Sustainable 60 ml + 150 ml Spray Packaging Solution with 30% PCR Pumps for the Canadian Market

1. Market Background

In the Canadian personal care and household cleaning market, brands are under dual pressure: on one hand they need high-impact, visually distinctive packaging, and on the other they must comply with increasingly strict sustainability and PCR/recyclability requirements from retailers and regulators.

For spray products (skincare mists, room sprays, household cleaners, etc.), packaging has to look good on the shelf, feel good in hand, and also tell a credible “eco story.” In practice, many brands discover that beautiful design ≠ stable mass production ≠ sustainability compliance—especially when colored decoration, multiple sizes and PCR components are all involved.

2. Customer & Application / Pain Points

The customer in this case is a Canadian brand / OEM working in personal care and household cleaning spray products, selling mainly through supermarkets, drugstores and e-commerce.

During the development of a new packaging line, they faced several typical pain points:

1. Non-standard size combination

   • The market is full of 50 ml, 100 ml, 200 ml formats, but this project required a 60 ml travel/mini size + 150 ml full size combination. Previous suppliers could not reliably cover both sizes within one unified design platform.

2. Stability of colored screen printing

   • The brand’s visual concept relies on multi-color screen-printed artwork with strict requirements for color consistency, adhesion and resistance to alcohol / cleaning agents.

   • Earlier samples from other suppliers suffered from visible batch-to-batch color variations and ink peeling, which directly hurt brand image.

3. Sustainability: pumps with PCR content

   • The customer wanted to clearly communicate recyclability and PCR usage, and specified 30% PCR (post-consumer recycled material) in the spray pumps.

   • At the same time, they were concerned that adding PCR might negatively affect spray performance, actuation feel and the premium white matte appearance.

4. Tight replenishment rhythm, need for stable long-term supply

   • Forecast volume was 500,000 sets per month, requiring a supplier that could support continuous production and provide flexibility during promotional peaks.

3. Our Solution (Product + Configuration)

We provided an integrated solution combining 60 ml + 150 ml plastic bottles with colored screen printing and white matte pumps using 30% PCR, aligning structure, decoration and sustainability in one package:

1. Size and bottle design

   • A custom 60 ml plastic bottle as travel / sample / trial size, ideal for GWP and trial campaigns;

   • A visually matched 150 ml plastic bottle as the main retail size, so both formats share the same design language and create a consistent shelf block;

   • Unified neck finish and thread design for both bottles, allowing the same pump to be used on both sizes and minimizing line changeover time.

2. Optimized colored screen printing

   • We ran several rounds of color drawdowns based on the customer’s brand palette, fine-tuning ink thickness and mesh parameters to ensure stable color, strong opacity and clean edges across batches;

   • We tested adhesion and resistance to standard cleaning agents and alcohol wipes, ensuring the printed graphics would not fade or peel under typical Canadian storage and usage conditions (including cold chain logistics where applicable).

3. White matte pump with 30% PCR

   • The pump body features a white matte finish, creating a clean, premium contrast with the colored bottles;

   • We introduced 30% PCR material into the pump components while maintaining mechanical strength, spring performance and sealing;

   • Small pilot runs verified spray pattern, dosing consistency, actuation force and rebound feel, confirming that adding 30% PCR did not compromise end-user experience, while enabling a credible sustainability claim.

4. Capacity and supply rhythm

   • Based on the customer’s annual forecast, we planned a base capacity of 500,000 sets per month, with reserved extra capacity for peak seasons;

   • We aligned delivery schedules with the customer’s production planning and set up a safety stock mechanism to balance supply stability and their warehouse constraints.

4. Customer Feedback

Since mass production and launch, the customer has summarized their feedback along three main points:

1. Unified look, strong shelf presence

   • The 60 ml and 150 ml bottles create a clear family look on shelf. Combined with colored screen printing and the white matte pumps, the brand block is visually consistent and easy to recognize;

   • Retail partners responded positively, noting that the series presents well as a unified range.

2. Stable printing and pump performance

   • Across multiple batches, the customer’s QC team reported satisfactory color consistency and adhesion of the colored screen printing;

   • Even with 30% PCR in the pumps, spray quality and hand feel remained consistent with their original expectations—end consumers detected no negative change, while marketing gained a stronger sustainability talking point.

3. Reliable supply and smooth communication

   • With a steady 500k sets/month rhythm, packaging supply became a predictable and reliable part of their operations;

   • The smooth sampling and approval process during development has also built a base for future series extensions.

5. Conclusion

This Canada-bound 60 ml + 150 ml bottle set with white matte pumps containing 30% PCR shows that for North American brands, meeting the combined demands of sustainability, visual consistency and supply stability requires designing from the perspective of the entire packaging system, not just individual components.

By integrating size combination, colored screen printing and 30% PCR white matte pumps into one coherent solution, the customer achieved:

• A distinctive, unified on-shelf identity;

• A sustainability message that is technically credible and easy to communicate;

• A scalable packaging platform that can be quickly adapted for new fragrances, formulas or channels (such as hotel amenities and subscription minis), saving development and validation time for future launches.