Common Issues of Liquid Foundation: From Transport to User Experience

As a high-quality cosmetics OEM/ODM factory, we frequently help global beauty brands troubleshoot issues that appear during the entire lifecycle of a liquid foundation. Many problems occur not only during formulation, but also during filling, storage, transport, and customer usage. Understanding these challenges allows brands to improve product reliability and user satisfaction.

Below are the most common foundation problems—categorized from production to end-user experience—and how professional OEM manufacturing helps solve them.

1. Issues During Transport & Storage

1.1 Phase Separation or Oil Layering

When foundations experience temperature fluctuations during long-distance shipping, oils may rise, or water phases may separate.
Typical causes:

• Insufficient emulsification

• Incompatible emulsifiers

• Extreme heat in containers

• Poor stabilization system

OEM Solution:
We reinforce thermal-stability emulsifiers and conduct high-low temperature cycling tests to ensure the formula stays stable across global shipping climates.

1.2 Viscosity Change After Transport

After long-term movement or high temperature, the texture may become either too runny or too thick.

OEM Solution:
We optimize rheology modifiers and conduct vibration-simulation tests to ensure stability throughout logistics.

1.3 Air Bubbles After Filling

Some products reach customers with trapped air bubbles visible inside the bottle.

OEM Solution:
We improve deaeration during production and adjust filling speed and temperature to minimize aeration.

2. Issues Found When Customers First Open the Foundation

2.1 Color Striping (Color Bands)

You may see dark or light stripes inside the bottle.
Reasons:

• Pigments not fully dispersed

• Poor pigment wetting

• Incorrect dispersant ratio

• Instability during standing or shipping

OEM Solution:
Advanced dispersion technology and high-speed milling ensure uniform pigment distribution.

2.2 Oil Droplets or Water Droplets on the Surface

This can make customers think the product is expired or defective.

Reasons:

• Partial emulsifier incompatibility

• Temperature cycling during transport

• Raw material polarity imbalance

OEM Solution:
We perform rigorous compatibility testing and adjust hydrophilic–lipophilic balance (HLB) to prevent separation.

2.3 Pump Clogging or Hard Start

Foundation may not pump smoothly during first use.

Reasons:

• Incorrect viscosity for packaging

• Air in pump chamber

• Highly creamy formulas not suited for pump design

OEM Solution:
We match formula viscosity to appropriate pump components and conduct pump-compatibility testing.

3. Issues During Daily Application (User Experience)

3.1 Caking, Patchiness, or Floating Makeup

This is one of the most common complaints.

Reasons:

• Formula dries too fast

• Powder/oil ratio imbalance

• Insufficient moisturizing ingredients

• Climate shock (dry weather, AC rooms)

OEM Solution:
We adjust humectants, film-forming agents, and silicone systems to improve spreadability and adhesion.

3.2 Wrong Shade Matching & Oxidation

Consumers often complain that the shade becomes too white, too yellow, or oxidizes into an orange tone.

Reasons:

• Inaccurate undertone design

• Using iron oxides that oxidize easily

• Poor anti-oxidation system

OEM Solution:
We use stabilized pigments and antioxidants to maintain color accuracy throughout wear.

3.3 Short Wear Time & Makeup Melting

Foundation breaks apart after half a day.

Reasons:

• Weak film-forming system

• Poor oil-control balance

• Incorrect silicone blend

• Humidity or sweat exposure

OEM Solution:
We customize long-wear systems, sweat-resistant polymers, and breathable film-forming technology.

3.4 Foundation Settling into Fine Lines

Common for dry skin users.

Reasons:

• Low elasticity base

• Fast evaporation

• Not enough flexible polymers

OEM Solution:
We adopt elastic silicone elastomers to keep foundation flexible and smooth.

3.5 Oxidative Smell After Open Use

Occasionally, consumers claim a “crayon-like smell.”

Reasons:

• Oils oxidizing over time

• Packaging not airtight

• Customer storing incorrectly (heat, sunlight)

OEM Solution:
Use highly stable oils and airtight containers; perform accelerated aging tests.

4. Why OEM Expertise Matters

A stable, high-performance foundation requires:

• Professional raw material pairing

• Strong pigment dispersion technology

• Full-process stability testing

• Packaging-formula compatibility validation

• Global climate simulation tests (−10°C to 45°C)

As an OEM/ODM factory specializing in premium formulations, we help brand clients develop foundations that remain stable from production → global transport → daily consumer use.