Frequently Asked Questions (FAQs) About Sourcing Ampoule Packaging

Cosmetic ampoules are small, sealed vials designed to contain a single dose of a liquid formulation. Unlike standard bottles, ampoules are hermetically sealed (airtight) immediately after filling, which creates a sterile environment.

They are typically made from glass or high-grade plastic and are opened by snapping the neck (glass) or twisting off a breakaway cap (plastic).

Ampoules have become a cornerstone of the Korean Beauty (K-Beauty) "glass skin" routine because they signal medical-grade efficacy.

• • "SOS" Treatments: They are often marketed as intensive, short-term recovery courses (e.g., a 7-day brightening program) rather than daily maintenance products.
• • Ingredient Stability: The format allows brands to use highly unstable, potent actives (like pure Vitamin C) without heavy preservatives, as the air-tight seal prevents oxidation.
• • Ritualistic Appeal: The act of snapping open a fresh vial every day adds a "clinical luxury" experience that highly engaged skincare consumers love.

This is a nuanced topic. While the materials used (Glass, PP, or PET) are theoretically recyclable, the format (size) often presents a challenge for standard curbside recycling programs.

• • The "Small Format" Issue: According to the Association of Plastic Recyclers (APR) design guidelines, items smaller than 2 inches (approx. 5cm) in two dimensions typically fall through sorting screens at Material Recovery Facilities (MRFs) and end up in the disposal stream.
• • Glass Handling: Similarly, small glass vials can be crushed into mixed cullet early in the sorting process or lost due to their size.
• • Recommended Solution: To maximize sustainability claims, we recommend advising consumers to check with their local municipality, exploring specialized "take-back" programs, or utilizing secondary packaging (like mono-material blister packs) that keeps the ampoules grouped for better sortability.

Ampoule filling is a specialized automated process:

1. Feeding: Empty ampoules are sterilized and fed into the machine.
2. Filling: Precision nozzles inject the liquid serum into the open neck.
3. Inert Gas Purging: Nitrogen is often blown into the ampoule to displace oxygen, further protecting the formula.
4. Sealing: Glass tips are melt-sealed with a gas flame; plastic tops are sealed using ultrasonic welding or heat.

OPC stands for One Point Cut. It refers to a manufacturing feature on glass ampoules where a small cut or score mark is pre-made at the neck, often accompanied by a colored dot. This ensures the ampoule breaks cleanly and easily at that specific point without shattering, reducing the risk of jagged edges or glass particulates.

Ampoules are most commonly used for low-to-medium viscosity fluids (like watery essences or light serums). Highly viscous creams or gels may be difficult to dispense through the narrow neck. We recommend testing your bulk formulation with samples to ensure smooth flow.

Yes, ampoules offer several areas for branding despite their small size:

• • Body Printing: Silk-screen printing or ceramic firing can be used to apply logos and text directly onto the vial.
• • Color Coding: Colored rings can be applied to the neck or stem to identify different treatments in a set (e.g., day vs. night formulas).
• • Material Finish: Glass can be frosted or amber-tinted (for light protection), while plastic can be colored to match brand palettes.

Because ampoules are small and (in the case of glass) fragile, secondary packaging is critical:

• • Blister Trays: Plastic or molded paper trays that hold multiple ampoules (e.g., a 7-day treatment set) securely in place.
• • Folding Cartons: The outer box provides real estate for ingredient lists, usage instructions, and regulatory info that won't fit on the tiny vial.
• • Breakers/Openers: Many luxury brands include a reusable plastic "breaker" tool in the box to help consumers snap the glass neck safely.

While glass is fragile, breakage rates are extremely low when packaged correctly. Suppliers typically ship empty ampoules in "shrink-wrapped bricks" or sturdy trays. For finished goods, high-quality secondary packaging (like custom inserts) is mandatory to prevent movement during transit.

Finding a supplier with the right technical capabilities is crucial for this format:

• • AJG Packaging: Known for expertise in "turnkey" solutions. They specialize in resealable plastic ampoule strips (often seen in unidose serums) and offer full contract manufacturing services to handle filling, sealing, and assembly.
• • Lisson Packaging: A major player in the global cosmetic packaging market offering an extensive catalog of both glass and plastic ampoules. They are well-suited for deep customization options and unique shapes to match K-Beauty trends.