Consumers in the UK and other European countries will have noticed that Unilever’s signature deodorant Lynx/Axe is now available in a new package.
Coster, a multinational provider of spray and aerosol dispensing systems headquartered in Italy, is among the lead suppliers chosen by Unilever for the relaunch of the world’s #1 male deodorant brand. The production of the new spray cap (codenamed “Dark Matter”) officially started in Coster’s state of the art Barlborough (Chesterfield) manufacturing facility.
Coster inaugurated its UK Barlborough site in 2014 starting with aerosol valve assembly in a 5000 sqm large production area. The operation, which is based on a fully automated production system, has become a benchmark for the aerosol industry, with over 1 billion valves already supplied into UK market.
Following the success of the valve assembly plant, Coster has moved quickly into the production of aerosol spray caps – a natural fit with the production range of the Coster Group. When Unilever, a long term and strategic partner to Coster decided to relaunch the Lynx/Axe deodorant range, the decision almost naturally fell on Coster as the partner of choice for the new spray cap.
There was one obstacle though: space, or a lack of it!
The success of the valve operation meant that the existing production space was fully utilised.
However, thanks to the foresight of the Coster Group, the original site was acquired with a surplus of land, and it was on this surplus of land that Coster embarked on phase 2 of the Barlborough success story.
Thanks to strength of the relationship between Coster and Unilever, this bold vision to expand the site and incorporate injection moulding could become a reality. And so it was, that in less than 12 months, a brand new state of the art production plant extension (4.000sqm) comprising 6 injection moulding machines and 2 assembly machines (with space for more!) was delivered on time and in full.
Supporting the local economy and drawing on resource from the surrounding areas, the new plant has seen the recruitment of a team of 10 new colleagues to run the production cells. Working in close collaboration with the Italian Coster moulding and assembly experts, the Italian teams have spent countless days training the new colleagues and forging close ties and building key relationships between Calceranica and Barlborough.
All of this resulted in the first production from the new facility being supplied into Unilever’s Leeds aerosol filling site on time and in full!
The new spray cap, codenamed “Dark Matter”, is an optimized version of its predecessor, maintaining the same functionalities of the current version with a lightweight design and fewer componentry. Coster participated in the whole development process, bringing its decade long expertise to design with Unilever the perfect packaging system.
As with all product development today, sustainability was at the core of the design principals behind Dark Matter.
Resin weight is significantly lower on Dark Matter than its predecessors which delivers a positive environmental impact without compromising on best in class functionality and performance.
Sustainability was also front of mind for Coster in designing the infrastructure necessary to make Dark Matter.
Each of the components of the spray cap are moulded with brand new, fully electric injection moulding machines that minimize energy consumption. The Barlborough facility also features high levels of environmental best practice in building design and construction, low energy LED lighting, roof windows that enable high levels of natural light and a heating system that re-utilizes air blown by the compressors rather than dispersing in the environment are some of the advances incorporated into the new building. The close proximity of Barlborough to Unilever Leeds also ensures minimal road travel, reducing associated carbon emissions.
Now that Dark Matter is fully implemented, the focus is set on successfully delivering millions of caps every week for the world’s most famous male deodorant brand – on time and in full, with highest quality standards.
If Dark Matter project is another success story, this can only be attributed to the people behind the project, from all involved sides: Unilever, Coster and all key equipment and service suppliers. But a special recognition must go to a man who was part of the Barlborough journey right from the beginning, when the first valves were made in 2014.
David Fearn will be always remembered as Barlborough’s first Operations Manager who built the production up from scratch. The whole Coster Group mourns his sudden and tragic passing on February 26th 2019, just a few short weeks after successfully delivering the Dark Matter project. David was part of the fabric of the Barlborough factory and his loss is sorely felt by everyone in the team.
However, David leaves a lasting legacy by ensuring that through his tireless work at Barlborough, millions of consumers everywhere can continue to use and enjoy one of the most famous deodorant brands in the world.
Coster receives two BAMA awards
Coster had a great night at the British Aerosol Manufacturers Awards [BAMA] 2019 evening scooping two highly coveted prizes. Receiving Highly Commended awards in the Aerosol Packaging and Sustainability categories is a great achievement and testament to the vision and hard work of the Coster team.
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Coster opens its second UK plant
Coster Group, a leading multinational provider of spray and dispensing packaging components and filling machines, has started production in the new facility located in Barlborough, Derbyshire (UK). The Barlborough plant is dedicated to the production of aerosol valves and extends over a 10,000 m2 lot in a small industrial park, strategically located in close proximity to the M1 motorway.
Coster is the first aerosol valve and actuator manufacturer to achieve cosmetic GMPs
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Coster valves and actuators used to trace free kick lines in major football competitions
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Coster launches new global website
On 25th November, 2013, Coster, the global producer of aerosol valves, actuators, pumps and filling equipment, turned 50 and celebrated the golden anniversary by creating brand new website content. The site was specifically designed to be easy-to-use and provide a lean navigation tool for both current and future clients delivering up-to-date and relevant content about Coster.
Coster inks milestone agreement with Catalent Pharma Solutions
Coster has just announced that it has signed an agreement with Catalent Pharma Solutions for the development and construction of a line designed for filling pMDIs (pressurized Metered Dose Inhalers). The high-output, state-of-the-art line will be part of Catalent’s currently expanding Inhalation Center of Excellence in Research Triangle Park (RTP), N.C, USA.
Coster boosts BOV production in the USA
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2013 marks a milestone for Coster: the company’s 50th Anniversary
When Coster started up in 1963, the company’s only product was filling equipment. At a later stage, aerosol valves were developed and the company subsequently designed and brought to market a complete offering of sprays, dispensers, and perfume pumps.
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New CMPE Easyfit perfume pump by Coster
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New V04.2480 nasal actuator for 20mm pumps
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Coster launches the CPMR mini-sampler pump
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Coster USA receives its ISO 14001:2004 certification
Coster USA recently announced that it has newly been awarded its ISO certification, 14001:2004. An effective management tool, ISO 14001:2004 enables Coster to monitor and control the environmental impact of its production activities, improve its performance on a continuous basis and implement a strategy aimed at addressing significant aspects and meeting prioritized objectives and targets.
IBSA selects Coster BOV filling line for pharma products
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A conversation with Dr. Claudio Contini
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The new Garnier Deo Mineral spray, by Coster
Coster has developed a new ergonomic spray cap equipped with an innovative diffusion system, exclusively for the Garnier Deo Mineral personal deodorant line. The design also features Coster´s new sliding lock mechanism, which provides the consumer with the ability to lock the product shut with a simple finger slide.
HYDRA: new Coster spray caps for household and insecticide products
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- Isabel Thomas
- Brand Launch
- Created 17 Apr 2019
- Modified 21 Jun 2019
- Hits 272