Beauty & Skincare Fulfilment: Handling Liquid Restrictions and Expiry Dates

The beauty and skincare industry is booming, with global e-commerce sales expected to reach £500 billion by 2027. But for brands selling online, fulfilment isn’t as simple as slapping on a label and shipping products. Between strict liquid regulations and perishable expiry dates, logistics can quickly become a compliance nightmare.

In this guide, we’ll break down the key challenges of beauty fulfilment and how to navigate them while keeping customers happy (and regulators happier).

Why Beauty Fulfilment is Uniquely Challenging

1. Liquid Shipping Restrictions

• Airlines classify many beauty products as “dangerous goods” (even innocuous-seeming items like nail polish or perfume)
• 100ml limit for liquids in air freight (unless shipped via ground)
• Special UN-certified packaging is required for some formulations

2. Short Shelf Lives

• Serums & natural products often have 6-12 month expiry windows
• Temperature fluctuations can degrade active ingredients
• Batch tracking is essential to avoid sending expired stock

3. High Customer Expectations

• 72% of beauty buyers say packaging influences brand image
• Damaged leaks = instant negative reviews
• Subscription boxes require precise kitting of complementary products

5-Step Checklist for Compliant Beauty Fulfilment

1. Reformulate or Re-package Problem Products

• Switch to powder or solid formats (e.g., shampoo bars)
• Use airless pumps instead of dropper bottles
• Invest in leak-proof inner seals (saves 40% in damaged returns)

2. Implement Smart Inventory Rotation

• FIFO (First In, First Out) systems prevent expired shipments
• Climate-controlled storage (15-25°C ideal for most actives)
• Automated expiry alerts when stock hits 3-month shelf life

3. Choose Carriers Wisely

• Ground shipping is often preferred over air for transporting liquids
• Specialised hazardous goods carriers for perfumes/alcohol-based items
• Local fulfilment hubs reduce transit time (and leakage risk)

4. Perfect the Unboxing Experience

• Custom inserts prevent breakage (foam vs. paper vs. moulded pulp)
• Sample sachets increase repurchase rates by 28%
• Recyclable materials appeal to eco-conscious buyers

5. Handle Returns Strategically

• Destroy (don’t resell) used/opened products (hygiene rules)
• Offer credit instead of returns for minor issues
• Pre-paid return labels increase customer satisfaction

How Prologue Fulfilment Solves Beauty Brands’ Biggest Headaches

✔ Liquid Logistics Expertise – Hazardous goods-certified shipping
✔ Climate-Controlled Warehousing – Preserves product integrity
✔ Expiry Management Systems – Auto-flagging of short-dated stock
✔ Premium Packaging Options – Custom-branded kits & inserts
✔ UK/EU Compliance Expertise – Navigates Brexit and CLP rules

Real-World Example: Saving a Skincare Startup £60k/Year

One vegan beauty brand was losing:

• £15k/month in leaked shipments
• 22% of subscribers are cancelling due to expired products

After switching to Prologue:

• Zero leak complaints in 6 months
• Auto-rotation system eliminated expiry issues
• Subscription retention up 37%

Key Takeaways

1. Not all 3PLs understand beauty – Choose partners with category experience
2. Prevention beats damage control – Invest in packaging/storage upfront
3. Expiry dates are revenue killers – Tech-driven tracking is non-negotiable