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Cosmetic Packaging Customization - Sustainable Options

Close-up view of eco-friendly cosmetic jars made from recycled glass
Sustainable cosmetic jars made from recycled glass

Part of a series on Cosmetic Packaging Customization, this post examines practical methods for customization using sustainable options. I cannot write this blog post without mentioning PPWR, as it will impact the industry and influence the decisions being made. So keep in mind that your customization must be in accordance with PPWR. You can still create premium, brand-specific designs.




Use mono-material packaging in your design


Material itself becomes a design element. Mono‑material packaging means the entire container is made from one single material. If multiple materials are used, the packaging must be engineered for easy disassembly so each part can enter the correct recycling stream.


logo for 100% mono-material


  • All PP, PET or HDPE,  is fully recyclable.

  • All glass and all aluminum is acceptable

  • Design for easy disassembly, do not use glue. A PET bottle with a PP dispenser is also acceptable if the pump/lid/closure can be easily removed






This aligns with PPWR principles: design for recycling, avoid incompatible material mixes, and ensure components can be separated without tools or force.




Use recycled materials


PCR (Post-Consumer Recycled). Using recycled content in cosmetic packaging reduces the demand for virgin resources. Many packaging suppliers now offer recycled plastics, glass, and paperboard options that meet cosmetic safety standards.


100% Recyclable

  • Made from recycled plastics

  • Promotes circular economy principles


PPWR sets minimum PCR percentages for different plastic types. PET bottles with 30–50% PCR. HDPE bottles with 10–30% PCR. PP jars or caps with 10–30% PCR (numbers will slowly increase over the years.)



About compostable packaging


PPWR does not favor compostable packaging, but it fully supports lightweight, renewable, or mineral‑filled materials that remain recyclable in existing EU systems. If you use these materials, tell your customers about it.


Acceptable examples include:

  • Sugarcane‑based PE (bio‑PE) → chemically identical to PE, 100% recyclable

  • Wheat‑straw PP blends → PP‑based, recyclable in PP streams

  • CaCO₃/PMU blends → mineral‑filled plastics that remain recyclable depending on formulation


These materials reduce fossil‑plastic content and carbon footprint without compromising recyclability, which is exactly what PPWR prioritizes.




Choose minimalist and lightweight packaging


Minimalist designs focus on simplicity, eliminating unnecessary layers, inserts, or heavy components. Using slim, lightweight bottles or jars with clean lines and limited decoration. Reducing the amount of material used in packaging lowers waste and transportation emissions.


Ways to customize minimalist packaging include:


bottle and jar on a green background

  • Do not use oversized or multi-layered products, use colors

  • Simplify shapes & reduce material volume by choosing straight forms, thinner wall and lightweight closures

  • Minimise decoration. Use direct print or wash-off lables

  • Removing secondary packaging like outer boxes or replacing them with simple sleeves made from recycled paper



This approach not only benefits the environment but also appeals to consumers who prefer sleek, modern aesthetics. Lightweight packaging also cuts shipping costs and carbon footprint.



Offer refillable and reusable containers


Refillable packaging encourages customers to reuse containers multiple times, reducing single-use waste. This option fits well with luxury or high-end cosmetic brands that want to build long-term relationships with customers.


Customization options for refillable packaging include:

refillable jar with pouch and bottle

  • Design light weight containers with elegant shapes and finishes

  • Inner refill: lightweight, mono‑material, PPWR‑compliant

  • Creating refill pouches or cartridges made from flexible recycled materials

  • Adding screw-on lids for easy opening and closing

  • Printing brand details directly on the container with durable, eco-friendly inks


There are some new interessting ways to use a refill pouch, but still it is for large MOQ`s. Refillable systems can be paired with subscription or loyalty programs to encourage repeat purchases and reduce packaging waste over time.



Final thoughts on sustainable cosmetic packaging customization


Sustainable packaging customization offers many paths to reduce environmental impact while creating attractive, functional products. Choosing mono-material packaging, recycled or recyclable materials, compostable options, minimalist and lightweight design doesn’t limit creativity - it forces brands to express identity through smarter, cleaner, more modern design choices. This is exactly where the industry is heading.





  • Packaging must use the minimum amount of material needed for functionality.

  • Packaging must be detectable in sorting systems.

  • Decoration must not hinder recycling or material separation.

  • Packaging must be recyclable in existing EU systems.

  • Packaging must be easy to disassemble without tools.

  • Finishes must not introduce non‑recyclable layers.

  • Refill systems must reduce waste and remain recyclable (encouraged).





© Norse Packaging


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