In the premium, sustainable packaging industry, aluminium, whether recycled or not, long seemed to be bound to become the benchmark material. Its rise often came at the expense of Zamak, prized as a staple material for its aesthetics in perfume caps, makeup cases, and premium skincare accessories. Although it is deemed less circular, this alloy valued for its density and high-end finish does offer ethical assets, but these are still little known.

Zamak’s environmental assets

Mainly composed of zinc, Zamak has a low carbon footprint and a melting point lower than aluminium’s. Recasting does not make it less qualitative, plus it can be recycled endlessly without losing its mechanical and aesthetic properties.

To highlight these sustainable advantages and put Zamak back into a circular system, French group Segede, specialised in metal transformation and tailor-made production for the luxury and beauty markets since 1955, launched a major recognition initiative.

Under the leadership of Claire Trescartes, the Director of Sustainable Development, representing the third generation at the helm of the family company, several actions were launched to prove the actual recyclability of post-consumer Zamak and have its value acknowledged as part of the PPWR (Packaging and Packaging Waste Regulation) European Regulation.

“Zamak is a niche material. Until now, no study had been conducted on its recyclability or carbon footprint. That is why I embarked on an in-depth project,” says Trescartes.

The material’s recycling journey, the European players involved in its separation, and its end-of-life recovery were accurately mapped. Now that this work has been done, the alloy is recognised as a fully recyclable material: it should be official by the end of the year in the guides validated by purpose-driven company CITEO. In addition, the data from the Life Cycle Assessment (LCA) will soon be added to the Ecoinvest reference points.

Segede carried out in-depth work to recreate recycled Zamak’s value chain, including collection, sorting, recasting, and bar supply. Thanks to such transparency, brands can now access certified data about the percentage of post-consumer materials, the carbon footprint, and traceability. The company also affixes the ZP5 mark on its items to make optical sorting easier.

Cooperation to boost recycled aluminium

Although it is recognised as easily recyclable, aluminium does not offer equal aesthetic performance. When it is post-consumer recycled (PCR), it loses brilliance, so it is less appealing to luxury brands. To overcome this constraint, Tesem unveiled a new technology in 2022: BRI&Va makes it possible to obtain radiance and touch characteristics similar to virgin aluminium’s in products containing up to 50% PCR aluminium.

Under the leadership of the Chanel group, three key industry players, i.e. Tesem, G. Pivaudran, and Pochet Group, chose to pool their expertise and take this solution to the next level. This pioneering initiative aimed at promoting wide adoption of the technology for large-scale industrialisation could eventually pave the way for extending it to recycled injected aluminium.

Anodised injected aluminium

On this front, at the latest Luxe Pack Monaco show, TNT Group, a specialist of Zamak and metal packaging solutions for the luxury industry, unveiled a patented injected aluminium technology innovation for an anodised finish, promising to combine brilliance, design freedom, and recyclability. The injected aluminium technology offering a shiny anodised finish removes constraints associated with Zamak and cold-forged aluminium, providing greater freedom of shape and design, heavier weight, and compatibility with local recycling industries. The process broadens creative and sustainable choices for luxury brands. TNT Group supports this strategy by offering LCAs which will provide, for each project, the environmental impact of the various options available to help with selecting the best material and technology choices in both a transparent and measurable way.

Low-carbon aluminium

Despite its advantages, aluminium is still pointed out for its high production carbon footprint. To take up this challenge, Axilone, a specialist of aluminium transformation for premium packaging solutions, has been rolling out a comprehensive range of low-carbon grades across all its production sites. This offer is designed to combine environmental performance and high-end quality by relying on green energy, recycled aluminium in a closed-loop system, and PCR aluminium. The alloys are carefully selected to preserve the products high-end visual appearance, while finishing processes guarantee a high brilliance level.

The offer was applied to Pure Metal Luxury, a collection of high-end, 100% aluminium-based caps designed for beauty packaging. The items feature thick walls and substantial weight, including the inserts, while remaining recyclable through local recycling systems. The aluminium is recycled (PIR/PCR) and low-carbon certified – obtained by cold extrusion. From a creative standpoint, Axilone offers great design freedom, making it possible to create complex shapes and a broad range of finishing processes, from anodising to special effects.