Recycled glass: eco-design of packaging

In recent years, the growing attention to sustainability and technological innovation have had an important influence on the perception of cosmetic product packaging and beyond.

Growing ecological awareness and legislative pressure to reduce the environmental footprint have led many brands to reconsider the entire production chain, paying particular attention to packaging. Packaging, in fact, has a significant impact on the total environmental impacts of a product, both for the use of raw materials and for the energy needed to transform them.

At the same time, end consumers are showing an increasing interest in the origin and fate of packaging, and this translates into a growing demand for eco-design solutions. In the market, this sensitivity translates into specific needs:

• circular or recyclable raw materials; 
• reduction of the weight of containers; 
• decoration and customisation techniques with reduced environmental impact; 
• transparency in procurement and production processes. 

In this context, recycled glass is emerging as a leading choice for the packaging of personal care and beauty products, thanks to unique characteristics in terms of environmental impact, resistance and versatility.  

Below we shed light on the key technical and business benefits, as well as the manufacturing and regulatory challenges that companies face. 

Why focus on recycled glass

Glass has always been considered a valuable material in the cosmetic sector: it guarantees high protection against oxygen and humidity, protects the formula from external contamination and, above all, conveys a sense of luxury and solidity to the end consumer. However, the production of virgin glass requires high melting temperatures and the use of raw materials such as silica sand, soda and calcium carbonate. The decision to switch to recycled glass – with percentages ranging from 20% to over 60-70% post-consumer (PCR) or post-industrial (PIR) content – represents a significant turning point in terms of: 

• reduction of melting energy: melting recycled glass requires lower temperatures than virgin raw materials; 
• lower consumption of resources: the extraction of raw materials and the amount of waste destined for landfills is reduced; 
• unaltered technical performance: if properly treated, recycled glass maintains adequate mechanical resistance and transparency; 
• high aesthetic value: any slight chromatic variations are often perceived as distinctive pluses, capable of conveying the idea of craftsmanship and attention to the environment. 

How to choose the right recycled glass packaging

Each brand has its own specific needs related to: 

• market segment: premium brands, mass market, organic niches; 
• production volumes: small batches for special lines or large batches for widely used products; 
• target price: defined according to the desired positioning and margins; 
• image and design: consistency with the brand identity, possibilities of decoration and finishes. 

Usually, companies that provide eco-design solutions offer a 360° consultancy and customisation service, guiding the customer in choosing the type of glass (transparent, coloured, satin), the appropriate recycling percentage, the decoration techniques and the combination of bottle body and closure. This co-design process is essential to combine aesthetics, functionality and reduction of environmental impact. 

Technical and regulatory challenges

Despite its undeniable advantages, recycled glass poses technical and regulatory challenges that you should be aware of: 

1. control of impurities: to obtain a finished product suitable for cosmetics, it is necessary to carefully select the cullet and remove any residues or foreign materials; 
2. colour uniformity: glass with a high PCR percentage may have slight colour variations. For brands that require perfect uniformity, careful management of production batches is required and sometimes integration with post-industrial glass cullet;
3. compliance with cosmetic and pharmaceutical regulations: strict standards of purity and safety must be respected, including any laboratory analysis for the release of heavy metals or other potentially harmful substances;
4. certifications and traceability: major international markets increasingly require certificates of origin for recycled material, as well as compliance with regulations such as REACH or ISO standards.

Replenishment and Eurovetrocap solutions

Producing recycled glass items means being part of a specific production campaign, in which the glassworks has set up the furnace to melt only recycled glass, filling it with regenerated glass cullet. However, it can be difficult for a customer to request production from recycled glass, as glassworks require minimum production volumes in the hundreds of thousands of pieces. In addition, once stocks are depleted, replenishment can be difficult, as the production of recycled glass only takes place in specific production campaigns, generally every 9-12 months. 

To meet these needs, Eurovetrocap has introduced a complete range of recycled glass bottles from 15 to 200 ml and jars from 30 to 200 ml, offering customers the possibility to purchase even small quantities. In addition, thanks to strategic replenishment management with glassworks, it minimizes the risk of outstocks, ensuring a smoother and more continuous supply.

Eurovetrocap’s sustainable packaging

At Eurovetrocap we have developed an internal laboratory dedicated to packaging solutions with reduced environmental impact. It’s called Zero In•Pack and it’s our way of embracing the principles of the circular economy, from the products we offer to the production chain. We are constantly working to ensure that the impact of cosmetic packaging is increasingly contained and for this reason we have expanded our catalogue with recycled glass proposals. Here are some examples: 

• Fragrance: bottles ideal for perfumes such as the Daumier 30 ml jar  with the possibility of customizing the finish (external painting, satin finishing, metallization);
• Make-up: containers suitable for foundations, concealers, coloured serums or primers, such as the 15 ml Laura and Make Up jar, with the possibility of adding different types of pumps;
• Skincare & Farma: jars and bottles ideal for face creams, anti-aging serums and specific treatments because they combine safety of the contents, chemical compatibility and aesthetic pleasantness;
• Home fragrance: bottles such as the 100 or 200 ml Round bottle that enhance the “natural” and “green” sensation of the product;

To complete the offer, we offer decoration services including screen printing in one or more colours (also with UV inks), satin effect varnishing (alternative to the traditional one that requires etching), hot stamping and engraving. The high-quality standards ensure abrasion resistance and a long service life of the pack. 

Our in-house eco-design laboratory

Zero In•Pack (ZIP) is the company’s research and development hub, aimed at constantly improving the environmental impact of our products. The team conducts comparative life cycle analyses (LCAs) on different packaging sets, studying how the substitution of one or more parameters (materials, container weight, type of decoration) can affect the main sustainability indicators: 

• CO₂ emissions and climate change; 
• overall energy consumption (with a focus on fossil fuels); 
• water consumption; 
• impact on fresh and marine waters (e.g. eutrophication, acidification); 
• use of land and mineral resources. 

The results of these analyses allow us to define precise guidelines for our customers who want to reduce the environmental footprint of their products. The introduction of recycled glass, in fact, allows a significant cut in greenhouse gas emissions, while the conversion to lighter painting systems lowers water consumption by up to 60%. 

Our most virtuous examples

Thanks to the collaboration with experts, designers and environmental technicians, in our Zero In•Pack laboratory we have worked on some recycled glass packaging solutions that have already proven their effectiveness: 

• Laurence jar: our bestseller in PCR version (up to 20-60% recycled content) combined with recycled PP lids. LCA (Life Cycle Assessment) analyses showed a significant average cut in impact compared to the totally virgin version; 
• Make Up line: with recycled glass bottles and the possibility of completing the pack with light dispenser pumps, also with recycled components. Fine aesthetics and significant reduction in fossil fuel consumption;  

In all cases, the collaboration between the internal laboratory and customers has allowed us to obtain tangible results, which have also been used in the marketing strategies of cosmetic brands, which have been able to communicate the green commitment of their products with transparency. 

The future is sustainable packaging

The packaging market is moving at great speed towards more sustainable solutions, also in response to European and international regulations that aim to make producers responsible. The availability of recycled glass is growing, and technologies for separating and cleaning scrap are increasingly efficient. 

In a landscape where innovation and sustainability go hand in hand, recycled glass represents a solution of excellence because it combines high recyclability, safety for the formula and an aesthetic that recalls values of luxury and quality. For brands, believing in sustainable processes guaranteed by the enhancement of eco-design means collaborating with suppliers specialized in:

• technical advice aimed at reducing environmental impact; 
• wide choice of formats and types of containers, from make-up to pharma; 
• possibility of customizing every aspect of the pack, from colour to decoration, maintaining or improving functional standards; 
• analysis of data deriving from LCA analyses for transparent and credible communication towards the end consumer and stakeholders.

The future of the cosmetics sector will be played on the ability to combine functionality, design and sustainability, and the companies ready to invest in these solutions today will be the ones that will lead the market internationally tomorrow. 

Contact us for a tailored consultation and evaluation. Only through direct comparison and the sharing of design data will it be possible to define the best packaging strategy and maximize both the environmental benefits and the aesthetic appeal of the product.