Refillable airless packaging FAQ

Airless Pak mono is BOTTLESS’s refillable airless packaging system. It combines a reusable dispenser with a lightweight, flexible refill pouch that holds the formula. “Mono” refers to its PE-based pouch structure.

Airless Pak mono works as the replaceable pouch inside a refillable airless system. Instead of pouring product into another bottle, the user keeps the dispenser and swaps the pouch. The pouch and the dispensing interface are designed to work together as one system.

An airless refill pouch is a flexible container that holds the formula and collapses as product is dispensed through an airless pump, so outside air does not replace the dispensed volume. In Airless Pak mono, the pump and dispenser are kept and only the pouch is replaced, rather than the whole rigid bottle.

They differ in what is replaced. Pour-in refills replace only the refill pack but require decanting. Refill jars and inner cups replace a rigid inner container. Refillable airless bottles usually replace a rigid inner cartridge. In Airless Pak mono, a lightweight flexible pouch is replaced while the airless pump stays in use. The best choice depends on the formula, dispensing needs and material goals.

No. The dispenser is designed to be reused while the refill pouch is replaced. Handling and replacement instructions are defined for each configuration.

Airless Pak mono is offered in formats from 30 ml to 300 ml. Smaller formats suit serums and treatments, mid-size formats suit lotions, creams and sunscreens, and larger formats suit body care, hair care and other liquid personal care. Contact BOTTLESS to confirm the configuration for your project.

The flexible pouch is designed to collapse as product is dispensed, instead of replacing the dispensed volume with outside air. Performance is validated for the selected formula and packaging configuration.

Serums, lotions, gels, creams and selected sunscreen formulations are good starting points, along with selected personal care liquids in larger formats. Each application starts with a review of the formula, dispensing requirements and packaging configuration.

Suitability depends on the formula’s flow characteristics and the selected pump. Share your viscosity data and dispensing requirements so the right tests can be defined.

Yes. Airless dispensing concerns how product leaves the pack and how outside air is managed during use. Barrier performance concerns transmission through the packaging material during storage and use. They are separate functions, so the pouch’s barrier properties are assessed on their own.

The system is designed to limit exposure to outside air during dispensing and to manage backflow. Microbiological performance and preservation requirements are validated for each product.

The pouch is designed to collapse during dispensing, helping minimize the product left inside. Actual residue depends on the formula and configuration and is measured with the target formula.

Airless Pak mono uses a PE-based multilayer pouch. The documented laminate contains approximately 93.15% PE by weight, together with an EVOH barrier layer and functional coatings, inks and adhesives. Recyclability is assessed for the final configuration.

Layer count and polymer composition describe different things. The documented pouch has seven layers for structure, barrier, sealing, printing and bonding. Most of its laminate mass is PE. “Mono” does not mean the pouch has one layer or contains only PE.

EVOH provides an oxygen-barrier function within the laminate. In the documented structure it is approximately 2.12% of the laminate mass.

No. The figure describes the documented pouch laminate only. It is not the PE share of the complete refill or dispenser assembly, and it is not a recycled-content or recycling-rate figure.

BOTTLESS can incorporate a proportion of post-consumer recycled (PCR) material. The components and PCR percentage are agreed for each project, subject to material availability, formula compatibility and performance validation. PCR content is separate from the laminate’s 93.15 wt% PE composition.

It brings several relevant design choices together: a lightweight replacement pouch, a dispenser designed for reuse, a documented PE-based laminate and options to incorporate PCR material. Brands can evaluate these alongside airless dispensing and formula compatibility in one packaging project.

No blanket compliance claim is made. The system is a useful design starting point; the final configuration, materials, recycled-content specification, intended use and supporting documents are assessed against the applicable requirements.

The EU Packaging and Packaging Waste Regulation (EU) 2025/40 has applied generally since 12 August 2026, while individual requirements follow their own schedules. Brands should review the requirements relevant to their current products and planned launches.

Yes. Airless Pak mono reached commercial launch in November 2025, and BOTTLESS is working on further brand applications and PoCs. Availability depends on the configuration.

Yes. Share your product category, preferred format and evaluation goals so BOTTLESS can scope the right sample request.

A proof of concept defines the target formula and configuration, evaluates filling and dispensing, checks compatibility against agreed performance criteria and identifies the steps needed for commercial launch.

The reference starting MOQ is 5,000 units, depending on configuration and project requirements. Contact BOTTLESS for a current quotation.

Pricing and lead time depend on configuration, customization, order quantity and production planning. Request a project-specific quotation.

Pouch graphics, dispenser appearance and decoration can be reviewed for your project. Feasibility, order quantity and the effect on the final material specification are confirmed before design approval.

Existing components and manufacturing arrangements can be reviewed as part of the project. Share the pump specification, filling process and formula requirements so compatibility and any changes can be assessed.

Plan separately for technical scoping, samples, formula and filling validation, artwork approval, pilot production and delivery. BOTTLESS can propose a project schedule once the configuration and evaluation scope are defined.

BOTTLESS is a packaging technology company based in Seoul and Paris. In Paris, BOTTLESS is part of Incubateur HEC Paris at STATION F.

Airless Pak was a finalist in Packaging Europe’s Sustainability Awards 2025, in the Driving the Circular Economy (Pre-Commercialized) category. Airless Pak is also listed as a Solar Impulse Efficient Solution, and founder Chiwon Yi was named among the Asia Pacific regional winners of the 2025 Founders Live Prime Time Pitch Challenge.

No. Recognition and media coverage give context about the company and its innovation. Formula compatibility, dispensing performance, recyclability and recycled-content claims still need evidence for the specific packaging configuration.