How are cosmetics produced?

The production of cosmetics in 2025 requires compliance with the dynamically changing European regulations. From developing the formula, through selecting raw materials, to designing the packaging – each of these stages of the cosmetic production process can be subject to specific regulations, such as restrictions on banned substances in cosmetics. But that’s not all. It is not enough to simply know how cosmetics are produced or what the new regulations for cosmetics in 2025 are. Manufacturers must also adapt their products to the growing expectations of consumers, especially Generation Z.

How are cosmetics produced? Choosing the laboratory is the most important step

Selecting the laboratory is the most important step in the cosmetic production process, as it determines the quality and innovation of the final product. The laboratory responsible for production must meet the highest quality standards, such as Good Manufacturing Practice (GMP). 

What is GMP in cosmetics? In practice, this term means that the laboratory must have the right technological facilities, experience in cosmetic production, and certificates confirming compliance with international standards. Thanks to the implementation of rigorous GMP procedures, cosmetics are produced under conditions that guarantee safety and the highest quality. Learn more: Types of GMP and HACCP certificates

Choosing a laboratory is not only about working with an external service provider but also about ensuring the safety and effectiveness of the final product. That’s why cosmetic manufacturers often choose to cooperate with laboratories that have a proven track record of successful projects. For many companies, contract manufacturing of cosmetics is the ideal solution, where external laboratories handle not only the development of the formula but also all stages of production. This cooperation model is highly beneficial, as the manufacturer can draw on the expertise and experience of specialists while also optimizing business costs.

Want to learn how to choose a cosmetic laboratory? Check out our article: 10 factors for choosing a partner in contract manufacturing

The cosmetic production process starts with developing the formula

What does the cosmetic production process in Poland look like? Once a laboratory that meets the highest quality standards has been selected, the next step is to develop the cosmetic formula. This stage begins with a thorough market analysis and understanding consumer needs. Based on this data, a team of experts designs the cosmetic formula. At this stage, decisions are made about which ingredients will best achieve the intended goals (moisturizing, skin regeneration, protection against external factors, etc.).

Generation Z – the beauty market must adapt to the consumer demands of this generation

The need to adapt to consumer demands also means being aware of the latest trends. Since Generation Z (people born after 1995) has enormous potential to drive the beauty industry, cosmetic manufacturers must take the requirements of this group into account. For Generation Z, the most important factors are: formula safety, personalization, and brand transparency, with purchasing decisions often influenced by social media recommendations, especially on TikTok. For this consumer group, the values represented by individual brands also play a crucial role.

Research on cosmetic raw materials is mandatory

The process of creating a formula is closely linked to research on raw materials, which must meet specific quality criteria. They are carefully selected and tested for purity, stability, and safety to ensure that they retain their properties throughout the product’s shelf life. This is why laboratories conduct stability tests, in which the formula is exposed to various factors such as changes in temperature, humidity, or light. The results of these tests help refine the formula so that the product is both effective and safe for the consumer.

Banned substances in cosmetics 2025

Manufacturers, distributors, and suppliers must continuously monitor changes in cosmetic regulations. For example, 2025 brought an expansion of the list of substances banned in cosmetics, maintained by the European Commission. 

Which substances are banned in cosmetics from 2025 onwards? The list of substances restricted or prohibited in cosmetic products (due to potential health risks for consumers) includes in 2025:

• alpha-arbutin – the use of this ingredient in face creams should be limited to a maximum concentration of 2%, while in body lotions to 0.5%;
• kojic acid – the use of this ingredient in skincare products should be limited to a maximum concentration of 1%;
• retinoids (retinol, retinyl palmitate, retinyl acetate) – the new regulations also introduce changes regarding retinol content in cosmetics. Restrictions effective from November 1, 2025, will prohibit the marketing of cosmetics exceeding the recommended concentration of retinol, i.e., above 0.3% in face, neck, and décolleté products, and above 0.05% in body care cosmetics. Products not compliant with the 2025 cosmetic regulations will be withdrawn from the market from May 1, 2027;
• colloidal silver – the ban on placing on the market applies from February 1, 2025, and from November 1, 2025, the ban on making it available on the market will also apply;
• diphenyl-(2,4,6-trimethylbenzoyl)phosphine oxide (TPO) – from September 1, 2025, TPO will be banned in cosmetics. It will no longer be possible to use or sell cosmetic products (e.g., hybrid nail polishes) containing TPO;
• triclosan – the new EU cosmetic regulations 2024/2025 set a maximum concentration of up to 0.3% in selected products (e.g., hand soaps). The use of this substance is also banned in toothpastes intended for children under 3 years of age.

On September 27, 2023, the Commission Regulation (EU) 2023/2055 was published, which gradually introduced restrictions on synthetic polymer microparticles (microplastics). The ban on microplastics in exfoliating cosmetics already applies, while further bans will come into force in the coming years: microplastics in rinse-off cosmetics (from 16.10.2027), leave-on products (from 16.10.2029), and makeup, lip, and nail products (from 16.10.2035).

Designing cosmetic packaging in line with sustainability principles

The next stage of the cosmetic production process is designing the cosmetic packaging. Well-designed packaging must protect the product against external factors such as light, moisture, or contaminants that can affect the quality and effectiveness of the cosmetic. The choice of packaging material is also a decision about production costs and the final market price of the product.

The cosmetic packaging must include all the necessary information, such as composition, expiration date, instructions for use, or warnings. All these elements must comply with the legal regulations in force in the market where the product is to be sold.

New EU regulations – cosmetics 2024/2025 and their packaging

Between 2025 and 2026, a new EU regulation on cosmetic packaging and packaging waste will gradually come into force. The 2025 cosmetic regulations emphasize not only reducing plastic but also transparent packaging labeling. 

Changes apply, for example, to the labeling of fragrance allergens. Cosmetics must carry clear labels if the concentration of allergens in rinse-off products exceeds 0.01%. The same fragrance allergen labeling rule for 2025 applies when the concentration exceeds 0.001% in leave-on cosmetics (e.g., creams, lotions, toners).

The new EU cosmetic regulations 2024/2025 also introduce: 

• a mandatory label “releases formaldehyde” – when the concentration of formaldehyde donors exceeds 0.001%. Therefore, it is worth not only auditing formulas but also preparing new labels in line with upcoming regulations;
• a mandatory warning in the case of toothpaste containing triclosan – “Do not use for children under 3 years.”

Testing and research – safety first

An essential element of the cosmetic production process is quality control, which includes both laboratory tests and clinical studies aimed at confirming that the product meets all the assumptions set during the formulation stage.

Before the final product is released to the market, dermatological tests are also carried out. Thanks to these, potential side effects such as irritation or allergies can be ruled out. Depending on the type of cosmetic, these tests may be performed on volunteers or using advanced in vitro techniques that simulate conditions on the skin. 

Another important aspect of testing is the evaluation of the cosmetic’s effectiveness. This is carried out on the basis of clinical trials, which can last several months. The last stage before placing the product on the market is production process validation, which guarantees that every cosmetic produced will meet the same high-quality standards.

What does the cosmetic production process in Poland look like – summary

Cosmetic production is a complex, multi-stage process that requires the involvement of many specialists, specialized laboratories, extensive knowledge, and experience. In 2025, the European cosmetics industry faces many challenges – on one hand, it must move towards innovation, while on the other, it is mandatory to rigorously comply with dynamically changing legislation. Added to this is the need to adapt to consumer requirements – especially Generation Z (those born after 1995), for whom formula safety, personalization, and brand transparency are crucial. 

This is why so many producers choose contract manufacturing of cosmetics, carried out by specialized companies such as Laboratorium Galenowe Olsztyn with GMP certification until 2028. Thanks to this solution, instead of worrying about the new 2025 cosmetic regulations and how to ensure the highest standard of quality and safety, the brand can focus on product development, marketing, and building customer relationships.
To learn more about this cooperation model, check: Contract cosmetic manufacturing – a practical guide

Cosmetic production – frequently asked questions

I. What does the cosmetic production process look like?

The cosmetic production process includes choosing a laboratory, developing the formula, designing the packaging, safety testing, production, and quality control.

II. Which ingredients will be banned in 2025?

The 2025 cosmetic regulations introduce restrictions on, among others, kojic acid, retinoids, alpha-arbutin, triclosan, and colloidal silver.

III. What is the difference between a cosmetic and a drug?

Cosmetics are products intended for hygiene and care, they do not cure diseases and are not subject to the strict clinical trials required for drugs.

IV. Is a GMP certificate required for cosmetic production?

A facility specializing in cosmetic production must comply with GMP requirements. A GMP certificate confirms compliance of processes with quality standards.

V. When will the new packaging regulations come into effect?

The new EU regulation on packaging and packaging waste will gradually come into effect in 2025–2026.

VI. What are microplastics and why are they banned?

Microplastics are small polymer particles. The EU bans the use of microplastics in cosmetics, including scrubs and rinse-off products, to reduce environmental pollution.

VII. What are the most popular beauty market segments?

The largest beauty market segment is body and face care cosmetics, which accounted for about 17% of the market in 2023. From 2024–2029, it is also forecast that body and face care cosmetics will remain the product category with the largest market share. 

VIII. Do consumer trends change cosmetic production?

Yes, in the cosmetic production process, the preferences of Generation Z must be considered. The beauty market should focus on natural, personalized, and ethical products.

BIBLIOGRAPHY

1. Biotechnologia (2024). Current and future changes in cosmetic law [online] Available at: https://biotechnologia.pl/kosmetologia/obecne-i-przyszle-zmiany-w-prawie-kosmetycznym,23319 [online access: 28.07.2025]
2. Health Products Regulatory Authority (2025). TPO added to European Union list of prohibited ingredients [online] Available at: https://www.hpra.ie/news-events/news/article/tpo-added-to-european-union-list-of-prohibited-ingredients [online access: 28.08.2025]
3. District Sanitary and Epidemiological Station in Chodzież (2025). New regulations regarding TPO substances in cosmetics [online] Available at: https://www.gov.pl/web/psse-chodziez/nowe-regulacje-w-zakresie-substancji-tpo-w-kosmetykach [online access: 28.08.2025]
4. District Sanitary and Epidemiological Station in Sępólno Krajeńskie (2025). Announcement of the Chief Sanitary Inspector for the cosmetics industry [online] Available at: https://www.gov.pl/web/psse-sepolno-krajenskie/komunikat-glownego-inspektora-sanitarnego-dla-branzy-kosmetycznej [online access: 28.08.2025]
5. Commission Regulation (EU) 2023/1545 of 26 July 2023 amending Regulation (EC) No 1223/2009 of the European Parliament and of the Council as regards the labelling of fragrance allergens in cosmetic products.
6. Commission Regulation (EU) 2023/2055 of 25 September 2023 amending Annex XVII to Regulation (EC) No 1907/2006 of the European Parliament and of the Council concerning the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) with regard to synthetic polymer microparticles.
7. Commission Regulation (EU) 2024/996 of 3 April 2024 amending Regulation (EC) No 1223/2009 of the European Parliament and of the Council as regards the use in cosmetic products of vitamin A, alpha-arbutin and arbutin, and certain substances potentially disrupting the endocrine system.