BillerudKorsnäs and Aisa combine on fiber-based toothpaste and cosmetics tube

17 May 2021 --- BillerudKorsnäs and Aisa Packaging are challenging conventional plastic toothpaste and cosmetics tubes with a fiber-based alternative made from FibreForm.

A first in paper tubes, BillerudKorsnäs’ FibreForm material replaces plastics on tube shoulder and sleeve without compromising on user experience.

The lower-carbon material also allows for up to ten times deeper embossing than regular paper, yielding “memorable” 3D tactile effects. 

“Before joining on this development, we had previously contacted a few brands to find out their interest. Whether it is the European, American or Asian markets, the demand is there,” Lovisa Westergren, sales director for FibreForm at BillerudKorsnäs, tells PackagingInsights.

Environmental benefits
Ranking third in Innova Market Insights’ 2021 top packaging trends, “Fiber-based Frenzy” highlights the growing popularity of plastic-replacement fiber-based innovations.

The fiber-based material enables Aisa to replace up to 70 percent plastic in the tube’s functional shoulder component. With the tube sleeve made of more than 85 percent paper, the new hybrid shoulder contributes to a majoritively paper tube.

The FibreForm material was selected for its “exceptional results” in strength, forming, embossing and industrial performance.In terms of how low FibreForm’s carbon footprint is, BillerudKorsnäs “does not communicate figures” but the company estimates a “significant gain in lower carbon emissions” compared to traditional plastic tube materials.

Furthermore, FibreForm is a cold-formable material, requiring less energy in production than plastics. The material is also biodegradable and has previously been used for paper plates, trays and bags.

“The work we are doing on the next generation of tubes including the shoulder and the stopper will allow us to get closer to 85 percent fiber on a complete tube – never seen before,” Westergren flags.

R&D challenges
The current structure of the tube developed by BillerudKorsnäs and Aisa “cannot be communicated at the moment,” says Westergren. “We must always use a barrier to protect the contents and respond to the sealing phase; it is an ongoing work in progress.”

Going from the traditional plastic tube to a paper tube further required some minor adaptations to the the coefficient of friction, the head bond traction and burst.

However, BillerudKorsnäs indicates its collaboration with Aisa offers a smooth manufacturing process. FibreForm replaces conventional plastic in Aisa’s machines without them having to be rebuilt.

Paper solutions for personal care
Rethinking standard plastic packaging in personal care is gaining ground, such as Colgate’s re-engineered toothpaste tubes. The recyclable tube is made from the same plastic used to make bottles, so it recycles like a bottle, but squeezes easily like a tube.

German cosmetics brand i+m released a deodorant cream in a biodegradable jar. The Sulapac-produced material is a plant-based biocomposite that biodegrades without leaving permanent microplastics behind.

Meanwhile, fiber-based bottles have caught the attention of GSK Consumer Healthcare, Stora Enso, Absolut Vodka, Coca-Cola and PepsiCo.

By Anni Schleicher