In an era where environmental concerns are paramount, businesses in many sectors are increasingly focused on sustainable practices. Lush Cosmetics, a well-known company in the beauty industry, has made significant innovations in waste processing.
I recently had the opportunity to visit some of Lush’s production facilities and their Green Hub in Poole, UK, meeting with sustainability leaders including Ruth Andrade from Lush’s Earthcare team. Some of the key aspects of their strategy on display included their fresh manufacturing process and circular focus of their Green Hub.
Controlled Fresh Manufacturing and Limited Waste
Fresh cosmetics is a core element of Lush’s product-line which has led the company to develop a manufacturing model different than competitors, more akin to food production than cosmetics. For instance, they have a decentralized manufacturing footprint to ensure they are close to customers. “We actually have factories in our biggest markets in order to flexibly meet demand and limit the environmental impact of long-distance transportation of finished goods,” Andrade told me. This strategy also helps reduce overproduction.
When working with fresh and active ingredients there can be occasional differences in inputs, particularly when it comes to fruits and vegetables. Lush’s manufacturing staff are trained to know how the small batch cosmetics should look, feel and smell. If at any point in the production process a manufacturing team member believes their mix is not of the highest standard, it can be adjusted before anything is further produced – which also mitigates some of the risks of excessive product waste.
Globally, Lush operates its own self-imposed freshness policies. In the UK this means that from the day a product is manufactured, it must be shipped to stores within 28 days, or 42 days for seasonal ranges. Any product that exceeds this freshness policy will not be sent out and will instead be donated to charities and Community Interest Companies.
As Andrade describes, this approach isn’t just environmentally sound; it also ensures product efficacy. “It’s really getting the benefit of keeping the bioactive compounds by using the whole fruit and the whole vegetable” in a timely manner she told me.
Re-use, Recycle, Repurpose, Recover and Repair at the Lush Green Hub
The Green Hub, Lush’s bid to embrace the circular economy, was originally opened in 2015 and expanded further in 2022 with £2.3m investment to create a 40,000 sq. ft space. Bringing together six departments, the hub was launched under the five Rs of re-use, recycle, repurpose, recover and repair.
Lush has long embraced ‘naked’ packaging, using the bare minimum to wrap and box its products. And the company aims for a closed-loop system for recycling their signature black pots which are made of polypropylene. Customers are encouraged to return used pots, which are then processed and reused.
The Green Hub processed almost a thousand tonnes of manufacturing and packaging waste last year. Andrade explained that in “2009 we decided to start taking our packaging back… it was intense because we had to clean the pots ourselves.” At the Green Hub, a primary function includes granulating plastic as part of Lush’s ‘Bring it Back’ recycling scheme, but also the location treats wastewater from its manufacturing and laundry processes, repairing machinery to prolong its life, and donating surplus products and lifestyle items to charities and grassroots groups.
This facility allows the company to recycle 81% of their UK manufacturing waste, repair over 1431 electrical items and donate more than 152,000 products to those in need in 2023 alone.
In an industry often critiqued for its environmental footprint, Lush’s efforts in waste processing show that commercial success and environmental stewardship can go hand in hand.