New applications take shape in DuPont™ Surlyn® 3D overmolding

In Japan, Yoshida Industries has started mass production of two containers for skincare products which benefit from a protective outerlayer of Surlyn® that simultaneously heightens their visual appeal.

Meanwhile the European subsidiary of the Tae Jin Corporation, Unifyer, has invested in tooling and machinery to create uniquely new shapes for the packaging of mascara and lipgloss tubes, based on Surlyn® 3D, that help create a luxurious impression. Finally, in Italy, glass manufacturer Luigi Bormioli is developing new concepts for the overmolding of glass with Surlyn®, with the potential for new decoration techniques, visual effects and heightened product safety.

Surlyn® 3D overmolding technology was first presented by DuPont Cosmetics Solutions at Luxe Pack 2008 as a new and innovative process of overmolding polymer inserts with Surlyn® for even greater packaging differentiation. Benefits of the new technology include the cost-effective production of visually-appealing and more durable containers for cosmetics and fragrances that combine glass-like transparency with luxury decorative effects and increased consumer safety and convenience.

One of the first companies to put Surlyn® 3D overmolding patented technology into practice is the Japanese cosmetic packaging manufacturer Yoshida Industries Co., Ltd. It has commenced commercial production of containers for the skincare products of two leading brands whereby colored and decorated polyester inserts are overmolded with a thin and transparent outerlayer of Surlyn® PC 2000. Benefits of the Surlyn® outerlayer include the integration of a transparent, smooth surface which has a magnifying effect on the colored/decorated insert beneath it; the creation of a thick, glass-like bottom to the container for enhanced visual luxury; and the formation of a protective coating around the decorated insert for greater convenience and durable aesthetic appeal.

In an eye-catching take on standard mascara and lipgloss tubes, Unifyer has incorporated Surlyn® 3D overmolding to create a unique packaging that can help generate a premium brand image. The tube-shaped insert, produced for instance in DuPont™ Selar® PA for its transparency and compatibility with cosmetic formulations, is encased within a transparent rectangular prism molded from Surlyn® PC 2000.

Beyond the visual appeal of the antagonistic shapes within the packaging and the magnified colors of the insert, the use of a Surlyn® outerlayer brings a heightened sense of crystal luxury to these small containers, as well as enduring protection for what is essentially a nomadic product. Moreover, Unifyer investment in injection blow molding equipment enables the containers with Surlyn® 3D technology to be cost-effectively produced in a single step.

The integration of glass with Surlyn® 3D overmolding technology is the concept being pursued by Italian glass manufacturer Luigi Bormioli in partnership with the Italian molder Pibiplast. By either partially or fully encasing a specifically developed glass bottle with Surlyn®, new possibilities in terms of shape and decoration can be created for traditional glass designs for cosmetic and fragrance packaging. The Surlyn® outerlayer can be used to magnify, enhance and durably protect visual effects, as well as rendering the bottle or container far less susceptible to breakage or damage. The use of a glass insert, on the other hand, helps retain the overall luxurious sense of weight (if required), as well as ensuring high chemical compatibility with the content’s ingredients.

“We are pleased to see the number of design options for Surlyn®3D currently being considered within the cosmetics market, and are delighted to see the first concepts going into mass production,” says Philippe Milazzo, global market manager for cosmetic and personal care packaging at DuPont Cosmetic Solutions. “Our new technology really does appear to have global appeal, as designers and brand owners seek to gain even greater product differentiation and communicate the equity of their brand.”

DuPont Cosmetic Solutions brings DuPont’s “Miracles of Science” to the world of beauty and personal care by expanding the possibilities of its comprehensive range of materials and technologies, and by fostering partnerships focused on technology and consumer insight. Its primary aim is to develop new and differentiated cosmetic solutions that meet brand owners’ and designers’ needs for innovation while enhancing the consumer experience and bring more fun, emotion and well-being.

DuPont Packaging and Industrial Polymers is a world-class manufacturer of high-performance resins and films for a variety of packaging and industrial applications. Its best-known ethylene copolymer products include Surlyn® resins for packaging and industrial applications, Bynel® coextrudable adhesives, Selar® PA amorphous polyamide barrier resins, Nucrel® acid copolymers, Elvax® EVA copolymers, Elvaloy®, Elvaloy® AC, Entira™ , Biomax® PTT and Fusabond® modifiers.

DuPont is a science-based products and services company. Founded in 1802, DuPont puts science to work by creating sustainable solutions essential to a better, safer, healthier life for people everywhere. Operating in more than 70 countries, DuPont offers a wide range of innovative products and services for markets including agriculture and food, building and construction, communications, and transportation.

The DuPont Oval, DuPont™, The miracles of science™, and Surlyn® are registered trademarks or trademarks of E.I. du Pont de Nemours and Company or its affiliates.