Stick Formats That Stack Up

The stick package is most commonly associated with lipsticks and deodorants, but new stick options have made this format a practical configuration for soft solid foundations, blushes, bronzers, cream eye shadows, sunscreens, skin treatments and even solid fragrances.

Versatility is at the heart of stick packaging’s growing appeal. Formulas can be either top or bottom filled, and the entire package is excellent real estate for decorative brand marketing. For beauty consumers, the format is leak-free and secure for easy portability, and product can either be swept directly onto skin or easily accessed with an applicator brush or sponge.

Mónica Arcos, category specialist at Quadpack, says sticks are booming, and it’s only the beginning thanks to cross-category adoption. “Largely driven by the solidification trend, all categories are adopting sticks in their portfolio,” she says.

“Sticks as a category have big potential because of a number of trends we observe in the market including water reduction, solidification and beauty-on-the-go.”

See more: Why Stick Packaging is So Popular

Lipsticks with a Twist

With pandemic era masks slowly coming off, colorful lipsticks and restorative lip treatments and balms are experiencing renewed consumer demand.

HCP Packaging offers complete packaging solutions for the lipstick/twist-up stick category and its options also give brands the option to combine two products in one configuration. “Our portfolio includes double-ended twist-up sticks, or combination packs with a twist-up mechanism for solid formulas on one end and a lip gloss applicator on the other,” explains Cheryl Morgan, the company’s creative marketing manager. “For a mix-and-match approach, the ‘Push & Pull Lipstick’ contains two mini sticks within a highly portable case and can be effective for lipsticks, concealer, color correctors, contouring, highlighter or blush.”

Because lipsticks lend well to sustainable refilling, HCP has a variety of stock full size, super slim, mono-material PP/PET/aluminum, and paper lipstick packaging options, which can also be combined with custom parts if a brand is seeking a completely unique look.

HCP’s recent brand work includes partnerships with Ariana Grande’s R.E.M Beauty for its Lip & Cheek Stick two-in-one balm package, which features weighted PCR materials, and a tactile, silver matte finish combined with a transparent, “lens-effect” domed cap for convenient shade identification.

“Lipsticks are often considered ‘trophy’ beauty items; designed to be luxurious, opulent and treasured,” says Morgan. “A trend for ‘vintage’ style lipsticks is definitely apparent at the moment; usually full-sized mechanisms with almost over-sized and attention-grabbing fashion parts with styling inspired by eras gone by.”

HCP recently produced “a most opulent lipstick” for Yumee’s Signature Collection. It was inspired by ornate Chinese porcelain and silk embroidery with silhouettes echoing the glamorous clothing worn by the literati during the Tang Dynasty.

The brand’s signature hues elegantly combine with a high-shine gold metallic finish for an aesthetic that’s fashionable, fresh and feminine. Synonymous with the style and sophistication of couture fashion, intricate gold and environmentally friendly faux leather detailing emulates the allure of mini handbags and key rings.

Cameo Metal Products’ stock metal-cased lip balm stick is designed for hot fill applications like lip balms and ointments, and is designed to look as good on the shelf as it feels when held in the hand.

“Our .15oz Metal Cased Stick package is a slim, clean design,” says Cameo’s CEO Anthony Di Maio, adding that the company offers up to four-color decorating on the body portion of the stick plus deco options for the cap to create unique looks for any client. “We have capabilities to emboss the top of the cap to give a stock package an upscale custom look.”

Di Maio says the majority of Cameo’s brand partners use its stick packing predominantly for lip balm and sunscreen products. A small number also use them for fragrance stick products.

HCT by kdc/one is reporting an increased interest in its PET mono-material lipsticks, which have recently been expanded with more sizes and refillable options. The company also launched a new 100% aluminum (and fully recyclable) lipstick/lip balm package. Megan Langdon, global director of design, HCT by kdc/one, says there are two options that share the same cup diameter, but one has a heavier, luxe base (and is still 100% aluminum).

On the trend front, Langdon says lipstick caps have become a highlight in the realm of eco-friendly reusable packaging. “In order to encourage consumers to reuse their existing cases and caps, case designs have been refreshed to become something consumers want to hold onto with the use of premium materials and personalization,” she says, noting that magnetic closures and improved designs for refillable cases that still deliver a satisfying “click” are additional trends.

Ecological Advancements

A number of stick packaging providers have made great strides related to improving the environmental friendliness of their products and processes.

Remarking on her company’s growing library of stock components for sticks, Langdon says HCT by kdc/one has recently been optimizing stock designs to be more sustainable. “HCT’s approach to sustainable packaging isn’t one size fits all,” she says. “We look at different pillars of sustainable packaging design to make sure that each new component fits into at least one of these sustainable categories: Designed for Recycling, Bio-sourced materials, Post-Consumer Recycled material, and Refillable designs.

“We have been including bio-sourced material into some of our caps to cut down on virgin plastic and adding a refillable element to an existing tool like our mono-material mechanical eco-PET pencil to cut down on single-use material.”

Viva Healthcare Packaging (Canada) Ltd. manufactures sticks that meet the current requirements of the rigid polypropylene (PP) recycling stream. The company’s newest stick designs can be replenished with Cartridge Refills that are easy to click in place and remove and, according to the company, cut plastic consumption in half with each use.

“Consumers don’t need to throw out their empty sticks anymore; they can re-use their sticks and replenish them with easy-to-use Cartridge Refills,” says Viva’s Melanie Gaudun, business development manager. “Viva’s Barrel, Cap and Cartridge Refills can include 100% PCR in a mono-material design that is compatible with the rigid PP recycling stream—this is one stick you won’t want to part with.”

Viva currently specializes in oval deodorant and anti-perspirant type sticks with in-mold label decoration. The company offers in-mold labels to provide high-definition artwork with full, 360-degree coverage on cap and barrel faces, and includes options for spot gloss/spot matte, foil effects and velvet soft-touch finish.

Lume is currently taking advantage of Viva’s in-mold label oval sticks, with its range of cheerfully colored Whole Body Deodorant Sticks, using 100% polypropylene PCR resin with white colorant.

Quadpack is making good on its endeavors to produce experiential products that have a “positive impact on the environment and society.” The company’s Arcos explains that Quadpack’s sustainability efforts focus on PCR content, POM/POK/PBT-free mechanisms and refillable systems to help minimize packaging waste while also working on mono-material designs that use recyclable materials.

“Mechanisms usually contain POM, POK or PBT, materials which will likely soon be banned,” she says. “Sustainability is a journey, one which has us continually improving our offering.”

To that end, Quadpack is broadening its panstick lineup with the launch of Infinite Panstick in three top fill capacities (4.5-, 10- and 15g) with bottom filling to follow. The system is airtight, meaning its ideal for water-based and soft formulations, and it boasts a refillable, 100% PP mechanism.

Quadpack also offers a variety of lipstick packaging, including a PET pack that’s made to compatibly support long-lasting (isododecane) lipstick formulas and treatment formulas with active ingredients like retinol.

Quadpack’s latest premium lipstick launch is Iconic Woodacity, a refillable, wooden lipstick container that’s designed for minimal impact and maximum consumer engagement. The package incorporates Aptar’s precision Iconic mechanism, which is compatible with most filling lines without any adjustments. It’s also POM-free, glue-free and lubricant-free and allows for a smooth actuation of the bullet.

The mechanism is contained in a 100% certified and sustainably sourced ash wood mono-material casing that’s custom-designed and manufactured by Quadpack. The casing opens and closes with Quadpack’s new and patented ‘Solo Twist’ system. The intuitive twist gesture features an oval-shaped interior which ensures that the cap auto-locks on a quarter turn.

Refilling is also easy. Consumers simply pull out the used mechanism and snap in the new one. They can also keep various colors and insert the one they want to use today, further reducing the pack’s impact.

Roberts Beauty offers many innovative sticks including patented propel/repel collections and hot-pour formula-friendly packages for eye, face, lip, skin and body formulas. Its newly designed, fully sustainable manual stick concepts are a product of the company’s efforts to expand the use of sustainable alternatives for stick packaging, specifically with reclaimed ocean plastic resin and mono-material minimalist designs, while at the same time finding opportunities to streamline its manufacturing processes.

“Roberts Beauty is taking a full-circle sustainable approach to design, sourcing and manufacturing, continuously exploring new and innovative materials including our Oceanworks reclaimed ocean plastic as well as new developments in PCR and plastic-free initiatives,” says the company’s Jaelynn Burkamper, manager, creative and innovation. “We’re reducing the number of parts and materials used where possible for efficient design, manufacturing and easier recycling.” 

One of Roberts Beauty’s most recent stick packaging brand partnerships was with DP Hue’s Root Touch-Up Stick, which called for a two-in-one stick plus applicator configuration. “The challenge for this project was to [find/design] a component that is airtight to properly house and protect the customer’s waterless stick formula,” says Burkamper. “The final solution was this easy-to-use double-ended applicator with the formula on one end and the blending brush on the other for an effortless user experience.”

Roberts Beauty is additionally working with another brand partner on a launch scheduled for later this year that will hinge on its patented Brik Stik propel/repel package made of 47% reclaimed Oceanworks resin. “This package boasts 10% more product than traditional stick packages while also reducing the amount of space needed in shipping cubes and retail settings,” says Burkamper.

More New Debuts

The new Bottoms Up stick packaging range from CTK Cosmetics is available in both top and back filled options—allowing it to be compatible with many formula types and textures.

“Our Bottoms Up stick collection…allows the consumer to use 100% of the product,” explains CTK’s Tony Lee, vice president, package innovation. “Existing stick products on the market are built with a normal ‘cup’ mechanism and about 1/3 of the product ends up going to waste—this is frustrating for the consumer and this wastage hampers the recycling process.”

CTK Bottom Up Stick is a recyclable PP mono-material and is offered in four stock sizes with volumes spanning 4-, 7-, 10- and 20g for varied use across different formulation spectrums. CTK recently developed a refillable version and is open to customizing the design to tailored brand requests.

NF Beauty Group offers refillable sticks, airtight stick packaging, and even paper stick packaging, and as that range implies, the company also offers a variety of filling and deco options. “With the Paper Stick, for example, we have the option to do unique paper printing that wouldn’t usually be possible with typical plastic packaging,” says the company’s Andrea Greff, design manager. “Our most popular ‘customization’ comes in the form of ‘materiality,’ with different applications and percentages of PCR content for clients who request and want to meet their sustainability goals.”

One of NF Beauty Group’s latest personal care brand partnerships was with P&G for its Vicks VapoStick package. The product is a new iteration of the brand’s time-honored Vicks VapoRub ointment and relies on Solid-Water Technology to create a non-greasy, lightweight, water-based formula with easy “spreadability” in a no-touch, no-mess swiping gesture. The 1.25-oz stick is made with a recyclable mono-material and features a custom tooled, embossed cap.

And finally, Libo Cosmetics launched Como Beauty Stick, an eco-friendly collection inspired by Italy’s Lake Como to signify the importance of sustainable beauty. Made with 100% aluminum, the beauty stick can be reused, recycled, reformed and reprocessed endlessly while retaining its quality. The sleekly designed stick can also reduce up to half the amount of carbon emission when recycled into a new product.