Less material in every replacement
Only the lightweight pouch is replaced, not the dispenser.
Sustainability & PPWR
PE-based refill packaging for the PPWR era.
Reduce the disposable. Reuse the durable.
The 4RE approach separates a reusable airless dispenser from a lightweight replacement pouch, with a PE-based, mono-material direction for the pouch designed to support recyclability, so beauty brands can prepare for the PPWR era without giving up airless performance.
4RE
What is the 4RE circular packaging system?
Swap the pouch
Replace the refill pouch and continue using your dispenser.
Keep what lasts
The airless dispenser is the component designed to stay in use.
PE-based design
A PE-based refill structure, designed with recyclability in mind.
Material reduction
How much packaging material does a refill save?
Up to 90% less packaging material for the replacement refill, compared with a conventional rigid airless pack of the same volume.
Savings depend on format, configuration and the comparison baseline. Over several refills, the comparison should count the reusable dispenser once and every pouch used to deliver the same total amount of product.
How we compare over N fills
Airless Pak mono: D + N × R
Rigid airless pack: N × C
Reduction: 1 − (D + N × R) / (N × C)
D = reusable dispenser mass · R = refill pouch assembly mass · C = complete rigid pack mass at the same fill volume. The initial fill counts toward N. This is a material-mass comparison, not a carbon footprint (LCA).
Pouch materials
What is the Airless Pak mono pouch made of?
Airless Pak mono uses a PE-based multilayer pouch. The documented laminate contains approximately 93.15% PE by weight, with an EVOH oxygen-barrier layer and functional coatings, inks and adhesives.
- Structure
- MDOPE-EVOH / BOPE / PE, 7 layers
- Documented pouch
- 30 ml (1.01 fl. oz.), 85 × 85 mm, 25 mm gusset
- Total thickness
- 146.5 µm (spec range 143–152 µm)
- Basis weight
- 137.3 g/m² (laminate, not a single pouch)
- PE share
- 93.15 wt% (MDOPE + BOPE + PE)
- EVOH share
- 2.12 wt%
| Layer | Function | Thickness µm | Density g/cm³ | g/m² | Mass % |
|---|---|---|---|---|---|
| Varnish | Matte surface finish | 1.5 | 1.00 | 1.50 | 1.09 |
| MDOPE | Machine-direction oriented PE: structure, print surface | 22 | 0.97 | 21.34 | 15.54 |
| EVOH | Oxygen barrier | 3 | 0.97 | 2.91 | 2.12 |
| Ink + adhesive | Reverse-printed graphics, bonding | 3 | 1.00 | 3.00 | 2.18 |
| BOPE | Biaxially oriented PE: stiffness, handling | 25 | 0.95 | 23.75 | 17.30 |
| Adhesive | Lamination bond | 2 | 1.00 | 2.00 | 1.46 |
| PE | Inner sealant, product contact | 90 | 0.92 | 82.80 | 60.31 |
| Total | PE layers = 127.89 g/m² (93.15 wt%) | 146.5 | — | 137.30 | 100.00 |
Outside (top) to product side (bottom). PE layers in green.
Varnish · 1.5 µm
MDOPE · 22 µm
EVOH · 3 µm
Ink + adhesive · 3 µm
BOPE · 25 µm
Adhesive · 2 µm
PE sealant · 90 µm
Pouch dimensions (dieline)
- Front / back
- 85 × 85 mm
- Bottom
- 50 mm flat, folding to a 25 mm gusset
- Corner radius
- 5 mm
- Heat seal
- 7 mm
- Finish
- Matte varnish
- Spout
- Fitted on the pouch side edge
Documented configuration: 30 ml BOTTLESS pouch, material data last updated 6 August 2026.
Film materials glossary
- MDO-PE
- Machine-direction oriented polyethylene. Stretched in one direction for stiffness and dimensional stability; used as the outer print film.
- BOPE
- Biaxially oriented polyethylene. Stretched in two directions for balanced stiffness and strength across the pouch.
- EVOH
- Ethylene vinyl alcohol copolymer. A very thin oxygen-barrier layer, protected inside the laminate because its barrier weakens with humidity.
- PE
- Polyethylene. The inner sealant layer: heat-sealable, flexible and in direct contact with the product.
93.15 wt% describes the documented pouch laminate only. It is not the PE share of the complete refill or dispenser assembly (spout, valve, cap, pump), and it is not a recycled-content or recycling-rate figure. Thickness % and mass % differ because each layer has a different density.
Recycled content
Can Airless Pak mono include PCR material?
Yes. A proportion of post-consumer recycled (PCR) material can be incorporated. Applicable components and recycled content are defined for each project, subject to compatibility and performance requirements.
PE composition (93.15 wt%) and PCR content are different measures. The first describes which polymer the laminate is made of; the second describes where the material came from.
PPWR
How does Airless Pak mono align with the EU PPWR?
The Packaging and Packaging Waste Regulation (EU) 2025/40 has applied generally since 12 August 2026, with individual requirements on their own schedules. It drives packaging reduction, recyclability, recycled content, reuse and refill, and clearer packaging information.
| PPWR direction | What Airless Pak mono brings | What each project confirms |
|---|---|---|
| Minimize packaging weight and volume | Lightweight pouch replaced instead of a complete dispenser | Complete-pack mass and volume at the same function and fill |
| Design for recyclability | Documented laminate with 93.15 wt% PE; functional layers disclosed | Non-PE layers, spout, valve and the target recycling route |
| Recycled content in plastic packaging | PCR material can be incorporated | Components, content, source evidence, contact and performance needs |
| Reuse and refill | Dispenser kept in use, pouch replaced | Repeat-use performance, hygiene and user instructions |
| Clear labeling and sorting guidance | Component-by-component material information | Market-specific labels, disposal guidance and timelines |
This mapping is BOTTLESS’s design assessment, not an EU evaluation or a compliance certificate. Sources: European Commission PPWR overview, Regulation (EU) 2025/40. Choosing between refill formats? See the refill packaging guide.
Clear claims
What we say, and what we don’t.
Each environmental attribute is described on its own, with its scope.
- Material reduction is a mass comparison, not a CO₂ claim.
- “Mono” means a PE-based structure, not a single layer or 100% PE.
- Airless dispensing and oxygen barrier are separate functions.
- Minimal residue is a design goal measured per formula, not a 0% guarantee.
- Recyclability depends on the final construction and local infrastructure.
- No biodegradable or compostable claim is made for the PE-based pouch.
Discuss your PPWR packaging roadmap.
Start with your formula, format and market. Define the refill system, material specification and PCR requirements together.