Salvalco Designs Metered-Dose Aerosol Valve, Soapbottle's Solid Bar Soap, and Kornelis Caps & Closures Redesigns Oil Bottle Closure
See a few examples of packaging that reduce material usage from Salvalco, Soapbottle, and Kornelis Caps and Closures from ThePackHub’s Innovation Zone.
Salvalco's metered-dose aerosol valve replaces LPG with nitrogen propellant
UK-based company Salvalco has developed Eco-Dose, a metered-dose aerosol valve designed to offer a more sustainable alternative to conventional liquefied petroleum gas (LPG) propelled aerosol systems. Aimed primarily at the air care market, Eco-Dose replaces traditional hydrocarbon propellants with inert nitrogen gas. This change addresses key environmental and health concerns, such as volatile organic compound (VOC) emissions and flammability risks associated with LPG-based aerosols. The valve is engineered to deliver consistent and controlled dispensing, making it suitable for both domestic and industrial use cases involving air fresheners, odor neutralizers, and similar applications. Its design supports reliable product performance without requiring changes to existing can formats, making it adaptable for manufacturers seeking to reduce environmental impact without compromising usability. By using nitrogen, the system not only reduces emissions but also eliminates the need for fossil-fuel-based propellants. While the core functionality remains aligned with industry standards for pressurized dispensing systems, the environmental benefits come from the shift in propellant chemistry and the minimization of carbon-intensive components.
One bar is equivalent to roughly 12 oz (340g) of liquid soap and can last two to four months depending on usage.ThePackHub
Soapbottle’s seeks to replace plastic bottles and pumps
German start-up Soapbottle’s has introduced a solid soap bar as an interim step toward its longer-term goal of creating rigid packaging made entirely from soap. Initially conceived as a bottle made of soap containing liquid soap, the product has shifted direction due to ongoing development challenges. The current Soapbottle Solids are highly concentrated bar soaps measuring approximately 11 cm x 5.5 cm x 2.5 cm and weighing 150g. According to the company, one bar is equivalent to roughly 12 oz (340g) of liquid soap and can last two to four months depending on usage. The product is claimed to be more durable and longer-lasting than conventional liquid soap, with added benefits of faster lathering and reduced water consumption during manufacture. It is fully biodegradable and designed without any plastic, aligning with efforts to reduce single-use plastic waste from pump bottles and containers. Each bar comes with a cotton ribbon, made in a traditional German ribbon weaving facility, which users can thread through a hole in the soap for convenient hanging.
Kornelis design reduces the number of components and is manufactured entirely from a mono-material, making it compatible with existing recycling streams. ThePackHub
Kornelis Caps & Closures, based in the Netherlands, has redesigned an oil and vinegar bottle closure to reduce material usage, improve recyclability, and simplify production. The initiative was prompted by a customer operating in a niche market whose original mold had reached the end of its service life. Due to reduced production volumes, investing in an identical replacement mold was not financially viable. Instead, Kornelis proposed a redesign focused on reducing complexity. The resulting closure eliminates the need for a separate tamper-evident seal by incorporating a longer sleeve and flexible legs that secure the closure firmly to the bottle while retaining tamper evidence functionality. The updated design reduces the number of components and is manufactured entirely from a mono-material, making it compatible with existing recycling streams. This supports the principles of the proposed Packaging and Packaging Waste Regulation (PPWR) in the EU. Consumers no longer need to dispose of a separate seal, as all parts remain attached to the bottle, enhancing the closure’s circularity and convenience. The new solution also results in a lighter closure, reducing plastic usage and facilitating more efficient production. By partially reusing existing mold components, Kornelis avoided high capital expenditure and streamlined the injection molding process.
One bar is equivalent to roughly 12 oz (340g) of liquid soap and can last two to four months depending on usage.ThePackHub
