A 2K preform technology as a pouch airless system shows how product yield, material logic, and brand identity can be rethought – and why packaging must increasingly be understood less as a shell and more as a functional system. The technology uses a flexible inner pouch that contracts in a controlled manner during use, and an outer casing whose shape is no longer limited by the internal mechanics. For brands, this offers the opportunity to reinterpret packaging design.
Airless packaging is considered the gold standard for sensitive formulations. However, the industry is under increasing regulatory pressure: the Packaging and Packaging Waste Regulation (PPWR) is forcing manufacturers to consistently reduce material, improve recyclability, and increase the use of recycled materials (PCR materials). At the same time, implementation remains complex: material definitions, recyclability, and regulatory requirements are sometimes ambiguous and difficult to quantify in practice.
A central problem with this is that PCR materials are not available in unlimited quantities and are subject to quality and safety requirements – especially in the cosmetics sector. Consequently, brands today must develop packaging solutions that not only appear sustainable but also have regulatory longevity.
2K Preform Technology: Separation of Function and Material Logic
This is where 2K Preform technology comes in. At its core, it is based on a two-component injection moulding process that combines two materials in a single process step. This creates a functional composite system without downstream assembly processes. The key difference to classic airless systems lies in the architecture: while conventional systems are based on a piston, 2K Preform technology uses a flexible inner pouch that contracts in a controlled manner during application. This results in an almost complete emptying of the product – up to 98 percent can be achieved depending on the formulation.
Design freedom without technical compromises
A key advantage of the technology lies in its design freedom. While conventional airless systems are heavily constrained by form, the new system allows for almost any shape. Whether round, angular, conical or organic – the outer shell is no longer limited by the internal mechanics. This opens up opportunities for brands to achieve or reinterpret iconic packaging designs. At the same time, so-called „dead space“ – unused volume in the packaging – is almost completely eliminated. This is a relevant factor, particularly in the context of the PPWR, as material efficiency is increasingly being assessed from a regulatory perspective.
Material choice re-imagined: PCR, recycling and regulatory freedom
Another key technological lever lies in the decoupling of the product and outer material. As the inner pouch completely separates the product from the outer container, this creates new degrees of freedom in the material selection for the outer packaging. Depending on the concept, this can be made from PCR plastic, aluminium, glass, wood, or other materials. This resolves a central problem of conventional packaging systems: compatibility between recyclate and formulation. Additionally, the amount of testing required is significantly reduced, as the product does not come into direct contact with the outer material. The inner pouch itself is generally made from virgin material for functional reasons, as it plays a crucial role in product safety and dispensing behaviour.
Minimalism on the go
The innovative travel cosmetics brand Passport2skn provides an example of the practical application of 2K preform technology. The brand packages its high-quality facial skincare products in a way that they can be used on-the-go without decanting, without additional systems, and with minimal material usage. The focus here is a 30ml format solution specifically developed for travel and e-commerce scenarios. The packaging combines a low dead weight with a compact, stable outer structure and an integrated airless function.
The pouch airless system also offers an additional practical advantage in e-commerce: As the flexible inner bag visibly contracts in combination with a transparent or translucent outer container during emptying, end customers receive a clear visual indicator of the remaining product content. Users can recognise early on when a reorder will be necessary. For brands, this not only means more stable customer loyalty but also a reduction in abandoned purchases due to spontaneous redirection to brick-and-mortar retail.
The 2K preform technology is a consistent further development of existing airless logics. It combines three central industry requirements: maximum product yield, regulatory future-proofing, and design freedom. At the same time, it shows that innovation in packaging rarely begins on the visible surface – but rather in the invisible architecture behind it.
Source: Inotech
