Cosmetics Processing


The cosmetics industry is a global powerhouse, encompassing an expansive array of products designed to enhance beauty, promote skin care, and provide personal care solutions. Beyond its aesthetic appeal, the cosmetics sector is a dynamic and rapidly evolving industrial domain with a profound impact on economies, research and development, and manufacturing.

The cosmetics manufacturing industry can be described as an industry that manufactures cosmetics.

These cosmetics include:

  • Color cosmetics, for example, mascara and foundation,
  • Skincare cosmetics, for example, cleansers and moisturizers,
  • Haircare products, for example, shampoos, conditioners, and hair colors,
  • Toiletries, for example, soap and bubble bath.

A small number of multinational corporations dominate the cosmetics manufacturing industry.

The cosmetics manufacturing industry is a science-driven and highly innovative sector. Research and Development programs delve into all imaginable aspects of beauty and well-being, from investigating consumer behavior and beauty aspirations, the biology of skin, hair, teeth, and oral cavity, to new innovative technologies and bettering sustainable development methods.

Thanks to new markets and customer groups, the demand for cosmetic products is growing. As a result, new players are entering this competitive environment.

In this race for market share, time-to-market and flexibility in manufacturing are decisive factors. This calls for modern, fully automated processing technology that also takes advantage of the latest digital technologies.

The cosmetics processing industry exhibits high innovation, particularly within organic and prestige product lines.Cosmetics Processing and Manufacturing - Cream manufacturing

Cosmetic powders have been used since ancient times, for example, as makeup. The role of powders as and in cosmetics has developed from crudely pulverized natural powders to highly sophisticated nanomaterials, with powder manipulation processes growing in their complexity and sophistication.

An essential advantage of cosmetic powders is the many stability-related benefits to the final product.

Cosmetic powders are usually marketed as loose (flow) powders or compacted (pressed) powders.

They are used to provide adhesiveness, slipperiness, absorbance, smoothness, and the bloom effect they provide to the skin or hair.

Technical, scientific knowledge brings significant advantages to the formulator in the increasingly competitive and technological area.

Most cosmetic powder products are similar and standardized concerning their ingredient composition.

Typically, cosmetic powders contain these ingredients:

  • Fillers, for example, talc, kaolin, calcium and magnesium carbonate, metallic stearates, silica, and silicates,
  • Colors, for example, pigments, lakes, mica, bismuth oxychloride,
  • Preservatives,
  • Perfume,
  • Binding agents include mineral oils, fatty esters, lanolin and derivatives, gums, and emulsifying agents.

The composition of these ingredients, along with their particle size and physical properties, impacts the technical quality of the final powder formulation.

Picture: GEMCO Tumble Blender with VAC-U-MAX Pneumatic Conveying System

As the global cosmetics industry evolves and grows with new styles, trends, and innovations, processed cosmetics must also be modernized.

Powders form a substantial part of the base materials needed for cosmetics.

Cosmetic powders processing requires screening, mixing, milling, drying, and agglomeration technology.

In cosmetic powders processing, it is crucial to effectively and cost-efficiently achieve superior hydrophobic (waterproof) and other material properties and better distribution of active ingredients.

Specialized process equipment is also crucial to effectively blend cosmetic powder and enrobe it in a hydrophobic coating.

While hydrophobic materials are not new in the cosmetics and personal care industry, optimizing the process is essential to create high-performance, powder-based products ranging from makeup and mascara to sunblock.

In manufacturing cosmetic products, precision drying is often required as well.

A cosmetic powder improves the appearance of the skin and increases the softness and smoothness.

Essential process equipment for the formulation of powder cosmetics includes:

Even during a financial crisis, the global cosmetics industry continued to grow. This is partly because of substantial innovations in all aspects of this industry, including the use of powders and powder-based cosmetic products.

Improved coating technology, such as fluid bed coating, helps avoid pigment degradation and enhances resistance to interaction with naturally present skin oiliness, extending product efficiency.

There is also an increasing development of microspheres with a soft-focus effect and coated and micronized pigments that help to provide good skin coverage.

The powder presence in cosmetic formulations can grant a perfect finish to makeup products and provide good sensorial properties.

Innovations in the cosmetics industry are not short-term, and it can take over five years of innovative research and formulation to bring a new product to the market.

Innovations are also not static. Every year, a quarter of all cosmetic products on the market are improved or are entirely new.

Although innovation in our industry is a constant process, revolutionary breakthroughs are rare.

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Articles about Cosmetics Processing

Experts for Cosmetics Processing

Chris has been working at Spiroflow for over 10 years and is currently in the role of technical sales manager. He handles all the technical drawings and specifications during the sale and aides our drawing office while the equipment is designed, he also assists the manufacturing department with the build. His vast knowledge of powder handling and mechanical design is why he is involved in every aspect of designing our powder handling solutions.
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Travis has over 20 years of experience in the dry bulk solids industry and is the President at Vortex, an engineering and manufacturing company that specialises in process valves and loading solutions specifically for solids handling. Travis has worked on solution-driven installations across six continents and has a strong knowledge of market-specific regulations and requirements within the industry.
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Matthew Bailey – Technical Lead

Matthew is a mechanical engineer holding an honours degree from the Auckland University of Technology and has been responsible for BFM® Global’s product development, testing and compliance programme for almost 5 years. Matt’s experience is centered on the powder handling industry with a specific focus on flexible connectors, and all the compliance requirements around them. From food to pharmaceutical and all industries in between, Matt works with our Distributor partners, end users and OEMs from Europe, Asia and the Americas to solve application challenges. He regularly attends industry tradeshows around the world and understands the complex requirements of each different market.
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