Lean Manufacturing: A myth in beauty industry?

Lean Marketing & Circular Economy Are the Future of Beauty

One of the biggest problems across industries today- whether it’s fashion, food, or beauty- is overproduction and waste. Brands produce in bulk, products go unsold, and eventually, they’re either heavily discounted or discarded.

The beauty industry alone generates 120 billion units of packaging waste every year, and studies show that up to 25-30% of beauty products remain unsold. That’s not a business inefficiency—it’s an environmental disaster.

 The Hard Truth: More Production = More Pollution

Manufacturing is responsible for nearly 30% of global carbon emissions. And mass production only worsens the problem. Every time a brand overproduces, it’s not just stock sitting in a warehouse- it’s excess raw material, wasted energy, unnecessary packaging, and an overall larger carbon footprint.

This is why I believe that the future of beauty needs to be different.

Building Mehr Skincare the Lean Way

At Mehr Skincare, I don’t want to follow the same wasteful production model. Instead of producing large quantities and hoping they sell, I want to focus on lean production and circular economy principles—where we produce only what’s needed, minimise waste, and rethink the entire supply chain for sustainability.

Here’s what that could look like in practice:

• Small-batch production to reduce excess stock
• Minimal, sustainable packaging to cut down on waste
• Listening to real customer demand before creating new products
• Finding ways to reuse or recycle materials instead of discarding them

We’re Not There Yet—But That’s the Goal

As a young brand, I know that this shift won’t happen overnight. But I want to build Mehr Skincare with sustainability at its core, not as an afterthought.

There are a few hurdles I anticipate- and my thoughts on tackling them:

1. Supply Chain Complexity: Sourcing sustainable, high-quality ingredients and packaging in small batches can be tricky. I plan to build strong relationships with niche suppliers and leverage technology to streamline procurement.
2. Production Flexibility: Scaling up without overproducing means maintaining agile manufacturing processes. Investing in adaptable production systems and using data analytics to forecast demand accurately will be crucial.
3. Cost Management: Sustainable materials and small-batch production can be costlier. To manage this, I aim to integrate cost-saving innovations early and educate consumers on the value of eco-friendly products. The revenue being earned at this stage will also be re-invested into the brand’s philosophy.
4. Market Education: Shifting consumer behaviour towards lean, sustainable consumption requires clear communication. I’ll focus on transparency to build trust and showcase the environmental benefits.

By tackling these challenges head-on, I’m confident that a sustainable, lean model isn’t just idealistic- it’s achievable and scalable for a Mehr Skincare.

For India, moving towards a circular economy- where resources are reused, waste is minimised, and sustainability drives business decisions- is the way forward. I want Mehr Skincare to be a part of that change!