Reducing plastic waste in consumer products requires more than just recycling – it starts with smart design. One innovative approach is the combination of concentrated formulas and refillable packaging, which significantly reduces plastic consumption while maintaining product quality and convenience.
Since the early 1990s, companies like Kao have been developing refill systems to minimise single-use plastics. By concentrating ingredients, they reduce the size of packaging, lowering material use and transport emissions. Today, nearly 80 % of Kao’s products are available in refillable formats, cutting plastic waste by 76 % between 1995 and 2024. This shift encourages consumers to adopt more sustainable habits while ensuring high product performance.
Innovating recycling for a circular future
Refill packs, however, present recycling challenges due to their multilayer film structure, which combines polyethylene, PET, nylon, and sometimes aluminium foil for durability. Kao developed a specialised film-to-film recycling process by sorting out aluminium-lined packs and using compatibilizers to enhance material blending and minimise impurities in the recycling loops.
Their pilot plant in Wakayama, Japan, is advancing this technology, proving that complex plastic waste can be reintegrated into new packaging. This innovation not only reduces reliance on virgin plastic but also sets a precedent for sustainable packaging solutions across industries.
