Let’s talk refillable – Changing the way we look at ‘use and throw’ packaging!

Refill packaging

Let’s talk refillable

Changing the way we look at ‘use and throw’ packaging

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Reusable packaging systems often show environmental benefits over single-use systems.

Packaging plays an important role in safely distributing products throughout today's society and supply chains. With a consumption of about 40% of plastics and 50% of paper in Europe, the packaging sector is a large user of materials. Packaging has a lot of environmental impacts, while it also represents a significant cost in the current supply system. Reusable packaging has been suggested as an option to significantly reduce environmental impacts.

At the same time, consumers are also becoming more eco-conscious and abstaining from ‘use and throw’ - a culture which has drastically impacted our surroundings and given rise to modern-day calamities which can severely affect the planet and all its living habitats.

Refill packaging – Closing the loop

One of the most relevant ways to boost business, Refill packaging works well with a wide variety of products, including skincare and cosmetics, homecare products, FMCG, food & beverages, etc. By opting for refillable packaging, brands can capitalize on the sustainability movement and break into a new market of millennials who are actively seeking out such products.

GOOD THINGS COME IN REFILLABLE PACKAGES

The major benefit of refill packaging is of course less wastage, but is that enough for big brands to switch to it over the traditional single-use packaging? They believe in big numbers, proven facts, and the impact it would create on buyers. Mintel’s Global Packaging Trends 2020 report suggests recyclable products and in-store refilling will be at the forefront of the global sustainability trends driving consumer buying decisions numbers and major influence on the way consumers purchase products.

Besides sustainability, refill packaging offers multiple advantages such as:

Reduced packaging cost

Lesser transportation cost

Building long-term customer relationships

Refills in market - Ahead of the recycle curve

Olay Regenerist Whips

One of the most popular brands to embrace ‘refillables’, the actual container holds a jarful of moisturizer and comes with an additional recyclable refillable pod which is made from 100% recycled paper. After the original container is emptied, consumers can place the refillable pod into it and thus use it all over again.

This was one of P&G’s first attempt to tap into the potential refill packaging market, which was to be followed by several of their best-selling brands such as Cascade, Crest, Tide, Ariel and Pantene.

Dove Refillable Deodorant

“Buy once, refill for life” – that’s the motto of the world’s leading brand, Dove in the deodorant category. The deodorant case is made of durable stainless steel, which gives it a sleek and minimalistic look, is good for the planet and comes with a lifetime guarantee, thus making it a one-time only investment for the consumers. It is conveniently designed to fit into the customer’s beauty routine and its refill uses 54% less plastic out of which 98% is recyclable as compared to the earlier variants.

Mugler Fountaine By L’oreal

L’Oreal has been much ahead of the game and seems to have adapted to the sustainable refill packaging trend more than two decades back with Mugler Fontaine range of perfumes. The brand offers in-store refilling stations where the perfume bottles can be refilled at much reduced prices.

Amid COVID-19, customers are becoming increasingly wary of visiting the stores to refill and brands now need to built safety and trust in them when it comes to hygienic refilling of their empty bottles.

They should aim to clearly communicate to customers the health and safety measures in place whilst operating in-store refill stations. Mugler is now extending its offering and delivering refill bottles directly to customers, which are available for a bigger selection of its fragrances.

Sustainability Store By Unilever

Supermarket chain Asda in support with Unilever, launched its flagship sustainability store in UK comprising of a refill zone which includes muliple leading household and beauty brands from Unilever. With three different refill formats – it is an attempt for the FMCG giant to ‘trial & learn’ and understand what works best for the consumers.

The Touch - free refill machines provides dispensation in aluminium and stainless-steel bottles using the Return, Refill and Repeat supposition. According to Unilever, these three Refill Stations could save the equivalent of 30,000 plastic water bottles in just one store in one year, based on a 500ml bottle size and predicted sales of Persil, Radox, Alberto Balsam, and Simple refills.

The The In-home refills provides dispensation in aluminium offer Eco-Refill packages, allowing shoppers to use the Cif spray bottle for life. Eco-Refills use 75% less plastic than the standard cleaning bottle, having the potential to save 990 tonnes of plastic every year.

Self-serve containers allow PG Tips & Pukka loose tea to self-dispense fully into bio-degradable bags. The customers will be able to take their own reusable container or buy a new one from the store and once it is full, it will be weighed and printed with a label, ready to purchase!

Refill packaging combined with customization, sustainability and eco-friendliness can bring a world of change to the products. It can position a brand as eco-caring and speak about its propositions to the existing and potential customers. The refill packaging wave is sure to scaleup in the future and create a big difference on the impact of plastic waste generated over the years.

At Packfora, we offer comprehensive and sustainable packaging solutions which are pro-planet and pro-consumers while maximizing the impact of packaging for your business.

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End to end development of packaging development | Milk-based product format

Refill packaging

End to end development of packaging development

Milk-based product format

BRIEF TO PACKFORA ​

Execute End to End Packaging development including the filling machinery and packaging documentation.

Packaging Procurement

01

Identification of right quality vendors for each of the packaging BOM.

02

Advisory on "should cost model", provide choice of vendors for competitive bidding.

03

Supporting the procurement function for negotiation via techno-commercial inputs.

Packaging Lines

01

Identification of right quality suppliers as per product and packaging needs

02

Defining technical specifications for machinery.

03

Placement of 5 vendors for each product format for competitive bidding.

04

Strategic advice on shortlisting and order placement

05

Packaging line qualification and process validation.

Packaging Development

Packaging Design for Bottle, Cup, Lidding film, Lid, Intermediate packaging and Secondary packaging.

Building design for right cost efficiencies for manufacturing.

Choice of right technology of manufacturing for given packaging material.

Identification of right material specifications and structures.

Development of Mold, Printing Cylinders / Stereos

Development of qualification protocols for each packaging BOM.

Qualification of molds and Print proofs.

Optimization of specification to bring cost efficiencies.

Testing, validation and Issue of final Drawings and Specification including and KLDs for artwork.

Development of Test methods for testing all Packaging components.

Development of Supply guidelines for packaging material suppliers including Food safety.

Overall Benefits to the Business

Machine Capex reduction by 15%.

A cost reduction of 20% from the budget for packaging material.

One of its kind in market -a 2 Layer Thermoformed cup development to powerfully communicate the product cues.

A single point of contact for all packaging needs delivering end to end techno-commercial project management.

Innovation & Sustainability Led Growth Plan | Leading Personal Care Brand

Refill packaging

Innovation & Sustainability Led Growth Plan

Leading Personal Care Brand

BRIEF TO PACKFORA ​

Deliver packaging innovation to meet global sustainability commitment with inclusion of PCR, while delivering cost savings and consistent product performance

PACKAGING INNOVATION

01

Designed an innovative multilayer Rigid plastics Jar

02

Developed a consumer-friendly Refill system

03

Sustainability mix framework for packaging application

PACKAGING DEVELOPMENT

01

Develop supplier network for executing the innovation

02

Scouting technology solutions (Mold and Manufacturing process innovation)

03

Develop a cost reduction matrix

Overall Benefits to the Business

Delivering to the global sustainability mission of the organisation by inclusion of upto 50% PCR

Reduction of fossil based packaging material up to 50% with increased use of PCR

Up to 20% cost reduction to enhance brand margin

Ecommerce-ready pack

Innovation & Sustainability led growth plan | Leading paper manufacturer

Refill packaging

Innovation & Sustainability led growth plan

Leading paper manufacturer

BRIEF TO PACKFORA ​

A leading Indian paper manufacturer entrusted Packfora with the task of helping them build a strong pipeline of innovation for growth, centered around sustainability.

PACKAGING STRATEGY

01

Market sizing & analysis to identify multiple segments for innovation

02

Sustainability framework for current & future packaging applications

03

Facilitation of the innovation process for client stakeholders to generate idea portfolio

04

Market potential estimation and execution roadmap for shortlisted innovations

PACKAGING DEVELOPMENT

01

Identification of technical & performance specifications for current packaging

02

Development of alternate paper and enhanced paper-based innovations to replace current

03

Technical action standards for the identified new innovations

04

Identification of ecosystem partners to develop and pilot innovation

Overall Benefits to the Business

Structured understanding and analysis of market and segments

Opportunities spanning multiple segments - packaged food, food service, home & personal care

Accelerated development of new packaging offering ideas and their requirement specifications

Strong portfolio of sustainability led initiatives

Strong portfolio of sustainability led initiativesRoadmap for innovation led growth - over 10 key ideas with INR 300 Cr+ revenue potential

Accelerated packaging enhancements for re-launch (2D + 3D) | Personal Care Start Up

Refill packaging

Accelerated packaging enhancements for re-launch (2D + 3D)

Personal Care Start Up

BRIEF TO PACKFORA ​

Personal Care Start Up approached Packfora to ensure premium packaging solutions for re-launching in an accelerated time frame of just 8 weeks.

PACKAGING CHALLENGES

01

Existing packaging lacks in brand and shelf impact.

02

Key design challenge - to cue premiumness, with strong roots in technical formulation.

03

Packaging material selection not adequately appealing for the consumers.

04

Only 8 weeks left for re-launch timeline recovery.

PACKAGING DESIGN SOLUTION

01

Analysed category codes for packaging design and developed new designs.

02

Creative graphics and packaging to set the brand apart - both in terms of positioning and individuality.

03

Seamless and creative 2D (pack graphics) + 3D (pack structure) solutions appealing to consumer sensibilities.

PACKAGING STRUCTURE

Identified a range of stock vendors with different alternatives on material & finishes for proposed pack designs.

Quick prototyping solutions to provide mock-ups of alternative designs to validate final selection.

Vendor selection and commercial negotiation support.

Overall Benefits to the Business

Winning pack design with unique brand values and better shelf impact.

Access to a wide ecosystem of vendors to quickly select the best structure for re-launch pack.

Seamless support across design (2D) & structure (3D) for packaging to ensure fast turnkey solution.

Re-launch plan on track with new and significantly improved packaging in just 8 weeks.

Identifying value proposition for growth opportunities | Plastics Packaging Vendor

Refill packaging

Identifying value proposition for growth opportunities

Plastics Packaging Vendor

BRIEF TO PACKFORA ​

A leading rigid plastics vendor engaged Packfora to understand and improve their equity with customers and their customer pitch process.

BUSINESS CHALLENGES

01

Gap in terms of understanding the requirements of key customers.

02

Not able to articulate their own strengths in context of customer needs.

03

Improve customer engagement process and further Institutionalize it internally.

04

Business image not in sync with industry leadership status as a supplier.

OUR SOLUTIONS

01

Designed a framework to understand customer needs in terms of innovation, supply chain efficiencies, agility and sustainability.

02

Helped in recognizing and focussing on newer technologies which may be of interest to specific customers.

03

Identified key manufacturing and process strengths which can be highlighted for business opportunities.

04

Developed a process to prioritize and improve the articulation of own strength while pitching to meet customer needs.

05

Value added coaching provided to the internal team while preparing and reviewing a pitch deck.

Overall Benefits to the Business

Improved value proposition and engagement with customers in growth opportunities.

Enhanced capability of the internal team to identify customer needs and pitch more effectively.

Highlighted capability and market relevant solutions in areas like PCR usage, innovative labelling and embellishments, local source of advanced pumps, etc.

Fresh communication with some large but dormant customers, increasing the share of spend.

Initial customer presentations led to select new offerings move towards pilot engagement stages.

Sustainability & Simplified Packaging operations for business | Automobile Tyre Manufacturer

Refill packaging

Sustainability & Simplified Packaging operations for business

Automobile Tyre Manufacturer

BRIEF TO PACKFORA ​

A leading tyre manufacturer approached Packforato ensure the packaging structure used is in compliance with government guidelines of recyclability and to simplify packaging operations.

PACKAGING INNOVATION

01

Packaging materials need to be in sync with government guidelines on sustainability.

02

Complex packaging operations - multiple small volume SKUs, high inventories and variable printing frequency - need to be more streamlined.

PACKAGING DEVELOPMENT

01

Provided optimal specifications with sustainability norms, thus enabling 100% recyclability which helped meet government guidelines effectively.

02

Developed flexible packaging structure to reduce SKU complexity.

03

Introduced newer technologies in variable printing which helped in reducing print frequency.

04

Provided assistance to the client with end-to-end packaging supply chain planning.

05

Unlocked savings in terms of packaging materials cost.

Overall Benefits to the Business

Unique, 100% recyclable structure which sets them apart from competitors in the Automobile industry.

Massive improvement in packaging process - from manual to semi-automatic, increasing efficiency by 50%.

2X Faster time to market on packaging changes, thus gaining responsiveness for business.

Reduction in unskilled labour needs.

Savings potential for more than 1 crore INR p.a.

Identifying 360 & approach in design + deploy for innovative packaging

Refill packaging

Identifying 360 & approach in design

deploy for innovative packaging

BRIEF TO PACKFORA ​

A leading global foods company approached Packfora to develop end-to-end innovative solutions for their coffee brand launch.

PACKAGING EVOLUTION

01

Benchmarking Market best practices

02

Technology 2 stage moulds development Manufacturing develop decoration routes

03

Sourcing Technology selection supplier infrastructure Cost modelling and negotiations support

PACKAGING DEVELOPMENT

01

Competition benchmarking to make right business choice

02

Barrier extrapolation to cut down on storage stability time

03

Developed cost-effective local quality supply partners for agility

Design for ease of Filling, Headspace, Batch Coding and Transportation

Fail-fast design iterations before mould making to ensure first time right

Delivered a consumer centric design

Overall Benefits to the Business

Ergonomic and optimized consumer centric design delivered

First time right Jar and Closure delivery, fast launch

Modular design to have flexibility to launch quick & low Capex for new shapes and sizes

Significant rebates in Capex due to design standardization

Recyclable packaging footprint

Develop strategy to enable sustainable packaging transition

Refill packaging

Develop strategy to enable sustainable

packaging transition

BRIEF TO PACKFORA ​

The African Government Development Board & a Leading Development Agency approached Packfora to provide technical and industry expertise to enable sustainable packaging transition at country, region & industry level.

SCOPE OF ENGAGEMENT

01

Develop an outline of strategy to enable sustainable packaging transition at country, region & industry level.

02

Identify specific policy measures, investment opportunities and prospective investor partners to help drive shift to viable sustainable packaging solutions for local economy and region.

RESULTS DELIVERED

Identified current state of packaging material usage and policy implementation in the local economy.

Identified current state of packaging material usage and policy implementation in the local economy.

Outlined necessary policy framework including EPR, PCR and governance mechanisms for sustainable packaging transition in local economy.

Benchmarked current packaging to global standards required for export in specific industry segments. Identified relevant scale & technology solutions to enable more sustainable packaging structures and recycling in the local economy & region.

Identified potential investment partners in four key material and industry areas. Enabled introductions for development bodies to initiate investment promotion