With only about 21% of consumer recyclables being captured by curbside recycling efforts (The Recycling Partnership), beauty brands are increasingly turning to mono-material packaging to help make recycling easier and more efficient. 

Mono-material packaging simplifies recycling because it removes the biggest barrier consumers face: confusion, explains Amy Pan, General Manager, Epopack. “Most traditional beauty packaging is made of mixed materials; think jars with plastic bodies, metal springs, or layered components that need to be separated before recycling,” she says. “The reality is, very few people have the time or know-how to dismantle packaging correctly, so much of it ends up in landfills.” 

“[Mono-material packaging] allows end customers to place empty packs directly into recycling bins without having to disassemble and separate non-recyclable parts,” comments Jerome Fraillon, President and CEO, Alder Packaging. “This simplicity increases the likelihood of recycling compliance and success. It also supports industry initiatives like PACT take-back programs, since mono-material lipsticks, compacts, and other small components are easier to process.”

This great news, however, is somewhat tempered by availability issues. “The primary drawback of mono-material packaging is availability,” Fraillon explains. “Compared to traditional mixed-material components, there are fewer industrialized stock tools on the market today. This can mean limited options for brands or, in some cases, a longer lead time while waiting for tooling production once a preferred component is selected.”

Daniel Son, Sales Manager at Taesung, has observed a growing demand for packaging configurations that emphasize mono-materials. “Consumers and brands are both paying closer attention to sustainability, and the eco-friendly packaging market continues to expand by over 5% each year,” he says, noting that younger generations, who will drive future consumption, are especially focused on value-driven choices and prefer sustainable options. 

Pan has also noticed that conversations with clients have shifted. “Sustainability is no longer a ‘nice to have’, it’s become central to brand identity,” she says. “Brands want packaging that tells a clear story, one that aligns with consumer expectations for both eco-consciousness and luxury aesthetics.” 

Pan, Son, and Fraillon all expect demand for mono-material packaging to remain strong. Fraillon also expects a forthcoming evolution in the mono-movement. “Many brands are now focusing not only on sustainability, but also on regionalization and sourcing packaging closer to where products are sold,” he says. “This dual focus on mono-material innovation and near-shore supply introduces new challenges for suppliers, but also opens opportunities for collaborative problem-solving and creative design.”

An Easier Path for Tubes

Tubes have long been a go-to configuration for recyclable packaging. For CCL Tubes, which offers mono-material tube packaging with and without dispensing cap options, HDPE tubes might just be one of the easiest mediums for recycling. 

“Tubes made of HDPE mono-material resins can be recycled in the traditional HDPE bottle stream,” says Rick Zierer, Director of Sales & Marketing, CCL Tubes.

One of CCL Tube’s latest mono-material brand partnerships was with Nu Skin for its line spanning shampoo, conditioner, and a range of personal care products. Nu Skin chose several fill sizes from CCL Tubes’ Epoch line of 1.5- and 2-inch diameter tubes. The tubes are made of the custom-colored mono-material Braskem resin, which is derived from sugar cane, plus flip-top HDPE closures. Decoration included premier screen printing. 

Related: Why Tubes Have Become a Go-To Choice

“In 2019, Nu Skin made a public commitment that by 2030, all packaging will include one of the five Rs in the story [refuse, reduce, reuse/repair, repurpose, recycle],” comments Hillary Tipton, Director of Product Scale Up and Commercialization at Nu Skin. “The Epoch line was the perfect flagship line with its ethno-botanical story and Force for Good Donation. By making this change, Nu Skin is estimated to save approximately 7.5 metric tons of virgin plastic.”

Advances in Airless and Pumps

Conversely, one of the toughest packages to produce in the mono-material format is an airless configuration—and some companies have achieved it.

The development of an all-PP mono-material pump is particularly difficult, explains Taesung’s Son, but it boils down to clever engineering. “For example, if the core system parts such as the pump piston, pump check valve, and bottle piston are made entirely of PP, the high friction can cause abrasion issues,” he says. “This is why many companies still mix PP with PE [and] we also faced this challenge, but after numerous trials and adjustments, we successfully developed a pump made of 100% mono PP.”

Taesung’s PP Mono Airless Bottle (30ml/50ml) pump effectively passed a vacuum leakage test at 600 mmHg for 10 minutes, proving that it delivers the same stability as conventional pumps with metal springs. “It combines reliable performance with true mono-material recyclability, which is a strong advantage for global beauty brands,” Taesung’s Son says.

Most recently, Taesung provided an all-PP airless bottle, cream jar, and airtight stick for the launch of a new vegan skin-care line. The brand behind the line emphasizes clean beauty, and places sustainability at the core of its values, and it’s a collaboration that Son says highlights the growing demand for clean beauty and eco-friendly solutions.

The brand selected Taesung’s 30-, 50- and 120ml airless bottle with a 0.5cc dosage; 50g cream jar; and 10- and 20g air-tight sticks. Each item is made entirely of 100% PP, ensuring full recyclability without material separation.

Related: Why Airless Is Growing in Popularity 

The packaging was injection-molded in a variety of colors, and most often finished with a matte coating, creating a clean and simple aesthetic that fits well with the clean beauty concept.

SR Packaging specializes in PP mono-material jars, tubes, and dropper bottles, as well as PE tubes, lipsticks, and EBM (extrusion blow-molded) airless packaging configurations. 

The company’s latest launch is an all-PP EBM Airless Grande, which, at OFC 524 ml, weighs only 40g. Each EBM airless bottle has an antioxidant inner pouch with an EVOH barrier that prevents contents from contact with air and maintains freshness. It also reduces 70% plastic usage and increases 30% filling capacity compared to conventional piston-type airless.

SR Packaging recently partnered with Stratia Skincare to provide a 30ml EBM airless bottle and pump for its C+C Serum vitamin C treatment product. According to Sophie Tu, Marketing Director, SR Packaging, the brand chose to silkscreen print its text and on-pack decorations.

The package proved to be a great fit for the product. “The product is a waterless formula and has a high viscosity for its unique texture,” she says. “The company converted to EBM Airless to improve the dispensing experience and help users use the product till the last drop without leaving residue behind.”

In addition to offering lotion pumps with PP return springs, UKPack also supplies mono-airless PP bottles, jars, and stick containers for sunscreens and deodorants.

Acure tapped UKPack for a mono-material stick configuration for its Invisible Sunscreen Stick SPF 50. “This PP mono-material stick was ideal for the brand because it matches their eco-conscious positioning with a fully recyclable design, while also delivering the durability and twist-up functionality needed for a sunscreen stick,” says Lucas Ji, Founder and Chief Packaging Designer at UKPACK. “Its bold, clean look further reflects the brand’s approachable identity.”

HCT by kdc/one’s catalog currently includes dozens of mono-material products, with 10 launched in the last year and many more in the pipeline. Its newest innovation, called the Calico Airless Pump, is crafted primarily from mono-material PP and engineered for simplicity and performance with a refillable design. In addition to its recyclability, the Calico Airless Pump features co-extrusion technology to minimize product waste.

Additionally, HCT by kdc/one’s Mono Duo Pump features a dual-chamber system that keeps two complementary formulas separate and delivers them together in one powerful pump. Designed with sustainability in mind, the Mono Duo Pump is made entirely from mono-material PP and is also refillable.

“HCT by kdc/one has long been committed to sustainability innovation in packaging design and reducing our carbon footprint overall, says the company’s Angela Buggea, Global Director, Creative Trends and Sustainability. “One of our key design intentions is mono-material designs utilizing PP, PE, PET, AL, HDPE, and tin as well as other recyclable materials that are compatible with current recycling streams.” 

Elegant Jars

Jars are often the go-to container for thick creams and other high-viscosity formulations. Now, jars that pair mono-material vessels with mono-material closures are having a real moment. 

Epopack creates a versatile range of jars, bottles, and caps that are all made entirely from PET. In the past year, the company launched the MJ8 Jar, which the company’s Pan says captures Epopack’s philosophy of merging precision, style, and sustainability. 

“At first glance, the MJ8 looks and feels like a luxury glass jar, thanks to its heavy-wall design, sleek low profile, and perfect 1:1 ratio, but it’s made entirely of PET,” she says. “That means brands can deliver a premium experience to consumers while still keeping the packaging in a single-material recycling stream.”

One of Epopack’s recent collaborations was with an Australian organic skincare brand with a fundamental commitment to sustainability. Epopack created a 15ml jar crafted entirely from 100% PCR. To elevate the look and feel, the brand chose a frosted, matte finish that delivers a refined, modern aesthetic while staying true to their natural ethos. “Because the jar is a mono-material design, there’s no need to separate components for recycling; it’s as seamless and straightforward as their approach to clean beauty,” Pan says.

In addition to offering components in PET, PP, and aluminum, with a broad range of options including bottles, atmospheric pumps, airless pumps, lipsticks, compacts, chubby sticks, deodorant sticks and fragrance caps, Alder Packaging’s portfolio includes mono-material lipsticks (aluminum, PET, or PP), glass jars with full aluminum caps (minus the removable foam liner), and all-PP airless packages. “By following guidelines such as How2Recycle’s labels, brands can combine two mono-material components and still maintain recyclability, as long as the parts are separated before disposal,” says the company’s Fraillon. Over the past year, Alder has partnered closely with industry leaders like Verescence and Axilone to bring new mono-material solutions to market for its customers. One highlight is a glass jar developed with Verescence, paired with a fully aluminum cap from Axilone and Alder. 

In addition, Alder worked closely with a partner factory to innovate a mono-material PP airless package, further expanding the range of sustainable options available for viscous formulas in 30-, 50-, and 100ml sizes.

Looking Ahead

In the last year, Epopack’s Pan has seen demand for mono-material packaging in beauty and personal care accelerate at a remarkable pace. “A few years ago, it was primarily the forward-thinking brands asking us about sustainable solutions,” she says. “Now, we’re hearing from established global players who recognize that consumers are holding them accountable for their packaging choices. Increasingly, educated consumers are also influencing demand.

Pan expects this demand to grow even stronger. “With legislation around packaging waste tightening worldwide, and consumers continuing to vote with their wallets, mono-material packaging will become less of an option and more of a new standard,” she concludes. “The brands that embrace it early are the ones that will lead the conversation and earn the trust of tomorrow’s beauty consumer.”

Read Next

All Eyes on ‘Made in NA’ Manufacturing

Sample Packaging for Beauty: What’s New & Why Minis Are Hotter Than Ever