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📦 Packaging Blueprint

Packaging Options — the Blueprint

Every format that can be done for P1 and P2, with costs, MOQs, hygiene logic, and the suppliers who bring it to life. A decision surface, not a design exercise. Researched 8 Jul 2026; estimates flagged (est.). Canonical home: Obsidian → 02/Packaging.

✅ Breakthrough: BOV is fillable in Australia. Aeropac (Queanbeyan NSW) explicitly lists bag-on-valve filling — MOQ 5,000, cans 50–750ml, 6–10 week lead. And the launch math is now clear: P2 can launch at ~500–1,000 units; P1 BOV has a ~5,000-unit floor (with a 100-unit MVP fallback via fine-mist pump + New Directions filling).
P1 — Spray Body Serum (100–250ml)
The Plan
Bag-on-Valve aluminium aerosol
Laminated bag welded to the valve inside an alu can; compressed air squeezes the bag — propellant never touches the formula.
Pros99% evacuation · continuous 360° spray · protects formula → suits reduced-preservative formulas (sensitive-skin gold) · non-flammable
Consviscosity ceiling ~5,000 cP (confirm vs valve spec) · specialist filling · 15–25% dearer than standard aerosol
~$2.50–5.00/unit filled (est.) · MOQ 5,000 (Aeropac ✅)
WhoAeropac (fill, NSW) · Jamestrong (AU cans) · Aptar valves via Ultrapak AU
MVP fallback
Fine-mist pump + aluminium bottle
Pre-compression pump, fine mist per stroke. Same no-touch experience, no aerosol rules.
Proscheapest · no specialist filling — New Directions AU fills from 100 units · keeps the metal look · easy DTC shipping
Consnot continuous · thin formulas only (HV inserts exist for serums)
US$1.82 bottle+sprayer listed ✅ (SKS 80ml) · MOQ from 1 case
WhoUltrapak (Aptar pumps) · SKS/Cary · New Directions (fill)
Alternative
Continuous-mist pump (Flairosol-type)
Spring-piston chamber gives seconds of propellant-free mist per priming stroke.
Prosaerosol-like mist, zero propellant, no DG shipping, low MOQ stock
ConsPET plastic bottle — clashes with the aluminium/tool aesthetic unless sleeved
~US$2–4/unit small qty (est.)
Alternative
Airless pump bottle
Piston/pouch, no dip tube — vacuum draws product; near-total evacuation.
Prosbest preservation short of BOV · handles serum-to-cream viscosity
Consdosed, not continuous spray
US$1.62 listed ✅ (SKS 50ml) · China ~$0.20–0.70 @5k (est.)
Ruled out
Standard aerosol (LPG propellant)
Whypropellant mixes into the formula, flammable, cold-blast feel, 90–95% evacuation — wrong fit for sensitive skin
P2 — Eyelid Cream (10–30ml)
⭐ Strongest fit
Tube + metal cooling tip (zamac/steel)
Product extrudes through a zinc-alloy tip that doubles as the applicator — and pulls heat from the skin on contact.
WhyCooling + no-finger application for hot, itchy eyelids — the sensory thesis in hardware. Applicator-direct hygiene; metal sanitises easily.
~$0.60–1.80/unit (est., quote-only) · MOQ from 1,000 (Dermapack ✅) / 100 C-stock ✅
WhoHCT by kdc/one (premium: SPPAM 15 = airless + cooling tip in one) · Xinfly · Dermapack · Function
Hygiene lead
Mini airless pump (15ml)
Dosed piston airless — air never re-enters, near-100% evacuation.
Whysupports a leaner preservative system — matters on compromised eyelid skin (and the non-stinging requirement)
APC stock from 300/case ✅ (US$500 min) · AU: Vision Packaging (APJY)
Construction
Tube material choice
Alu collapsibleairtight, stays collapsed (no air suck-back = quasi-airless), 100% recyclable, pharma standard
ABL laminate>99% O₂/light barrier, cheap ($0.03–0.30 @10k ✅), poor recyclability
PBL/PEcheapest + low-MOQ stock (Bianco AU: 500 plain ✅) — but sucks air back in
Ruled out
Open jar
Whyfinger-dipping = documented worst contamination profile; near the eye that forces heavy preservation (irritation risk) or microbial risk. Never.
Hygiene ranking (drives the choice): airless / metal-tip tube / aluminium tube  >  laminate + small nozzle  >  PE tube  ≫  open jar. Sealed formats allow leaner preservative systems — directly supports "non-stinging."
Suppliers — who brings it to life
LayerAU suppliersKey facts
Cartons / boxesInke Packaging · PackQueen · noissueInke from 10 units, FSC + Climate Active ✅ · PackQueen from 25 (Melbourne-made) · noissue FSC + soy inks
LabelsPaperlust · Label Powerfrom $0.06/label ✅ · cosmetic-grade specialist (Brisbane)
Bottles / tubes / pumpsThe Packaging People · New Directions · Ultrapak · Bianco · Vision · Weltrade · PlasdeneTPP sells single samples · New Directions fills from 100 units · Ultrapak = Aptar distributor AU/NZ · Bianco tubes MOQ 500 · Weltrade PCR at scale
Aerosol / BOVAeropac (fill) · Jamestrong (cans) · Moorebank (backup)Aeropac: BOV listed ✅, MOQ 5,000, 6–10 wks · Jamestrong: alu cans made in Taree NSW — "Australian-made, infinitely recyclable" story
Low-MOQ internationalSKS / Cary / Berlin (by the case, listed prices) · APC (airless ~300/case) · EPOPACK (PCR, 5k) · HCT (cooling tips) · Xinfly/Dermapack (metal-tip tubes)
The launch math: P2 = stock tube + label ($0.06+ ✅) + Inke carton → viable at 500–1,000 units. P1 BOV floor = ~5,000 units (~$2.50–5.00/unit filled (est.)) — or start with the 100-unit fine-mist MVP and upgrade to BOV at scale. First hard numbers for the P1-vs-P2 decision.
Inke → Aeropac (BOV) → Jamestrong cans → New Directions → The Packaging People → Ultrapak (Aptar AU) → Weltrade → HCT cooling tips → Testing & Approvals → Strategy →