French closure manufacturer Novassu is expanding its technical capabilities and the use of recycled materials in premium packaging for luxury cosmetic brands. The company, which produces closures for lines from Chanel, Givenchy, Estée Lauder and Coty, relies on a CXZ 250/1000-750 Multinject injection molding machine from KraussMaffei. The system combines 2K sandwich and index plate technologies, supports multilayer and monomaterial processing, and is prepared for a third component. In the current project, the machine is used to produce crystal-clear cube caps with 30% recycled content, while KraussMaffei’s APCplus function helps maintain consistent shot weight when processing varying recyclate batches.
Flexible sandwich and 2K processes for premium cosmetic closures
The CXZ 250/1000-750 Multinject at Novassu is equipped with a sandwich platen that enables injection of a recycled core layer inside an outer skin layer of new material. This configuration allows Novassu to integrate recyclate into high-end closures while maintaining a high-quality surface finish suitable for luxury cosmetic brands. At the same time, the machine can be operated in standard 2K mode or for monomaterial applications, giving the company a wide process window for different product requirements.
The index plate functionality is central to this flexibility. It enables rotation of the cavities for overmolding and multilayer processes, which is particularly relevant when combining different polymers or colors, or when building up complex geometries in several steps. According to Novassu, this was a key factor in the decision to invest in KraussMaffei’s injection molding technology. The machine layout provides the company with options to adjust to changing customer specifications without the need for entirely new equipment.
Managing Director Gérald Paris underlines the importance of this approach: "We only invest in machines that offer us maximum flexibility – no off-the-shelf. Our business is continuously evolving, and we need a strategic partner who can also bring in experience from other industries." This orientation towards configurable rather than standard machinery is intended to support both current production and future developments in design and materials.
Sandwich injection molding with 30% recycled content
In one of the current applications, Novassu uses sandwich injection molding with recycled material on the inside and virgin material on the outside. The company developed the crystal-clear cube cap itself and combines contract manufacturing with its own product design activities. The 2K closure incorporates 30% recycled content, while the outer layer delivers the optical quality required in the luxury segment.
The machine is already prepared for a third component, which opens additional options for visual effects and material combinations. Potential applications include multicolor injection for marbling effects or other decorative features integrated directly in the molding process, reducing the need for downstream decoration steps in certain cases.
The CXZ 250/1000-750 Multinject features a sandwich platen, allowing recycled material to be injected as a core layer within skin material.
At its site in Molinges, Novassu operates around 20 KraussMaffei machines from the CX and PX series, covering a clamping force range from 500 to 4,000 kN. Around 60 employees produce components with dimensions from 10 to 100 millimeters and also carry out finishing operations such as hot stamping. This combination of molding and finishing enables the company to supply complete closure solutions for the cosmetic industry from a single location.
Material shift from ionomer to classic thermoplastics
The choice of raw material is critical for cosmetic closures, in particular due to regulatory requirements. Materials must be FDA-certified, which can complicate the adoption of recyclates. However, certain materials, such as PET derived from beverage bottles, benefit from established and efficient recycling systems and comparatively low contamination levels. As a result, they are suitable for closure parts that do not come into direct contact with perfume or cream, making them an option for increasing recycled content in packaging components.
Novassu is currently transitioning from ionomer materials to classic thermoplastics. Ionomer can only be recycled chemically, which restricts its recyclability in conventional mechanical systems. In contrast, PET with low contamination can be mechanically recycled. This change in material enables Novassu to integrate recycled PET into selected closure components and aligns with the technical capabilities of KraussMaffei’s machine portfolio at the site.
The shift also opens up the possibility of using KraussMaffei’s all electric PX series injection molding machines more extensively. Since 2019, all machines at Novassu have been equipped with APCplus. This function automatically adjusts the switchover point and holding pressure based on melt viscosity. By compensating for fluctuations in material properties, it helps to keep the shot weight constant. This is particularly relevant when processing recyclates, which often show batch-to-batch variations.
According to Gérald Paris, the impact on production performance is measurable: "With APCplus, we’ve significantly reduced scrap and improved our product quality. This is a clear benefit also in terms of cost-efficiency." For high-volume closure production, the reduction of reject rates and improved process stability translate into lower material consumption and more predictable output.
Partnership with KraussMaffei supports growth plans
Novassu plans to expand its production capacities with additional injection molding machines in a new 3,000 m² hall. The company also aims to advance technologically, particularly in the areas of multilayer processing, recyclate integration and design-oriented applications. In this context, the cooperation with KraussMaffei plays a central role. Proven processes and modular machine concepts are intended to give Novassu room to develop new closure designs and open up additional market segments.
The combination of sandwich technology, index plate solutions and process control via APCplus provides the basis for stable production of high-quality closures containing recycled material. At the same time, the prepared third component and the compatibility with all electric PX machines offer a path for further process developments. For luxury cosmetics brands, this translates into access to increasingly sustainable closure concepts without compromising visual and tactile quality.
From Chanel to Givenchy – Novassu creates premium closures for the world’s leading luxury cosmetic brands.
