Replacing blister and foam in haircare packs
Haircare is where plastic inserts have held on longest, for a simple reason: shampoo and conditioner bottles are tall, tapered and slippery, and a vacuum-formed blister holds a tapered bottle very cheaply. Switching materials only works if the replacement holds that shape just as well.
A moulded fibre insert can, as long as it is formed to the bottle's actual taper rather than to a cylinder:
- Taper-matched cavities that grip the bottle where it is widest and support it where it is narrowest.
- Pump and flip-top clearance, so a dispenser head is not compressed by the tray wall.
- Foam-replacement pads for tubs and jars, pressed as part of the same tool as the tray.
- Retail and e-commerce variants: a shallow tray for shelf cartons, and a deeper full-wrap version for courier shipments.
Where the switch does not pay is very low volumes of a very complex blister. A bespoke VAC tool is cheap; a bespoke fibre tool is not. Above roughly 10,000 units per design the arithmetic turns, which is also where our MOQ sits.
MOQ 10,000 pieces per design; tooling 7–15 days, production 15–25 days after sample approval. Send two filled bottles from each size in the range and we will check the taper against the finished pack weight. See also our electronics range, or talk to us about a blister conversion.
FAQ
Q: Are you a manufacturer or trading company?
A: We are a manufacturer founded in Hong Kong in 2013, with two production bases in Dongguan, China and Ho Chi Minh City, Vietnam, and a total manufacturing area of 26,000 square meters. You are welcome to visit or audit our factory.
Q: What is your MOQ for custom molded fiber packaging?
A: Our standard MOQ is 10,000 pieces per design. If your project requires a different quantity, contact us at info@csl-packaging.com and we will review the options with you.
Q: What is the production lead time?
A: Lead time is generally 15-25 days after sample approval, depending on order quantity and technical difficulty. The exact schedule is confirmed together with your order.
Q: Can the insert be customized to my jar or bottle dimensions?
A: Yes. We custom-mold each insert based on your jar diameter, depth and shape. Send your 3D drawing or a physical sample, and we will build a custom mold and provide samples for approval before mass production.
Q: Is the molded fiber packaging recyclable and biodegradable?
A: Yes. It is made from renewable plant fiber with no plastic lamination, so it is fully recyclable and biodegradable - a plastic-free choice for cosmetics and personal care brands.
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