Eyebrow pencils may seem simple, but their core structure is highly technical. Many brands encounter a common issue: the eyebrow pencil core breaks easily, whether during sharpening, application, transportation, or even simple storage.

As a high-end cosmetic OEM/ODM factory specializing in brow products, we frequently address this challenge for brand clients through formulation optimization, mechanical testing, and production quality control.

Below explains why eyebrow pencil cores break—and how to fix the problem effectively.

1. Why Do Eyebrow Pencil Cores Break Easily?

Eyebrow pencil cores break for structural, formulation, or processing reasons. Here are the most common causes.

1.1 The Core Is Too Hard or Too Brittle

A core that is too hard can become brittle and snap under pressure.
Common causes include:

• excessive powder load

• insufficient oils/waxes

• poor binding between powders and waxes

• too much high-melting wax

This creates a rigid, fragile core that breaks when force is applied.

1.2 The Core Is Too Soft or Overly Oily

If the formula is too soft, the core may bend or crumble.
This usually comes from:

• excess emollients

• low-melting waxes

• unbalanced oil–wax ratio

Soft cores lose structural integrity and break during sharpening or twisting.

1.3 Poor Dispersion of Powders

If pigments or powders are not evenly dispersed:

• weak points form inside the core

• internal cracks develop

• breakage occurs during use

This is a mixing/dispersion issue at the manufacturing stage.

1.4 Temperature Instability During Production

Brow pencils rely on precise heating and cooling.
Problems occur when:

• filling temperature is too high

• cooling rate is too fast

• uneven cooling causes microcracks

These internal cracks weaken the pencil core even if it looks fine externally.

1.5 Low Mechanical Strength

Mechanical strength should meet specific standards.
If the formula hasn't undergone:

• bending resistance test

• impact test

• temperature-cycle test

…the product may break in normal consumer use.

1.6 Packaging or Component Issues

For twist-up pencils, breakage can be caused by:

• loose internal mechanism

• misaligned core channels

• too-tight twisting resistance

• insufficient elasticity of support structure

Even a perfect formula breaks if the component doesn't protect it.

2. How a High-End OEM Factory Solves Eyebrow Pencil Breakage

As a professional OEM/ODM manufacturer, we optimize eyebrow pencil durability through advanced formulation and engineering control.

2.1 Adjusting the Wax–Oil–Powder Ratio

We rebalance:

• wax hardness

• oil viscosity

• powder load

• binding agents

This ensures the core is firm enough to hold shape yet flexible enough to avoid breakage.

2.2 Enhancing Powder Wetting and Dispersion

Using high-shear mixing, we ensure:

• powders are fully coated

• pigments disperse evenly

• no internal weak spots exist

A uniform internal structure dramatically improves core strength.

2.3 Improving Mechanical Strength via Testing

Before mass production, we test:

• compression strength

• bending resistance

• drop/impact performance

• high–low temperature stability

Only pencils that pass all criteria move into production.

2.4 Optimizing Production Temperature and Cooling Curve

We control:

• heating temperature

• pouring temperature

• cooling rate

• curing time

Stable cooling prevents internal cracks and brittleness.

2.5 Matching Pencil Formula with Proper Component

We evaluate:

• twist mechanism smoothness

• tolerances inside the channel

• core diameter compatibility

• stability during twisting

Formula and packaging must match perfectly to prevent breakage.

3. Should Brands Worry About Pencil Core Breakage?

Yes—because consumers judge quality quickly.
Broken eyebrow pencils give the impression of:

• poor formula quality

• weak durability

• cheap packaging

• unreliable product performance

For brands aiming for a premium image, stabilizing the pencil core is essential.

Conclusion

Eyebrow pencil cores break due to brittle formulas, excessive softness, poor powder dispersion, unstable production temperature, or component mismatch. As a high-quality cosmetic OEM/ODM factory, we ensure durability by optimizing formulas, strengthening mechanical properties, and performing strict stability tests.

Brands looking to produce long-lasting, stable brow pencils can rely on our expertise in pencil formulation and precision manufacturing.