponte, VP of Project Engineering, APC Packaging. “In addition, to enhance sustainability efforts, the jar can be integrated with up to 50% PP PCR content.”
One of APC’s latest brand partnerships was with Origins, which utilized a PP jar and PP cap for its 6.7oz Ginger Souffle Whipped Body Cream. Ponte explains APC Packaging created the mono-material jar and cap produced from PP. “Origins is an Estée Lauder brand, which has corporate sustainability goals,” he says. “Their consumer base is aligned with sustainability as a key driver for the brand.”
Taesung uses only PP in its sustainable mono-material packaging series, and among the company’s new offerings is a new airtight PP mono-stick package, an airless pump with a bottle, and a tube bottle with a PP mono pump that launched recently.
“Our packaging doesn’t have to be dissembled for recycling,” comments Rocky Yoon, Taesung’s Sales Manager. He asserts that the quality of Taesung’s PP mono-material packaging also has proven stability thanks to the technology the company employs during its product development.
Epopack offers PET mono-material packaging in the form of jars from 10- to 100ml sizes. It’s a streamlined packaging format that Amy Pan, CEO, says not only enhances functionality but also significantly improves recyclability and reusability.
The MJ6 jars experienced a rise in popularity, leading Epopack to extend its offerings to include PET dropper bottles with a collar, tube, and bottle all made in PET. “This product is the ultimate solution for glass users who suffer breakage issues or are limited by the availability of customization,” she says.
Choosing a mono-material package configuration gives brands the inherent benefit of avoiding unintentional color variations. “The MJ6 series mono-material jars are all made in PET so it can be crystal clear, allowing the brand to showcase the products in color and texture at any angle,” she says.
She acknowledges that each material used for mono-material packaging has its limits; however mono-material packaging remains an ideal solution for sustainability. “[It’s] simplified the consumer’s responsibility down to just dropping the packaging in the recycle bin,” she says. “With the simplicity of design, the recycle process is much more efficient and accurate. It pushes for a good and positive cycle for reusing the material and running for another cycle.”
“Demand for mono-material packaging in the beauty and personal care segment has been steadily increasing over the past five years, driven by consumer demand for more sustainable, recyclable packaging solutions,” comments Viva’s Gaudun.
APC’s Ponte agrees, adding that the prioritization of sustainability is leading to a higher preference for eco-friendly, mono-material packaging solutions. “Many beauty and personal care brands have committed to sustainability goals, including reducing plastic waste and increasing the use of recyclable materials, [and] mono-material packaging fits well within these commitments,” he says. “Consumers are becoming more environmentally conscious and are actively seeking products with sustainable packaging.
This shift is driving brands to adopt mono-material packaging solutions.”
Gaudun firmly believes this trend will continue as long as recycling infrastructure remains limited. “Mono-material packaging is becoming a staple in the industry and is likely to remain in high demand moving forward,” she concludes.
A Rise in Consumer-Friendly Cosmetic Tubes
While the packaging industry alone can’t fix the problem, creating packages made entirely out of one type of plastic—known as mono-material packages—can help improve the likelihood that consumers will recycle since there’s no need to disassemble and separate components before tossing the package in a recycling bin. Not only is the consumer convenience factor appealing to beauty brands, using mono-materials is also a responsible win-win that helps satisfy corporate sustainability business targets and strategies.
Additionally, mono-material packaging plays a part in helping to reduce contamination in the recycling stream, comments Melanie Gaudun, Business Development and Marketing Manager, Viva Healthcare Packaging (Canada) Ltd. “With fewer materials involved, mono-material packaging can lead to lower energy consumption during production and recycling,” she says. “Using a single material simplifies sourcing and inventory management, which can reduce lead times and improve supply chain efficiency.”
Viva specializes in injection-molded mono-material packaging, offering a range of sustainable options like mono-material polypropylene tubes (tube + closure + applicator + in-mold label) and mono-material polypropylene deodorant sticks (barrel + cap + internal components + in-mold labels), as well as a polypropylene jar and closure and a refillable heavy wall jar system featuring a polyethylene jar, closure, and inner refill pod. The company’s latest design is a mono-material polypropylene roller-ball tube.
Dr. Squatch opted to enhance the sustainability and shelf appeal of its deodorant stick packaging by using Viva’s mono-material wide deodorant stick and Viva’s D48.5 mono-material round oval tube for its line of Ball Barrier Dry Lotions, which Gaudun says creates a cohesive, eco-friendly packaging set. “Both products feature a mono-material polypropylene structure and a high percentage of PCR, reinforcing Dr. Squatch’s commitment to sustainability, while ensuring their products stand out on the shelf,” she says.
The brand’s custom-colored wide deodorant stick is 2.65 oz., and is comprised of 100% recycled PP barrel, cap, and inner mechanisms, with an in-mold labeled cap and barrel and custom debossed logo in the top of the cap. Its 3.4 fl. oz. is Viva’s D48.5 round oval tube, which is comprised of a custom-colored 35% recycled PP sleeve, 100% recycled PP shoulders, and 100% recycled PP molded matte flip-top cap. The tube also features 360° shoulder to crimp in-mold label decoration.
“The wide deodorant stick and D48.5 round oval tube were ideal for Dr. Squatch because they significantly enhanced the brand’s shelf presence, offering a larger canvas for high-definition artwork and branding through in-mold label decoration,” Gaudun explains. “Additionally, the mono-material polypropylene structure with a high percentage of PCR not only aligned with the brand’s sustainability goals, but also provided a cohesive and visually impactful packaging solution across different product categories, making it a perfect match for their products.”
Eco-Aligned Airless
Packaging that emphasizes environmental responsibility is a central tenant in an overall packaging strategy for many beauty brands. A recent launch from Dermalogica, part of Unilever’s Prestige brand portfolio, is a prime example.The company boosted the recyclability of its multi-tasking Porescreen Mineral Sunscreen SPF 40 with a pump airless system tube from Wistadts, a company that’s also committed to sustainability and understands the challenges of developing multifunctional products.
Related: Harnessing The Advantages of Airless Packaging
The product, which not only provides sun protection, but also improves pores and tone with a radiant tint, incorporates a microencapsulated and challenging SPF formula that requires a high-quality airless system to protect the product integrity, preserve the microcapsules so that they do not break until they meet the skin, and ensure the SPF formula will pass through without clogging.
“To meet the demands of this innovative formula, our team created a sustainable packaging solution that ensures functionality, performance, and a premium product experience,” says Elizabete Gomes, Marketing and Business Manager, Wistadts, who notes that the packaging earned an award at this year’s Paris Packaging Week. “This is a mono-material packaging, made 100% in PE and 100% recyclable without rejectable waste, which is suitable for the method of collection, separation, and recycling, generating a high-quality PCR that can be easily reinserted into the circular economy for the manufacture of new packaging.”
Wistadts launched its first mono-material airless system made entirely of PE in 2018. The company has also introduced a complete range of PE mono-material airless systems focused on the skincare market, in compliance with the upcoming European demands for sustainability and to address environmental concerns related to the challenges of recycling packaging made from different resins. “Our choice of PE resin isn’t just for its well-known benefits—it’s about providing mono-material airless systems suitable for flexible tubes as well, thereby generating high-quality PCR (post-consumer resin) that recyclers can rely on,” Gomes says, adding that the company is also producing mono-material items in PP.
“Our customers and partners are increasingly aware of the importance of sustainability, especially with the new European Union regulations mandating the use of truly recyclable packaging and contributing to the circular economy by 2030 through high-quality PCR (Post-Consumer Recycled) materials,” she says. “However, the issue of packaging waste is real, and…it’s a growing concern for everyone, including consumers, who are making more conscious and sustainable choices.”
The sustainably focused airless and atmospheric packaging produced by FusionPKG adheres to guidelines aligned with progressive industry standards sought by retailers like Sephora, Ulta, and Credo. The company provides more than 175 mono-material package options integrated with APR-certified Airless-One and Atmos-One 100% polyolefin pump engines in a range of outputs from 0.09- to 1.0ml that are engineered with end-of-life in mind to promote a lower environmental impact with a lighter overall weight to reduce costs and environmental impact during transport.
The company’s Brady Bacchus, Marketing Manager, says FusionPKG is also placing emphasis on polypropylene in its full package stock selection, offering to provide 100% PCR possibilities. “We now offer an assortment of recycle-ready packaging including mono-material options with 100% PCR possibilities by eliminating harmful materials like acrylic, metal, POM, and more, while also doubling our recycled resin usage to reduce raw material consumption while increasing demand for post-consumer recycled resins,” she says.
And to help overcome the branding limitations presented by metallization decoration, which can curb recycling processes, FusionPKG’s assortment of mix-and-match packaging options can be decorated with silkscreen, hot stamping, and color injection for upscale customization.
Earlier this year FusionPKG collaborated with emerging brand Minu on its newest Brightening Sunscreen Minerals launch at Credo. The company chose FusionPKG’s mono-material 50ml Lift Airless bottle featuring 100% PCR in all PP parts and the Airless-One pump engine technology and customized the look with silkscreened branding. Bacchus says the final product is a recycle-ready, high-performance airless solution “to help promote a circular economy and a happier planet.”
UKPACK offers skincare product-friendly PP plastic for its mono-material airless pump packaging solutions. The company’s airless pump bottles come in a variety of capacities ranging from 15- to 200ml with a dosage of 1.0cc.
Allen Chen, UKPACK’s Marketing Manager, says the company also provides mono-material lotion pumps with neck finishes of 24/410 and 28/410. “For these lotion pumps, we offer PP plastic bottles in sizes of 200-, 230-, 300-, and 500ml, with a dosage of 1.5cc,” he says. “These are perfect for personal care and mother-and-baby products such as creams, body lotions, hand creams, and liquid soaps.”
UKPACK is also currently developing mono-material lotion pumps with a larger dosage capacity.
Embracing PP & PET’s Potential
For Lumson, sustainable packaging is a convergence of ecological responsibility, functionality, and elegance. The company’s newest mono-material offering is an Eco Dropper with a PP bulb and collar that’s compatible with the PP recycling stream.“It’s a solution that simplifies recycling because once the product is finished, all the components can be disposed of into the same recycling chain [and] the mono-material cover takes sustainability to a higher level for those brands seeking ‘ethics and aesthetics’,” says Matteo Carraro, Lumson’s Product Sustainability and Business Analyst Manager.
Prior to their disposal in the recycling chain, these types of mono-material packages have functional advantages for brands, too. “In this case,” Carraro says, “using mono-material packaging can be helpful in terms of decoration yield [because] the components [are] made of the same polymer [and have] the same surface tension. For example, the Eco-dropper’s components can be all easily [decorated] in the same color…to get a fully customized [look].”
Traditional cosmetic packaging is evolving, too. Every component of the mascara containers from Pibiplast can be molded entirely in PP or PET. Chiara Pani, the company’s Strategic Marketing Director, says beyond the bottle, the real challenge was in finessing cap and rod molding techniques. “The expertise we have gained has enabled us to develop larger caps and rods, such as those used for lip gloss and all-over products, where the dimensions are larger, thus presenting a greater challenge,” she says.
Related: What's New in Sustainable Packaging?
Pibiplast’s Essentia mono-material packaging range was created with the aim of developing dedicated molds to replace materials such as ABS and POM (which are typically used for caps and rods) in favor of 100% PET or PP. “In PP, we offer packaging specifically for mascara, while in PET, our range is broader, including not only mascara components but also bottles suitable for products such as lip gloss, liquid lipstick, concealer, or eyeshadow,” says Pani.
The company’s most recent mono-material launch is the Jumbo Flaconette. With a capacity of 15ml, it’s an ideal solution for multi-use formulas like foundation/concealer, highlighter, or bronzer, while its larger flocked applicator delivers easy and comfortable application for all areas of the face. The Jumbo Flaconette is available in both virgin and recycled mono-material, ensuring high recyclability at the end of the product’s life cycle.
One of the newest mono-material solutions offered by APC Packaging is the double-walled PWTJ jar, which can be easily recycled as a single unit. “Its innovative double-wall feature provides flexibility for a range of decorative possibilities, allowing the outer jar to be either opaque or translucent, thereby enabling a clear view of the inner jar,” says Rick Ponte, VP of Project Engineering, APC Packaging. “In addition, to enhance sustainability efforts, the jar can be integrated with up to 50% PP PCR content.”
One of APC’s latest brand partnerships was with Origins, which utilized a PP jar and PP cap for its 6.7oz Ginger Souffle Whipped Body Cream. Ponte explains APC Packaging created the mono-material jar and cap produced from PP. “Origins is an Estée Lauder brand, which has corporate sustainability goals,” he says. “Their consumer base is aligned with sustainability as a key driver for the brand.”
Taesung uses only PP in its sustainable mono-material packaging series, and among the company’s new offerings is a new airtight PP mono-stick package, an airless pump with a bottle, and a tube bottle with a PP mono pump that launched recently.
“Our packaging doesn’t have to be dissembled for recycling,” comments Rocky Yoon, Taesung’s Sales Manager. He asserts that the quality of Taesung’s PP mono-material packaging also has proven stability thanks to the technology the company employs during its product development.
Epopack offers PET mono-material packaging in the form of jars from 10- to 100ml sizes. It’s a streamlined packaging format that Amy Pan, CEO, says not only enhances functionality but also significantly improves recyclability and reusability.
The MJ6 jars experienced a rise in popularity, leading Epopack to extend its offerings to include PET dropper bottles with a collar, tube, and bottle all made in PET. “This product is the ultimate solution for glass users who suffer breakage issues or are limited by the availability of customization,” she says.
Choosing a mono-material package configuration gives brands the inherent benefit of avoiding unintentional color variations. “The MJ6 series mono-material jars are all made in PET so it can be crystal clear, allowing the brand to showcase the products in color and texture at any angle,” she says.
She acknowledges that each material used for mono-material packaging has its limits; however mono-material packaging remains an ideal solution for sustainability. “[It’s] simplified the consumer’s responsibility down to just dropping the packaging in the recycle bin,” she says. “With the simplicity of design, the recycle process is much more efficient and accurate. It pushes for a good and positive cycle for reusing the material and running for another cycle.”
Looking Ahead
As global regulatory bodies work to enact polices to help stem the flow of waste and improve recycling efficiencies and compliance, expect mono-material packaging options to change with the times.“Demand for mono-material packaging in the beauty and personal care segment has been steadily increasing over the past five years, driven by consumer demand for more sustainable, recyclable packaging solutions,” comments Viva’s Gaudun.
APC’s Ponte agrees, adding that the prioritization of sustainability is leading to a higher preference for eco-friendly, mono-material packaging solutions. “Many beauty and personal care brands have committed to sustainability goals, including reducing plastic waste and increasing the use of recyclable materials, [and] mono-material packaging fits well within these commitments,” he says. “Consumers are becoming more environmentally conscious and are actively seeking products with sustainable packaging.
This shift is driving brands to adopt mono-material packaging solutions.”
Gaudun firmly believes this trend will continue as long as recycling infrastructure remains limited. “Mono-material packaging is becoming a staple in the industry and is likely to remain in high demand moving forward,” she concludes.
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