Aptar creates reloadable airless pack for Clarins Total Eye Lift, cutting material impact by 73%

GLOBAL – Aptar has developed a reloadable airless pack for Clarins Total Eye Lift Eye Cream that reduces packaging material impact by 73% compared to the previous pack, using 50% less metal, 33% less plastic, and 29% less cardboard, based on a metal outer shell with plastic refills.

The format is based on Aptar Beauty’s patented Gaïa reloadable airless system, paired with an outer pack for Clarins. 

The design aims to decrease material use while retaining the appearance and feel associated with the premium eye cream category. 

The pack is covered by two patents: one relates to a push-and-pull refill mechanism modelled on a ballpoint pen, and the other covers a double tamper seal system to improve product protection and reduce contamination risk.

The Engineering of Reloadable Luxury

Airless dispensing systems use a vacuum mechanism to deliver product without a dip tube, ensuring that almost all formulation is dispensed and minimising oxidation of sensitive ingredients. 

In a standard airless pack, the entire assembly, outer shell, inner pouch, pump, and cap, is discarded after use. 

The Gaïa system separates the durable metal outer shell (designed for repeated use) from the plastic refill (discarded after each fill). 

The 73% material impact reduction is calculated per complete product lifecycle, including the outer shell amortised over multiple refills. 

For a daily-use eye cream, the refill model means less packaging entering the waste stream every three to four months.

Consumer Experience and Tamper Evidence

The push-and-pull refill mechanism modelled on a ballpoint pen allows users to replace the empty refill without tools or complex disassembly. 

The double tamper seal system addresses a common concern with refillable cosmetics: ensuring that the replacement refill has not been opened or contaminated before purchase.

For Clarins, a brand positioned in the premium skincare segment, the metal outer shell preserves the weight and tactile feel that consumers associate with luxury, while the plastic refill reduces cost and environmental footprint.

Industry Leadership in Sustainability

Xavier Joseph, Aptar Beauty global marketing and innovation vice-president, explained that these recognitions highlight the strength of the partnership with Clarins and the shared commitment to pushing the boundaries of packaging innovation. 

He noted that this project showcases how custom-engineered, high-performance solutions can deliver both sustainability features and premium value for customers.

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