Shaping the Future of Beauty: Trends in Cosmetic and Personal Care Packaging

Jan 3rd, 2025

From sustainable innovations to new acquisitions, packaging suppliers are delivering newness in 2025.

AdobeStock by wayhome.studio

The beauty and personal care industry is experiencing a dynamic shift, with consumers increasingly prioritizing sustainability and conscious consumption. This heightened awareness is driving a wave of innovation in packaging design, pushing brands to explore eco-friendly materials, minimize waste, and enhance the consumer experience. From refillable systems and minimalist aesthetics to the integration of technology, packaging is no longer just a vessel; it's an integral part of the brand story and a key factor in consumer purchasing decisions.

KDC/One Acquires Italy's Laffon S.r.l. To Boost Makeup Packaging CapabilitiesKDC/oneKnowlton Development Corporation, (KDC/One), a formulation, packaging and manufacturing solution provider, recently acquired Italian-based Laffon S.r.l., a specialist in makeup packaging manufacturing. This allows KDC/One to focus on evolving market demands of consumers who are increasingly looking for partners with regionalized capabilities.

Log in to view the full article

Recyclable Packaging

Albéa's New Blown Film Line Expands North American Sourcing of Recyclable HDPE Tubes

Albéa Expands North American Sourcing of Recyclable HDPE Tubes

Albéa Tubes is now producing its Greenleaf plastic laminate web at its Brampton, Ontario site following the installation of a new blown film line. The move boosts North American sourcing of recyclable HDPE tubes, per the company.

The Greenleaf tubes are recycling ready in the HDPE stream where collection and recycling are available, per the Association of Plastic Recyclers.

The Brampton site is now “a game-changer in offering sustainable solutions made in North America supporting customers in the transition from common aluminum foil containing tubes to all-plastic laminate Greenleaf tubes for such products as toothpaste, personal care items, cosmetics and pharma markets," says Bruno de Carvalho, VP and general manager for Albéa Tubes America.

Brampton plant manager Jerzy Debski says, “Our new line adheres to international standards, ensuring the best quality products and meeting our customers’ demanding requirements."

The Brampton facility was established in 2000 and specializes in extrusion lamination of multi-layer web for aluminum-barrier laminate (ABL) tubes for personal care and cosmetics, oral care, and other applications.

Albéa Cosmetics & Fragrance Launches the North America Collection

Albéa Cosmetics & Fragrance has debuted the North America collection, with packaging options for lipsticks, mascaras, jars and more.

Albéa Cosmetics & Fragrance has debuted the North America collection, delivering sustainable packaging options for lipsticks, mascaras, jars and more for the North American market.

Albéa’s North America collection features a range of 10 sustainable and stylish packaging solutions for beauty brands, including:

“Elixir”: a 30 ml bottle, ideal for serums, made from eco-friendly materials like r-PET and r-PP.
The “Ella” bottle: fully recyclable and made from PP, suits skin care with its trendy square shape.
“Swipe Duo” bottle: combines complementary products in a dual-bottle design, made from 100% PCR PET for sustainability.
“The Moeraki” bottle: offers ergonomic, one-handed use and features a 30% PCR PP cap.
“BIM Family” compacts: provide slim, modern packaging for cosmetics.
“Twirl”: a refillable jar with a secure locking system and minimalist design.
“Bloom” stick and the “On Fleek” stick: offer sustainable and versatile options for lipsticks, balms and face sticks.
“Mesmerize” mascara and the “Impact” brush: deliver precision for lashes and brows.

The North America collection can be produced in Albéa Matamoros, the Mexican hub for mascara, lip gloss and lipstick packaging. This allows Albéa to serve North America more efficiently with faster delivery times, reduced transportation emissions and more sustainable supply chain practices.

Estée Lauder and Strategic Materials Inc. Release Findings Revealing Opportunity for Increased Recycling of Glass Packaging Materials

The Estée Lauder Companies (ELC) and Strategic Materials, Inc. (SMI) have published the findings from a cosmetic glass recycling case study. The study revealed that glass packages with light transmission below 3% may have difficulty passing sortability tests for recycling and that, to increase the likelihood of the material being sorted correctly, the light transmission threshold for glass packaging should fall above 5%.

This approach accounts for any variability in measurement results, particularly for low light transmission readings. ELC and SMI believe these findings will support the industry in creating glass that yields a higher output of recyclable cullet in an attempt to increase global glass recyclability rates.

ELC and SMI have collaborated on testing a variety of 200 glass beauty packaging for the last four years to gain a better understanding of what makes cosmetic glass packaging more efficiently sortable. The testing also aimed to determine how to best overcome the challenges of delivering luxury decorations, colors and formats that can be identified as recyclable.

While authors of the study recommend that further research continue to be conducted, they’ve identified several aspects of packaging design that play a role in a sortability: including:

Glass composition
Color
Thickness of the glass
Decorations (i.e. use of gradient, metallized inks, coatings)
Labels
Closures
Product residue

In addition to new insights on the recyclability of various decorations, colors and formats, the study includes design best practices that can serve as a guide to product developers, package designers, suppliers and brands to help advance circularity.

ELC plans to train its packaging designers, product developers and glass packaging suppliers on the key criteria that were identified in the case study so they can make informed decisions when selecting and designing packaging materials.

ELC and SMI have published this case study as a resource with the Glass Packaging Institute, where industry professionals will have access to the findings and best practices.

Laura Hennemann, senior vice president of sustainability and corporate affairs, SMI, says, “While the majority of glass packaging recycled in North America today comes from the food and beverage industry, we have an opportunity to further advance circularity by looking towards the cosmetics and personal care industry. Through our collaboration with ELC, we are able to uncover what kind of glass cosmetics packaging can be most effectively recycled in practice and at scale and our hope is to remove barriers so that we can maximize recyclability yields and outputs to drive circular recovery throughout the system.”

Robert Peterson, senior vice president, global engineering and packaging, The Estée Lauder Companies, adds, “At ELC, we’re continually investing and innovating at every step of our packaging process to help drive more responsible packaging solutions that help enable our brands to deliver high-quality, luxury experiences to our consumers. We’re proud to collaborate with SMI, and other recyclers, suppliers, and industry partners, to incorporate more sustainable concepts into glass packaging designs and to advance responsible packaging solutions for our brands and the personal care and cosmetics industry at large.”

Cosmetic and Skin Care Packaging & Tools

Wheaton Packaging's New Glass Bottles & Deco Technique

Wheaton Packaging has unveiled two new offerings: Ecoglass bottles and a Crystal Effect Painting deco option.

The Ecoglass line includes a new 200 ml bottle from Wheaton that was produced for refilling and reuse. The supplier says that the Ecoglass line is designed to be more lightweight, using less glass mass than traditional bottles, resulting in a significant reduction in energy consumption, in addition to a reduction of around 15% in CO₂ emissions.

The screw cap on the bottle allows the perfume to be refilled, as well as facilitating the recycling process. The standard bottle collection has three sizes available, 100 ml, 50 ml and 30 ml.

Wheaton’s Crystal Effect Painting Deco effect, meanwhile, utilizes the application of a varnish that creates a special effect around the painting, giving each bottle an exclusive aesthetic.

The brand claims that this process enhances the sophistication of glass packaging, providing consumers with a more visually captivating appearance, but also a tactile sensation.

New Cosmetic Brushes from Anisa Beauty

Anisa Beauty has launched two new cosmetic brushes, the Angled Cream Blush Brush + Multi-Powder Blush Brush.

The company claims that the angled cream blush brush is made with slightly domed, dense-yet-flexible fibers to blend cream and liquid formulas into the skin. The angled design and dense fiber blend allow for a range of applications, including lifting effects and dimension-building for the cheeks. The new multi-powder blush brush from Anisa is made with ultra-soft fibers meant to help press and sweep blush across the cheekbones. The company claims that the large, tapered head aids in precise application and even coverage, while its dense yet fluffy construction allows for a buildable finish.

Both of the new cosmetic brushes from Anisa retail for $32.

Wooden Caps

Byredo's Mojave Ghost Absolu de Parfum Features a Sustainable Cap Made From Sulapac Biocomposite

The luxury perfume house Byredo has appointed FaiveleyTech to create the cap for its new fragrance, Mojave Ghost Absolu de Parfum. The cap is made with Sulapac biocomposite material, allowing the brand to maintain its aesthetic while still reducing environmental impact.

Inspired by the fragrance’s raw and authentic character, the cap mimics the look and feel of Japanese burnt wood.

To achieve this, Sulapac provided a biocomposite material that reduces reliance on fossil fuels. The design was brought to life through a combination of advanced tooling and injection molding techniques. The cap’s magnetic closure ensures a seamless fit with the bottle.

Beryl Tomaschett, sales director of FaiveleyTech Orgelet, says, "FaiveleyTech is proud of this new exclusive creation for Byredo. The teams brought forth an audacious and original project, evoking craftsmanship and nature, which we draw inspiration from. Our processes were pushed to their limits with great energy, and the result, in both the fragrance and the packaging, highlights the brand's original signature."

Upgraded Woodacity Hidden Cap for Cosmetic Packaging

Woodacity Hidden Cap for Beauty Packaging

International beauty packaging manufacturer and provider Quadpack has introduced a sustainable upgrade to its monomaterial wooden cap, Woodacity Hidden, which features a click or friction fit for various pump systems.

Designed and manufactured at the Quadpack Wood factory in Spain, the upgraded cap features the patented Woodacity closure system that functions just like plastic, but using only sustainably sourced wood. To further minimize impact, water-based, biodegradable glue is used to seamlessly join the pieces.

Woodacity Hidden can be customized with a variety of luxury finishes and outer shapes, without affecting its impact. Crafted from maple or ash, all wood reportedly comes from controlled sources. Quadpack also offers FSC-certified wood to create a chain of custody of the raw material. At the end of its life, consumers can discard it, without needing to separate.

Polyfoil Mono-Material Barrier Mini Tubes

Neopac has introduced the Polyfoil MMB Mini tubes at CPHI Milan. The tubes are available in downsized diameters of 13.5-16 mm. Neopac claims to have designed these tubes in an effort to expand its line of high-barrier mono-material solutions, and to continue making advancements in high-barrier packaging technology.

Neopac’s Polyfoil MMB Mini tubes provide an aluminum-free packaging solution for products requiring strong barrier properties, such as certain pharmaceutical, dental and ophthalmic formulations. The brand reports an excellent oxygen transmission rate (OTR) barrier and versatile product compatibility, which is claimed to ensure the integrity and shelf life of sensitive medications. Neopac says the Polyfoil MMB Mini tubes can be combined with HDPE closures.

Advantages of the new Polyfoil MMB mini tubes, per the brand, include:

Enhanced shelf appeal
Versatile closures
Lower environmental impact
Regulatory compliance

Neopac’s Polyfoil MMB Mini tubes are produced at the company’s facility in Oberdiessbach, Switzerland, which has adopted an ISCC+ certification. The plant is powered by clean energy, utilizing both hydroelectric and solar power, reinforcing Neopac’s commitment to sustainable manufacturing.

Martina Christiansen, director of sales, at Neopac, says, “Our new Polyfoil MMB Mini tubes reflect our ongoing commitment to innovative packaging that meets the highest standards of product protection and performance, while incorporating eco-friendly elements. We’re excited to showcase the new tubes at CPHI Milan, providing an ideal platform for engaging with the global pharmaceutical community and demonstrating our commitment to versatile solutions even for sensitive formulations.”

New Developments in Cosmetic & Personal Care Manufacturing

KDC/One Acquires Laffon

This acquisition builds on the company's purchase of HCT Group in 2020. Laffon has earned a reputation for its makeup packaging produced in its highly automated production facility located north of Milan. Laffon's technical and automated production facility specializes in injection molding, decoration and assembly of components, as well as digital and screen printing.

Laffon reportedly prioritizes the use of raw materials derived from renewable sources, while also carrying out assessments on the lifecycle of materials and using energy-efficient machines.

Sandra Wisniewski, global president beauty and personal care at KDC/One, says, “This strategic acquisition significantly enhances our ability to offer innovative packaging solutions, complementing our comprehensive full-service capabilities that include ideation, design, formulation development and manufacturing.”

Denis Maurin, president of sales and innovation, HCT by KDC/One, adds, This acquisition marks a new chapter in HCT's journey. We are thrilled to extend our manufacturing capabilities to Europe and look forward to welcoming the talented Laffon team to the KDC/one/one family. The addition of Laffon to our business means we can now provide our cosmetics clients with a comprehensive, regional end-to-end solution in Europe, enhancing the agility of our services. Moreover, Laffon aligns perfectly with our commitment to offering highly sustainable packaging solutions.”

Luca Rossi, managing director at Laffon, says, “We are excited to become part of the KDC/One family. This is an ideal move for both parties, as we merge our best-in-class packaging capabilities in the cosmetics industry with KDC/One's comprehensive service offering to the beauty sector.”

Federal Package Network Inc. Launches Two New Websites

Federal Package Network, Inc. has launched two new company websites, fplabs.com and federalpackage.com, to help define and further establish its space in the beauty and personal care markets.

Earlier this year, Federal Package Network, Inc. launched FP Labs to better cater to growing beauty brands seeking full-service contract manufacturing capabilities, R&D formulation, compounding and blending, filling operations, container labeling, pack-outs, and product testing.

The new websites offer a look at the full range of contract manufacturing capabilities of FP Labs, its levels of service and capabilities, and the variety of products they produce within their portfolio. Meanwhile, the revised Federal Package website highlights the range of containers for a variety of applications, including the Eco Smart container platform that includes post-consumer recycled (PCR) and post-industrial recycled (PIR) plastic content as well as biodegradable options for a more sustainable alternative to virgin plastics.

Jeffrey Martin, FP Labs and Federal Package director of marketing, says, “the launch of the new fplabs.com allows us to showcase our R&D, compliance and quality control expertise in a singular, complete way. Similarly, the relaunch of the new federalpackage.com helps us to redefine the side of our business as a provider of premium and sustainable containers for a variety of applications.”

Packaging Giants Texen and Quadpack Join Forces

PSB Industries’ plan to combine its subsidiary Texen with Quadpack into a single entity, announced on July 15, 2024, has been completed successfully. As part of the process, Quadpack Industries SA will be delisted from the Euronext Growth stock market in Paris.

PSB’s board of directors, chaired by François-Xavier Entremont, appointed Quadpack’s CEO Alexandra Chauvigné as the new group CEO.

The combination of the two subsidiaries places the group in the top five cosmetics packaging companies worldwide, per PSB, with industrial facilities across six countries.

Texen and Quadpack will operate as standalone businesses and continue to maintain their own models and customer relationships. In parallel, a strategic plan will be drawn up to develop synergies and drive innovation, with the long-term goal of leading the transition of the beauty packaging industry to becoming more eco-friendly, according to PSB.

Entremont says, “We look forward to this new phase in our evolution where the shareholders see great potential for growth. We are confident that, with Alexandra at the helm of the group, bringing her extensive experience in the packaging sector, the value created by the combined group will be significantly amplified, with a knock-on effect on all stakeholders.”

Chauvigné adds, “I am delighted to take on the leadership of the new group. Texen and Quadpack are a perfect fit, with very complementary business models and the potential to create many opportunities and synergies, as we jointly aim to deliver the best value to all our stakeholders.”