G&Co Thermoforming launches thermoformed Sulapac packaging with biobased flocking

The new compact combines a Sulapac Flow thermoformed body with cellulose-based flocking — allowing for fully biodegradable packaging with high biobased content.

Conventional thermoformed packaging with flocking relies on two distinct layers of fossil-based plastic: a thermoformed polymer body and a synthetic velvet coating bonded to its surface. Developed by G&Co Thermoforming in partnership with Sulapac, this new compact replaces both with bio-based, biodegradable alternatives — producing a powder compact that meets the tactile and mechanical requirements of prestige cosmetics without conventional plastic materials in any component.

 

Sulapac Flow body with cellulose flocking

The compact body is thermoformed from Sulapac Flow, a wood-based composite material engineered for high-throughput forming processes. Cellulose-based fibers replace the synthetic flock typically applied by electrostatic deposition, delivering the characteristic soft-touch surface finish demanded by luxury packaging specifications.

Standard flocked packaging uses fossil-based plastic in both the body and the flock fiber. This is the first thermoformed solution in which both material layers are bio-based and biodegradable — with no compromise to mechanical performance or surface quality.

 

Luxury-grade properties from bio-based inputs

Sulapac Flow provides sufficient rigidity and snap-fit precision for powder compact applications and various other high precision applications. The cellulose flock achieves comparable surface uniformity and tactile softness to synthetic alternatives, addressing the primary concern raised by prestige brands evaluating non-conventional packaging solutions: Can sustainable materials meet luxury standards?

The thermoforming process is compatible with existing production tooling and line speeds, ensuring the efficiency and scalability of the solution.

 

The luxurious eco-packaging innovation introduced at PCD Milan

The novel packaging solution made of Sulapac Flow 1.7 material and cellulose flocking was presented at PCD Milan in May 2026 where the innovation received a lot of interest among cosmetic brand development and procurement teams. If you want to learn more material specifications and sampling timelines, contact G&Co Thermoforming at info@gecothermoforming.com.