KAJ's refill roll-on is designed to reduce plastic use in a practical and measurable way, without compromising functionality or packaging aesthetics. The construction consists of 5 elements and can be produced in an All PP version, with a PP insert, which supports easier recycling and a cleaner waste stream. The pack is intended for repeated use - estimated for up to 6 insert replacements.
The insert is available in 30 ml and 50 ml formats, in PP or PET. The full pack can also be produced using recycled materials.
The refill process is simple and intuitive: after unscrewing the cap and the fitment with the ball, the pack can be easily cleaned and refilled in two ways.
Option 1 is insert replacement - the ready-made insert is purchased, the seal is removed and the insert is replaced.
Option 2 is refilling from a doypack or bottle. After reattaching the fitment, the pack is ready to use again.
Across 6 usage cycles, plastic reduction versus a standard roll-on pack - in terms of the ball, fitment and cap - reaches 50% with insert replacement and 60% with refill from a doypack or bottle.
The solution also offers broad customization possibilities: decoration, printing and labeling of both the case and the insert, insert positioning relative to the case window, gloss or matte finishing, different color options and larger capacities. It is a packaging concept that provides real support for the circular economy.
