Climate change is no longer a distant concern. It is already creating challenges for the cosmetics industry. With every spike in temperature, every heatwave, and every unexpected shift in weather, these stresses accumulate and place added pressure on both the products and the packaging designed to protect them. Even if a formulation is perfected, performance can suffer if the jar warps, the label peels, or the pump begins to leak. A single compromised batch on the shelf can weaken customer confidence and undermine years of brand building.

Packaging experiences stress at every stage of the supply chain. Manufacturing, transportation, and storage all create physical demands, but heat remains the most unpredictable factor, especially when products stay in warm warehouses or move through regions with high temperatures. Most cosmetic packaging is made from plastics such as polypropylene, polyethylene, and PET. These materials perform reliably under normal conditions, but when they are transported in a truck that can reach close to 55°C, lids may start to warp and seals can weaken or open. Sustainable options, including biopolymers and recycled plastics, are often more sensitive to heat. Without proper testing in place, these issues may only surface once products reach consumers, which can lead to costly returns.

This is where material science becomes essential. Dynamic Mechanical Analysis (DMA) shows how packaging reacts to stress and changes in temperature, accelerating a process that typically takes months into just a few days of testing. Thermogravimetric Analysis (TGA) tells you when a material begins to lose moisture or additives, which signals the early stages of degradation. Differential Scanning Calorimetry (DSC) determines the precise temperatures at which plastics soften or begin to melt. With this data, packaging decisions become more accurate and dependable.

Integrating these tests into the development process delivers clear and practical benefits:

Identify issues early: Detect material weaknesses in the laboratory rather than on store shelves

Strengthen material sustainability decisions: Ensure recycled or bio-based plastics meet performance expectations, without compromising sustainability goals

Speed up development: Understanding failure points helps teams move from prototype to production without endless guesswork

Build customer confidence: Packaging that remains stable under heat reinforces product quality and strengthens customer confidence in the product

Here is how it plays out in real life. Picture a premium moisturizer in a frosted polypropylene jar. It looks perfect at room temperature. However, once it is shipped through a heatwave, the lid can twist and the finish may lose its quality. DMA shows exactly how much stiffness the jar loses as temperatures rise. TGA indicates the point when additives begin to evaporate. DSC shows the temperature threshold where the plastic softens. Based on these findings, engineers can adjust the design. They can increase wall thickness, modify the polymer blend, or reinforce the seals so the jar maintains its appearance and performance in different conditions.

Analytical testing also supports smarter and more sustainable packaging decisions. Using lighter and thinner materials reduces resource use, lowers energy and shipping costs, and decreases the carbon footprint. With reliable data guiding these choices, you do not need to choose between sustainability and performance because you can achieve both.

Understanding how your materials respond to heat and stress helps you balance performance, sustainability, and cost with confidence. Adding unnecessary reinforcement can waste resources, while cutting corners can lead to product failures. Thermal analysis gives you the data needed to design packaging that is durable and visually consistent.

With climate change raising temperatures around the world, DMA, TGA, and DSC are no longer optional. They are essential tools for developing reliable packaging. With a technical partner like DKSH Technology, you gain access to the latest insights and hands-on support that help keep your packaging strong, your customers satisfied, and your brand aligned with its sustainability commitments.

Sources:

• Plastic pollution amplified by a warming climate | Nature Communications
• Understanding the Impact of Temperature on Packaging Materials | Packaging Distributors of America
• Thermal Analysis Testing: Plastic and Rubber | Smithers
• Heat Resistance of Eco‑Friendly Packaging Materials for Cosmetics | EUROLAB
• A Full Green, Sustainable Paper‑Based Packaging Material with High‑Strength, Water Resistance, and Thermal Insulation | MDPI