To switch to metal-free pumps, start with an audit of your current dispensers, match each formula to an all-plastic option, then test, trial and roll out in stages. Most brands can keep their bottles if the neck finish matches. Plan for compatibility testing, a line trial and updated recycling claims before launch.
Why brands are making the switch
Most traditional pumps and sprayers use a metal spring, and often a metal ball, inside a plastic body. That mix of materials makes them hard to recycle, because sorting and reprocessing systems are built around one material at a time.
A metal-free pump uses plastic parts only. That takes metal out of the dispenser, removes metal parts from the product path, and supports recyclability where facilities accept it. Some metal-free pumps go further and are APR-recognized for recyclability.
For brands with sustainability goals or retailer packaging targets, the dispenser is often one of the last parts of the pack to fix. The good news is that switching is a manageable project when you take it step by step.
Step 1: Audit your current dispensers
Start with a simple list of every SKU that uses a pump or sprayer. For each one, record:
- The formula type and how thick it is
- The current dispenser type (lotion pump, treatment pump, trigger, mist, foamer, dropper, airless)
- The dosage per stroke
- The neck finish, such as 24/410 or 28/400
- Where the product is sold (retail, e-commerce, salon, professional)
- Annual volume
This list becomes your plan. It shows which SKUs share a dispenser, which are easy swaps and which need more work.
Step 2: Match each formula to a metal-free option
Next, map each current dispenser to a metal-free equivalent. The table below is a starting point.
| Current dispenser | Metal-free option at APG | Key specs |
|---|---|---|
| Lotion pump | Infinity Lotion Pump, Infinity V2 Lotion Pump (mono), Clip-lock all-plastic lotion pump | V2: PP mono, up-lock, 1.5cc. Clip-lock: PP, 3.5cc |
| Treatment pump | All-plastic treatment pump | PP, full over cap |
| Trigger sprayer | Infinity Trigger Sprayer, All-plastic trigger sprayer pump, Passive vented all-plastic trigger | 28/410 and 28/400; Infinity also 28mm ratchet |
| Mini trigger | Infinity Mini Trigger | 24/410 and 28/410 |
| Fine mist sprayer | Infinity HV Fine Mist Sprayer | 0.5cc, 0.2cc, 0.19cc; 20/410, 24/410, 28/410 |
| Foaming pump | Infinity Foamer Pump, Infinity Mini Foaming Trigger | Foamer: PP, APR recognized |
| Airless pump | Eternal Pump airless bottle (mono material), Mono all-plastic airless pump bottle | Eternal: PP, 15ml, 30ml, 50ml |
| Dropper | Infinity Dropper, All-plastic dropper bottle | All-plastic |
Pay close attention to dosage. If your current pump gives a different amount per stroke, your usage instructions, and possibly your label claims about number of uses, will need to change. For help reading neck finishes and dosage, see how to choose a metal-free pump for your formula.
Step 3: Test compatibility with your formula
Metal-free pumps use plastic springs or other plastic mechanisms in place of metal. The way they interact with your formula can differ from your current pump, so testing is essential.
Run stability and compatibility tests with the new pump on your actual formula and bottle. Check that the pump primes, dispenses a consistent dose, returns smoothly and does not leak. Also look for changes in the formula or the pump parts over time, especially with oils, fragrances and solvents. Our guide on how to test a metal-free pump with your formula walks through a full test plan.
Ask your supplier what experience they have with similar formulas.
Step 4: Run a line trial
A pump that works on the bench must also work on your filling and capping line. Run a small trial with your filler before you place a full order.
- Confirm the neck finish fits your bottles. If it does not, plan a bottle change at the same time.
- Check that dip tubes are cut to the right length for your bottle height.
- Set capping torque and check for cross-threading. Confirm the recommended torque with your supplier.
- Check feeding and orientation on any automated equipment.
- If you ship direct to consumer, run drop and leak tests on packed units.
Some metal-free products are designed to fit existing lines. The Infinity Trigger Sprayer, for example, needs no custom filling equipment.
Step 5: Update your claims and artwork
Switching to a metal-free pump may let you update your on-pack and online claims. Keep the wording accurate. Say "designed for recyclability" or, for APR-recognized products, "APR-recognized for recyclability". Say "recyclable where facilities accept it". Avoid broad claims such as "100% recyclable everywhere".
Make sure the claim covers the right part of the pack. A metal-free pump on a bottle with a hard-to-recycle label or sleeve may still create a problem for the whole package. Review the bottle, label, cap and pump together.
Step 6: Roll out in stages
Most brands do not switch every SKU at once. A staged plan lowers risk and lets you learn as you go.
- Phase 1: Start with one or two high-volume SKUs that use a standard neck finish and a simple formula.
- Phase 2: Move the rest of the line that shares the same dispenser.
- Phase 3: Tackle harder SKUs, such as thick or oil-rich formulas, or products that need a new bottle.
Plan around your current pump inventory and supplier lead times. Ask us about lead times and minimums early so the changeover fits your schedule.
How APG can help
APG makes cosmetic and personal-care packaging, with a plant in Defiance, Ohio for molding and decoration. We can help you map your current line to metal-free options and supply samples for testing. Popular starting points include:
- The Infinity Lotion Pump, APR-recognized with a patented all-plastic up-lock design.
- The Infinity V2 Lotion Pump, PP mono all-plastic with a 1.5cc dose.
- The clip-lock all-plastic lotion pump with a 3.5cc dose.
- The Infinity Trigger Sprayer, with no custom filling equipment needed.
- The Infinity Foamer Pump, PP and APR recognized.
Browse our metal-free pumps and sprayers to see the full range.
Common questions
Can I keep my current bottles?
Often, yes. If the metal-free pump is available in your current neck finish, you may only need to adjust the dip tube length. Test the fit before you commit.
Will a metal-free pump dispense the same amount?
Not always. Check the dosage of the new pump against your current one and update instructions or claims if it changes.
How long does a switch take?
It depends on how many SKUs you have and how much testing each formula needs. Stability testing is often the longest step, so request samples early.
Is all-plastic the same as mono-material?
No. All-plastic means no metal parts. Mono-material means one type of plastic. Some products are both, such as the Infinity V2 Lotion Pump, which is PP mono all-plastic.
Do I need to change my label?
You may want to update recycling claims and usage instructions. Keep claims accurate and specific to the components that qualify.
Ready to plan your switch? Request samples or a quote.