When a cosmetic brand approached us for a custom lip balm packaging project, they already had a clear goal in mind — they wanted to develop a more sustainable lip balm packaging solution for their product.
However, creating sustainable packaging is not simply about replacing one material with another. A successful packaging solution needs to consider multiple factors, including material performance, visual appearance, production feasibility, and the final user experience.
The customer came to us with the idea of developing an eco-friendly lip balm package, while our role was to help transform this concept into a practical and functional packaging solution.
Through continuous communication and evaluation of different options, we worked together to determine the suitable materials, printing methods, and internal structure for this project.
The final goal was to create a sustainable lip balm packaging solution that could balance environmental considerations, premium appearance, and smooth product usage.
Developing Sustainable Lip Balm Packaging: From Sustainability Goals to Material Selection
Material selection was one of the most important parts of this project.
Many people think sustainable packaging simply means choosing a different material. However, in actual production, the decision requires careful consideration.
The selected materials need to meet several requirements:
- Supporting the sustainability goals of the brand;
- Maintaining sufficient packaging strength;
- Providing good printing performance;
- Ensuring the final product experience.
For this project, we reviewed the materials commonly used in paper tube packaging and adjusted the material selection based on the customer’s sustainability requirements.
Choosing a More Suitable Inner Material
For many paper tube packaging projects, grease-resistant paper is a common choice for the inner structure.
The reason is that this type of material can provide better oil resistance and moisture protection, which can be useful for products containing oily ingredients.
However, some grease-resistant papers achieve these properties through additional coating layers, which may include plastic-based components.
For customers without specific sustainability requirements, this type of material can still be a practical option.
However, sustainability was a key priority for this project.
After discussing the customer’s requirements, we selected a paper-based inner material without plastic components to better match the environmental direction of the packaging.
Creating Premium Appearance Through Printing Selection
The outer paper selection was another important consideration.
Based on the customer’s original design concept, coated paper was initially one possible option because it usually provides:
- brighter colors;
- smoother surface;
- stronger visual impact.
However, coated paper contains an additional coating layer, which was not the ideal choice for this sustainability-focused project.
Therefore, we recommended switching to white kraft paper, which does not have the same coating layer and better matched the customer’s requirements.
One challenge with white kraft paper is that the printing effect is naturally different from coated paper.
Because the surface does not have the same smooth coating, colors may appear slightly softer.
To maintain a premium appearance, we recommended using spot color printing instead of standard CMYK printing.
For this project, three spot colors were selected.
Through careful color control and printing adjustment, the packaging was able to achieve a more consistent and refined visual result while maintaining the sustainability goals of the project.
This experience also showed that sustainable packaging does not mean sacrificing design quality. With the right combination of materials and printing techniques, brands can still achieve a premium appearance.
Designing the Push-Up Structure for Better User Experience
For push-up lip balm packaging, the internal structure plays an important role in how consumers interact with the product.
Unlike ordinary paper tube packaging, a push-up lip balm tube needs to consider the movement of the product during actual use.
During the initial sampling stage, we provided our standard white sample with an 8mm push plate structure, which is commonly used for this type of packaging.
During testing, we noticed that when the tube was empty, the internal air pressure could slightly influence the movement of the push plate. When opening the upper lid, the push plate could move upward slightly.
After identifying this situation, we communicated further with the customer to better understand the characteristics of their lip balm formula.
Adjusting the Structure Based on Product Characteristics
Through communication with the customer, we learned that the lip balm formula was relatively oily and had a softer texture.
For this type of product, the fitting between the push plate and the tube wall needs careful adjustment.
If the fitting is too loose, the product may not remain stable during use.
However, if the entire push plate is made too tight, the pushing resistance may become too high, affecting the user experience.
Therefore, instead of using the same diameter throughout the entire push plate structure, we developed a more balanced design.
The final structure used different fitting levels:
- The lower part of the push plate was designed with slightly more tolerance to allow smoother movement.
- The top contact area, approximately 1mm in thickness, was designed with a tighter fit to improve product stability.
By adjusting different areas of the structure, we achieved a balance between:
- smoother pushing performance;
- stable product positioning;
- better control during use.
After confirming the improved structure, the design was applied to mass production.
From Prototype to Production: Bringing the Concept to Life
Before mass production, both our team and the customer conducted testing on the samples.
The evaluation included:
- packaging structure;
- material performance;
- compatibility with the lip balm formula;
- overall user experience.
After the samples were approved, the packaging moved into mass production and was delivered to the customer.
The customer then completed the filling process and prepared the final product for market presentation.
The packaging solution was later submitted by the brand for a packaging award, receiving recognition for its sustainable design approach and overall packaging concept.
What We Learned from Developing Sustainable Lip Balm Packaging
This project was more than simply creating a paper tube for a cosmetic product.
It was a process of transforming a sustainability concept into a practical packaging solution through:
- careful material selection;
- printing technique optimization;
- structural improvement;
- manufacturing experience.
A successful sustainable lip balm packaging solution is not only about choosing environmentally friendly materials.
It also requires understanding how materials behave, how products interact with packaging, and how consumers experience the final product.
For custom packaging development, the best solutions come from balancing sustainability, design, and functionality together.
For readers interested in learning more about this project, pls read the original blog here:
