Airless Packaging

Airless packaging is a dispensing system that uses a non-pressurized vacuum mechanism to deliver product without letting air enter the container. When the actuator is pressed, a vacuum draws product upward while a piston rises from the base to fill the vacated space. This prevents air from contacting the formulation and ensures precise doses until the container fully runs out.

Airless packaging extends product shelf life by protecting formulations from oxidation, contamination, and moisture. It also enables precise, consistent dosing and allows users to dispense nearly all of the product, minimizing waste. These advantages make it especially valuable for sensitive formulations like serums, eye creams, and pharmaceutical gels.

Airless packaging is widely used across personal care and pharmaceutical products. In personal care, common applications include serums, eye creams, lotions, foundations, and sunscreens. In pharmaceuticals, it protects sensitive formulations such as gels, ointments, creams, fluids, and combination formulas from oxygen, light, and moisture.

PP (polypropylene), a plastic resin, is the most common material used in airless packaging, though AS, ABS, PMMA, PETG, MS, and metal are also used. Sustainability comes from incorporating PCR (post-consumer recycled) content, ocean-bound plastic, or mono-material construction.

Airless packaging can be customized through structure, size, material, and decoration to match a brand's product and identity. Capacity ranges from 3ml to 250ml, with single, dual-chamber, and refillable structures available in materials from standard plastics to PCR and ocean plastic. Beyond stock options, custom tooling lets brands develop distinctive bottle shapes and proprietary forms unique to their identity.

A dual-chamber airless bottle dispenses two separate formulations from a single container, keeping them isolated until the moment of use. This is useful for products with reactive ingredients that must stay apart for stability, or for delivering a precise ratio of two components. Evergreen offers single, dual, and refillable airless structures.

Airless packaging supports a wide range of decoration methods for brand differentiation and shelf appeal. Evergreen offers silkscreen, electroplating, hot stamping, heat transfer, water transfer, and spray coating in glossy, matte, soft touch, and gradient finishes. Shrink sleeve, PS labeling, and metal wrapping are also available for additional design flexibility.

Quality control for airless packaging centers on verifying that the vacuum mechanism functions reliably and the product stays isolated from air. Testing typically includes piston movement and vacuum integrity checks, leak testing, dispensing consistency across multiple presses, and visual inspection of decoration and finish. Evergreen QC engineers are onsite at all productions globally, with every facility audited across 165 quality management metrics.