A cream in a jar, a gel in a tube and a toner in a pump bottle each place different demands on the filling process. When choosing packaging for a cosmetic product, two practical questions matter. How will the formulation behave on the filling line? And how will the customer dispense it? Both are worth considering early in product development.
At our manufacturing facility, we operate four production lines. We fill cosmetic products into jars, bottles, airless containers, tubes, sachets and stand-up pouches. We select the line and adjust the filling settings based on the formulation’s properties, the packaging design and the target fill quantity per unit.
What does cosmetic filling and packaging involve?
Filling and packaging turns a finished bulk formulation into a product ready for sale. The main steps are filling and closing each container. Depending on the project, the process may also include labelling, packing individual products into cartons and preparing them for shipment.
Before starting a batch, we agree on how much product goes into each unit, which closure to use and how the finished units should be packed. This helps us choose the production line and plan each step.
What determines which cosmetic filling line we use?
Viscosity and how the formulation behaves during filling
Viscosity affects how a formulation flows through the filling equipment. A liquid toner and a thick cream can have the same nominal fill volume and still require different settings. For products that tend to foam, the settings can help limit foam formation during filling. For scrubs, we also consider the size of the exfoliating particles and how the formulation passes through the dosing system.
We use these details to select the line and set the filling parameters so that each unit receives a consistent dose throughout the batch.
Packaging dimensions, fill quantity and closure type
Two bottles with the same capacity can differ in shape, neck diameter and closure type. The packaging specification helps us assess whether the selected line can fill and close the container.
The target fill quantity also matters. If a project includes several pack sizes, such as a full-size product and a sample, we assess each format individually.
How do you choose packaging for a cosmetic formulation?
The packaging needs to work on the filling line, remain compatible with the formulation and make the product easy to use. Three questions help narrow down the options.
Does the dispensing method suit the formulation? A pump should deliver a suitable amount for each application. With a tube, the formulation should be easy to squeeze through the opening. A jar gives direct access to the product, which can be practical for thicker creams and scrubs.
Are the formulation and packaging compatible? In compatibility testing, we assess how the formulation behaves in contact with the intended packaging and its components. Depending on the project, we look for changes in colour, odour or consistency, as well as discolouration or deformation of components that come into contact with the product.
Can the selected pack run on the filling line? We consider the dimensions, closure type and target fill quantity. If you have already selected a bottle, tube or jar, sharing the specification or samples before ordering packaging for the full batch helps us assess whether the format is suitable.
For an emulsion in an airless container, for example, we consider how the container will be filled and closed and whether the pump dispenses the finished formulation as intended. That is one reason to include the final packaging in the R&D process early on.
Four production lines at MG Evolution®
At our manufacturing facility, each of our four production lines handles specific packaging formats.
Liquid filling line
We fill bottles, airless containers and vials. Depending on the formulation, this line can handle products such as toners, biphasic products, emulsions and gels.
Jar filling line
We fill glass and plastic jars with products such as creams, gels and scrubs.
Tube filling line
We fill heat-sealable tubes with formulations such as emulsions, gels and pastes.
Sachet and stand-up pouch filling line
We fill cosmetics into flexible packaging. Sachets can also be used for product samples.
Can you outsource cosmetic filling and packaging as a standalone service?
Yes. At MG Evolution®, filling and packaging is available as part of full-service contract manufacturing or as a standalone service. If you already have a formulation, a finished bulk product or selected packaging, we can assess the project based on your specifications.
When you get in touch, please include the product type, packaging format and closure, target fill quantity per unit, and planned number of units. If you have a packaging specification or a sample of the bulk formulation, let us know. These details help us identify a suitable line and establish what needs to be confirmed before filling begins.