Exclusive interview | Vortex, the patented technology by Coster optimising spray performance of insert less spray caps

October 9, 2023

The customised design is able to recreate inside the spray cap the same swirls as those generated by standard inserts, delivering a spray effect on par to that of spray caps with traditional insert.

Tell us a bit about Coster:

Coster Group is a leading multinational provider of primary packaging components of spray and dispensing solutions, filling machinery and anodisation services.

The company is family owned and was founded in 1963 in Italy. It counts nowadays 1,000 employees. Coster addresses all segments of the market with a complete range of aerosol valves and actuators, spray pumps, dispensers and filling equipment and has a global production network spread across four continents. Sustainability is the key driver of Coster innovation roots and the Group’s mission statement. Coster aims to be a reliable partner, helping brands make the best products through its engineering and manufacturing excellence.

Give us a short introduction to Vortex

Actuators with insert have recognised spray performances, however, they pose recyclability issues as they are made of two different plastic resins. The sorting and separation of the insert, considering its dimensions, can be tricky. Hence the need to have mono material products which can ensure the same performances.

The problem is well-known and today some insert less solutions already exist, but not all of them are functionally able to achieve the same performance as standard aerosols in every product application.

Coster has recently developed and launched a patented technology, named Vortex, that optimises the spray performance of insert less spray caps. The customised design is able to recreate inside the spray cap the same swirls as those generated by standard inserts, delivering a spray effect on par to that of spray caps with traditional insert.

The idea behind this technology is to offer a sustainable yet efficient solution in terms of spraying performance, where the assembly phase is not required, also resulting in a relative economic advantage.

Vortex is suitable for different products such as deodorants, air-fresheners, insecticides, hair sprays, and more.

What are the new innovations’ main characteristics and its main essential features?

The main feature of this technology lies in its design: the spray caps are conceived to be without an insert but to spray as if they had one. The path that the product follows inside the spray cap is the same because Vortex is able to reproduce the same product break up and it guarantees spray performances comparable to those of a standard spray cap.

Being a mono material product, the advantage is primarily in terms of sustainability. Furthermore, as it is a single piece, the assembly phase is eliminated, speeding up and streamlining time-to market and supply chain procedures.

How sustainable and/or innovative is the pack?

What makes the packaging sustainable is the fact that it is 100% recyclable. Indeed, thanks to its design, Vortex has been conceived with the spray cap made only of polypropylene, as it does not have the POM (acetalic resin) insert, which contaminates PET recycling streams.

In addition, it is all about reduction, starting with the components of the spray cap: since there is no insert, the assembly process is eliminated, resulting in reduced energy consumption and an overall benefit on the lifecycle impact of the product, which is 100% PCR manufacturable.

What trend or challenge in the industry is it addressing?

Sustainability has never been a trend in Coster. It’s one of its core values which drives the company’s innovation journey.

With the introduction of Vortex to the market, Coster aims to provide its customers with sustainable solutions that perform like the standard aerosol configuration, while offering final consumer effectiveness and green consciousness.

What technical challenges did you need to overcome to manufacture this pack, if any?

“When we came up with the idea of developing an insert less technology for spray caps, we were aware that it would have been challenging to launch an efficient product on the market, which could guarantee the same product experience with a strong sustainable identity”, states Andrea Raineri, Chief Innovation & Sustainability Officer. “Our technical team worked carefully on the design and performed several tests before they developed the final version”, explains Mr. Raineri.

What reactions have you had from clients?

“Sustainability is a must-have for all FMCG brands and every new project must be developed with an eco-friendly footprint. There are several ongoing projects with very positive feedbacks from our customers – from small to medium-sized companies, to multinational partners. It is a matter of finding the right technology design variation that can best fit with the customer bulk” says Alfeo Tecchiolli, Head of Discovery and Innovation. “Vortex technology has already been tested and validated on several Coster’s actuators and spray caps, and it could be applied on many others” concludes Mr. Tecchiolli.