The bottle in the bottle style

The 'bottle in the bottle' is an innovative and intelligent packaging concept for cosmetics and pharmacy products, developed by the German company Gaplast GmbH and using DuPont packaging resins. The outer-bottle, made from a stiff thermoplastic, such as PET, encloses a flexible bag of DuPont™ Surlyn®. Thanks to the minimal adhesion between the Surlyn® and the exterior material, the inner-bag easily detaches itself from the bottle and evenly contracts during extraction of the contents. At the same time, a specially designed applicator ensures that the bottle contents do not come into contact with the ambient air (so-called 'AirLEssMOTION') and enables the germ-free dispensing of the product.

The bottle is produced using coextrusion blow molding, whilst a patented process helps attach the inner-bag of Surlyn® to the top and bottom of the outer-bottle. This ensures that the bag remains stretched in the vertical when emptied, and contracts only in the horizontal. Supported by the dispensing appliance - a so-called airless pump - a virtually complete emptying of the bottle is enabled. Depending on the shape and size of the bottle, residual contents range from one, to a maximum of four, percent ..from here