Stick packaging has emerged as one of the fastest-growing formats in the personal care industry, transforming how products from deodorants to cosmetics are delivered to consumers. Once primarily associated with deodorants, solid “twist-up” sticks are now having a major moment across personal care shelves in color cosmetics, sun care, skin care, and body care. This surge is driven by consumer demand for convenient, mess-free applications and the push for more sustainable, travel-friendly solutions. In response, packaging suppliers have expanded their offerings of stock and custom stick containers in various sizes and materials to help brands capitalize on this trend. In this post, we explore market trends behind the stick-packaging boom, common use cases, material and sustainability innovations, decoration and branding opportunities, and how stick formats stack up against sprays and tubes. For detailed product info, explore our stick packaging page.
Market Trends: Stick Packaging on the Rise
Stick packaging is gaining momentum across personal care, with global deodorant stick sales alone projected to grow to $4.5B by 2031 (Source).
Beyond function, stick packaging also looks the part—its sleek, compact design is easy to brand and stands out on shelves or in a travel bag. With ample surface area for decoration and customization, sticks offer strong visual appeal while supporting a premium, modern aesthetic.
Solid sticks also support waste reduction goals, using less packaging and eliminating water or propellants. This aligns with broader trends in sustainability and the shift toward low-waste, portable product formats.
From Deodorant to Lip Balm: Common Uses for Stick Packaging
Stick packaging has moved far beyond deodorants, becoming a go-to solution for a wide range of personal care products thanks to its mess-free application, portability, and durability.
- Deodorants: Still the most recognizable use, stick deodorants offer controlled, leak-proof application without aerosols or pumps. They’re ideal for on-the-go lifestyles and continue to evolve with natural and sustainable formulations.
- Sunscreen: Stick sunscreens are gaining ground for facial and travel use. They avoid mess, eliminate hand contact, and are TSA-friendly—especially popular for kids and active users.
- Lip Balm: A staple in stick packaging, lip balms are hygienic, pocket-sized, and easy to brand. Their twist-up format is intuitive and endlessly customizable.
- Cosmetics & Balms: Blush, foundation, highlighter, solid perfume, and CBD balms are now widely available in stick form. These products benefit from precise, no-mess application and work well in hybrid formats like lip-and-cheek tints.
Evergreen Resources offers round and oval sticks in sizes ranging from 15g to 100g, with top-fill, bottom-fill, refillable, and bullet designs—all tailored to your product’s needs and compatible with high-end decoration.
Materials That Power Stick Packaging
Stick packaging is engineered for durability, functionality, and now—sustainability. Most sticks start with polypropylene (PP), a lightweight, impact-resistant plastic that’s ideal for twist-up mechanisms and is widely recyclable. Its compatibility with waxes and oils makes it a long-standing favorite for deodorants, lip balms, and cosmetics.
Today, the material landscape has expanded:
- Mono-Material Sticks: Engineered for recyclability, mono-material designs use a single resin—typically polypropylene—across all components, allowing the entire package to move through one recycling stream without sacrificing performance.
- Refillable Sticks: Designed for reuse, refillable stick systems minimize single-use waste by allowing consumers to replace only the inner cartridge. Ideal for brands aiming to drive circularity and deepen customer loyalty through sustainable routines.
- PET Sticks: Known for high recyclability, PET (polyethylene terephthalate) is the most widely accepted plastic in curbside recycling. It offers a strong sustainability profile along with excellent durability and clarity.
- PCR Plastics: To reduce virgin plastic use, brands can opt for post-consumer recycled (PCR) polypropylene, with Evergreen offering packaging solutions containing up to 100% PCR content.
- Bio-Based Resins: Made from renewable feedstocks like sugarcane or corn, bio-based plastics help lower carbon emissions while delivering the strength and moldability needed for stick formats.
- Paperboard Tubes: Plastic-free and compostable, paper push-up sticks are a natural fit for low-waste brands. Best suited for solid, drier formulas that don’t require airtight sealing.
- Aluminum or Hybrid Options: For a premium, long-lasting aesthetic, some brands use aluminum shells or hybrid constructions. Though harder to recycle, they deliver a tactile, high-end experience and strong product protection.
From standard PP to paper and PCR blends, Evergreen Resources supports a wide range of materials to match your formulation, sustainability goals, and brand positioning—without sacrificing quality or aesthetics.
Design & Branding Impact
Stick packaging offers more than just practicality—it’s a powerful branding tool. The cylindrical or oval shape provides a 360-degree surface area that acts as a blank canvas for bold design, logo visibility, and shelf impact. Whether you’re creating a high-end cosmetic or an everyday essential like deodorant, the stick format gives you the space to tell your brand’s story visually and tactilely.
Decoration techniques include
- Hot stamping for metallic accents
- Matte or soft touch for a distinct in-hand feel
- Direct-to-plastic printing for seamless application without labels
- Embossing or debossing for tactile branding elements
Design goes beyond aesthetics—it also signals quality. A soft-touch coating can create a luxurious feel, while color-matching components or using frosted, clear, or metallic materials give your product a distinctive look. Explore different designs below.
Evergreen Resources supports a full range of high-end decoration capabilities, helping brands achieve a style that aligns with their identity—whether clean and minimalist or bold and expressive. Paired with the ergonomic appeal of the twist-up format, stick packaging becomes a functional, on-brand experience your customers remember. Learn more about our advanced decorations.
About Our Offerings
Evergreen Resources offers a wide range of stock and custom stick packaging solutions, available in both round and oval profiles and in capacities ranging from 15g to 100g. Options include top-fill, bottom-fill, bullet fill, and refillable formats designed for reliable, user-friendly dispensing.
With support for sustainable materials—including mono-material, fully recyclable, PCR plastics, bio-resins, and paper-based designs—alongside a variety of decoration capabilities, Evergreen helps brands align their packaging with both aesthetic and environmental goals. Whether you’re developing a small-format balm or a full-size personal care product, our packaging options are built to adapt to diverse product needs and branding strategies.
Conclusion
As stick packaging continues to grow in popularity across personal care categories, brands are looking for packaging partners who understand the balance of function, sustainability, and shelf appeal. At Evergreen Resources, we work closely with clients to develop packaging that fits their formulation, supports their sustainability goals, and reinforces their brand identity. Whether you’re exploring refillable formats, eco-friendly materials, or custom decoration, our team can help bring your vision into focus efficiently and with attention to detail.
