A challenging market for sustainability, cosmetic and beauty products, is undergoing a packaging makeover. Exemplifying the eco-driven movement is a new reusable PET bottle for those markets and for personal care products. It was developed by reusable bottle system provider zerooo, which is helping enable a real-world circular economy.

Zerooo along with packaging and recycling specialist Alpla and zerooo initiator Sea Me GmbH developed the 300-mL PET bottle as a standardized, reusable packaging solution.

The first retail brands will launch in September in Germany. These include Sea Me’s own labels as well as sodasan, i+m Naturkosmetik, Speick, Denttabs, Aveo from Müller, and 4 People Who Care.

Product categories include shampoo, shower gel, detergent, body lotion, and dental care products.

The reusable packaging program will then spread to other countries starting with Austria in October.

The reusable bottles are available in clear, milky white, and brown versions (shown below) with additional formats are planned. The bottles are compatible with standard caps.

Empties can be returned to the approximately one thousand collection points of zerooo retail partners for a deposit of €0.50, the equivalent of $0.56.

Promoting Closed Loop Cycles with Design for Recycling

As a globally active packaging manufacturer and recycling specialist, Alpla is promoting closed “bottle-to-bottle” cycles with its own plants. The zerooo reusable PET bottle was developed with the Sea Me team at Alpla’s in-house STUDIOa design center at the company’s headquarters in Hard, Germany.

“With ‘Design for Recycling’, we are setting the course early on for optimum recycling and the longest possible service life,” says Alexander Tränkle, industrial designer, Alpla. “Every detail counts when it comes to shape, color, and material. The reusable system extends the life cycle of the plastic bottle, saves material, and reduces the carbon footprint.”

Digital Labeling and Serialization

“With a wealth of knowledge, the Alpla development team provided us with significant support in implementing the brand and reusable packaging requirements,” explains Mirko Waraszik, director of supply chain and zerooo co-founder at Sea Me. “We are proud to have succeeded in integrating the individual serialization of bottles directly into the production process for the first time. This innovation enables groundbreaking data applications for packaging in the context of reuse.”

Every zerooo reusable PET bottle is unique. A laser-engraved 2D data matrix code— the “zerooo ID” ��— provides information about the content and circulation history.

Transparency and Quality Assurance

“The digital labelling enables transparency and ensures the quality of the bottles,” says Jörg Schwärzler, senior technology manager, Alpla. “By combining it with the information from the label, it can also be complemented with further product data. The reusable PET bottle is compatible with all automatic return systems. At the end of their life cycle, the bottles and caps are sorted and recycled.”

The Future of Sustainable Packaging

The launch of the reusable PET bottle marks a significant step forward in the adoption of circular economy practices within the cosmetics industry. Several leading brands within the sector, including sodasan, i+m Naturkosmetik, Speick, and Denttabs, have already committed to using the zerooo system. The reusable PET bottle offers a sustainable alternative to traditional single-use packaging and is designed for easy cleaning and refilling, making it a convenient choice for consumers. Consumers can return empty bottles to designated collection points for a deposit, ensuring that the packaging is properly recycled and reused.

Alpla brings its expertise in design, manufacturing, and recycling to the partnership. The company’s in-house design centre, STUDIOa, played a crucial role in developing the reusable PET bottle. “With ‘Design for Recycling’, we are setting the course early on for optimum recycling and the longest possible service life,” said Alexander Tränkle, industrial designer at ALPLA. “Every detail counts when it comes to shape, colour and material. The reusable system extends the life cycle of the plastic bottle, saves material and reduces its carbon footprint.”

“The digital labelling enables transparency and ensures the quality of the bottles. By combining it with the information from the label, it can also be complemented with further product data,” added Jörg Schwärzler, senior technology manager at ALPLA. The reusable PET bottle is compatible with all automatic return systems, making it a convenient and efficient option for both consumers and retailers.