Project packaging is often dictated by the product type and texture. It’s important the product is properly contained and protected but also accessible for the consumer. The perfect balance of looks, functionality, and protection can be hard to achieve, however with our expert advice from Fillcon, businesses are in good hands.

Whether you sell cosmetic or beauty liquids, we have the packaging expertise and advanced filling facilities to help your business grow. Find out all you need to know about gel packaging below or read our various guides and blogs for more packaging and cosmetic industry insights.

How are Gels Packaged?

The most critical aspect of gel packaging is that all the gel is contained and protected from possible contaminants. As with all product packaging, gel packaging should prevent leakages and be resistant to tears, snags, and piercings.

Gel packaging is open lined with film to ensure the gel is contained, as well as to protect packaging integrity by creating a barrier between the product and the material. For example, lots of skincare gels may contain acids and ingredients that can even degrade packaging over time, so lining is critical. At Fillcon, we offer recyclable sachets with effective anti-microbial coatings, so product protection from bacteria and harmful materials is assured, without compromising on recyclability. Foodstuffs and other consumable gels should be packaged with special care as there may be regulations and standards for the anti-microbial properties of packaging materials.

View Fillcon’s sachet services >

See more: What is the Best Material for Cosmetic Product Packaging

Ultimately, packaging for gels, as with most products, should be suitably airtight to reduce the chance of product spoiling. Flexible packaging is often used for gel and other viscous products and can be given more protection from rough and tumble during transport with outer packaging like boxes.

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Also, flexible packaging is favoured for its ‘squeezability’; gel can be easily removed from packaging by squeezing, maximising the amount of product out of the packaging, value for money for the consumer, and less wastage for the business. There are numerous benefits to using pouches for packaging, as explored in this blog.

As gels are viscous, they are well suited to a full range of packaging types. Whether in bottles or tubes, or sachets and pouches, gels should be well protected and easy for consumers to access.

Best Packaging for Gels

Gels are commonly packaged in both hard and flexible packaging, usually depending on the application. In this section we outline the most common packaging type for gels, and which are best for different needs and situations.

Sachet Packaging for Gels

Best for: individual uses/doses

Sachets make for ideal gel product packaging as they contain liquid well and are extremely cheap to transport in comparison to other packaging types. Often holding one or two uses of the product, sachets are precisely filled with exact amounts to ensure enough product is filled without creating excessive waste. Whether sachets are used for samples or travel sized products, or more, they are a versatile and cost-effective solution for gel packaging.

Everything You Need to Know About Sachet Filling >

Sachets can also be filled with tissue too, such as a sheet face mask, which absorbs the gel and makes for a convenient packaging solution. Find out more about tissue sachets.

Pouch Packaging for Gels

Best for: wholesale refills

Similar to sachets, pouches are popular flexible packaging solutions for a wide range of products. Larger pouches are great for either wholesale transporting gel products from one location to another or providing consumers with on-the-go solutions. Pouches have been become increasingly popular in recent years for recyclable refill packaging, used to reduce the amount of harmful waste created by one-time-use packaging.

For more information on environmentally friendly pouch packaging, get in touch with our experts.

See more: Best E-Commerce Packaging for Beauty and Cosmetics Brands

Gel Packs Packaging

Best for: temperature control

One of the most common gel products is gel packs which can be frozen or heated to provide an ice pack for shipping. The packaging for gel packs is flexible and can be frozen without a loss in integrity – usually plastic is used and not something that could absorb liquid and also freeze like paper. Although this plastic packaging type is not recyclable, it is the most effective at packaging these products.

See more: Everything You Need to Know About Recyclable Packaging

Bottle Packaging for Gels

Best for: large amounts

Especially in the beauty and cosmetics industry, bottles are used to store gels that are frequently used by consumers and contain many uses. For example, shower gels are often contained within bottle packaging, with optional hooks for hanging and various pumps, lids and caps to suit the application. Other uses of bottles for gel products include skincare and cosmetic makeup.

Tube Packaging for Gels

Best for: controlled product dispensing

For gel products used in small amounts infrequently, tubes are a popular choice. High concentrate beauty gels, for example, suit tubes as consumers only require a small amount of product. The smaller opening and long-lasting durability of tubes, especially aluminium tubes, make them ideal for holding medium product amounts and dispensing a small, controlled amount.

6 Benefits of Using Cosmetic Tube Packaging >

Glass or jars are not suitable packaging for gels as these are not squeezable, are breakable, and often expose the product to elements even when not in use. Glass is especially not desired for beauty/cosmetic products as this could easily be smashed in a shower, for example.

Sachet Manufacturing for Gels with Fillcon

Here at Fillcon we specialise in manufacturing sachets and filling a full range of packaging types – from our own sachets to pouches, tubes, bottles, jars and more! Whether your business stocks gel products or supplies cosmetic sample sachets, we are on hand to help manufacture and fill your flexible packaging needs. At our advanced facilitieswe manufacture and fill thousands of sachets per day, with cleanliness and quality ensured.

We offer a range of packaging solutions to fit your gel packaging needs, with consideration made for UV protection, seal strength, micro bacterial protection, and even eco-friendly credentials. See our full range of eco-friendly packaging solutions here.

Get in touch with our expert team to find out more or quote for your next product filling project!

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