Metal Packaging: Metal Trends
Zamac compacts and rings, which can be adorned with rhinestones, designed by HCT Packaging. These packages can house lip gloss, lip balm, and solid fragrance. The supplier launched a new range of stock Zamac packages at the Cosmoprof trade show in April.Zamac and metallization are two of today’s top choices.
By Marie Redding, Senior EditorMetal remains popular with beauty brands. Lately, it has been the material of choice, especially for cosmetics and fragrances. In particular, package designers have been using metal in two ways: using Zamac, a heavyweight metal, for products such as jewelry-style cosmetics; and metallization, to give plastic packages a metal look.
Growing Demand for Zamac
Zamac is the perfect choice for small compacts, especially ones that can be worn as jewelry. Not only is the material durable, but it is also heavyweight and, thus, luxurious.
For some, a custom-tooled Zamac package isn’t in the budget. For these customers, supplier HCT Packaging (Bridgewater, NJ) has been striving to provide the industry with newly designed stock Zamac packages.
The new stock range was introduced to the industry at the Cosmoprof trade show in Bologna, Italy, in April. “We showed a new solid-fragrance compact and a mini-trio compact with an applicator, both with magnetic closures,” says Rebecca Goswell, creative director, HCT Packaging.
Another one of the supplier’s new designs is the Triangular Multi-strass Ring, which was designed to look like an ornate piece of jewelry. The ring’s top slides open to reveal a compartment that is perfect for a lip gloss, lip balm, or solid fragrance. “The ring is decorated with rhinestone jewels to add a feeling of luxury and glamour,” says Goswell.
Although Zamac has been in high demand, stainless steel is another option for beauty packaging, depending on product and package design. Pressed aluminum sheets, which can be sprayed or anodized in a wide variety of colors, are another choice. “Aluminum sheets are a lighter alternative to Zamac and are often used in combination with an overshell to cover plastic inserts and bases,” says Goswell.
Matching with Metallization
When a component must contain some plastic, opting to use vacuum metallizing might be the best solution to achieve a metal look. This is also the case if a plastic package needs to match the look of other metal packages in a product line. Coach’s pressed-powder compact is one example of this.
Estée Lauder’s BeautyBank team metallized this plastic compact with the Coach logo.
Coach’s compact is plastic, but vacuum metallizing transformed its surface to look like metal. “During the [metallizing] process, a thin coat of vaporized aluminum adheres to the compact. The ‘C’ design was then silk-screened on top,” explains Scott Roman, director of package development for Estée Lauder’s BeautyBank division, which was licensed to develop Coach’s beauty line.
Too Faced Cosmetics used metallization to make its plastic Lips of Luxury package look high-end.
Too Faced Cosmetics also used metallizing to give its Lips of Luxury packaging a more-glamorous look. The lipstick containers are decorated with a shiny pink finish that was achieved by vacuum metallizing. “Pieces of aluminum were placed into a vacuum chamber, where they were turned into a gaseous form that imparted a thin layer of aluminum. The shell of the lipstick container is aluminum, which was anodized in a chemical bath. This created the super-shiny finish,” explains Jerrod Blandino, creative director, Too Faced Cosmetics.
“The look and feel of metal is luxurious,” he adds. “It feels like jewelry in your hand, as opposed to the lifelessness of plastic.”
What Is Zamac?
Zamac is a mixture of zinc, aluminum, magnesium, and copper. It is often used to create metal accessories, such as charms. “Zamac is a very versatile alloy that is easy to injection mold. It is also relatively inexpensive to create tools for,” explains HCT Packaging’s Rebecca Goswell.
In its natural state, Zamac alloy is a dull, dark-gray material. However, it can be electroplated in a variety of finishes and colors. “Electroplating gives the component excellent barrier properties, making it suitable for products for which there would be a serious compatibility issue if plastic were used—such as for solid-fragrance hot-pour formulations,” explains Goswell.
Coach Uses Metal Packaging to Convey Luxury
The Coach brand trusted Estée Lauder’s BeautyBank division to develop the brand’s first fragrance and cosmetic lines. The goal was to make sure that the packaging conveyed the same luxurious image as a coveted Coach handbag—so metal was used throughout the line.
The Classic Appeal of a Metal Lipstick Case
Metal was used throughout Coach’s upscale cosmetic and fragrance lines. A metal lipstick case was
supplied by Axilone.
The BeautyBank team says that the glamorous feel of a heavy, well-made metal lipstick case couldn’t be achieved with metallized plastic. Instead, a metal lipstick case supplied by Axilone USA (New York City) was chosen.
The lipstick case was decorated all over with Coach’s signature “C” pattern by using a double-anodizing process. Scott Roman, director of package development for Estée Lauder’s BeautyBank division, explained how the unusual decoration was achieved.
The metal overshell for Coach’s purse spray was supplied by Pivaudran. It was decorated with Coach’s
signature “C” pattern.
“First, anodizing the aluminum gave the entire package a shiny finish. Next, the ‘C’ pattern was laid over the metal, and a chemical was screened over it. When the chemical was removed, everything had a matte finish except for the shiny ‘Cs’,” says Roman.
Metal and Fragrance: Solving Compatibility Issues
Fragrance ingredients have a tendency to break down metal over time. To avoid compatibility issues for Coach’s purse-spray fragrance, the BeautyBank team put the fragrance in a glass vial, which was then covered with an aluminum outer shell. Because the juice is not in contact with the aluminum shell, compatibility issues were avoided.
The outer shell was decorated using the same double-anodizing process used on the lipstick case. The package was produced by G. Pivaudran (France), and the pump was supplied by Valois of America (Congers, NY).
For the solid-fragrance Zamac compact, direct contact between the product and the metal did pose a slight challenge. The BeautyBank team looked into several solutions. “We decided to use an unusually thick layer of metal plating to resolve this issue,” says Roman.
Many companies have been launching solid fragrances in metal packaging resembling charms, key chains, rings, and other novelty items. Estée Lauder’s BeautyBank division solved a few compatibility issues that these metal packages presented.
The small, thin rectangular compact hangs from a ball chain to resemble the signature charm that hangs from Coach’s leather fashion accessories. Metal Dynamics Inc. (Cranston, RI) supplied the package. The firm is the same supplier that produces the jewelry and accessories for the Coach fashion line. “We chose this supplier because it had the right enamel red and knew the specific shade of silver used for Coach’s other items. We were able to get things approved by Coach more quickly and move ahead faster on this project by working with [Metal Dynamics],” explains Roman.
Durable Metal Is Eco-friendly
The brand Group Marcelle seeks environmentally friendly packaging. This tin by J.L. Clark fits the bill.
A metal cosmetics package is sturdy enough to last long after makeup is finished. For this reason, Canada-based cosmetics brand Groupe Marcelle chose a tin for its Bronzing Palette.
Denyse Beaulieu, creative manager, Groupe Marcelle, says, “We were able to reduce our use of materials by fitting five products into one package. Once the products are finished, the case encourages reuse by turning into a handy little box. Also, both the tin and plastic clasp are recyclable materials. We love it when a package encourages the ‘three Rs’—reduce, reuse, and recycle.”
The tin is supplied by J.L. Clark (Rockford, IL). The metal lid and base are held together by a plastic hinge that makes metal containers easy to lock and unlock, and that provides a more-secure close.
J.L. Clark worked with the team at Groupe Marcelle to design a thermoformed tray with cavities for the makeup products. When the makeup is finished, the tray can be removed.
Metal Containers Available at Low Minimums
J.L. Clark (Rockford, IL) has introduced a line of premium metal tins that can be supplied at low minimums.
The line includes 15 domestically produced tin styles, including talc tins with powder shakers and tin compacts for makeup and lip gloss. Various shapes are available, as well as options for clear windows and a unique plastic ring hinge.
The stock tins can be decorated using pressure-sensitive labeling and multicolor lithography.
“Premium metal isn’t just for big consumer packaging companies anymore,” says Michael Matus, vice president of sales and marketing for J.L. Clark. He adds, “As the need for sustainability increases, [recyclable] metal is all the more attractive.”
Metal Upgrades a Tube
The team at Sonya Dakar dressed up its face wash tubes with metal collars. The tube is a patented one-piece design by World Wide Packaging.
Even when used sparingly, metal components can add a special touch. The team at Sonya Dakar used a metal collar to dress up the tubes for its face washes and masks.
The tubes formerly had flip-top caps that were sprayed silver. “The caps were prone to breakage, and the silver would eventually chip off,” explains Yigal Dakar, vice president of sales and marketing, Sonya Dakar. To replace the original tubes, Yigal chose an innovative one-piece tube, which is a patented design by World Wide Packaging (Florham Park, NJ). “We customized a metal collar around the plastic disc-top cap,” says Kimyon Holmes, vice president of sales, West Coast, World Wide Packaging.
Yigal loves the new package. “The metal collar is a nice dressing for the plastic part, which can otherwise have a tendency to look unsightly,” she says. “It definitely makes the tube look like it contains a high-end product.”