Airless: INOTECH focuses on its “2K” Pouch System
NOTECH Kunststofftechnik GmbH, headquartered in Nabburg, Germany, and specializing in plastics technology, has over the years evolved into a systems provider offering solutions ranging from product development to mass production.
Founded in 1990, the company—which has focused on plastics processing, particularly in injection molding but also in multi-component technologies, not to mention mold manufacturing—has approximately 400 employees and operates seven sites across three European countries.
In addition to manufacturing packaging for the cosmetics industry, Inotech also produces technical components for the automotive, household goods, and medical sectors. In the packaging sector, one of its specialties remains the manufacture of airless pouch packaging—its famous “2K system.” Key projects this year include continuing automation in the assembly sector and developing new products using their Airless Pouch technology. Also worth noting is the ongoing development of an airless spray package that requires no gas, valve, or similar components, yet delivers an excellent spray performance. We spoke with Lena Radetzky, Head of Packaging.
Inotech was founded in 1986 by Josef Gleixner, the current owner and CEO, under the name Plast Engineering. In 1990, the company changed its name to Inotech Kunststofftechnik GmbH. In 1994, a second plant was established in the Czech Republic, Inotech CZ, and the following year, the German company developed its “2K” technology, which uses a flexible inner pouch. The Health & Beauty division was created in 2006, followed immediately by the market launch of the first airless systems, and then by the filing of patents for the first 2K preform and the first 2K bottle in 2010. A third plant was established in 2013 in Bulgaria, Inotech BG OOD, and that same year the Group opened a logistics center in Tachov, in the Czech Republic. In 2020, the acquisition of FWE Formen und Werkzeugbau in Eslarn enabled the Group to expand its production capacity. Finally, in 2024, Inotech opened a new logistics center in Weiden.
2K Technology
“The most significant development in the field of beauty product packaging,” explains Lena Radetzky, “is our patented 2K preform technology for manufacturing airless systems in pouches.” In this process, a preform is produced by 2K injection molding and, depending on the application, is blown either into a blow mold or directly into a container. “Thanks to this technology, which allows the pouch to be blown directly into the container,” explains Lena Radetzky, “virtually any existing packaging can be converted into an airless system, regardless of its shape.”
As for the technique of blow-molding preforms in a mold, it allows for the production of pouches that can be inserted into a container as refills or that are ready for recycling (separable). Here again, the shape of the container is not particularly important, and since the product is contained within the pouch, the outer shell can easily be made from post-consumer recycled (PCR) materials or other materials, as it does not come into contact with the product.
“This type of packaging obviously protects the product from contamination and oxidation,” explains Lena Radetzky, “because air does not penetrate the pouch, which is particularly important for sensitive formulations. It allows for nearly complete removal of the product without residue, thereby optimizing its use. “The use of our 2K preform in the form of an airless pouch illustrates how to rethink efficiency, material design, and brand presentation.” This technology is based on a two-component injection molding process that combines two materials in a single step. The result is a functional composite system that requires no subsequent assembly steps. “The key difference from conventional airless systems lies in the design,” explains Lena Radetzky. “While conventional systems use a piston, 2K preform technology employs a flexible inner pouch that contracts in a controlled manner during application. This results in nearly complete product discharge—up to 98% depending on the formulation.”
One of the main advantages of this pouch technology, as is well known, obviously lies in the freedom of packaging design because, unlike piston-based airless systems, this system allows for virtually any shape. Round, square, conical—the outer shell is no longer limited by the internal mechanics. At the same time, unused space inside the packaging is almost completely eliminated.
“We also offer piston-type airless systems,” notes Lena Radetzky, “which offer numerous advantages as well. They protect the product from contact with air and contamination, extend its shelf life, and reduce waste. Their high flexibility, durability, and cost-effectiveness make them a preferred packaging solution, offering significant benefits for both brands and consumers.”
Environment: What Are the Solutions?
The Packaging and Packaging Waste Regulation (PPWR) requires manufacturers to continuously reduce their material consumption, ensure recyclability, and increase the use of post-consumer recycled (PCR) materials. At the same time, its implementation remains complex: definitions of materials, recyclability, and regulatory requirements are sometimes ambiguous and difficult to assess in practice.
“Our ‘Airless Pouch’ technology,” explains Lena Radetzky, “allows us to design the outer layer of the packaging from virtually any material (bioplastic, wood, paper, PCR, aluminum, etc.) without the need for extensive testing, since the contents come into contact only with the inner pouch, which weighs an average of just 3 g. This means it’s possible to use a high percentage of PCR, for example, without compromising the contents or requiring extensive testing. Furthermore, our technology allows us to significantly reduce packaging size by optimizing space and facilitating the use of product residues. Of course, one of the major challenges lies in the limited availability of post-consumer recycled (PCR) materials, which are subject to strict quality and safety requirements, particularly in the cosmetics sector.”
New Developments
Among the new developments, one worth noting is based on the concept of converting standard PET bottles into airless bottles. In this process, a PET Preform is blow-molded inside the PET bottle. The shape of the bottle plays a secondary role, allowing customers to adopt, for example, iconic shapes tailored to the brand that enjoy high brand recognition. This solution is particularly well-suited for viscous products, as it guarantees the customer maximum product yield.
Also worth noting is a new line of airless packaging developed for Caremare.
“The client used our 30-ml and 50-ml INO1 dispensers,” explains Lena Radetzky, “as well as the 100-ml Airless Classic model. The external components that do not come into contact with the product were made from ocean-recovered plastic (Tide Ocean Material) and contain up to 70% post-consumer recycled materials (PCR).
For this travel cosmetics line, the client passport2skn deliberately chose our 30-ml INO1 dispenser. It’s the ideal size for travel: lightweight yet reliable for a wide variety of formulations. In addition, the color palette—and in particular the contrasting ring between the cap and the bottle—makes it highly recognizable.”
