How Airless Pump Bottles Are Made
How Airless Pump Bottles Are Made
Airless pump bottles are designed to provide a sleek, modern look that elevates your brand image. They protect your products from oxidation and offer zero product waste by dispensing an exact dose every time.
Labeling and branding play a major role in marketing and consumer perception. Well-executed labels convey essential information and contribute to the overall aesthetics of the packaging.
Injection Molding
During the injection molding process, raw plastic pellets are melted in a container with an extruder screw that creates friction and enough heat to melt the plastic. After melting, the plastic is injected into a preform mold that has been designed to shape the final neck finish of an airless pump bottle. The still malleable plastic is then captured by a cavity mold and pressurized with compressed air to ensure that it forms the exact shape of the bottle.
Afterward, the molded bottles are cleaned and sterilized to prevent any contamination from interfering with the product inside. Then, they are shipped to customers and distributed through various methods depending on customer requirements. For example, some products may be sent directly to customers, while others are delivered to distribution centers for further processing or storage.
Injection molders are responsible for ensuring that their manufacturing processes are as efficient and green as possible. They do this by minimizing waste and ensuring that all unused polymer materials are reused in another production run. This method of disposal is known as closed-loop recycling and is an integral part of the injection molding process.
Moreover, injection molders are also dedicated to creating high-quality cosmetic packaging that meets strict environmental regulations. Consequently, their products are typically made with BPA-free polymers like PET and polypropylene. These polymers Duo-mixed bottle are known for their strength, clarity, and resistance to chemicals.
Assembly
In the final assembly phase, all the individual components come together to create the finished airless pump bottle. This crucial step involves meticulously attaching the pump mechanism and connecting it to the bottle body, as well as incorporating any additional features like caps or lids. This is a critical point, as improper attachment can significantly impact the effectiveness of the bottle’s dispensing system.
Airless pump bottles provide a hygienic and efficient way to dispense cosmetic products. Their airtight and vacuum design also protects products against moisture, heat, oil, and other environmental elements, extending their shelf life. This makes them ideal for storing high-quality beauty products that require careful handling.
During the design phase, our expert product designers work closely with clients to achieve the perfect balance between aesthetics, ergonomics, branding elements, and the desired dispensing mechanism. This is achieved through a continuous feedback loop that allows for constant modification and fine-tuning.
Once the bottle is completed, it undergoes a series of rigorous tests to ensure that it meets all quality and performance standards. For example, a test that assesses the suction capacity confirms that the bottle can effectively draw up and dispense liquid products. Once all the tests have been successfully passed, the bottles can proceed to the labeling and branding stage. Here, labels that contain vital product information are carefully applied to the bottle using various printing methods.
In-Process Monitoring
In order to guarantee a high-quality product, rigorous inspections of incoming materials and comprehensive in-process monitoring are performed throughout the manufacturing process. This ensures that each airless pump bottle complies with stringent specifications, undergoes appropriate sterilization, and adheres to industry standards for safety and hygiene. Any bottles that fail to meet these criteria are discarded and not sold, maintaining consistently high-quality standards throughout the production process.
During the production process, careful consideration is also given to the bottle’s packaging materials and structure. For instance, airless pump bottles manufactured by Cosmopacks are designed to prevent contact between skincare products and the air, minimizing oxidation and preserving the efficacy of ingredients and aromas. Additionally, the double-layered walls of these bottles make them more durable and can be made to be opaque in order to protect sensitive ingredients from harmful UV rays.
After passing a thorough visual inspection, the airless pump bottles undergo a series of functionality tests to assess their performance and reliability. This includes examining the pumps’ ability to dispense a precise amount of liquid Duo-mixed bottle and verifying that all additional features, such as twist-lock caps or snap-on caps, function properly.
In addition to ensuring that the pumps and additional features are functioning as intended, functional testing is also performed to evaluate the integrity of the airless treatment pump bottle’s construction. This includes assessing whether the large piston is attached to the inner wall of the bottle securely, checking that the seal between the base cap and the pump is tight, and verifying that there are no visible signs of damage or defects on the exterior surface of the bottle.
Final Evaluation
Airless pump bottles offer a controlled dispensing system that helps to maintain the quality of cosmetic and skincare products by preventing air exposure. The hermetic seal minimizes contamination from external elements and extends the shelf life of a product. This is particularly beneficial for formulations that are sensitive to air and light.
Our skilled product designers work closely with clients throughout the design phase to create an ideal bottle that meets or exceeds their expectations. They utilize an iterative process, making adjustments and modifications as necessary. This ensures that each bottle is designed to meet or exceed client specifications, including aesthetics, ergonomics, branding, and the desired dispensing mechanism.
When the final product is ready, it undergoes a rigorous testing program. This includes evaluating the tightness of seals to ensure that they are leak-proof and airtight. It also consists of assessing the bottle’s ability to withstand various pressure differentials and temperature fluctuations to simulate real-world conditions and test its integrity.
The precise dispensing mechanism of an airless bottle reduces product waste, saving manufacturers money and minimizing environmental impact. Moreover, the hermetic seal helps to protect cosmetics from oxidation and degradation, further enhancing their effectiveness and potency. Additionally, many of our airless bottles are refillable or easily recyclable, encouraging sustainable practices and reducing packaging waste.
