Packaging plays a much bigger role in product success than most people realise. It influences customer trust, protects your formula, and shapes how your brand is perceived on the shelf. Across skincare, supplements and food products, we continue to see the same avoidable mistakes that can cost brands time, money and momentum.
If you are preparing for a new launch or updating your packaging, these are the top five pitfalls to watch out for and how to avoid them with confidence.
1. Choosing the wrong plastic for your formula
This is one of the most common and costly mistakes. Many brands are unaware that certain formulas are only compatible with specific plastics. Essential oils for example do not perform well in HDPE. They can penetrate or soften the material over time which affects the quality of both the bottle and the product. PET is usually the better choice when working with essential oils because it offers stronger resistance and stability.
pH levels also matter. HDPE generally performs better with formulas that have a pH of 7 and above. PET is typically more suitable for products that sit below pH 7. Without this understanding, brands often choose packaging based on appearance instead of compatibility and this can lead to leaching, paneling, swelling or shortened shelf life. Working with a supplier who understands material compatibility is the simplest way to avoid this mistake. Proper testing at the start protects you from expensive remakes and prevents product failures later.
2. Skipping tamper evident features
Customers need to feel safe when they open a product for the first time. Anything applied to the skin or taken orally should have a clear, reliable tamper evident feature. This is not only good practice for trust and safety, but it also helps with compliance in many categories.
Consider your sealing method early in the design process. Induction seals, pressure seals and shrink sleeves all offer different benefits depending on your bottle style and formula. When this step is overlooked, brands often discover too late that their chosen bottle and closure are not compatible with the seal they need. Planning early removes that stress completely.
3. Ignoring MOQs and lead times
It is easy to fall in love with a custom bottle, colour or finish, and many brands do. The challenge comes when minimum order quantities or production lead times do not match your launch plan. Custom colours and tooling usually require higher volumes and a longer timeline. If you discover this too late, the entire project can be delayed.
Being upfront about your realistic volumes and your launch deadline helps your supplier guide you to the right solution. A custom piece may require five thousand units or more and a lead time of ten to twelve weeks. If you need a faster turnaround, stock packaging is often the better move. Clear planning keeps your launch on track and avoids unnecessary stress.
4. Skipping stability testing before production
Rushing into a production run without completed stability testing is one of the biggest risks a brand can take. Stability testing is what confirms how your formula behaves inside your chosen packaging over time. It highlights issues like colour changes, ingredient separation, reactions with materials, pressure build up, leaks or paneling.
Many brands skip this step to save time, only to discover later that their formula reacts poorly with the packaging or does not hold up under real world conditions. Fixing these issues after production has started is expensive and often requires reworking both the formula and the packaging.
Always run testing with your actual formula and your pre-production packaging and complete the following: Aesthetic Test, Print Test, Sealing Test, Capacity Test, Stability Test. To find out more about each of these tests click here. It protects your investment and ensures your customers receive a consistent, reliable product.
5. Underestimating the power of branding
Packaging is far more than a container. It is your first point of communication with a potential customer and it shapes how people perceive your brand. If your packaging looks cheap, unclear or misaligned with your values, customers may overlook your product entirely.
Think carefully about colour, shape, labelling space, texture and the overall feel of the pack. Whether your brand aims to look clinical, sustainable, premium or approachable, your packaging should express that clearly. A strong visual identity instantly lifts perceived value and supports stronger on shelf performance.
Final thoughts
Getting your packaging right is not just about choosing a bottle that looks good. It is about selecting a material that protects your formula, creating a safe and compliant customer experience, and setting up your brand for long-term success. With the right planning and advice, these common mistakes are completely avoidable.
At Weltrade Packaging, we support Australian brands across skincare, supplements and food products with practical guidance, industry knowledge and reliable packaging solutions. If you want to avoid costly setbacks and launch with confidence, our team is here to help.