Coveris innovation slashes sleeve material by 30%, cuts steam use for Dr Beckman

FRANCE – Coveris has developed a mono-material LDPE sleeve for Dr Beckmann’s first liquid fabric softener in France, using approximately 30 percent less material than conventional shrink sleeves while eliminating the steam tunnel and reducing total operating costs by up to 50 percent.

The project moved from concept to commercial launch in just six months, leveraging Coveris’ SleeveFlex Ultra Stretch technology, an elastic sleeve made from single-material LDPE film suitable for both PET bottles and HDPE containers. 

The sleeve’s low-density construction enables easy separation in sink-float recycling processes, supporting bottle-to-bottle PET recycling while creating a fully mono-material PE packaging solution on HDPE, helping brands meet current and future Packaging and Packaging Waste Regulation requirements.

How 30% Less Material and Steam-Free Processing Cut Operating Costs

Compared with conventional shrink sleeves, SleeveFlex Ultra Stretch uses approximately 30 percent less material and eliminates the need for a steam tunnel, saving around 150 kilograms of steam per hour. 

The flexible sleeve also removes requirements for temperature-controlled transport and special storage conditions, helping reduce total operating costs by up to 50 percent. 

For high-volume household products, these relatively modest reductions per pack translate into significant savings across annual production. 

Coveris acted as a full-service packaging partner, supporting Dr Beckmann with technology selection, machinery integration and commissioning of the production line, helping bring the solution from concept to market readiness within the six-month timeframe.

Mono-Material Design Supports PPWR Compliance and Recycling Performance

The sleeve’s LDPE construction is engineered to separate effectively from rigid packaging during sink-float recycling processes. 

When applied to PET bottles, the sleeve separates from the higher-density bottle material, preserving PET bottle-to-bottle recycling. When combined with an HDPE container, the packaging forms a compatible polyolefin-based structure. 

Labels and sleeves represent a relatively small share of total packaging weight, but their material composition and separation behaviour significantly influence recycling performance.

The development reflects a wider shift in sustainable packaging, where improvements increasingly need to deliver both environmental and operational benefits, reducing film use, eliminating steam and simplifying end-of-life separation while addressing recyclability, material efficiency and production economics within the same packaging system. 

Dr Beckmann required a packaging solution that combined premium shelf appeal with sustainability for the launch of its Quick Wash Fabric Softener in France, with Coveris’ solution delivering strong visual impact alongside its environmental credentials.

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