Packaging supplier Amcor has achieved a 16.67% reduction in plastic used in the flexible tubes it supplies to skincare brand Bulldog. The redesign is expected to cut approximately 8.5 metric tonnes of plastic per year.
The reduction comes from slimming down the wall thickness of the 50mm diameter tube sleeves used in Bulldog’s 100ml and 150ml products. The change was developed through collaboration between Amcor and Bulldog to make the packaging more resource-efficient without compromising product performance.
To confirm the tubes remained functional, Amcor ran extensive trials to ensure squeezability and structural integrity were preserved. Print quality and leak resistance also met required standards. The thinner sleeves still work with existing caps and shoulders, so Bulldog’s filling operations remain unchanged.
Alongside the material cutback, Amcor has increased the post-consumer recycled (PCR) content of the tubes to over 62%. The brand has also continued its use of sugarcane-derived plastic for virgin content—an approach Bulldog adopted in 2017 to reduce fossil fuel reliance.
Joe Horton, Sales Director at Amcor, emphasized the long-term goals driving the redesign. “This latest iteration of the 100ml and 150ml flexible tubes is proof of both Bulldog’s and Amcor’s commitment to a circular society where more sustainable consumption and recycling are the norm,” he said.
James Barnes, Brand Director at Bulldog, echoed the importance of balancing sustainability and shelf appeal. “The result of our continuing successful collaboration with Amcor is a consumer-facing product that has enhanced its sustainability credentials while still looking highly attractive,” he said.
The project reflects growing pressure across the personal care industry to reduce packaging waste and increase recycled content, especially in high-volume items.