How Shell is Making Cosmetics Manufacturing More Sustainable

The cosmetics industry has faced increasing pressure in recent years to move away from crude-oil based ingredients, driven by growing consumer demand for natural and sustainable products and a greater focus on sustainable manufacturing processes. 

With this in mind, oil and gas company Shell has launched Shell Silk Alkane, a new innovation that will help advance the sustainability of cosmetics manufacturing.

Shell Silk Alkane is a range of synthetic fluids that enhances cosmetic production by providing functional performance without relying on crude oil derivatives.

It uses Gas-to-Liquids (GTL) technology, which converts natural gas into high-purity synthetic molecules suitable for industrial applications including cosmetics manufacturing. 

Traditionally, cosmetic manufacturing processes have relied on crude oil derivatives, which contribute to various environmental problems including climate change, pollution and deforestation.

In contrast, GTL technology involves extraction and refining processes that generally have less environmental impact than those associated with crude oil – Shell Silk Alkane is vegan, biodegradable and exhibits low ecotoxicity to water, soil, birds and plants.

Vanessa Boag, Vice President of Global Marketing at Shell, states: “With the beauty and personal care industry shifting towards more responsible and biodegradable alternatives, Shell Silk Alkane emerges as a versatile, high-performance substitute for commonly used emollients and with its soft and silky sensory profile and stability.”

“Shell Silk Alkane is more than just an ingredient: it is the embodiment of The Silk Spot – a space where elegance, performance, versatility and biodegradability converge.”

Understanding Gas-to-Liquids technology

GTL technology represents a significant development in manufacturing sectors, transforming natural gas into various liquid products previously derived from crude oil.

As well as ingredients for cosmetics manufacturing, this includes areas such as transportation fuels and motor oils.

GTL products are almost free of the impurities commonly found in crude oil, such as sulphur and nitrogen. This benefits manufacturing processes by minimalising contamination risks and improving product quality.

The process begins with converting natural gas into synthesis gas, a mixture of hydrogen and carbon monoxide, followed by the removal of impurities.

This synthesis gas is then turned into liquid hydrocarbons through a catalytic process, culminating in cracking and isomerisation to yield the desired properties.

Shell has been pioneering GTL technology since the 1970s, having established both the world's first commercial GTL plant in 1993 and the largest in Qatar by 2011. The company has invested over US$1bn and holds more than 3,500 patents associated with the technology.

Applications of Shell Silk Alkane in manufacturing

Shell Silk Alkane ingredients are specifically developed for applications like hydrating and protecting hair and skin, integral to manufacturing personal care products.

These GTL-derived ingredients are virtually odourless and ideal for formulating cosmetic products with odour-neutral characteristics.

Additionally, GTL's vegan and DNA-free certification demonstrates sustainability credentials tailored for sensitive skin compatibility, ensuring strong hydration and smooth application—a critical consideration for manufacturers focusing on product experience and consumer satisfaction.

Shifting away from crude oil in manufacturing

The cosmetics industry is witnessing a transition from crude oil-derived components to more sustainable options, propelled by consumer demands for natural ingredients in personal care.

The Chemical Abstracts Service, part of the American Chemical Society, notes that this trend reflects broader industry shifts.

Manufacturers are increasingly substituting traditional petrochemical origins with alternatives like vegetable oils or biosynthetically produced squalene.

This means that commonly used substances such as mineral oil, petrolatum and paraffin wax — essential for creating texture in balms and creams — as well as surfactants like sodium lauryl sulfate and polyethylene glycols, are gradually being replaced.

Natural gas, while a fossil fuel, is recognised for its lower environmental impact compared to other fossil sources, thus making it an appealing option for reducing the carbon footprint in manufacturing.

The extraction and processing of natural gas are generally less environmentally detrimental, with fewer pollutants and hazardous byproducts, supporting the development of safer, more sustainable manufacturing processes.

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