The cosmetics industry has grown rapidly, bringing innovative textures, colors, and formats. However, many products on the market still experience formulation flaws that affect performance, stability, or user experience. As a high-end cosmetic OEM/ODM factory, we often help brands diagnose these problems and upgrade their formulas to achieve professional, reliable results.

Below are the most common formulation defects seen in makeup and skincare products—and how professional manufacturers resolve them.

1. Instability and Separation

One of the most frequent problems is phase separation, where oil and water split over time.
Common causes include:

• insufficient emulsifiers

• poor emulsion stability

• incorrect pH or viscosity

• unstable ingredients under heat/light

This leads to watery layers, oil pooling, or uneven textures.

2. Poor Pigment Dispersion

In color cosmetics, improper pigment grinding causes:

• streakiness

• patchy payoff

• uneven foundation shades

• hard-pan or cracking in powders

Good dispersion requires proper wetting agents and controlled high-shear mixing—something many low-cost formulas skip.

3. Pilling and Poor Compatibility

Some formulas ball up or “pill” when layered with other products.
This is caused by:

• incompatible polymers

• too many film-formers

• unstable silicone blends

• excessive powder content

A well-designed formula should work smoothly with typical skincare routines.

4. Excessive Greasiness or Dryness

Unbalanced formulas may feel too oily, heavy, or overly dry and tight.
Common reasons:

• inappropriate oil-phase ratio

• wrong emollient selection

• overuse of matte agents or absorbent powders

• lack of moisture-locking ingredients

A balanced sensory profile is critical in modern cosmetics.

5. Color Oxidation or Shade Shifting

Foundations and concealers may turn orange, darker, or dull throughout the day.
This happens due to:

• unstable pigments

• incorrect antioxidant system

• interactions with skin sebum

• poorly stabilized emulsion structures

A robust oxidation control system is essential for long-wear base makeup.

6. Texture Inconsistency After Storage

Products may become grainy, watery, or lumpy after temperature cycling.
Especially common in:

• foundations

• balms

• lipsticks

• creams

This results from incorrect melting points, wax ratios, or temperature-sensitive ingredients.

7. Poor Adhesion and Low Long-Wear Performance

Some eyeliners, foundations, and brow products smear quickly.
Causes include:

• weak film-formers

• incorrect volatile balance

• lack of long-wear polymers

• under-optimized viscosity

High-performance formulas require precision in polymer and resin selection.

8. Microbubble Formation in Gels and Liquids

Gel masks, lip products, and primers sometimes develop bubbles on the surface.
This is usually due to:

• poor vacuum defoaming

• high-speed mixing

• incorrect filling temperature

• rapid cooling

Bubble-free products require strict process control.

9. Cracking in Pencils and Sticks

Eyebrow pencils, lip pencils, and concealer sticks may break easily.
Reasons include:

• brittle wax structure

• unbalanced wax-to-powder ratio

• poor powder wetting

• improper cooling curve

Mechanical strength testing is crucial before mass production.

10. Inadequate Preservation or Microbial Stability

Some formulas fail to meet microbial stability needs, leading to risks such as:

• mold

• bacteria growth

• formula spoilage

• odor changes

A strong preservative system and challenge testing are essential.

How a High-Quality OEM Factory Solves These Flaws

As a professional OEM/ODM manufacturer, we address formulation flaws through:

• advanced ingredient selection

• high-shear dispersion technology

• precise emulsification

• rheology and viscosity optimization

• full mechanical and stability testing

• temperature-cycle testing

• packaging compatibility evaluation

• strict quality control at every stage

We help brands upgrade formulas, reduce defects, and deliver stable, high-performance products that satisfy global consumers.

Conclusion

Cosmetic formulation flaws are common across the industry, but they can be prevented with proper R&D, rigorous testing, and high-level manufacturing capabilities. As a high-end OEM factory, we specialize in optimizing formulations to achieve stable, safe, and reliable results for brand clients worldwide.