Personal Care | Skincare

Sunscreen Packaging Case Study: A Shift Towards Better Protection and Sustainability

Explore how BEAUTI-FLTR evolved its sunscreen packaging from a simple plastic tube to a premium aluminium solution, improving product protection, user experience, and sustainability while supporting everyday SPF use.

About BEAUTI-FLTR

Rooted in the ritual of everyday protection, BEAUTI-FLTR was created to make sun care feel more intuitive and enjoyable — something that fits naturally into daily life, rather than feeling like a chore.

The brand entered the market with its SPF 50+ Feather Light Sunscreen, focusing on a lightweight texture and easy, everyday use.

As the brand grew, the team began looking beyond just the formula. Packaging became part of the conversation, not just how it looks, but how it performs, how it feels in hand, and what it says about the brand.

Introduction

For many sunscreen brands, packaging decisions aren’t made all at once. They evolve over time — shaped by product performance, customer feedback, and a clearer sense of what the brand stands for.

This is the case for BEAUTI-FLTR, a brand that started simple, then gradually refined its packaging to better reflect both its formula and its values.

Where It Started: Keeping It Simple

In the early stage, BEAUTI-FLTR went with a 75ml plastic tube with a flip cap, finished with two-colour screen printing and a matte texture.

It was a practical choice:

Easy to produce and cost-efficient
Familiar and convenient for everyday use
Clean, minimal look that aligned with the brand’s aesthetic
Lightweight for shipping and retail

At this point, the goal was clear — launch efficiently and get the product into customers’ hands.

And it worked.

The Turning Point

As the product gained traction, expectations shifted.

Customers were using the sunscreen daily, carrying it around, applying it on the go. At the same time, the brand itself was becoming more defined, especially around performance, experience, and sustainability.

That’s when the team started asking a different question:

Is the current packaging still doing the product justice?

The Upgrade: Aluminium Tube with Needle Cap

For their next launch, BEAUTI-FLTR moved to a 120ml aluminium tube with a precision needle cap, paired with clean offset printing on a white base with black text.

Sharp and sleek, it’s a subtle shift visually, but functionally, it changes a lot.

Better Protection for the Formula

Sunscreen formulas, especially high SPF products, can be sensitive to light and air exposure, which makes packaging an important part of maintaining product performance over time.

The aluminium tube offers a more enclosed environment, helping to:

Limit exposure to external elements
Support consistency over time
Keep the product feeling fresh throughout use

A Step Towards More Conscious Materials

As BEAUTI-FLTR evolved, sustainability became a more visible part of the brand’s direction.

Aluminium offered a material option that:

Is widely recyclable
Can be reprocessed with relatively lower energy compared to new production
Aligns with growing expectations around responsible packaging
Can be rolled as it’s used, making it easier to get the most out of the product

Alongside the aluminium tube, BEAUTI-FLTR also introduced a FSC-certified product box.

The box isn’t just for protection during transport, it adds a subtle unboxing moment, giving users a sense of care and attention right from the shelf.

By using responsibly sourced materials, the packaging complements the brand’s sustainability goals while enhancing the overall experience. These choices don’t shout about sustainability; they simply make the experience feel considered, intentional, and quietly elevated.

It’s a subtle improvement that becomes more noticeable over time.

The Outcome

For BEAUTI-FLTR, the move to aluminium wasn’t about making a dramatic change, it was about supporting the product, the experience, and the values the brand stands for.

Every detail, from the accessory to the sustainable material, was chosen to fit naturally into daily routines, help the formula perform its best, and quietly reflect the brand’s commitment to thoughtful, responsible design.

It’s a subtle evolution, but one that feels right: packaging that works for the product, for the people using it, and for the world around it.

And for growing sunscreen brands, it’s a good reminder: sometimes the biggest improvements come from refining what’s already working.

About Primepac

PrimePac is a custom packaging provider in Australia. We believe in a collaborative approach, working closely with our clients to create innovative and sustainable packaging that stands out, drives sales, and aligns with brand identity. We work with great companies of all sizes and we’ve helped more than 1,100 businesses that seek to differentiate their products in a competitive market.