Cosmetic Packaging Why eco -design and weightreduction matter

Jean-Claude Jammet – Director, Innovation & Developme nt

Mat’Days – November 2015

We will talk about....

● Eco-design at Albea

● Eco-designed products

● Tubes

The art of reduction

Slender cap

Greenleaf manufacturing process

Access Denied cap

● Rigid cosmetic packaging

Attraction compact mechanism

●Recycling

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IntroducingAlbéa

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AlbéaAt a glance

Albéa is a global leader in beauty, personal care, oral care, pharmaceutical and food packaging

16,000+EMPLOYEES

38 INDUSTRIAL FACILITIES IN 14COUNTRIES ACROSS THE WORLD

SALES:

US$ 1.6 BILLIONIN 2014 (+2% vs 2013)

INVESTMENTS:

100 MILLIONUS$ IN 2014

INNOVATION, DEVELOPMENT & DESIGN:

∼ 200 PEOPLEIN TOP 50 PATENT FILERS IN FRANCE

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A comprehensive product rangeFour expertise

#1 in plastic and laminate tubes

TUBES

#1 in foam pumps and fragrance samplers

#2 in fragrance pumps

recognized expertin lotion pumps

DISPENSING SYSTEMS

#1 in mascara (pack + brush)

#1 in lipstick (mechanism + shell)

recognized expertin fragrance caps, compact, lipgloss, skincare packs

COSMETIC RIGID PACKAGING

market-valued provider of promotional items, stock items and accessories, full-service solutions

BEAUTY SOLUTIONS

Serving the world’s leading brands

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Contributing to our customers’ success

Clarins Travel kit

MacLightful C Cream

L’Oréal ParisSublimist

L’Occitane Hand cream

Unilever DiamondAttraction

GSKAquafresh

Make Up ForeverSkin Equalizer

Dior - DiorshowNew Look

Avon color palette

Rimmel Match Perfection

EtamReine du Bluff

Kiko - False lashesConcentrate

DiorBaume Rouge

O Boticário Intense

LancômeLip Lover

SephoraOutrageous Curl

Estée LauderPerfectly

Clean

Estée LauderModern Muse

GuerlainLe Petite Robe Noire

NaturaDeo Spray

Chanel - Hydra Beauty Micro Serum

LancômeAbsolue L’Extrait

DiorJ’adore

My BurberryMoisturizing Body Mist

Lise Watier - Clin d’ŒilFalse Eyelashes

■ Semi-automatic assembly

■ Automated assembly

■ High-speed complex assembly

■ Just-in-time delivery

■ Supplier-managed inventory

■ Dual sourcing

■ Complex turnkey projects

■ Complementary sourcing of packaging and accessories

Conversion Decoration

■ Extrusion

■ Tube laminate (web) production

■ Tube-making

■ Injection

■ Blow-moulding (IBM, EBM)

■ Multi-injection

■ Elastomer over-moulding

■ Metal forming (stamping, eyeleting, embossing)

■ Printing

■ Varnishing■ Metalizing

■ Electroplating

■ Laser■ Hot stamping

■ Anodizing

■ Labelling

Assembly End-Markets

Services

I&DNPD

Technical know-how100% integrated

Raw Materials

AssemblySupply-Chain

Conversion Decoration End-MarketsInnovation & Development

■ Plastic resins/ films

■ Aluminum■ Inks

■ Metal

■ Mold design

■ Mold prototypes■ Printing plates

■ Sample production

■ Compatibility testing■ Functional testing

(impact resistance, resistance to wear)

■ Industrialization

DecorationConversion

■ Project Management ■ Intellectual Property ■ Regulatory Affairs ■ Full Service ■ Kitting ■ Account Management

Eco-Design& Cosmetic Packaging

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Innovation and Development CapabilitiesCSR as a key area of focus

Innovation DevelopmentDesign

We invent new technologies and

new processes to make

packaging stand out and be

more efficient, more competitive,

environmentally-friendlier

We turn into reality the packaging

that our customers have

imagined, overcoming technical

challenges and designing to cost

We manufacture or source

innovative items that offer

improved ergonomics, visual

differentiation, new gestures ,

affordable price, trendier look

Rapid prototyping

& virtual representation

Intellectual property

(over 2,000 patents)

200-people team

across the world

Advanced materials and technologies

Computer-Assisted

Design for creation,

optimization & manufacturing

Eco-design starts withLife Cycle Analysis

e-DEA is our Life Cycle Analysis tool, designed for packaging.It is based on Simapro, one of the most widely-used LCA softwares.

Albéa’s investment in eDEA v2.� Customized data base� More thorough evaluations

� Albéa supports the use of a common tool & methodology across the Cosmetics industry (through organizations such as Elipso)

2002Alcan Packaging develops ASSETTM LCA tool

2008Specific resourcededicated to LCA and eco-design

2010 - 2011Acquisition of e-DEA tool from EVEA, including specific developments for packaging

Life Cycle Analysis Understanding the impacts

0

20

40

60

80

100

120

Carbon footprint

gCO

2 eq

Carbon FootprintPlastic tube 250 ml – Coex with Slender cap

End of Life

Transport

Finishing

Processing

Raw materials

In our industry, the biggest impacts come from:- Raw materials used- Manufacturing process

These are are two priorities!

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Plastic TubesWeight Reduction

*LCA measures done on a standard plastic tube with flip-top cap, diameter 50mm -150ml

ACHIEVEDSleeve thickness reductionLight cap designUse of recycled PE� 25% weight reduction in 10 years.

NEXT STEPSHead weight reductionFurther sleeve reduction (400µm)�Total 50% weight reduction

expected

Incremental progress

Technological rupture

*

*

*

-9% gCO2 eq

-13% gCO2 eq

-11% gCO2 eq

Up to

- 33%CO2 equ. *

Slender CapTM

Weight Reduction

*ASSETTM comparison with standard cap

Slender cap was launched as the lightest flip-top cap for tubes.

It delivers 50% PP material savings and 40% carbon footprint impact*!

Laminate TubesGreenleaf TM manufacturing process

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Ø (mm)Traditional PBL

sleeve thicknessGreenleaf®

sleeve thickness

19, 22, 25, 30 and 35mm 300µm 250µm

35, 40, 50mm 350 – 400 µm 330µm

• *comparison of 2 tubes: Greenleaf 250 µm vs PBL 300/25 having same haptics, ø50mm, 150ml, with Slender Cap • **for an average cardboard for toothpaste tube: 11g of cardboard

• Ultra-thin plastic-barrier laminate (PBL) web with high performance

• Sleeve weight reduced by 17%• Innovative energy-efficient process

• Elimination of on-shelf packaging• No need of cardboard

• Competitiveness• Material use reduction• Energy consumption reduction• Waste reduction

• Recyclable in HDPE stream according to EcoEmballages and Cotrep studies

Ultra-light & recyclable laminate tube

-11% carbon footprint impact*

-16% carbon footprint impact**

Cost savings versus traditional

PBL tubes

Access Denied capWeight reduction

Access Denied provides the same functionality as a sleeved cap

Benefits:

●Remove shrink film sleeve

● Include the functionality in the cap (tongue)

Savings:

●Avoid additional shrink film

●Single production step

Cosmetic Rigid PackagingAttraction

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Metal-free and magnet-free compact

• Attraction is a closure system for compacts with no metal and no magnet . This proprietary technology ensures a smmoth closing mechanism.

• The system’s innovation lies in a 100% plastic, pin-less hinge, removing the need for neodymium magnets to close the compact.

• Neodymium magnets have negative environmental impact -cf LCA overleaf

• Attraction hinge technology fits all compact shapes.

Attraction vs standard magnet closureLCA Analysis

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1.4% weight reduction delivers huge positive carbon footprint impact

0102030405060708090

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Magnetometric

Attraction

Tube recyclingThe French experiment

THE FRENCH EXPERIMENT As part of this experiment, a few packaging companies were selected to evaluate andimprove the recyclability of plastic packaging :

In France, only 22% of plastic packaging was recycled in 2014 sinceonly PE/PP/PET bottles are considered for plastic packaging recycling. Other packaging, such as PE tubes, PP yogurt pots & PET trays are not.

To increase plastic packaging recycling, France chose to extend recycling to all plastic packaging, proceeding first in an experimentation project.

This project took place in 2012-2014 with lead from Eco Emballages , the French organization in charge of organizing sorting, collection & recycling of packaging.

In France, only 22% of plastic packaging was recycled in 2014 sinceonly PE/PP/PET bottles are considered for plastic packaging recycling. Other packaging, such as PE tubes, PP yogurt pots & PET trays are not.

To increase plastic packaging recycling, France chose to extend recycling to all plastic packaging, proceeding first in an experimentation project.

This project took place in 2012-2014 with lead from Eco Emballages , the French organization in charge of organizing sorting, collection & recycling of packaging.

Bottles Tubes Yogurt Trays

2014 ✔ ✘ ✘ ✘

Goal2020

✔ ✔ ✔ ✔

Plastic packaging recycling in France

The first sorting experimentation was made between 2012-2014. During this period, 4 millions inhabitantswere given instructions to sort, collect and recycle other packaging than bottles, including tubes.

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Tube recyclingGroundbreaking news

Plastic tubes (mono/coex)Plastic barrier laminate tubes

are recyclable in PE stream

• PP cap evaluated as non-critical since the rate of PP in HDPE stream remains below 10%*• Varnish evaluated as non-critical• EVOH barrier evaluated as non-critical by Cotrep and other studies* since EVOH represents in average 3% of tube

composition

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In Conclusion

The cosmetics market is driven by differentiation.

Differentiation often goes hand-in-hand with attractive & innovativepackaging: premium decoration, design, new gestures etc.

Eco-design, which improves the packaging’s environmental footprintand often improves its competitiveness, contributes to differentiation.

Corporate Social Responsbility is a shared ambition, uniting brands and their suppliers – and an increasingly strong business driver.

Conclusion

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