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Vortex Vortex

Vortex

Coster has developed proprietary “Vortex” technology to optimize spray performance of insert-less actuators.
The idea behind this technology is to offer a sustainable but also efficient solution in terms of spraying performance that also presents relevant cost advantages.

The problem

The growing demand for more sustainable packaging is driving the development of mono-material solutions designed to facilitate disposal and recycling at end of life.

While most aerosol actuators can be easily separated from the can, their recyclability is often compromised by the presence of a POM (acetal resin) insert, which can contaminate PET recycling streams.

At the same time, inserts are typically required to achieve optimal spray quality, as conventional insert-less actuators generally deliver lower atomisation performance.

Inserts are essential components for achieving high-quality spray performance

  • Nebulization control: they break up the fluid into fine particles for consistent spray quality
  • Spray pattern definition: different geometries create different spray outputs
  • Engineering precision: manufactured with tight tolerances to ensure repeatability

For these reasons, POM has traditionally been a suitable material for moulding inserts thanks to its properties.

Vortex Technology solution

Vortex Technology recreates the same swirling effect typically generated by inserts, directly inside the cap, delivering a spray performance on par with standard caps using inserts, ensuring consistent and reliable results. Same output, simplified design.

Improved recyclability
By eliminating the POM insert, Vortex removes the main source of material contamination in recycling streams. This enables a more efficient separation process and supports the transition toward fully recyclable packaging.
High spray performances
Vortex Technology recreates the internal swirl typically generated by inserts, ensuring a fine, consistent spray. The result is a performance level comparable to traditional insert-based systems, without compromising output quality.
Cost Efficiency
A single-material cap design makes the product easier to handle, integrate, and dispose of. This streamlined approach improves both manufacturing efficiency and end-of-life management.
Simplified Design
Removing the insert reduces material usage and simplifies the production process. Fewer components mean lower assembly complexity and potential cost savings across the entire supply chain.