The Challenge
A customer with a strong sustainability focus wanted to reduce the environmental impact of an existing tube packaging range without compromising the premium appearance and visual impact of the brand. The objective was to decrease material usage, increase recycled content, and improve production efficiency while maintaining product performance and shelf appeal.
The Solution
Working closely with the customer, our packaging and technical teams developed a new tube specification featuring a reduced sleeve thickness, decreasing from 0.50mm to 0.35mm. The redesigned structure incorporated 46% post-consumer recycled (PCR) material while retaining a virgin outer layer to ensure a high-quality print finish and consistent colour reproduction.
To further reduce material consumption, a lightweight polypropylene flip-top cap was introduced. In addition, an advanced high-resolution printing process was implemented, enabling superior graphic quality while reducing the number of print applications and minimising component waste during production.
The Results
The project delivered significant sustainability and commercial benefits:
19% reduction in overall material weight
46% PCR content inclusion
30% reduction in tube sleeve thickness
£0.01–£0.02 cost saving per unit
Reduced production waste through improved print efficiency
By combining innovative packaging design with advanced manufacturing techniques, the customer achieved a more sustainable solution without compromising product appearance, functionality, or brand impact.
