Airless Pumps: Types, Structure, and Analysis of Common Issues

In recent years, the use of airless packaging in cosmetics has surged significantly, driven by the market trend towards natural and preservative-free products. Currently, the airless packaging market is predominantly led by airless pump dispensing systems, with airless bottles holding the largest share. In the past few years, airless pump tubes have also captured a significant portion of the market.

The demand for airless pump dispensing systems is fueled by continuous innovation in cosmetic packaging, product positioning by brands, and advancements in formulations. In recent years, we have witnessed more complex structures and shapes than ever before, along with an increase in custom airless bottles, providing more options for end brands. Nowadays, cosmetic brands continuously launch natural and preservative-free formulas, which are highly sensitive and can greatly benefit from airless pump packaging solutions.

Sustainability is another hot topic in the packaging industry. Whether a product's packaging is eco-friendly is a critical consideration for major brands. Natural and nearly preservative-free skincare brands are the primary buyers of airless pumps, but the complexity of these products often makes it challenging to achieve full environmental friendliness. Airless pump solution providers are striving to optimize product structures, reduce the number of components, use more eco-friendly and recyclable plastics, eliminate metal springs, and employ other methods to make products more sustainable. 

Whether in airless bottles or tubes, airless pump structures offer significant advantages over traditional suction pumps.

Protection of Sensitive Formulas: The most significant advantage of airless pumps is their ability to protect sensitive formulas from oxidation, contamination, and spoilage during storage and use. Skincare products are generally produced, packaged, and filled in sterile environments, and with airless pump dispensing systems, the entire process ensures comprehensive protection of the formula, effectively extending its shelf life.

360° Usage: Airless pumps allow for 360-degree usage, including inverted use. This feature ensures that the product can be dispensed effectively regardless of location, environment, or usage method, greatly enhancing the consumer experience and meeting market demands.

Accurate Dosing and Minimal Residue: Airless pumps are designed for precise dosing, with almost negligible residual amounts, significantly reducing waste.

Maintaining Product Integrity: The airless pump dispensing system effectively isolates air, providing excellent oxygen barrier properties. This protection ensures that the product’s color, fragrance, viscosity, and other characteristics remain unchanged from production to consumer use.

Airless pump dispensing systems are widely used in the cosmetics and skincare industries, with nearly every cosmetic brand offering custom packaging with airless pump systems, such as for moisturizing, sunscreen, and whitening products. Another significant application of airless pump dispensing systems is in hair care products. A Korean brand has launched a 300ml airless bottle for hair conditioners. Specially designed airless bottle packaging has also been used in Colgate's premium toothpaste products. As airless pump dispensing systems become increasingly recognized and accepted by brands and consumers alike, their application prospects will continue to expand.

There are three common types of airless pump dispensing systems, all developed based on airless pump heads, with differences in bottle structure that achieve the airless pump dispensing effect in different ways:

Piston Airless Bottles:

Piston airless bottles are the most widely used and visually appealing, with a structure divided into two main parts:

Airless Pump Head: Airless pump heads vary in structure, with common types including internal spring and external spring structures. Both offer excellent sealing, but involve complex structures and numerous components. Other types include silicone pump heads and all-plastic airless bottles.

Bottle: The bottle contains a movable piston that seals tightly against the inner wall. As the product is dispensed, the piston rises, ensuring consistent dispensing.

Airless Tubes:

Airless tubes replace traditional flip caps and maintain their shape after dispensing, while offering the precise dosing, minimal residue, and 360-degree usage of airless pumps, providing a high-quality feel that enhances brand value.

Bag-in-Bottle Airless Bottles:

Bag-in-bottle airless bottles occupy a smaller market share. They consist of a two-layer blow-molded bottle with a hard outer layer and a soft inner layer, similar to a PE bag. As the product is dispensed, the inner layer contracts. This type offers greater design flexibility for bottle shapes, making it an attractive option for creative packaging designs, although it comes with higher costs and technical challenges compared to piston airless bottles.

Common materials used in airless pump dispensing systems include:

PP (Polypropylene): Widely used due to its low cost, non-toxicity, chemical resistance, impact resistance, high-temperature tolerance, ease of molding, good transparency, and full recyclability. However, it has poor surface adhesion for secondary processing and lacks a premium feel.

ABS: Known for its dimensional stability, ease of processing, and suitability for vacuum coating and spray painting.

LDPE (Low-Density Polyethylene): An environmentally friendly material with good chemical resistance, though prone to cracking and not heat-resistant.

PETG: Highly transparent, with strong gas barrier properties, pressure resistance, chemical resistance, and moisture resistance. However, it is not heat-resistant and is challenging to recycle.

AS (Acrylonitrile Styrene): Highly transparent, with good softening temperature, impact strength, heat resistance, and resistance to oil and chemical corrosion.

These materials are chosen based on their specific properties, contributing to the overall performance and appeal of airless pump dispensing systems.