Cosmetic Packaging Why eco-design and weight reduction matter Jean-Claude Jammet – Director, Innovation & Development Mat’Days – November 2015
Cosmetic Packaging Why eco -design and weightreduction matter
Jean-Claude Jammet – Director, Innovation & Developme nt
Mat’Days – November 2015
We will talk about....
● Eco-design at Albea
● Eco-designed products
● Tubes
The art of reduction
Slender cap
Greenleaf manufacturing process
Access Denied cap
● Rigid cosmetic packaging
Attraction compact mechanism
●Recycling
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IntroducingAlbéa
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AlbéaAt a glance
Albéa is a global leader in beauty, personal care, oral care, pharmaceutical and food packaging
16,000+EMPLOYEES
38 INDUSTRIAL FACILITIES IN 14COUNTRIES ACROSS THE WORLD
SALES:
US$ 1.6 BILLIONIN 2014 (+2% vs 2013)
INVESTMENTS:
100 MILLIONUS$ IN 2014
INNOVATION, DEVELOPMENT & DESIGN:
∼ 200 PEOPLEIN TOP 50 PATENT FILERS IN FRANCE
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A comprehensive product rangeFour expertise
#1 in plastic and laminate tubes
TUBES
#1 in foam pumps and fragrance samplers
#2 in fragrance pumps
recognized expertin lotion pumps
DISPENSING SYSTEMS
#1 in mascara (pack + brush)
#1 in lipstick (mechanism + shell)
recognized expertin fragrance caps, compact, lipgloss, skincare packs
COSMETIC RIGID PACKAGING
market-valued provider of promotional items, stock items and accessories, full-service solutions
BEAUTY SOLUTIONS
Serving the world’s leading brands
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Contributing to our customers’ success
Clarins Travel kit
MacLightful C Cream
L’Oréal ParisSublimist
L’Occitane Hand cream
Unilever DiamondAttraction
GSKAquafresh
Make Up ForeverSkin Equalizer
Dior - DiorshowNew Look
Avon color palette
Rimmel Match Perfection
EtamReine du Bluff
Kiko - False lashesConcentrate
DiorBaume Rouge
O Boticário Intense
LancômeLip Lover
SephoraOutrageous Curl
Estée LauderPerfectly
Clean
Estée LauderModern Muse
GuerlainLe Petite Robe Noire
NaturaDeo Spray
Chanel - Hydra Beauty Micro Serum
LancômeAbsolue L’Extrait
DiorJ’adore
My BurberryMoisturizing Body Mist
Lise Watier - Clin d’ŒilFalse Eyelashes
■ Semi-automatic assembly
■ Automated assembly
■ High-speed complex assembly
■ Just-in-time delivery
■ Supplier-managed inventory
■ Dual sourcing
■ Complex turnkey projects
■ Complementary sourcing of packaging and accessories
Conversion Decoration
■ Extrusion
■ Tube laminate (web) production
■ Tube-making
■ Injection
■ Blow-moulding (IBM, EBM)
■ Multi-injection
■ Elastomer over-moulding
■ Metal forming (stamping, eyeleting, embossing)
■ Printing
■ Varnishing■ Metalizing
■ Electroplating
■ Laser■ Hot stamping
■ Anodizing
■ Labelling
Assembly End-Markets
Services
I&DNPD
Technical know-how100% integrated
Raw Materials
AssemblySupply-Chain
Conversion Decoration End-MarketsInnovation & Development
■ Plastic resins/ films
■ Aluminum■ Inks
■ Metal
■ Mold design
■ Mold prototypes■ Printing plates
■ Sample production
■ Compatibility testing■ Functional testing
(impact resistance, resistance to wear)
■ Industrialization
DecorationConversion
■ Project Management ■ Intellectual Property ■ Regulatory Affairs ■ Full Service ■ Kitting ■ Account Management
Eco-Design& Cosmetic Packaging
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Innovation and Development CapabilitiesCSR as a key area of focus
Innovation DevelopmentDesign
We invent new technologies and
new processes to make
packaging stand out and be
more efficient, more competitive,
environmentally-friendlier
We turn into reality the packaging
that our customers have
imagined, overcoming technical
challenges and designing to cost
We manufacture or source
innovative items that offer
improved ergonomics, visual
differentiation, new gestures ,
affordable price, trendier look
Rapid prototyping
& virtual representation
Intellectual property
(over 2,000 patents)
200-people team
across the world
Advanced materials and technologies
Computer-Assisted
Design for creation,
optimization & manufacturing
Eco-design starts withLife Cycle Analysis
e-DEA is our Life Cycle Analysis tool, designed for packaging.It is based on Simapro, one of the most widely-used LCA softwares.
Albéa’s investment in eDEA v2.� Customized data base� More thorough evaluations
� Albéa supports the use of a common tool & methodology across the Cosmetics industry (through organizations such as Elipso)
2002Alcan Packaging develops ASSETTM LCA tool
2008Specific resourcededicated to LCA and eco-design
2010 - 2011Acquisition of e-DEA tool from EVEA, including specific developments for packaging
Life Cycle Analysis Understanding the impacts
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20
40
60
80
100
120
Carbon footprint
gCO
2 eq
Carbon FootprintPlastic tube 250 ml – Coex with Slender cap
End of Life
Transport
Finishing
Processing
Raw materials
In our industry, the biggest impacts come from:- Raw materials used- Manufacturing process
These are are two priorities!
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Plastic TubesWeight Reduction
*LCA measures done on a standard plastic tube with flip-top cap, diameter 50mm -150ml
ACHIEVEDSleeve thickness reductionLight cap designUse of recycled PE� 25% weight reduction in 10 years.
NEXT STEPSHead weight reductionFurther sleeve reduction (400µm)�Total 50% weight reduction
expected
Incremental progress
Technological rupture
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-9% gCO2 eq
-13% gCO2 eq
-11% gCO2 eq
Up to
- 33%CO2 equ. *
Slender CapTM
Weight Reduction
*ASSETTM comparison with standard cap
Slender cap was launched as the lightest flip-top cap for tubes.
It delivers 50% PP material savings and 40% carbon footprint impact*!
Laminate TubesGreenleaf TM manufacturing process
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Ø (mm)Traditional PBL
sleeve thicknessGreenleaf®
sleeve thickness
19, 22, 25, 30 and 35mm 300µm 250µm
35, 40, 50mm 350 – 400 µm 330µm
• *comparison of 2 tubes: Greenleaf 250 µm vs PBL 300/25 having same haptics, ø50mm, 150ml, with Slender Cap • **for an average cardboard for toothpaste tube: 11g of cardboard
• Ultra-thin plastic-barrier laminate (PBL) web with high performance
• Sleeve weight reduced by 17%• Innovative energy-efficient process
• Elimination of on-shelf packaging• No need of cardboard
• Competitiveness• Material use reduction• Energy consumption reduction• Waste reduction
• Recyclable in HDPE stream according to EcoEmballages and Cotrep studies
Ultra-light & recyclable laminate tube
-11% carbon footprint impact*
-16% carbon footprint impact**
Cost savings versus traditional
PBL tubes
Access Denied capWeight reduction
Access Denied provides the same functionality as a sleeved cap
Benefits:
●Remove shrink film sleeve
● Include the functionality in the cap (tongue)
Savings:
●Avoid additional shrink film
●Single production step
Cosmetic Rigid PackagingAttraction
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Metal-free and magnet-free compact
• Attraction is a closure system for compacts with no metal and no magnet . This proprietary technology ensures a smmoth closing mechanism.
• The system’s innovation lies in a 100% plastic, pin-less hinge, removing the need for neodymium magnets to close the compact.
• Neodymium magnets have negative environmental impact -cf LCA overleaf
• Attraction hinge technology fits all compact shapes.
Attraction vs standard magnet closureLCA Analysis
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1.4% weight reduction delivers huge positive carbon footprint impact
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Magnetometric
Attraction
Tube recyclingThe French experiment
THE FRENCH EXPERIMENT As part of this experiment, a few packaging companies were selected to evaluate andimprove the recyclability of plastic packaging :
In France, only 22% of plastic packaging was recycled in 2014 sinceonly PE/PP/PET bottles are considered for plastic packaging recycling. Other packaging, such as PE tubes, PP yogurt pots & PET trays are not.
To increase plastic packaging recycling, France chose to extend recycling to all plastic packaging, proceeding first in an experimentation project.
This project took place in 2012-2014 with lead from Eco Emballages , the French organization in charge of organizing sorting, collection & recycling of packaging.
In France, only 22% of plastic packaging was recycled in 2014 sinceonly PE/PP/PET bottles are considered for plastic packaging recycling. Other packaging, such as PE tubes, PP yogurt pots & PET trays are not.
To increase plastic packaging recycling, France chose to extend recycling to all plastic packaging, proceeding first in an experimentation project.
This project took place in 2012-2014 with lead from Eco Emballages , the French organization in charge of organizing sorting, collection & recycling of packaging.
Bottles Tubes Yogurt Trays
2014 ✔ ✘ ✘ ✘
Goal2020
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Plastic packaging recycling in France
The first sorting experimentation was made between 2012-2014. During this period, 4 millions inhabitantswere given instructions to sort, collect and recycle other packaging than bottles, including tubes.
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Tube recyclingGroundbreaking news
Plastic tubes (mono/coex)Plastic barrier laminate tubes
are recyclable in PE stream
• PP cap evaluated as non-critical since the rate of PP in HDPE stream remains below 10%*• Varnish evaluated as non-critical• EVOH barrier evaluated as non-critical by Cotrep and other studies* since EVOH represents in average 3% of tube
composition
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In Conclusion
The cosmetics market is driven by differentiation.
Differentiation often goes hand-in-hand with attractive & innovativepackaging: premium decoration, design, new gestures etc.
Eco-design, which improves the packaging’s environmental footprintand often improves its competitiveness, contributes to differentiation.
Corporate Social Responsbility is a shared ambition, uniting brands and their suppliers – and an increasingly strong business driver.
Conclusion
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