“Our job is to make sustainability affordable, scalable, and competitive,” says Tomás Espinosa, CEO of Schwan Cosmetics.
Why styrene had to go
The decision to eliminate styrene from cosmetic and beauty packaging is not just a technical one; it’s a strategic move towards greater sustainability and regulatory alignment. As legislation tightens and consumer expectations shift toward more environmentally responsible products, brands are under increasing pressure to rethink their material choices.
For example, the European Union’s Single-Use Plastics Directive and emerging Extended Producer Responsibility (EPR) frameworks create financial incentives for brands to transition away from hard-to-recycle materials, while major retailers implement sustainability requirements that effectively exclude styrene-based packaging.
Schwan Cosmetics is responding proactively, replacing traditional styrene-based plastics with materials like polyethylene terephthalate (PET) and polypropylene (PP).
FLX-TECHNOLOGY: innovation without compromise
At the heart of the transformation is the patent-pending FLX-TECHNOLOGY. This seamless, high-performance solution swaps out traditional ABS or styrenics for PET and PP while preserving every visual and tactile cue that defines a brand.
“FLX-TECHNOLOGY changes everything in terms of sustainability, but nothing in terms of design or performance,” says Sandra Schäfer, Director Research & Development at Schwan Cosmetics. The new packaging is made from up to 92% recyclable materials and is completely styrene-free. The remaining material share, like polybutylene terephthalate (PBT), is used only where mechanical performance demands it, for example, in lead holders or sharpeners.
What sets FLX apart is that it delivers the same high-end functionality without requiring additional components like O-rings or seals, while maintaining the same wall thickness. This not only reduces overall material usage but also simplifies the recycling process, moving Schwan’s portfolio closer to mono-material design, an increasingly important benchmark in sustainable packaging.
Designed for circularity
Schwan’s material strategy is built around recyclability and long-term adaptability. By switching to PET and PP materials specifically designed for circular use, the company ensures compatibility with existing recycling infrastructures while setting the stage for future innovations. Looking ahead, the packaging is engineered to integrate post-consumer recycled (PCR) content in the future, eliminating the need for redesigning and enabling future carbon savings.
While many cosmetic pencils still rely on mixed materials and elastomeric seals, FLX is engineered as a near mono-material solution. Its high mechanical precision removes the need for additional gaskets, simplifying recycling and reinforcing sustainability without compromising functionality.
Scalable, smart, and sustainable without a premium price tag
Schwan Cosmetics has eliminated the traditional sustainability premium through manufacturing efficiency innovations and supply chain optimization. Since FLX replicates the look, feel, and dimensions of existing packaging components, brands can switch to styrene-free solutions without changing artwork, tooling, or filling lines, ensuring zero disruption to production or consumer experience.
With this innovation, Schwan Cosmetics demonstrates that performance aesthetics and cost can, and must, go hand in hand. The company’s approach is not just about replacing materials; it’s about rethinking how packaging performs, how it’s made, and what role it plays in a circular economy.
