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.
Coster awarded ECOVADIS Gold Medal for CSR achievements
Coster Group has been awarded this year, for the first time, with the Gold medal in recognition of CSR achievements and efforts by Ecovadis across four themes: Environment, Labor & Human Rights, Ethics & Fair Business and Sustainable Procurement.
ISO 22716:2008 certification for good manufacturing practices in cosmetic products has been achieved by Coster's pump production plant located at Calceranica al Lago, Trento. All dispensing, perfumery and spray pumps produced at "Coster 2" will be made in line with the highest manufacturing and service standards required by the industry.
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.
Capri, the new actuator from Coster, is a two piece spray actuator with overcap suitable for 1" male aerosol valves. It consists of a finger pad with integrated spray channel, conveniently fitted within the collar. The finger pad has been ergonomically designed with a ribbed finish for an easy and comfortable actuation. Capri has a universal unisex look, which makes it easy to adapt and customize to a variety of products.
Football fans watching this summer's Brazil 2014 World Cup can't fail to have noticed the official vanishing spray used by the referees in all 64 matches and equipped with a Coster aerosol valve and V05.992 actuator ensuring that players respected the regulatory 9.15 metre distance between the free-kick position and the defenders.
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 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.
Reduced lead times and outstanding customer service: These are among Coster USA’s priorities in view of the fast-growing demand of BOVs (Bag-On-Valves) in the local market. Pursuant to this strategy, Coster is proud to announce the installation of a first-in-class high-output fully-automated line to produce BOVs at its South Elgin facility near Chicago.
Pharmaceuticals have long been and are still being pre-dominantly produced in the form of pills, tablets, creams, unguents, syrups, powders and injectables. The aerosol form has proved its usefulness, effectiveness and versatility for the delivery of numerous active principles in many different health therapies. Coster has developed an integrated solution for clients wishing to expand their product portfolio with aerosols.
CMPE Easyfit is the latest Coster precompressed perfume pump: the dispensing system is the same as that of the MPE and MHPR, assuring the same high performance. This new micro-pump is available in 60 µl and 90 µl dosages. There is no contact between spring and product, and the metal closure is suitable to fit 15 mm FEA standard bottle neck. The metal closure is suitable to fit 15mm FEA standard bottle necks.
Coster, a leading multinational provider of aerosol spray dispensing packaging components and filling machines, has launched a new nasal actuator for crimp-on pumps which is suitable for adults and children alike. The actuator comprises two side wings for a proper and comfortable actuation and its long skirt hides the pump, increasing its visual appeal to users.
The Coster subsidiary in Spain, Costertec, has recently launched a mini-sampler pump called CPMR. This new micro-pump is available in a 50 µl dosage and has reduced dimensions in comparison with the popular CPMS Coster pump. The new mini-sampler pump is suitable for nebulizing perfumes and other liquid products as the actuator is smaller and equipped with a newly-conceived, more compact micromist.
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.
In line with its strategy to increase its presence in the pharmaceutical field, Coster has recently installed a new fully automatic line for filling BOVs (Bag-On-Valves) for Swiss company IBSA. The line is now fully operational at IBSA’s manufacturing site near Milano. The line has a capacity of filling 3,000 cans per hour and has been conceived and designed to produce a variety of IBSA’s successful products, among them an anti-inflammatory topical gel.
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.
- Isabel Thomas
- Brand Launch
- Created 17 Apr 2019
- Modified 21 Jun 2019
- Hits 397