The challenges are almost always the same: wrong choice of glass or plastic, incorrect closures that lead to leakage, labels that fade, droppers that malfunction with oils, or even fonts that consumers cannot read. The cost of correcting packaging mistakes is far greater than choosing the right packaging from the beginning. That is why manufacturers follow strict evaluation processes before finalising any jar, bottle, cap, dropper, tube, or dispenser.

Choosing the Wrong Packaging Material (Glass vs Plastic)

Many new brands select packaging based only on aesthetics without understanding product compatibility. A beautiful jar or sleek bottle is useless if it reacts with essential oils, causes oxidation, or weakens over time. As manufacturers, we repeatedly see issues where active ingredients degrade faster simply because the packaging was not chemically stable. The right material protects the formula, maintains pH, and ensures shelf stability. When selecting between glass, PET, HDPE, or aluminum, always evaluate the viscosity of your product, sensitivity to light, and long-term storage conditions.

• Choose packaging based on product chemistry, not just looks.
• Test for compatibility with essential oils, acids, and hydrosols.
• Avoid cheap plastics that warp, cloud, or react with formulas.

Using Low-Quality Caps, Pumps & Droppers That Leak

One of the most common complaints new brands receive is leaking pumps and droppers. This happens due to poor threading, weak sealing, incompatible plastic, or low-quality pump springs. As manufacturers, we always advise stress testing because transportation friction shifts caps, loosens droppers, and causes leakage. A leaking product damages the customer experience instantly and also leads to returns and negative reviews.

• Always conduct drop tests and pressure-leak tests.
• Prefer high-quality droppers with strong rubber bulbs.
• Ensure airtight locking systems for facial oils and serums.

Ignoring the Importance of Light Protection (Amber vs Clear)

Many botanical formulations oxidize quickly when exposed to sunlight. Yet, new brands often choose clear bottles because they “look premium.” This mistake ruins product stability. Amber, blue, or matte UV-coated bottles protect ingredients like vitamin C, cold-pressed oils, hydrosols, and plant extracts. From a manufacturer’s perspective, nothing impacts shelf life more quickly than UV exposure, especially in natural and preservative-free formulations.

• Use amber bottles for cold-pressed oils and essential oils.
• Clear packaging is suitable only for stable formulations.
• UV-protective coatings add value for sensitive ingredients.

Choosing Fancy Shapes That Are Hard to Fill or Ship

While unique bottle shapes look attractive, they cause major operational challenges during manufacturing. Odd shapes don’t sit properly on filling machines, increasing wastage and spillage. They also break easily during shipping and are difficult to label because of curved surfaces. As a manufacturer, we recommend starting with classic, stable shapes that support speed, efficiency, and accuracy in filling lines.

Points:

• Avoid overly tapered or asymmetrical bottles in the beginning.
• Ensure your packaging fits easily into standard filling equipment.
• Choose shapes that provide smooth label application.

Using Illegible Fonts & Poor Label Design

New brands often prioritize aesthetics over readability. Fonts that are too thin, too small, or too stylish make the product hard to read—especially the ingredients list and usage instructions. From a compliance perspective, this leads to legal issues and customer distrust. Labels must be clean, readable, professional, and printed with high contrast to survive rubbing, water exposure, and oil contact.

• Use simple, high-contrast fonts for easy readability.
• Ensure mandatory information stands out.
• Avoid overcrowding your label with unnecessary text.

Not Listing Ingredients in the Correct Order (Legal Non-Compliance)

Many new brands do not follow INCI guidelines or the rule of listing ingredients in descending order of concentration. This can lead to regulatory rejection, customer complaints, and even penalties. Manufacturers strictly follow standard INCI naming because it ensures transparency and global acceptance. Incorrect ingredient lists also reduce customer trust.

• Always follow INCI names, not common market names.
• List ingredients from highest to lowest percentage.
• Add allergens separately if the formula requires them.

Not Adding Batch Number, PAO & Manufacturing Details

Most beginners do not know that packaging must legally include batch number, MRP, PAO symbol, manufacturing date, shelf life, and manufacturer details. Missing these elements makes your product non-compliant and legally unsafe to sell. As manufacturers, we ensure every label follows regulatory norms to protect both the brand and the customer.

• Batch number ensures traceability and safety.
• PAO symbol shows how long the product is safe after opening.
• Manufacturer details build transparency and trust.

Wrong Choice Between Jar, Pump, Dropper & Tube

Packaging must match product viscosity. Creams in droppers, gels in jars, powders in pumps, all these are common mistakes. As manufacturers, we see that incorrect dispensing leads to contamination, wastage, and poor customer experience. Packaging must deliver product smoothly and hygienically.

• Use droppers for thin, liquid serums.
• Pumps for lotions and gels.
• Jars only for thick butters and balms.

Overlooking Sustainability & Recyclability

Today’s customer is conscious, educated, and eco-aware. Brands using multilayer plastics, PVC, or non-recyclable packaging lose long-term appeal. Instead, using glass, PET, HDPE, aluminum, or biodegradable labels improves your brand perception. Manufacturers now offer Sustainable Beauty Packaging options that align with modern consumer values.

• Choose recyclable plastics like PET or HDPE.
• Offer refill packs for lotions, shampoos, and oils.
• Use biodegradable labels and minimalistic designs.

Not Conducting Compatibility, Stability & Transit Testing

The biggest mistake? Launching a product without proper testing. Packaging must go through:

1. Stability testing (temperature + humidity)
2. Compatibility testing (chemical reaction with product)
3. Transit testing (shipping pressure, friction, shaking)

Most new brands skip these due to cost, but manufacturers consider them essential for long-term success and safety.

• Always test packaging with your final formula, not samples.
• Check for color changes, cracks, leaks, and odor shifts.
• Simulate road and courier transit before finalizing packaging.

Conclusion

Packaging is not just about looks, it is the backbone of a safe, stable, and trustworthy beauty product. The right material, correct labeling, secure closures, and proper testing protect both your formula and your brand reputation. Most new brands fail not because of the product, but because the packaging was never designed with compatibility or practicality in mind. By avoiding these common mistakes and choosing packaging strategically, your brand becomes stronger, more reliable, and more consumer-friendly. Smart packaging isn’t an expense, it’s an investment in long-term success.