Case Study: Custom Essential Oil Bottles for a French Aromatherapy Brand

Discover how a French aromatherapy brand sourced custom essential oil bottles. Reliable B2B packaging solutions for premium wellness products.

Client Background

A beloved French perfume brand had new packaging requirements. For three decades, the brand has been extracting organic essential oils from the lavender-producing regions of the Alps. Renowned for their purity and stability, they sought custom essential oil bottles that would preserve this craftsmanship and protect their light-sensitive oils.

The vision was obvious: 15 ml and 30 ml cobalt blue bottles that will be immediately recognizable in the natural beauty market, which will feature tamper-suit caps, accurate droppers and hand-painted gold strips. He chose Vastal for our expertise in the functionality combination with sophisticated aesthetics. A challenging effort was presented by creating such unique custom essential oil bottles.

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Our challenges

But after the initial prototype, three major challenges emerged. First, Cobalt Blue Glass, used for UV security, had a wide range of shades, with some bottles very light, which reduced the image of the stability of the brand. Second, the dropper, an important component to administer essential oils, disappointed the inspector, stuck in the neck of the bottle on initial use. Third, hand-painted gold stripes were especially at risk of falling during shipping tests, completely inconsistent with high-end beauty of the brand. If these issues were not addressed, they could potentially damage the reputation of the brand for quality, so the customer immediately requested a quick and accurate solution.

Problem Analysis

Our team immediately launched a comprehensive investigation in these issues. The color of uneven glass was due to an inconsistent cobalt oxide mixture in melted glass, resulting in insufficient pigment in some batches. The narrow 18 mm bottle glued to the dropper stemped from the neck, resulting in excessive friction with the rubber ball. Gold stripes were at risk of falling as there was a lack of a primer to increase adhesion in bottles, preventing the pigment from following the glass firmly. Fortunately, these were not design issues and could be resolved through adjustment of the production process.

Our solution

Taking advantage of our experience in essential oil bottle manufacturing, we developed an analog solution for each problem. To ensure consistent color in the Custom Essential Oil bottles, we installed automated sensors to monitor the cobalt oxide content during glass melting, ensuring precise pigmentation with every batch. To address the dropper issue, we widened the neck of the bottle to 20 mm and changed the rubber bulb to a smooth, less flexible design. We tested 10 prototypes before finding the optimal solution. For the gold stripe, we applied a clear primer, then heat-cured it for enhanced adhesion, and added a protective film for shipping.

25ml Empty Dropper Bottle with Purple Press Dropper

30ml Flat Square Amber Bottles with Dropper

Results

The resulting Custom Essential Oil bottles delighted the customer: the cobalt blue glass is rich and uniform, with reliable UV protection; the dropper glides smoothly without snagging; and the gold stripe survived rigorous shipping tests intact. We distributed 30,000 bottles (20,000 15 ml bottles and 10,000 30 ml bottles) on time for our seasonal product launch.

Customers said about packaging, with a comment, “The bottle is very beautiful, and the dropper is very easy to use.” In the first month, sales of the rebranded product line increased by 25%, with customers praising the bottles for “raising brand awareness.” These custom essential oil bottles are now an integral part of the brand’s story.