Coveris develops mono-material sleeve for Dr. Beckmann

Coveris has developed a new mono-material sleeve for Dr. Beckmann’s first liquid fabric softener launch in France, combining lower material use with simplified production and improved recyclability.

The solution uses Coveris’ SleeveFlex Ultra Stretch technology, an elastic sleeve based on a single-material LDPE film. The project moved from initial concept to commercial launch in approximately six months.

Material use falls by around 30%

Compared with conventional shrink sleeves, SleeveFlex Ultra Stretch uses approximately 30% less material.

Reducing film weight can lower raw material consumption while also decreasing the amount of packaging entering the waste stream. For high-volume household products, relatively small reductions per pack can translate into significant savings across annual production.

LDPE structure supports material separation

The sleeve’s low-density LDPE construction is designed to separate from rigid packaging during sink-float recycling processes.

When applied to PET bottles, the sleeve can separate from the higher-density bottle material, helping preserve PET bottle-to-bottle recycling. When combined with an HDPE container, the packaging can form a more compatible polyolefin-based structure.

Technology supports preparation for PPWR

Coveris positions the sleeve as a way for brands to simplify packaging structures while preparing for stricter European recyclability requirements under the Packaging and Packaging Waste Regulation.

Designing labels and sleeves to separate effectively from the main bottle is becoming increasingly important as recyclability assessments begin to consider the complete package rather than only its primary container.

Steam tunnel is no longer required

Unlike conventional shrink sleeve applications, the stretch sleeve does not require heat shrinking through a steam tunnel.

Coveris estimates that eliminating this stage can save around 150 kg of steam per hour, reducing both energy demand and the infrastructure required around the sleeving operation.

Operating costs could fall by up to 50%

The company says the new process can reduce total operating costs by up to 50% compared with conventional shrink sleeve systems.

Savings come not only from lower energy consumption but also from removing requirements such as temperature-controlled transport and specialised storage conditions associated with some sleeve materials.

Sleeve works with PET and HDPE bottles

SleeveFlex Ultra Stretch can be used with both PET bottles and HDPE containers, giving household and personal care brands greater flexibility when selecting the primary bottle material.

This versatility can be particularly useful for companies managing several product ranges or transitioning between different rigid plastic formats while trying to maintain consistent decoration and branding.

Coveris supported full production integration

Coveris acted as a full-service packaging partner throughout the project, supporting Dr. Beckmann with technology selection, machinery integration and commissioning of the production line.

This broader involvement helped move the project from development to market readiness within the six-month timeframe.

Sleeves become part of recyclability strategy

Labels and sleeves represent a relatively small share of total packaging weight, but their material composition and separation behaviour can significantly influence recycling performance.

The Dr. Beckmann project demonstrates how redesigning secondary packaging components can reduce material use and processing energy while also improving compatibility with established rigid plastic recycling streams.

Material reduction and process efficiency converge

The development reflects a wider shift in sustainable packaging, where improvements increasingly need to deliver both environmental and operational benefits.

By reducing film use, eliminating steam and simplifying end-of-life separation, Coveris is positioning SleeveFlex Ultra Stretch as a solution that addresses recyclability, material efficiency and production economics within the same packaging system.