Custom 50ml Refillable Airless Pump Jar for Clae

Clae was upgrading the packaging for its hero product, Super Tallow™ facial moisturizer.

The team were looking for a single 50 ml format that could work as both the primary pack and a refill system, while staying aligned with their clean, understated brand world.

They needed a solution that would:

• keep a rich tallow-based balm protected from air and light
• avoid customers dipping fingers into an open jar
• make it easy to sell a refill cartridge SKU alongside the main product
• deliver a soft, matte, chocolate-brown look that feels warm and minimal
• run smoothly on a growing but still compact filling and assembly line

Clae approached UKPACK with a brief for a 50ml refillable airless pack with precise color matching, matte surface, printed branding and a debossed logo on the lid.

Clae is a skincare brand built around simple, tallow-based formulas and a calm, neutral visual language.

The focus is on short ingredient lists, gentle performance and an elevated bathroom-shelf presence rather than loud graphics or complex storytelling.

The product in this project, Super Tallow™ facial moisturizer, is:

• a balm-like texture rather than a thin lotion
• designed for daily use on face and neck
• marketed as a “one ingredient” moisturizer for sensitive or minimalist routines

Because of this formula and positioning, the pack needed to meet several requirements:

• Hygienic dispensing – no need for users to scoop out product with their fingers.
• Airless protection – limiting oxygen exposure to help keep the balm stable over time.
• Refillability – the outer jar should be re-used while the inner cartridge can be replaced.
• Brand fit – a deep, rich brown, soft-matte surface with very clean, minimal decoration.

With many indie skincare brands exploring similar directions, UKPACK drew on its experience in refillable airless systems to help Clae find a structure that matched product performance, sustainability goals and brand aesthetics.

The first requirement was a true airless system that could still work with a refillable structure.

Traditional open-neck jars or simple inner pods would struggle with:

• continuous air exposure every time the lid is opened
• inconsistent dosing from users scooping out product
• hygiene concerns when multiple people share one jar

Clae wanted pump-based, one-handed dispensing in a compact, 50 ml size – and the same hardware also had to accept replacement cartridges.

Visually, Clae’s world is defined by a specific, muted brown and very restrained graphics.

The packaging team wanted:

• a soft, matte surface that looks calm and tactile, not glossy and cosmetic
• reliable color matching between outer jar, lid and refill cartridge parts
• low-key branding: simple white logo and product text, with a debossed logo on the lid instead of heavy decoration

The challenge was to achieve this look without turning the project into a fully bespoke tooling programme for every component.

Refill systems can easily become complicated.

Clae needed:

• a straightforward cartridge swap that customers can do at home without tools
• secure engagement between refill cartridge and outer jar to prevent loosening or rattling
• a pack architecture that fits smoothly into their filling and assembly workflow, without adding fragile or fussy parts

The chosen system had to feel intuitive for the end user and efficient for the production line.

UKPACK recommended its UKC42A refillable airless pump jar platform in the 50 ml configuration.

Key features:

• An airless pump engine that limits air ingress and helps protect the tallow-based balm.
• A clean, top-dispensing actuator that delivers controlled, finger-free dosing.
• A refillable inner cartridge that locks into a durable outer jar, allowing Clae to sell a replacement cartridge SKU without changing the look on shelf.
• The same hardware family is available in 15 g, 30 g and 50 g, giving room for future line extensions.

This approach allowed Clae to get the functionality of a bespoke airless system while leveraging an existing, proven platform.

To match Clae’s visual identity, UKPACK’s color lab worked from physical swatches and digital references to establish a custom brown masterbatch.

The final aesthetic was achieved with:

• Color-matched injection of the main components to achieve the correct base tone.
• A controlled matte spray coating to create a soft-touch, low-gloss surface that feels premium and photographs well.
• Silkscreen printing in clean white for the Clae logo and essential product information, keeping the graphic layout minimal and legible.

For the lid, UKPACK opened a new debossed logo insert, allowing the Clae wordmark to be pressed into the surface rather than printed, reinforcing the brand while keeping the overall look quiet and refined.

Beyond the engineering, the pack also had to be practical for both Clae’s team and their customers.

UKPACK optimised the UKC42A system with:

• A click-in refill cartridge that can be replaced by consumers in a few simple steps, without special tools.
• A secure interface between cartridge and outer jar to minimise movement, creaking or misalignment.
• A filling and assembly flow where cartridges can be filled, closed and then dropped into the outer jar and capped, minimising changes to existing line setups.

The result is a refill ritual that feels deliberate but not complicated, aligning with Clae’s emphasis on simple, thoughtful routines.

For Clae, the finished pack delivers on both performance and brand:

• Protected balm, consistent dosing: The airless pump jar helps limit air exposure and provides repeatable, controlled doses of the rich tallow moisturiser.
• Refill-ready architecture: A reusable outer jar and swap-in cartridge support Clae’s low-waste, long-term product vision without asking consumers to learn a complex system.
• Brand-true aesthetics: The deep brown colour, matte finish, white silkscreen text and debossed lid logo create a cohesive object that looks and feels like part of the Clae universe.
• Efficient launch path: By building on an existing refillable airless pump jar (UKC42A) platform and only customising where it mattered – colour, finish and lid insert – the brand kept tooling focused and brought the new pack to market on a practical timeline.

This project is a good example of how indie and growth-stage skincare brands can adopt refillable airless systems without over-engineering the pack or losing their visual identity.

Key takeaways:

• Use a proven refillable airless platform to get reliable function and then invest in targeted customization (color, finish, logo details) where the brand needs to stand out.
• Think about refill usability from day one – how the cartridge locks in, how it feels in the hand, and how easily the consumer can complete the swap at home.
• Align sustainability messaging with real structural choices: reusable outer components, simplified refills, and packs that look good enough to keep on the counter for years.

For brands exploring refill models or upgrading from open jars to airless solutions, working with an experienced cosmetic packaging manufacturer like UKPACK can shorten the path from idea to a refill system that actually works in real life.

Whether you’re refreshing a hero moisturizer or building a new refill system from scratch, UKPACK can help you:

• choose the right airless pump jars and airless bottles for your formula
• match colours, surface finishes and branding details so the pack feels like part of your world
• balance sustainability, tooling cost and line efficiency with structures that work in real life