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Mono-material: Hype or Real Sustainability in the Cosmetic Industry?

Updated: 6 days ago


The cosmetic industry has long been synonymous with luxury, design, and innovation—but it has also been associated with excessive plastic waste.
The cosmetic industry has long been synonymous with luxury, design, and innovation—but it has also been associated with excessive plastic waste.

Now, the sector is undergoing a green transformation due to customer demand and the EU Packaging and Packaging Waste Regulation (PPWR). For more information on this new regulation, Read our article on PPWR. Mono-materials have emerged as a key solution in the quest for sustainable packaging. But what does it really mean, and how does it work in real life?


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Understanding Mono-materials


Mono-materials refer to packaging made entirely from a single type of material, such as:


  • Polypropylene (PP) – used in jars, caps, and pumps

  • Polyethylene (PE) – common in tubes and bottles

  • PET – typically used for transparent containers


Unlike traditional packaging that combines multiple material types (or plastic and metal), mono-material designs make products easier to recycle. They are more environmentally friendly and better suited for a circular economy.


Hype or Real Sustainability?


Mono-material plastics are more than just a trend. The technical solutions exist, the economic incentives are clear, and the environmental impact is measurable. However, it takes more than just switching materials. It requires system thinking, design changes, and a willingness to challenge old habits.


Applications in the Cosmetic Industry


Mono-materials are increasingly used across a wide range of cosmetic packaging formats. By designing packaging with a single material type, brands can simplify recycling without compromising aesthetics or functionality. Here are some common examples:


Bottles and Pumps


  • Airless bottles designed with PP components to preserve product integrity and recyclability.

  • Flip-top bottles made entirely of PP or PE for easy dispensing.

  • Pump bottles with mono-material pump mechanisms, eliminating metal springs.

  • Squeeze bottles for shower gels or hair products, molded from flexible PE.


Jars


  • Double-wall jars made from PP, offering a premium look while remaining recyclable.

  • Single-wall jars for creams or balms, often molded in PET for clarity and durability.

  • Stackable jars with uniform PP lids and bases, ideal for travel or multi-product kits.


Tubes


  • Mono-material PE tubes with matching PE caps, used for serums, masks, or creams.

  • Twist-up tubes for solid products like balms or sticks, designed with all-PP components.


Refill Packaging


  • Refill pouches and service bottles made from mono-material, reducing material use.


These formats are being adopted by both indie and global cosmetic brands aiming to meet sustainability goals while maintaining brand identity and shelf appeal.


How Recycling Facilities Sort Mono-materials


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For mono-materials to be truly sustainable, they must be effectively recycled. This is where recycling and sorting facilities play a crucial role:


1. Optical Sorting


  • Packaging is identified using near-infrared (NIR) technology.

  • Mono-material plastics like PP, PE, and PET are recognized and separated from mixed materials.


2. Washing and Pre-treatment


  • Packaging is washed to remove cosmetic residue, labels, and adhesives.

  • Clean plastic ensures higher quality recycled material.


3. Granulation and Reprocessing


  • Plastics are shredded and melted into granules.

  • These granules are reused to produce new cosmetic packaging.

  • This enables a closed-loop system—ideal for a circular economy.


Challenges


  • Packaging with mixed materials (e.g., plastic + metal pumps) disrupts sorting.

  • Small components must also be made from the same plastic type for optimal recycling.


Trends and Innovations in Mono-materials


Mono-material plastics are driving trends in the cosmetic industry:


  • Minimalist Design – Fewer materials create cleaner aesthetics.

  • Refill Systems – Easier to implement with uniform plastics.

  • Transparency and Traceability – Consumers demand verified sustainability.

  • Collaboration with Recyclers – To ensure packaging is actually recycled.


Benefits for Brands and the Environment


By using mono-material plastics, cosmetic brands can:


  • Reduce carbon footprint.

  • Simplify waste handling.

  • Improve recyclability.

  • Strengthen sustainability credentials.


This offers both environmental and commercial advantages—a rare combination.


The Future of Mono-materials in Cosmetics


As the cosmetic industry continues to evolve, the adoption of mono-materials will likely increase. Brands that embrace these materials will not only meet regulatory demands but also cater to a growing consumer base that values sustainability.


Conclusion


Mono-materials represent a meaningful step toward a more sustainable future for cosmetic packaging. When design, production, and waste management work together, the cosmetic industry can transition from being part of the plastic problem to becoming part of the solution.



© Norse Packaging

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