Rexam has designed a new easy way to apply the traditional “Superstay” liquid lipstick/lip balm by Gemey Maybelline. The solution was to create a new two-in-one pack design, one side for liquid lipstick in a bottle with a flock-finished applicator, and the other for lip balm in a classic slimline.

Before, it consisted of 2 separate products, the lipbalm side of which was made by Rexam, and the whole product was sold in a carton coffret.

To meet today's "mover" and "on the go" trend, the challenge facing Rexam was to produce a complete two-in-one solution to make life easier for end-users, with no more need to carry two separate products to make up lips with perfect long lasting, comfort and shine. This was successfully accomplished with new “Superstay”, achieved by calling in the multiple global expertise of Rexam.

The technical challenges for this totally new product were linked primarily to project management:

The complex development of this duo thanks to the manifold skills and coordination between Rexam sites. There were 3 main components: the bottle for the liquid lipstick side, the connector and the slimline base for the balm side, all three made from PP. A custom cap was even developed concurrently to enable consumers to close the balm swivel mechanism section once the liquid lipstick part is finished.

The adaptation of Rexam's industrial facility to meet the brand's extremely ambitious requirements in terms of volumes.

They also involved: the quality of assembly and the fittingtogether of the