Saturday, 25 October 2008

The "kangaroo" bucket packaging

There are many consumer products, which consist of two components, and have to be packed separately as they have to be used separately, one after the other or mixed upon usage. Consequently they are often not properly used, because the consumer can’t find one of the components anymore or one is forgotten or neglected to be used. Following the successful introduction of the Eco-Cleaning Lab's Twin by TricorBraun, the same company introduces a "kangaroo pack" for Avlon Affirm Hair Care. Just as ingenious as simple.

'Hair Care Avlon Affirm’ is a two-step treatment for hair care, especially for hairdressing salons. The new 4-lb (1.8 kg) "kangaroo" bucket pack contains a "built-in space" in which a 4-oz (115 gr) pre-treatment bottle is stored. The content of the bucket is for the second treatment step. This merger of two packages avoids the problem that one of the bottles for the pre-treatment and the treatment itself, goes lost or is not used.


With the 'kangaroo' design, allowing the second bottle easily to be clicked into place in the recessed space in the bucket, Avlon Industries, a manufacturer of hair care products for the ethnic market, hopes to have introduced a constructive way to execute the two-step treatment correctly, by functionally merging the packages of the two components. Hair stylists may no longer overlook the pre-treatment, and can no longer use the excuse that the pre-treatment bottle was untraceable or ergo just skip the pre-treatment and forget the bottle to use what may be the case with separate products.

The unique packaging promotes the attention the product gets on the store shelves from both hair stylists and ordinary consumers.
Designed by TricorBraun, the 'kangaroo' bucket is, in addition to the attractive marketing aspect and increased efficiency in hairdressing salons, also in two ways cost saving. It increases the efficiency in production, as the two products don’t need to be packed separately in shipping boxes and the new ‘kangaroo’ packaging diminishes costs in the distribution chain, as the shipping boxes can contain now a relatively larger quantity of product.

© Weslley Murylo de Souza Steeman


Gaplast GmbH replaces a four-part production process with the one-piece AirLEssMotion Bag-in-Bottle System. The new co-extruded, blow moulded bottle consists of a rigid PP outer bottle and a flexible DuPont Surlyn inner bottle.

When an unnamed customer of Gaplast GmbH recently built a new factory, the company also decided to install a more efficient production process for its spray bottles with disinfectant. The existing 1 ltr bottles used for disinfecting laboratories and operating rooms required a four-step manufacturing process and a manual assembly. The bottles were HPDE extrusion blow moulded. A separate foil bag had to be fumbled into the bottles manually to guarantee the airless dispensing function, which is needed to ensure that germs or micro-organisms are not dispensed together with the disinfectant liquid. A connector and a gasket, manufactured by injection moulding, respectively, had to be welded to the foil bag to provide a sealing for the gasket.


Gaplast GmbH replaced the existing four parts from the old packinging by the one-piece AirLEssMotion Bag-in-Bottle System. The new co-extruded, blow moulded bottle consists of a rigid outside PP bottle and a flexible DuPont Surlyn inner bag. The old flexible inner bag was made from a polymer alloy of two different polymers. As the polymer alloy would stick to the PP wall of the outer bottle, a separation layer would have been necessary in the new bottle. Gaplast GmbH replaced the polymer alloy with a DuPont Surlyn bag.
However, when the dispenser was activated, the vacuum created by the dispensing pump turned out to be not enough to separate the Surlyn inner bag from the PP wall of the outer bottle. In order to solve this problem Gaplast GmbH made two ventilation holes in the outer bottle without punching the inner bag. These two holes ensure the inner bag to collaps once the dispenser is activated. Delamination of the inner bag from the wall of the outer bottle guarantees a constant dosage of the trigger pump. The airless technology and the gamma sterilization after filling eliminate the need of preservatives.

In addition to savings on raw materials, the new packaging also simplifies an efficient waste control, when removed, as bottle and bag belong the same polymer family.
The bag-in-bottle packaging received the prestigious 2008 Dupont Award.

© Weslley Murylo de Souza Steeman