Protecting Potency.
Defining Luxury.

Skincare Packaging Engineering Guide

In the skincare industry, packaging is the first line of defense for formulation stability. This guide explores the critical engineering principles behind Airless Systems, Material Selection, and Compatibility Testing.

1. The Mechanics of Airless Systems

Traditional lotion pumps rely on a dip tube and atmospheric pressure. When you pump out product, air must enter the bottle to fill the void. This air introduces oxygen and potential contaminants, which is fatal for “clean beauty” formulas with low preservative loads.

The Piston Mechanism: Golden Soar’s airless bottles utilize a floating piston mechanism. As product is dispensed, the vacuum created pulls the piston up from the bottom. This creates a “collapsing volume” effect. There is no dip tube, and crucially, no back-flow of air.

Evacuation Rate (Restitution)

A key metric for luxury consumers is being able to use “every last drop.” Glass bottles with dip tubes often leave 15-20% of the product wasted at the bottom. Our precision-engineered airless pistons are designed to scrape the inner walls of the bottle effectively. We guarantee a restitution rate of >95% for high-viscosity creams (30,000 cps) and >98% for serums.

2. Heavy-Wall Engineering: The Glass Alternative

Historically, luxury meant glass. But glass is heavy, fragile, and energy-intensive to ship. The modern alternative is Heavy-Wall Injection Molding.

We use materials like PMMA (Acrylic) y PETG to create bottles and jars with extremely thick sidewalls (up to 5-8mm).

• PMMA (Acrylic): Offers the highest optical clarity (92% light transmission), superior to standard glass. It is hard and scratch-resistant. We typically use PMMA for the outer shell of a double-wall jar to provide that “suspended in crystal” look.
• PETG (Polyethylene Terephthalate Glycol): Unlike PMMA, PETG is impact-resistant and will not shatter if dropped on a bathroom tile. It also offers better chemical resistance, making it suitable for single-wall bottles containing alcohol-based toners.

3. Chemical Compatibility Protocol

Packaging failure often happens invisibly: leaching, crazing (micro-cracks), or adsorption (flavor scalping). Before mass production, we conduct a mandatory 28-day stability test.

*Note: PMMA should almost never be in direct contact with the formula. We always recommend a Double-Wall structure with a PP inner cup.

4. Decoration & Finishing

Luxury is defined by finish. We offer advanced decoration capabilities:

• Inner Spraying: We spray the outside of the inner cup. When viewed through the clear outer shell, the color looks deep and multidimensional, yet the paint never touches the product.
• Metallization (Vacuum Plating): Giving plastic parts a chrome, gold, or rose-gold metal finish. We often use this for pump collars and caps to elevate the perceived value.
• Soft-Touch Coating: Applying a rubberized matte varnish for a velvety tactile experience, popular in the “clinical” and “dermatological” skincare segments.