Airless Packaging
Airless Lotion Bottles
Airless lotion bottles are larger airless packs, typically 75–200 ml, that dose body lotion, sun care and treatment fluids in 0.3–0.5 ml increments while keeping the formula sealed.
- 75 ml
- 100 ml
- 120 ml
- 150 ml
- 200 ml
At a glance
- Best for
- Premium body care · Sun care and after-sun · Professional and salon formats
- Formula fit
- Body lotion · Body serum · Sun care lotion
- Materials
- PP · PCR PP · HDPE outer alternatives
- Decoration
- Custom colour on outer bottle, actuator and overcap · Screen printing or UV printing on the outer wall
What are airless lotion bottles?
Larger airless formats are chosen for body care, sun care and professional ranges where the formula is used in volume and the cost of waste is high. A 0.3–0.5 ml dose per stroke gives controlled coverage instead of an unpredictable pour.
The main practical difference from smaller airless packs is fill efficiency: as capacity rises, the ratio of piston travel to wall area changes, so we test dose consistency at first-use and at low fill levels rather than only midway through the pack.
Typical specification range
Values below are the ranges we quote most often. Confirm against your formula viscosity, fill weight and destination market before freezing a specification.
| Parameter | Options we quote |
|---|---|
| Capacities | 75 ml, 100 ml, 120 ml, 150 ml, 200 ml |
| Materials | PP, PCR PP, HDPE outer alternatives, PE/EVOH pouch systems |
| Closures / dispensing | Airless pump 0.3–0.5 ml, Wide-plate cream nozzle, Locking actuator, Overcap, Refill cartridge |
| Customisation | Custom colour on outer bottle, actuator and overcap, Screen printing or UV printing on the outer wall, Hot stamping and metal-look collars, Soft-touch, satin, matte or frosted coating, Metallised actuator and collar finishes, Refill cartridge colour differentiation, PCR or mono-material outer components |
| MOQ | 1,000 pcs per design for stock moulds; 3,000 pcs for decorated orders; 10,000 pcs per size for custom moulds. |
| Sampling time | Stock samples in 5–10 working days; custom colour and decorated samples in 10–20 working days. |
| Production lead time | 15–30 working days after sample approval, depending on quantity, decoration and assembly complexity. |
Product features
Volume with dosing
A 0.3–0.5 ml dose covers a controlled body area, which reduces waste compared with a free-flow pour or a standard pump.
Protected large formats
Body formulas with vitamins, oils and actives get the same oxidation protection as a face serum pack.
Travel and shipping safety
Locking actuators and sealed chambers are tested inverted for leaks, which suits 100 ml+ travel and e-commerce shipping.
Who it is suitable for
- Premium body care
- Sun care and after-sun
- Professional and salon formats
- Self-tan products
- Body treatment serums
Suitable formulas and products
- Body lotion
- Body serum
- Sun care lotion
- Self-tan
- Massage gel
- Scalp treatment
Customisation options
Airless Lotion Bottles can be delivered as a stock-mould pack with your colour and decoration, or developed into a proprietary format. Decoration is specified against the final surface finish so print adhesion and colour hold in use.
- Custom colour on outer bottle, actuator and overcap
- Screen printing or UV printing on the outer wall
- Hot stamping and metal-look collars
- Soft-touch, satin, matte or frosted coating
- Metallised actuator and collar finishes
- Refill cartridge colour differentiation
- PCR or mono-material outer components
How these are manufactured
Parts are moulded by injection, injection blow or extrusion blow moulding depending on the format and material, then assembled, decorated and inspected in lots. Moulding parameters are recorded per mould so repeat orders match the approved sample. Read the manufacturing process.
Quality control
Dimension and weight checks, closure torque, leak and dose testing where relevant, colour verification (ΔE ≤ 1.5 opaque parts) and AQL 1.0/2.5 final inspection. Lot records are supplied with the shipping documents. See the inspection checklist.
Materials for this range
- PP — material guide
- PCR plastic — material guide
- HDPE — material guide
Frequently asked questions
Answers to the questions buyers ask most about airless lotion bottles. Send any specific question through the contact form and a packaging engineer will reply in writing.
Are airless lotion bottles cost-effective at 200 ml?
The pack cost per ml falls as capacity rises, and the 0.3–0.5 ml dose means fewer over-doses. For 200 ml formats the decision usually depends on protection requirements rather than pack cost alone.
Can body lotion be filled into an airless bottle?
Yes, if viscosity is within the engine's specification — typically up to about 60,000 cP for wide-plate systems. Very thick butters need a jar or a wide-nozzle airless jar instead.
How do I size the engine for a body product?
Choose dose by use case: 0.3 ml for facial and eye products, 0.4–0.5 ml for body lotion and sun care, then set capacity so the number of doses matches the intended use period.
What MOQ applies to airless lotion bottles?
Formats up to 200 ml start at 3,000 pcs for stock moulds and 10,000 pcs for custom outer moulds.
What is the MOQ for airless lotion bottles?
1,000 pcs per design for stock moulds; 3,000 pcs for decorated orders; 10,000 pcs per size for custom moulds.
Can I customise the colour?
Yes. Colour is matched to a Pantone reference or a physical sample and verified on production-resin parts. Custom colour on outer bottle, actuator and overcap is the standard route, and we supply samples for approval before the run.
Can you print or emboss my logo?
Yes — printing, hot stamping, coating, labelling and custom closures are all available for airless lotion bottles. Choose the method with your surface finish in mind: gloss print or foil works best on matte and soft-touch surfaces.
Can I request samples?
Stock samples in 5–10 working days; custom colour and decorated samples in 10–20 working days. Stock samples are supplied free (up to five pieces per SKU, courier at your cost); custom colour and decorated samples are quoted per project, typically USD 120–450.
Can you develop a custom mould?
Yes. Custom tooling is quoted as a separate line item with the cavity plan stated, usually from around 10,000 pcs per size and 25–40 calendar days from drawing approval to first-article inspection.
What is the production lead time?
15–30 working days after sample approval, depending on quantity, decoration and assembly complexity.
Do you ship internationally?
Yes. We ship airless lotion bottles to the United States, Canada, the UK, Europe, Australia, the Middle East, Southeast Asia, Japan, South Korea and Latin America, quoting FOB, CIF, DDP and air freight.
Which materials are available?
PP, PCR PP, HDPE outer alternatives, PE/EVOH pouch systems. Selection is driven by formula compatibility, clarity requirements, decoration and any recycled-content target.
Still have a question? Talk to a packaging expert.
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Quotes and samples for airless lotion bottles
Send the capacity, quantity, colour reference and decoration you need. We reply with MOQ, unit price band, sampling time and lead time — and we will tell you if a different format suits your formula better. Stock mould formats from 1,000 pcs per design; decorated orders typically from 3,000 pcs; custom moulds usually from 10,000 pcs per size.
No account required · NDA available · Quote replies within one business day (Mon–Sat, GMT+8)