Cosmetic Packaging
What We Package
We fill liquid, gel, cream, and powder cosmetic formulas across three core categories. If your product is shelf-stable and pumpable, pourable, or scoopable, it’s a candidate for our equipment.
Skincare
Serums, lotions, creams, facial oils, gels, masks, scrubs, cleansers, and toners.
Hair Care
Shampoo, conditioner, hair masks, leave-in treatments, scalp serums, and styling products.
Body & Personal Care
Body wash, body lotion, body scrubs, hand cream, foot cream, and bath products.
Common Use Cases
Brands come to us when they need single-serve formats for:
- Gift-with-purchase (GWP) programs — branded sample packs that ship with full-size orders
- Subscription box samples — consistent, retail-ready units at scale
- Travel and trial sizes — TSA-friendly formats that move product without committing shelf space to full SKUs
- Retail singles — point-of-sale impulse buys and checkout merchandising
- DTC fulfillment — Amazon, Shopify, and 3PL-ready packaging
- Trade show and event sampling — high-volume runs for product launches and field marketing
- Hotel amenity programs — branded sachets and pouches for hospitality accounts
OTC & Drug-Cosmetic Products
Many skincare and personal care products — including sunscreens, acne treatments, and anti-dandruff shampoos — are regulated as OTC drugs. We package those too under the same FDA-registered, cGMP infrastructure. Learn more about our OTC and pharmaceutical packaging capabilities.
Packaging Formats
We run multiple flexible formats for cosmetic and personal care brands. Sachets and pouches are produced on the same equipment using the same form-fill-seal process — the difference is size, not method, and the terms are often used interchangeably.
Sachets & Single-Serve Pouches
Our core format for cosmetic and personal care products. Three- and four-side seal packets formed, filled, and sealed in a single pass. Fill volumes range from low-volume skincare samples and serum singles up to multi-ounce body wash, lotion, and conditioner pouches. Available with tear notches, hang holes, and shelf-ready finishing.
Die-Cut Pouches
Custom-shaped pouches die-cut to a brand silhouette, product form, or retail merchandising hook. Strong fit for premium skincare, limited-edition launches, GWP programs, and brands that want packaging that does shelf work.
Spouted Pouches & Shaped-Seal Pouches
For products that need controlled dispensing — serums, oils, gels, lotions, body wash, shampoo, conditioner, and similar formats across small and large fill volumes. Our spouted and shaped-seal pouches use a tear-and-pour design: a contoured seal at the top creates a built-in pour spout when the consumer tears across it, delivering precise dispensing without the cost or complexity of a separate fitment. A strong fit for travel sizes, retail singles, sampling, and DTC fulfillment.
Stick Packs (Beauty Supplements)
For powdered beauty supplements — collagen peptides, biotin formulas, hair/skin/nail blends, marine peptides, and beauty drink mixes. Long, narrow single-dose format with premium feel and easy dispensing. Stick packs run powders only; liquids, gels, and creams fill into sachets, pouches, or die-cut pouches instead.
Kitting & Secondary Packaging
Multi-pack assembly, GWP sets, subscription box bundles, retail-ready displays, and ship-ready cartons. We pair filled sachets, pouches, and stick packs into branded multi-packs and promotional sets, either combined with a fill job or run as a standalone service using product you ship to us.
Print and Finish Options
Through our local print partners, we deliver:
- Full-color digital printing — fast turnarounds, low minimums, ideal for pilots and limited runs
- Flexographic printing — cost-efficient at scale for high-volume programs
- Front and back printing on every format
- Premium finishes including matte, soft-touch, gloss, spot UV, and metallic accents
- Custom die-cut shapes and registered tear notches
Frequently Asked Questions
What are your minimum order quantities for cosmetic packaging?
We offer low minimums starting at 2,500 units for basic sachets — among the lowest in the cosmetic co-packing industry, and a strong fit for indie launches, sample programs, and limited drops. Larger formats and custom print or finish requirements may carry higher minimums. From that 2,500-unit floor, we scale up to multi-million-unit production runs on the same equipment. The fastest way to a firm number for your specific project is a consultation call — we can usually provide a pricing estimate on the first call..
How long does a cosmetic packaging project take?
Timelines vary based on print lead time, film procurement, sample evaluation, and run size. We’ll walk you through a realistic timeline on the consultation call once we understand the specifics of your project.
Do you offer custom printing and finishing on cosmetic packaging?
Yes. We work with vetted local print partners to deliver full-color digital and flexographic printing, front and back, on every format we run. Premium finishes including matte, soft-touch, gloss, spot UV, and metallic accents are available, along with custom die-cut shapes and registered tear notches..
What kinds of cosmetic and personal care products can you fill?
We fill skincare (serums, lotions, creams, oils, gels, masks, scrubs, cleansers, toners), hair care (shampoo, conditioner, masks, leave-in treatments), and body care (body wash, lotion, scrubs, hand cream). For powdered beauty supplements — collagen peptides, biotin formulas, hair/skin/nail blends — we run stick packs. If your product is shelf-stable and pumpable, pourable, or scoopable, we can usually run it.
Do you offer spouted or tear-and-pour pouches?
Yes. We produce spouted and shaped-seal pouches that use a tear-and-pour design — a contoured seal at the top creates a built-in pour spout when the consumer tears across it. We do not offer pouches with separate spout fitments; the tear-and-pour design delivers controlled dispensing without the added cost or complexity. Available across small and large fill volumes.
Do you offer kitting and assembly for cosmetic programs?
Yes — see Kitting & Secondary Packaging in our Packaging Formats section. We assemble cosmetic multi-packs, GWP sets, subscription bundles, retail displays, and ship-ready cartons, either combined with a fill job or run as a standalone service.
Can you handle gift-with-purchase, subscription box, retail, and DTC programs?
Yes. Single-serve formats are the core of our business, and we run programs across GWP inserts, subscription samples, travel and trial sizes, retail singles, DTC fulfillment, trade show sampling, and hotel amenity programs. Run sizes range from low-minimum pilots to multi-million-unit production programs.
Do you formulate or manufacture cosmetic products?
No. IBR is a contract filler and co-packer only. We don’t formulate, blend, or manufacture finished cosmetic formulas. You bring the bulk product; we package it. If you need a formulator, we can refer you to qualified contacts in the industry.
Get a Quote on Your Cosmetic Packaging Project
Tell us about your product and we’ll get back to you with next steps — usually within one business day. In most cases, we can give you an initial pricing estimate on the first call.
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