In cosmetic and supplement manufacturing, packaging mistakes often appear small—but their impact can be significant.
Issues such as leakage, incompatibility with filling lines, poor material selection, or inconvenient dispensing can result in production delays, product returns, and damaged brand reputation.
Based on real production and filling experiences, here are the most common packaging mistakes brands and manufacturers should avoid.
Many brands focus heavily on how packaging looks, while overlooking functional requirements.
A bottle that looks premium may not be suitable for:
High-viscosity creams
Alcohol-based formulas
Sensitive active ingredients
What to consider instead:
Product viscosity and formulation
Dispensing method (pump, dropper, airless)
Compatibility with filling and capping equipment
Good packaging balances aesthetics and functionality.
Material choice directly affects product stability, safety, and cost.
Common issues include:
Using PET for products requiring higher chemical resistance
Selecting glass packaging without considering breakage risk
Over-engineering materials and increasing unnecessary costs
General guidance:
PET & HDPE: widely used for supplements and skincare
PP: suitable for jars, caps, and functional components
AS / PMMA: ideal for premium cosmetic packaging
Glass: best for high-end serums but requires careful handling
Material should match product formula, positioning, and logistics, not just appearance.
Packaging that works in theory may fail on the production line.
Typical problems:
Pumps not compatible with automated filling
Tight tolerances causing capping failures
Bottles deforming under filling pressure
How to avoid this:
Confirm compatibility with existing filling equipment
Test samples on actual production lines
Choose packaging designed for industrial filling
Production-friendly packaging reduces downtime and rejects.
Leakage is one of the most costly and damaging packaging issues.
Common causes:
Poor pump or cap sealing
Inadequate liner selection
Mismatch between bottle neck and closure
This is especially critical for:
E-commerce shipping
International transportation
Liquid and oil-based products
Leak-proof structure should be tested before mass production, not after.
The dispensing system directly affects user experience.
Examples of mismatch:
Lotion pumps for high-viscosity creams
Droppers for products requiring precise dosage control
Spray systems with unstable mist output
Choosing the correct dispensing solution improves:
Product usability
Consumer satisfaction
Brand perception
Decoration limitations are often discovered too late.
Common problems include:
Incompatible surface finishes
Logo distortion after printing
Limited decoration options due to material choice
Early planning allows:
Better decoration results
Cost control
Consistent brand presentation
Most packaging mistakes are preventable—with proper planning and technical support.
Working with an experienced packaging supplier helps you:
Select the right materials
Ensure filling compatibility
Optimize functionality and cost
Reduce production and logistics risks
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