Toleriane Ultra is a skincare product from La Roche-Posay, which provides intense soothing care to hypersensitive and allergic skin. Its packaging combines an innovative bag-in-bottle system with a special airless pump to protect this lotion, which is sensitive due to the complete absence of preservatives, from oxidation, drying out and penetration of contaminants.
The bag-in-bottle system consists of a strong bottle made from crystal-clear copolyester and an inner bag of highly transparent DuPont Surlyn with an additional oxygen barrier layer. This novel design is the fruit of a joint development between DuPont Packaging & Industrial Polymers and Gaplast, Saulgrub/Germany, a company which has successfully specialized in plastics packaging for pharmaceuticals and cosmetic products for over 40 years.
Bag-in-bottle systems, developed in the 1990s, have long proved their worth when it comes to reliable storage of highly sensitive ingredients. The innovation in the version now used by La Roche-Posay is the transparency of all the materials used. This means the contents can be checked at any time, keeping a consumer fully informed about the state and amount of the product remaining in the container. In addition, this innovative type of packaging allows the bag to be almost completely emptied, avoiding any unwanted product wastage while the external shape of the bottle remains unchanged.
Bag-in-bottle systems are produced by coextrusion blow molding. In the case of the packaging for Toleriane Ultra, Gaplast first extrudes a four-layer tube with a polyester outer layer to provide rigidity and a highly flexible, chemical-resistant inner layer with a Surlyn/EVOH/Surlyn structure. While still hot, the tube is directly transferred into a mold and pressed against the walls of mold cavity with compressed air. This creates the desired container shape and, at the same time, the bottom of the container is closed. Using deliberately created holes in the container bottom, Gaplast then blows compressed air between the outer container wall and the inner bag. Because the level of adhesion between the selected grade of polyester and Surlyn is very low, the two components can be particularly easily and gently separated.
Gaplast's special, patented manufacturing technology involves fixing the inner bag to the container bottom during the blow...