At PhycoHealth, we’ve always believed that packaging should respect the planet as much as the ingredients inside. Our mission has been clear from the beginning:
minimise plastics, protect oceans, and choose materials that genuinely contribute to a more regenerative world.
As we launch our new PhycoHealth Originals in their next evolution — clean, elegant aluminium bottles — here’s the full story of why we chose aluminium, what it means for your skincare, and the science behind its safety.
🌍Why Aluminium? Because Plastic Must Go
Despite endless promises of recycling, the truth is stark:
the majority of plastics never get recycled.
They persist in oceans, soils, waterways and, eventually, in our own bodies.
We’re not willing to contribute to that tide.
We explored every alternative:
Paper & Plant-Based Packaging?
Beautiful idea — but currently impossible without hidden plastic linings for strength and moisture protection. Until fully bio-based, polymer-free paper technology is ready at scale, we won’t rely on “greenwashed” versions of paper.
Glass?
We adore glass. But at scale, the energy costs, breakability, transport weight and carbon footprint make it a close second, not the frontrunner.
Aluminium?
Lightweight. Strong. Infinitely recyclable. And a material with a geological story as old as the planet itself — one that aligns beautifully with our sustainability goals.
So for this next evolution of PhycoHealth skincare, aluminium is number one.
🪨A Few Fascinating Facts About Aluminium (Hardly Anybody Knows These!)
Aluminium is the most abundant metal in Earth’s crust, making up about 8.1% of its composition. But here’s the twist:
1. Pure aluminium never exists naturally.
It is always bound in minerals like bauxite, locked tightly to oxygen and silica. Humans only learned to extract it less than 200 years ago. Before that, it was more precious than gold.
2. Aluminium is geologically stable and chemically “shy.”
It forms a natural oxide layer instantly when exposed to air — a protective coating that stops further reaction. This is part of why aluminium is so durable and corrosion-resistant.
3. Most aluminium ever made is still in use.
Around 75% of all aluminium produced in history remains in circulation. A truly circular material.
4. Aluminium is infinitely recyclable with 95% energy savings.
No degradation, no downcycling. Just a loop that can run forever.
5. Australia is a global aluminium leader
And is now shifting production toward renewable-powered refining, which means cleaner and more ethical aluminium is emerging rapidly.
These facts help explain why aluminium is one of the most important materials for a lower-impact, post-plastic world.
🔬 What About Aluminium and Human Health? Let’s Clear the Air.
This is often where concerns arise — mostly from internet myths and outdated studies.
Here’s the evidence, simplified and transparent:
Where aluminium exposure can be a concern
Very specific circumstances:
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High-dose occupational inhalation of aluminium dust in mining, smelting, and welding environments.
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Unlined metal cookware + acidic foods, which can cause small amounts of aluminium transfer (still far below toxicological thresholds).
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Poorly regulated antacid overuse — some antacids use aluminium hydroxide in very high doses.
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Dialysis patients in the 1970s–80s were inadvertently exposed to aluminium-contaminated water, causing neurological effects (a serious issue of that era — now well-resolved).
Those are the genuine exposure pathways — and they are well above normal consumer contact.
What the research shows
Extensive reviews from:
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WHO (World Health Organization)
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NHMRC (Australia)
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ATSDR (US Agency for Toxic Substances and Disease Registry)
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European Food Safety Authority (EFSA)
…conclude that normal consumer exposure to aluminium — especially via coated packaging — is extremely low and well below toxicological concern.
There is no credible evidence linking consumer exposure to aluminium packaging with disease.
❗ Important distinction
The concerns people sometimes mention (e.g., Alzheimer’s disease) trace back to early observational studies in the 1960s and ’70s.
Modern systematic reviews clearly show:
Aluminium exposure at consumer levels does not cause neurodegenerative disease.
The scientific consensus:
Aluminium is not a risk in daily life at the low exposures typical for food or cosmetic packaging.
🧪Why PhycoHealth Skincare Bottles are VERY SAFE
Our aluminium bottles are fully lined with a safe, food-grade, inert coating.
This inner lining is specifically designed to:
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Prevent aluminium contact with the product
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Prevent leaching
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Prevent sensory or chemical changes
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Protect delicate bioactives like Phyaluronic® and antioxidant botanicals
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Maintain stability, colour, fragrance, and efficacy
This is the same type of coating used for:
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infant formula tins
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beverages
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nutraceuticals
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pharmaceutical-grade packaging
Meaning: your skincare never touches aluminium. Not a drop.
And the lining does not compromise sustainability.
We use BPA-Free Coatings.
Moving to BPA-free coatings may seem like a small change, but it has significant ripple effects across the supply chain and circular economy.
Cleaner material chemistry = fewer pollutants in manufacture
Non-BPA coatings reduce:
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solvent loads
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residual monomers
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worker exposure
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wastewater treatment requirements
They are simply cleaner chemistry from start to finish.
Better alignment with future global regulations
EU, North America and Asia are rapidly phasing out BPA and bisphenol analogues in food and personal care packaging.
By choosing BPA-free now, we:
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avoid future compliance issues
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future-proof our packaging
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stay aligned with best practice, not minimum standard
Source → Use → Recycle → Reuse (∞ loop)
BPA-free liners:
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burn off more cleanly
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introduce fewer contaminants in the melt
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support higher-grade recycled aluminium
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reduce the burden on downstream filtration systems
The aluminium stays pure → which makes recycling more efficient → which increases the proportion of metal that returns to circulation.
This is how a material becomes truly circular.
🛡️Why Aluminium Is Better for Skincare Science
Our formulations contain sensitive natural compounds — seaweed glycans, peptides, antioxidants, essential oils and bioactive gels.
Aluminium offers:
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Superior light protection
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Complete oxygen barrier
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Moisture stability
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Temperature resilience
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Longer shelf-life
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Greater integrity for natural actives
It is simply a better home for our advanced, marine-based formulations.
♻️ And Yes, We’re Still Moving Toward Refill Culture
Our aluminium bottles are:
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durable
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designed for longevity
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printed with water-based, non-toxic inks
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part of a refill ecosystem we are expanding (including compostable refill sachets like our SeaFibre line)
This is not the end solution — but it is the best solution available today, without greenwashing or compromise.
💚 In the end: sustainability is about making better choices, not perfect ones
Every material has a footprint.
Our goal is to choose the materials that:
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reduce harm
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eliminate plastics
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protect oceans
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protect product integrity
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and support Australia’s shift to clean manufacturing
Aluminium ticks these boxes — cleanly, safely, scientifically.
We hope this gives you a deeper look into why aluminium is our choice today, how we ensure your skincare stays pure and protected, and how this step fits into our larger goal:
Healing humans without harming oceans.
References:
Australian Government, Department of Industry, Science and Resources. "Joint Media Release - Aluminium Forge: Australia's Manufacturing Future." Link
ScienceDirect. "Sustainability of Aluminum Production: The Environmental Impact of Aluminum Recycling." Link
United Nations Environment Programme (UNEP). "Plastic Pollution and its Impact on Marine Life." Link