Sheet Mask Manufacturing: Complete Guide from Formula to Packaging
Introduction: The Sheet Mask Phenomenon
Sheet masks represent one of the most successful product innovations in modern skincare—transforming a clinical treatment method into a $3.5 billion global market. For private label brands, sheet masks offer compelling advantages: relatively low MOQ, fast turnaround times, high perceived value, and strong e-commerce performance.
At XJ BEAUTY, sheet mask manufacturing represents 20% of our production volume, with expertise spanning traditional cotton to cutting-edge biocellulose formats.
Sheet Material Selection: The Foundation
Non-Woven Cotton: Most economical. Holds 15-20ml serum. Ideal for mass-market positioning.
Microfiber: Thinner and stronger. Superior facial adhesion. Holds 20-25ml serum. Mid-tier price point.
Hydrogel: Gel-based with cooling sensation. Holds 25-30ml serum. Premium positioning with transparent appearance.
Biocellulose: Fermented coconut fibers. Ultra-thin, exceptional adhesion, holds 30-35ml serum. Highest luxury positioning.
Bamboo/Plant Fiber: Eco-friendly alternative. Appeals to sustainability-focused consumers.
Selection depends on target market, price positioning, and formula compatibility. Hydrogel works best with water-based serums; non-woven materials accommodate emulsions.
Serum Formulation: Concentrated Efficacy
Sheet masks allow higher active concentrations than daily-use products:
Hydration Formula:
Multi-weight hyaluronic acid (1-2%)
Glycerin (5%)
Panthenol (3%)
Brightening Formula:
Niacinamide (5-7%)
Alpha arbutin (2%)
Vitamin C derivative (3%)
Anti-Aging with PDRN:
Plant-based PDRN (1-1.5%)
Peptide complex (7%)
Adenosine (0.5%)
Key considerations: Viscosity 500-2000 cP to prevent dripping; pH 5.0-6.5 for skin compatibility; gentle preservation for 24-36 month shelf life.
Manufacturing Process
Step 1: Serum Production - Formulated in temperature-controlled mixing tanks following GMP protocols. Batch size: 200-500L.
Step 2: Sheet Cutting - Fabric die-cut into face-shaped sheets with openings. Speed: 100-200 sheets per minute.
Step 3: Serum Saturation - Sheets immersed or sprayed with serum. Target weight: 20-30g total.
Step 4: Folding - Automated tri-fold or accordion-style for compact packaging.
Step 5: Packaging - Individual foil sachets heat-sealed maintaining 95-98% humidity. Secondary branded boxes available.
Quality Control Checkpoints
Serum Testing: pH, viscosity, microbial limits, active concentration verified
Weight Verification: ±2g tolerance through random sampling
Seal Integrity: Pressure testing prevents leakage
Stability Testing: 3 months at 40°C simulates 12-18 month shelf life
MOQ and Pricing
Typical MOQ: 3,000-5,000 pieces per formula
Cost Breakdown:
Serum formula: $0.30-1.50 per mask
Sheet material: $0.10-0.80 per mask
Packaging: $0.15-0.40 per mask
Labor/filling: $0.10-0.20 per mask
Total: $0.65-2.90 per mask
Retail positioning: Typically 4-6x manufacturing cost. Premium PDRN masks retail $8-15 each.
XJ BEAUTY's Sheet Mask Capabilities
We manufacture 500,000+ sheet masks monthly:
All material options (cotton to biocellulose)
Custom or stock formulations
Automated production for consistency
Individual sachet or jar packaging
45-60 day turnaround
Conclusion: Accessible Innovation
Sheet masks democratize advanced skincare, delivering treatment-level ingredients in user-friendly formats. For brands, they offer product line expansion with manageable investment and strong consumer appeal.
At XJ BEAUTY, our sheet mask manufacturing combines ingredient innovation (like PDRN integration) with production efficiency, helping brands capture this growing market segment.