Introduction: More than a Trend – A Brand Imperative
Sustainable packaging is no longer a trend in the cosmetic industry; it’s a defining feature of future-ready brands. Material trends in cosmetic retail packaging are rapidly evolving as brands face increasing awareness from consumers, retailer mandates and pressures from regulatory bodies to adopt more sustainable solutions. These solutions have become a creative opportunity in switching to alternative materials, minimizing packaging size, and reducing part weight through material lightweighting. These methods are widely recognized as key strategies in sustainable packaging.
In today’s dynamic environment, choosing the right materials not only helps brands achieve sustainability goals and stay compliant, but also offers a chance to reimagine and elevate packaging both structurally and visually.
Eco-Friendly Materials in Cosmetic Packaging
As the demand for sustainable materials continues to grow—from paper to plastic—it’s important to understand that sustainability means different things to different people. Here are four key terms commonly used when discussing sustainable packaging materials:
- Recyclability: Materials that can be collected, processed, and reused to create new products. Common examples include paper and certain plastics.
- Renewable: These materials come from natural sources that can be replenished, such as plant-based resources. For example, paperboards made from wood pulp.
- Biodegradable: Materials that can be broken down by microorganisms into natural elements over time. The timeline for biodegradation can vary widely.
- Compostable: A subset of biodegradable materials that break down quickly under composting conditions, usually within about 180 days in industrial settings.
Plastic materials like Polyethylene Terephthalate (PET) are widely seen as recyclable. When properly processed, PET can be reused in forms such as post-industrial (RPET) or post-consumer recycled PET (PCR), containing anywhere from 25% to 100% recycled content. There’s also a bio-based version of PET derived partially from renewable plant materials (up to 30%) such as sugarcane. Bio-PET is chemically identical to conventional PET, making it fully recyclable within existing PET recycling streams. This compatibility ensures that brands using Bio-PET can support closed-loop recycling systems without disrupting current infrastructure. Bio-PET offers the performance of conventional PET while increasing the use of renewable materials.
PET is generally accepted under most state Extended Producer Responsibility (EPR) mandates, but correct labeling is essential for effective recycling.
Paperboard is one of the most versatile and sustainable materials in cosmetic packaging. It can often check multiple boxes—recyclable, renewable, and biodegradable—depending on its composition. At Rohrer, we’re embracing the next generation of paperboard that includes post-consumer recycled (PCR) content, enhancing its circularity and reducing the reliance on virgin fiber. However, it’s important to consider that certain inks, coatings, or decorative finishes can limit recyclability or compostability. We help brands navigate these trade-offs, ensuring that every design remains functional, premium in feel, and compatible with recycling and recovery systems.
How Lightweighting Supports Sustainable Packaging
A central focus of Extended Producer Responsibility (EPR) regulations is minimizing material usage in packaging. This goes beyond simply reducing the size of packages. It also includes optimizing the thickness or robustness of materials—commonly referred to as “lightweighting.”
Lightweighting, reducing material caliper, can significantly lower environmental impact while helping brands meet regulatory requirements and sustainability goals.
In both paperboard and thermoformed plastic packaging, the main challenge of lightweighting is maintaining structural integrity. Fortunately, innovations in paperboard technology now offer improved rigidity even in lighter grades—allowing for reduced caliper without sacrificing performance. This often comes with the added benefit of cost savings.
In thermoforming, down-gauging may affect durability, but creative design strategies—such as incorporating structural geometry—can help maintain strength and performance.
Conclusion
Sustainability is more than a trend—it’s a brand imperative in the cosmetics industry. Brands must think of sustainable packaging as a creative solution where design and a positive impact on the planet can take place together.
We understand that every brand is on its own unique path toward sustainability. Whether you’re just beginning or looking for advanced eco-friendly packaging solutions, we’re here to meet you wherever you are on your journey. Trust Rohrer to deliver stylish packaging innovations that blend sustainability with premium performance and standout design.
Our experts can guide you to the right solution for your retail packaging needs, like our all-paper blister packaging, our new EcoVolve-30™ 30% PCR paperboard, or our PCR combo program. Learn more about these sustainable offerings today.
Stay tuned for the next installments of our blog series, where we’ll dive into key trends in structural and high-impact printing effects.
