Plastic lotion pumps, one of the most popular dispensing methods for viscous (thick liquid) products in the personal care and beauty industry, come in all shapes and sizes. When used as designed, pumps dispense the right amount of product time after time. But have you ever wondered what goes in a lotion pump to makes it work? While there are hundreds of different designs in the market today, the basic principle is the same, and Packaging Crash Course took apart one of these lotion pumps to give you an overview of these components, and how they contribute to the overall functionality of pumping the product from the bottle to your hand.
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Generally speaking, a lotion pump consists of the following components :
A lotion pump acts much like a air suction device that draws the product from the bottle to the consumer's hand despite the law of gravity telling it do the opposite. When the consumer presses down on the actuator, the piston moves to compress the spring and the upward air pressure draws the ball upwards, along with the product inside, into the dip tube and subsequently the chamber. As the user releases the actuator, the spring returns the piston and actuator into it's up position, and the ball is returned to it's resting position, sealing the chamber and preventing the liquid product from flowing back down into the bottle. This initial cycle is called "priming". When the user presses down on the actuator again, the product that is already in the chamber will be drawn from the chamber, through the stem and actuator, and dispense out of the pump and onto the consumer's hand. If the pump has a bigger chamber (common for high output pumps), it may require additional priming before the product will be dispensed through the actuator.
The output of a plastic lotion pump is often measured in cc (or ml). Commonly in the range of 0.5 to 4cc, with some larger pumps with bigger chambers and longer piston / spring components having output up to 8cc. Many manufacturers have multiple output options for each of their lotion pump offerings, giving the product marketer full control of dosage. For more information about pump output, please see our other Quick Question Monday article here.
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Products such as lotions, soaps, perfumes, facial creams, and many others, especially in the personal care industry, are formulated to be used in small amounts. Selecting the best dispensing method is important to maintain the product's integrity while delivering the best customer experience. The packaging selected must consider the viscosity of the product, how the formula interacts with the dispensing system, and ensure that the majority of the contents can be evacuated from the packaging. Airless pump technology is a type of dispensing system that is utilized in the personal care and beauty marketplace.
The defining feature of airless pump technology is its ability to create a barrier between the product and the external air that can quickly deteriorate the product. Airless pump technology does not use air to move the product from the packaging or rely on a pressurized system using air. Instead, a vacuum effect is used to activate the pump's components to dispense the product. The technology does not allow air to come in contact with the formula which greatly increases the product's life span.
Airless packaging consists of three parts: base, piston, and pump. These three components may have different configurations based on the output specifications for the product.
The base is the area that houses the piston and the pump. A small hole in the base allows air to be pushed or pulled inside the component.
Depending on the airless system design, either a piston or bag can be found between the product and the base of the container. A piston is more commonly used with airless pump technology. The piston acts as a squeegee against the sidewalls within the packaging. The consumer depresses the actuator which allows air to enter the base, moving the piston upward and pushing the product out of the actuator. A similar effect is achieved with designs utilizing a bag instead of a piston.
The pump creates the vacuum effect that passes through the base.
Airless pump technology can be used with aluminum cans, plastic bottles and jars. There are several types of airless bottle designs depending on how the product needs to be dispensed.
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The bag-in-bottle will have a collapsible bag inside the bottle. The product is filled into a collapsible bag. The airless pump dispenser becomes activated as the bag collapses. In this design, no air comes into contact with the system as a vacuum effect causes the bag to fold in on itself. The bag may be placed inside plastic bottles or jars.
In a piston system, pressure is created to push up against the product. When the pump is activated, the pressure raises the piston causing the plate to push the product through the dispenser cap or opening. Piston systems are commonly used in luxury cosmetics and skincare products. However, this system limits the packaging shape and is a less sustainable option.
For a Bag on Valve (BOV) system, the product is contained inside a foil bag with a valve attached. Air or nitrogen propellant remains inside the product packaging, but outside of the foil bag that holds the product. To activate the airless packaging, the pump is pressed and the product is squeezed out of the bag by the propellant. As the air or nitrogen fills the open space, the foil bag becomes compressed and pushes the product from the can or bottle. The BOV system is commonly used with aluminum cans and plastic bottles for aerosol-type products, but a very specific grade of plastic is required to withstand the pressure exerted onto the bottle.
Airless pump technology is designed to help preserve product integrity and also deliver optimal user experience, especially for products that should be used in smaller quantities. Often these types of products are also more expensive and consumers do not want any product going to waste. This technology prevents additional effort needed by users to access every last drop of product from the container. In addition to the technology's core protective and delivery function, the following are some additional benefits of using airless pump packaging.
Product spoilage occurs when it comes in contact with exterior air, dirt, dust, and other pollutants. Airless pump technology prevents contamination by keeping pollutants from reaching the product inside the packaging. The package prevents air or consumers from coming into contact with the product inside of the container until the product is evacuated.
Product efficacy can dictate customer sales. If the product spoils too quickly, consumers will choose a different product that will last longer. Airless packaging helps prolong the freshness of the product by not allowing contact with air. The product is completely sealed inside the jar, bottle, or can. The packaging can also slow or prevent the growth of bacteria that can occur when germs on a person's hands are introduced to the product through manual removal. Airless pumps prevent direct contact with the product.
Airless pump technology can allow a specific amount of product to be dispensed at once. This feature allows the user to dispense an exact amount of product with just a few presses of the pump. Metered dispensing helps lower the amount of product waste by dispensing an exact amount of product with each pump.
A common complaint with standard dispensers is that they cannot push out all of the contents. The product at the bottom of the container remains inaccessible due to the length or shape of the container. Any product with a thicker consistency will be difficult to remove manually resulting in product waste. However, with the technology of airless pump dispensers, users get nearly 99+% evacuation of the product, effectively reducing product waste.
The convenience of airless pump technology is that it can be used in any position. The container can be held upright, sideways, or sometimes even upside-down, and still operate effectively. Another feature is its 360-degree dispensing capability which makes this particularly convenient for lotions.
Products that work well with airless pumps are high-viscosity liquids, gels, and creams. It is also ideal for products that are sensitive to air or outside contaminants. Personal care and cosmetics are commonly found in airless pump dispensers. A dual airless chamber is another form of airless packaging used for products with ingredients that need to be stored separately but are combined when dispensed. The following products are commonly used with airless packaging:
Airless pump technology is a convenient and effective packaging solution that minimizes product waste, improves shelf life, and dispenses an exact amount of product. It works with a wide range of packaging, including airless pump bottles and airless jars which are a popular choice for elevated personal care and cosmetics product packaging. Contact our customer care team today to find out if airless technology is right for you and your brand.
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