Leoplast Group: Green Packaging from Italy

The Leoplast Group coordinates specialists in plastic injection moulding for the perfume and cosmetics industries. The company has more than 30 years of experience in the manufacture of technical components. Since 2004, Leoplast has been producing cosmetics packaging from 100 % VegetalPlastic – packaging made of renewable raw materials which are a sustainable alternative to packaging produced from mineral oil. Regenerated plastic is also offered. Leoplast is powered by 100 % green energy, the only producer making available a complete line for decorative cosmetics, and it was the first company worldwide - and still is apparently - to offer in 2007 a lipstick case made from 100 % vegetal-based material.

Leoplast's production site is located in Piedmont, in theTorino region of Italy. It is a SME with fewer than 50 employees. The company dedicates 500 square metres of their factory area to the production of bioplastics packaging. This packaging exceeds 12 million pieces per year: 6 million lipstick cases, 2 million jars and 2 million pieces of their Bio-Stone line alone. The expertise of the Italian company has already been acknowledged by awards – e. g. in New York (HBA / best packaging in 2007) - and accreditation by Ecocert and European Bioplastics e.V.

VegetalPlastic aims to contribute to environmental good practice, using 100 % renewable resources like corn, other plants and cellulose, for example, for injection moulding, assembling and decorating activities - thus significantly reducing the adverse production impact on the planet without compromising on performance, suitability and quality of cosmetics packaging. These new bio-degradeable raw materials are an alternative to petroleum-based resins. Bio-based materials used by Leoplast have huge environmental advantages compared with traditional plastics (SAN, PS or ABS) habitually used in cosmetics packaging: VegetalPlastic cosmetics packages made from cellulose-based resin come from 100 % renewable non-alimentary vegetal resources, like wood pulp from FSC forests. No fossil-based materials are used, so they save on fossil fuels, reduce greenhouse gas emissions, shorten the carbon cycle and allow several disposal options from industrial composting to recycling or incineration.
 

Thanks to its high level of expertise in bioplastics processing, Leoplast only uses food-grade biopolymer. Raw materials are PLA (NatureWorks /USA) and CA (FKuR Germany). Several natural and mineral colourings are used. Moreover, the materials are GMO, BPA and phthalate free. Cellulose-based resin combines high performance, ease of processing and remarkable mechanical properties. This kind of packaging has good impact strength, high surface gloss, strong chemical resistance and warmth to the touch. According to the manufacturing company this class of bioplastics represents a perfect compromise between the opposing demands of effective biodegradability on the one hand and food resistance and high thermal stability on the other. The term biodegradable applies if 90 % of the total converts within six months into carbon anhydride and water in standard composting plants. Products are compostable if they break down into harmless organic materials within a relatively short time frame under industrial composting conditions and do not have any toxic effects. The time taken can vary depending on the shape and thickness of the item.

Leoplast R & D give guidance to their clients on developing expertise in bioplastics and creating specific packs for green-oriented projects. Thanks to its continuous innovation, the company is a pioneer in this segment, uniting glamour, performance and sustainability. Leoplast is the only producer to make available a complete line for decorative cosmetics: lipstick cases, jars (with lids for creams or sifters for loose powder), large compacts (e.g. compact powder, bronzer and blush), small compacts (eye shadow, blush and gloss), mascara caps and applicators. The company has specific know-how in lipstick cases. Their BioMascara is the first oil-free mascara packaging, an innovative material which sets the company’s colour cosmetics packages apart from the rest by offering a packaging that can enhance branding opportunities. The company also produced the world’s first PLA lipstick in 2007.
 

At this year’s Vivaness from 17 to 20 February in Nuremburg, Germany, Leoplast delivered a speech on authentic, ecological sustainable design in natural cosmetics products which dealt with the question of what LOHAS ("Lifestyle of Health and Sustainability"), as an important target group for natural cosmetics, expects from packaging. Leoplast was also present at Cosmopack in Bologna in April and at Make Up in Paris in June. The company will also be at Beyond Beauty in Paris. Among the international customers are CargoCosmetics in Canada, Korres in Greece, Ciccarelli in Italy, Laboratoires BodyNature, Cosmédiet, Laboratoires Phyt’s, Aromastrati, Le Secret Naturel in France, Cosmeticas Cabinas in Spain, as well as Cosmeceutech in the USA . As Chantal Nourtier-Farget, Marketing and Communication, from Cosmédiet told Organic-Market.Info, her company has been using Leoplast's products since they were launched. The quality is more than satisfactory and the company will continue to use them. The packaging is not more expensive than the conventional alternative. Since Cosmédiet puts great emphasis on the environment, it is very important that the packaging is 100 % biodegradable, and this makes a clear difference to them – and to their customers. (Picture to the left: Products of Cosmédiet)
 
Marie-Laure Veillard of Leoplast told Organic-Market.Info in an interview that Leoplast also offers recycled traditional plastics (PIR post-industrial plastics).They have managed to industrialize the use of up to 100 % regenerated plastics with no change whatsoever to the quality and standards. These regenerated plastics come from clean industrial production wastes. Through the “second life plastic” brand, they’re able to certify the provenance (Institute for the Promotion of Plastics from Recycling). In contrast to what is done with recycled plastics that derive from chemical processes, their regenerated plastics do not come from a post-consumer chain; they use a purely mechanical process thanks to very specific selection and integrate the processed blend with virgin raw materials in precise proportions. To produce their packs, the use of regenerated plastics results in huge savings in fossil-based materials and energy. They also contribute to important savings in greenhouse gases. Moreover, the company avoids having to dispose of both the re-used regenerated plastics and the unused virgin raw material. (Picture: Products of Laboratoires BodyNature)
 

Leoplast has already presented prototypes of bottles and caps, but they are not yet at the manufacturing stage. Also, L'Oreal's technical agreement for their CA lipstick cases has been accepted, meaning that any L'Oreal company can order cellulose based-resin lipstick cases. This bioplastic pack complies with all L'Oreal technical requirements and it will be the first time that oil-based plastic material is replaced by a material of renewable natural origin.

Leoplast Group