The beauty packaging industry is under more pressure than ever to design, or redesign packaging to be sustainable, and comply with a myriad of stakeholder demands.  Shoppers want eco-friendly options, particularly the younger demographic. Retailers expect compliance and accountability. Regulation and plastic tax liabilities continue to grow. 

And let’s get real – there are some real hurdles to overcome: 

Formulation Compatibility

Creams, serums, and oils can be tricky as they require protection from air, light, and moisture to remain effective. Many sustainable packaging alternatives haven’t caught up yet, which means stability and shelf life can be at risk. There are some amazing boundary material innovations, including water-resistant barrier protection Hydroblox™ coming on the market, but sourcing and testing for efficacy take time.

Manufacturing Challenges

Many sustainable materials, like molded fiber or bio-based plastics, can’t run on existing manufacturing lines without modifications. Retrofitting production equipment is costly, time-consuming, and disruptive—especially for global brands operating at scale.

Aesthetics & Consumer Experience Matter

Cosmetic packaging is about more than function—it’s also about experience and the aesthetic. Packaging is the first point of consumer contact for most brands, so the pressure is on to look and feel on-brand and stand out on a crowded shelf. 

Cost Concerns

Sustainable materials and low-waste formats often come with higher upfront costs. While many consumers say they care about sustainability, only a fraction are willing to pay more for it.

So how can beauty brands move forward?

• Start small. Pilot one product with a refillable, recyclable, or compostable option. It’s a safe way to learn, measure results, and see how customers respond.
• Partner early. Work with suppliers in the design phase to explore materials that fit into current operations—or that can be rolled out gradually.
• Co-create. Ensure that design, engineering, compliance, and marketing are on the same page from day one. 
• Be transparent. Tell your sustainability story clearly through labels, QR codes, or digital. The journey to sustainable beauty packaging is difficult—but not impossible.

The design innovation required to create sustainable packaging, particularly in beauty, is not simple. With collaboration, creativity, and clear intent, it can become your brand’s most powerful point of difference. 

ABOUT THE AUTHOR

Deb Adams is the Founder of domo.design.

Photo: Shutterstock.com/ New Africa