ADF Innovation Awards 2025: Game-changing designs

January 6, 2025

Dominique Huret reviews some of the sustainable packaging solutions and innovative aerosol can concepts entered into the 2025 ADF Innovation Awards

In December 2024, an esteemed panel of judges, including brands such as KAO, Beiersdorf, Unilever, and many others, came together to evaluate entries for the ADF Innovation Awards. Jury member, Dominique Huret, independent packaging journalist at Cape Decision, discusses some of the stand-out concepts and designs.

PCR gains in popularity

The personal care category welcomed several entries, with two from Colep Packaging. The first is a 100 per cent PCR aerosol for Coty’s Mexx brand, in partnership also with Slovenian aluminium producer, Talum. Choosing a 100 per cent PCR aluminium as the base material, advanced manufacturing techniques were then used to shape the can into its ogival form, maximising strength while using minimal material. The aerosol was then rigorously tested and proven in a full-scale production environment and underwent extensive validation for quality, durability and performance standards. The product has been on the market since April 2024.

Colep Consumer Products also entered the Skin Fender SPF30 Protection Mist. This is an EcoAlu can made of 100 per cent PCR, with nitrogen as propellant gas. This hermetically sealed aerosol format protects the formula while providing consistent delivery and low environmental impact, minimising VOC emissions. The formulation presented challenges due to the ocean-friendly suncare formula and nitrogen’s eco-friendly properties. However, nitrogen does not dissolve ingredients like traditional propellants. Another entry in personal care, this time using 50 per cent PCR, is Narta Deodorant produced by L’Oréal in collaboration with Tubex. Thanks to the work of the can supplier, the PCR alloy has similar properties to the virgin alloy used previously. This ensured compliance during compatibility tests carried out on over 30 L’Oréal formula references. For the food segment, Colep Packaging saw another entry, showcasing the Olive Oil Spray in a 100 per cent PCR digitally printed aerosol can, produced by Maeva (Aceites) in partnership again with Talum.

Lightweighting & high-quality printing

Ball and Henkel have made it through to awards finalist stage in the sustainable innovation category with their Fa product, which claims to be the lightest impact extruded aerosol can on the European market. The proprietary ReAl second generation alloy has stronger mechanical properties, allowing further lightweighting while keeping aerosol performance and compliance with various regulations.

The Fa 150ml can weights 18.3g, while today the benchmark product weighs 20.2g.

In the area of digital printing for the awards, CPK claims to be the only can maker worldwide able to digital print inline ALU aerosols. This allows flexible production and high-quality visuals without compromising sustainability. Constraints involved in this aerosol’s production involved maintaining the structure of the pack, optimising it for BOV filling with a patented curling.

Envases Group has been chosen as a finalist for the FEA Aerosol Technology of the Year with its project for Rasasi, a leading fragrance brand in the Middle East. Firstly, this bottle is printed using Envases in-line printing technologies, including a 3D haptic effect applied directly during the production process. Secondly, the Spanish team overcame the technical challenge of seamlessly combining these technologies without any post-production touch-ups, while achieving matt and gloss in different areas of the bottle. The product was launched at the end of November.

The Asia CanTech 2024 award winner, Isimat’s Koi Can, was also entered into the ADF awards. Isimat is a German equipment manufacturer for printing technologies dedicated to tubes, acquired by the Kurz Group. Isimat’s patented inLine Foiling and silkscreen printing in one machine allows silkscreen print, matt spot decoration to create a multi-metallic effect.

Colep Packaging also entered its WD-40 can, the first single-pass digital printing for a three-piece tinplate aerosol. It is also lightweight, thanks to Colep’s thickness reduction programme. Digital debossing adds a tactile and visual dimension that enhances the product’s appeal.

Dispensing & special formulations

Powered by alu-air, Adidas partnered with DFNS, a specialist in footwear, and Tubex, for its aerosol entry, which has been chosen as a finalist in the household category. The alu[1]air technology is the world’s first air-powered dispenser made from recycled aluminium that delivers pure product under higher pressure and is free from harmful propellants. The can is made of 95 per cent recycled aluminium, with on-can printing. In addition, an innovative water[1]repellent solution was developed that is water-based, PFAS-free and has a 20-minute drying time.

Volcke has partnered with Coster to produce a spray for linseed oil named Omega 3-6-9, which has also been chosen as a household and food finalist. The piston-chamber system coupled with a three-way valve, allows the accurate delivery of a specific quantity of product at each actuation. The mass-based Opposed Virtual Impactor (mBOV), maintains all the typical strengths of the standard bag-on-valve (BOV) adding the metering feature. This is the first BOV with an integrated metering system on the market, based on compressed air as propellant.

The Polish Aerosol Service put forward its Bad Hair Spray aerosol, developed as an eco-friendly alternative to dry shampoo with high performance without LPG. Using nitrogen as a natural and non-toxic propellant, Bad Hair Spray uses specialised valves and applicator to ensure even spray distribution up to the last application.

Lindal, Envases and cosmetic company, Ouate Paris, joined forces to produce the ‘Mon hydratant crépitant’ spray entry. The technical innovation lies in optimising the balance between gas, valve and diffuser components to handle thickening, crackling foam without clogging or uneven dispensing.

Unique concept

Swedish startup, Meadow, showcased its Kapsul solution to the ADF judges and has been chosen as a finalist for Concept of the Year. The can’s end has been modified with precision engineering to enable its use across diverse sectors, including personal care, beauty, home care, food and beyond. Paired with a reusable plastic dispenser, brand owners can customise the packaging through licensing. Its twist-to-open mechanism minimises user effort and maximises ease of use and recycling. Several major industry players have already expressed interest in this concept. The winners of the 2025 ADF awards will be announced at Paris Packaging Week on 28 and 29 January 2025.