Michael Turner
Pack to the security standard: Every container must be clearly marked with a volume of 100 ml / 3.4 fl oz or less. Place all such containers into one transparent resealable pouch (maximum 1 litre/quart) and present that pouch separately at the security checkpoint for X‑ray screening.
Useful packing actions: Decant full-size face-base products into certified travel bottles, tighten caps and apply tape over threads or use leak‑proof travel caps; store the pouch in an outer pocket of the carry-on for quick removal. Keep receipts for any purchases made after security (duty‑free) – sealed duty‑free packaging plus receipt often allows larger volumes on board.
Alternatives to minimize volume: Opt for solid stick compacts, pressed powders, sample vials or single‑use sachets to avoid pouch limits. A small sponge or brush replaces bulky bottles and reduces the number of containers required.
Exceptions and routing notes: Medically necessary fluids and infant supplies may exceed 100 ml but must be declared at screening. Rules are broadly aligned across the US, EU and many other jurisdictions, yet some connections or non‑Schengen transfers may re‑screen items – check the departure and transit airport policies and the airline’s carry‑on allowances before travel.
Which carriers and airports permit cream cosmetic base in carry-on and where to check restrictions
Store creams and gel make-up base in containers of 100 ml (3.4 oz) or smaller, place all such containers together inside one transparent resealable bag up to 1 litre (≈1 quart), and present that bag separately at security; this rule is applied by major operators including British Airways, easyJet, Ryanair, Lufthansa, Air France, KLM, Delta, United, American, Emirates and Qatar Airways on departures from their hubs.
Regulatory specifics: EU/UK and most European airports follow the 100 ml + 1 L bag standard; the United States enforces the TSA “3-1-1” limit (container ≤3.4 oz, 1 quart bag, one bag per passenger). Creamy cosmetics and gels are treated as toiletries for screening; solid stick products are generally exempt from these measures.
Duty-free purchases: items bought after security in tamper-evident bags with original receipt are typically allowed onboard even when volume exceeds 100 ml, but transferring through another security checkpoint (transit) can void that allowance – check transit airport policy before relying on the sealed-bag exception.
Where to verify restrictions
Confirm rules via (1) the airline’s official “baggage” or “travel information” page, (2) the departure airport’s security or passenger info section, and (3) the national aviation authority (TSA for the United States, CAA or government travel pages for the UK, EASA/EU pages for EU states). For connecting flights, verify both departure and transit airport rules and the carrier’s transfer policy at least 24 hours before departure.
Packing tips: use travel-size jars clearly marked with capacity, keep the resealable bag accessible for separate screening, retain receipts for duty-free items, and declare medically required creams at security with supporting documentation. For unrelated travel gear recommendations, see best umbrella for daily rain.
Measure and label makeup base containers to meet the 100 ml / 3.4 fl oz carry-on limit
Use containers of 100 ml (3.4 fl oz) or smaller; verify actual fill with measurement tools and label each bottle with net volume in ml and fl oz plus open date.
- Acceptable container sizes: 10 ml, 30 ml, 50 ml, 75 ml, 100 ml – choose the smallest practical size to reduce spill risk.
- Measurement tools:
- Graduated cylinder (plastic or glass) with 1 ml graduations for accurate volume reads.
- Disposable syringes (10 ml or 60 ml) for creams and emulsions; pull/plunger method gives ±0.5 ml accuracy.
- Digital scale (0.1 g resolution) when dealing with dense creams – convert grams to ml using product density.
- Density conversion rule: most water-based emulsions ≈1.00 g/ml. Example conversions:
- If density ≈1.00 g/ml → 100 ml ≈ 100 g.
- If density ≈0.95 g/ml → 100 ml ≈ 95 g (weigh to target grams).
- When density is unknown, use graduated cylinder or syringe instead of scale.
- Filling technique:
- Tare empty container on the scale or note zero on syringe.
- Use a small funnel or spatula to transfer product slowly to avoid air pockets.
- Stop 1–2 mm below the cap threads to allow headspace; do not exceed the marked 100 ml line.
- Label format (print or permanent marker; waterproof tape over paper labels):
- Line 1: Product name (e.g., “makeup base – tinted cream”).
- Line 2: Net volume: “50 ml / 1.7 fl oz” (include both units).
- Line 3: Opened: “DD‑MMM‑YYYY” or “Opened: 21 Aug 2025”.
- Accuracy and margin of safety:
- Measure to ±1 ml and leave a small margin – aim for 95 ml when possible to avoid borderline rejections.
- Security staff may request to inspect or measure; clearly visible printed volume speeds checks.
- Container and sealing tips:
- Prefer clear PET or glass with volume graduations; screw caps with silicone liners reduce leaks.
- Use tamper-evident tape or heat-shrink seals for liquids under pressure or oily formulations.
- Documentation for transfers:
- Keep original product label or a photo of it inside carry-on for ingredient verification if a decanted sample is checked.
Related equipment and packing advice available at best digital camera for 150 pounds.
How to pack a face base under the 3-1-1 rule using travel bottles and resealable bags
Pack the face base in a single 100 ml (3.4 fl oz) travel bottle and place it inside a clear, resealable quart-size bag for screening access.
Choosing containers
Preferred: airless pump bottles or PET/HDPE screw-top bottles with silicone gasket – both reduce contamination and leaks. For very runny formulas use an airless pump; for thicker creams use a wide-neck jar (glass avoided due to breakage). Avoid metal tins for emollient formulas. Buy bottles explicitly marked 100 ml / 3.4 fl oz; many travel sets include 30 ml, 50 ml and 100 ml sizes.
Filling, sealing and testing
Sanitize hands and tools. Transfer product with a small funnel, disposable syringe or flat spatula. Fill bottles no higher than 85–90% capacity to allow pressure expansion. Wipe threads clean, place a square of cling film over the opening, then screw the cap down; for screw caps add one wrap of PTFE (plumber’s) tape on the thread for extra seal. Lock pump heads where possible and secure with a strip of tape. Place bottles inside the clear quart bag, seal, then invert and squeeze the bag gently for 10–15 seconds to check for leaks. If any seepage appears, double-bag and re-seal with fresh cling film under the cap.
Label bottles with product name and volume using an alcohol-resistant marker or a pre-printed sticker. Pack the sealed quart bag in an outer pocket or top compartment for easy access during screening.
Medical and cosmetic exemptions for larger cosmetic containers in carry-on
Present a signed medical letter and the original prescription at the security checkpoint and place the item in a separate tray for inspection; carry only the quantity required for the trip duration.
Documentation and labeling
Required: a clinician’s letter on official letterhead with passenger full name, clinical diagnosis or ICD code, product name and active ingredient, exact volume required for travel, issuance date, clinician name and contact details and a signature. Original prescription matching the product and original manufacturer packaging are strongly preferred; a clear photo of both on a mobile device is acceptable at many checkpoints but not guaranteed. Translations into the local language or an English summary are recommended for international departures. Label bottles with patient name and prescription number when possible.
Screening procedure and practical tips
Security staff will screen exempted items separately and may open containers, perform swab testing or request inspection by an officer. Declare the item immediately at the start of screening to avoid delays. Refrigerated items should be packed with gel or ice packs (subject to separate screening); bring a cold-proof insulated pouch if temperature control is required. Quantities above 100 ml / 3.4 fl oz are routinely permitted for medically necessary products, but allowances are limited to what is reasonable for the trip; airport/airline staff have final discretion. For non-prescription cosmetic products used for medical conditions (e.g., steroid creams, prosthetic adhesives, medically prescribed cosmetic bases), include medical justification on the clinician’s letter. Always check the departure airport and carrier policies before travel and keep contact details for the issuing clinician accessible.
Sample clinician note: “To whom it may concern: [Patient full name] requires [product name; active ingredient] for treatment of [diagnosis / ICD code]. Required amount for travel: [quantity]. Issued by [clinician name, qualification, contact number]. Date: [DD/MM/YYYY]. Signature: [signed].”
What security officers inspect: presentation, testing, and common reasons for confiscation
Store face-base items in original packaging with intact seals and visible labels; place all containers in a single clear resealable bag and present that bag separately at screening.
Typical screening steps
- X-ray analysis: any dense, oddly shaped or layered item will be flagged for secondary inspection.
- Visual check: labels compared to product appearance; unlabelled, homemade or altered containers are pulled aside.
- Olfactory assessment: strong solvent or alcohol smells can trigger flammability concerns and further testing.
- Explosive trace detection (ETD): officers may swab bag exteriors, zippers or container surfaces; a positive trace requires containment and extra procedures.
- Manual examination: staff may request opening or pouring a small sample into a test vial when appearance or ETD results are suspicious.
- Pressure/aerosol inspection: pressurised cans are examined for dents, leaks, missing caps or compromised safety features and are often removed if found unsafe.
Common reasons for confiscation and practical steps to prevent loss
- Unlabelled or decanted products – keep factory labels and, if possible, original cartons; avoid transferring creams into unmarked bottles.
- Damaged or leaking packaging – tape caps, replace cracked dispensers and double-bag items in spill-proof pouches.
- High volatile solvent or alcohol content – formulations with strong volatiles are frequently seized; check ingredient lists or material safety data sheets before travel.
- Open jars and single-use pots – uncovered containers are often discarded; use sealed travel-size pumps or sealed sachets instead.
- Noncompliant container size or shape – oversized items and unconventional bottles draw refusal; split product into multiple approved containers that remain visible.
- Separation, discoloration or particulate matter – products showing phase separation or particles are treated as suspicious; replace expired or degraded items prior to transit.
- Homemade or artisanal blends without documentation – carry labelling or a provider’s note for custom cosmetic or therapeutic preparations.
- Undeclared medical exemptions or missing prescriptions – present a signed medical letter, original prescription and product packaging to reduce the chance of seizure.
If removal occurs, obtain an incident reference or receipt from screening staff to pursue return or appeal through the airport security office or airline customer service.
Leak prevention and placement in cabin bag: sealing, padding, cabin arrangement
Place bottles upright inside a hard-shell toiletry case with inner seals and absorbent padding; secure each cap with plastic wrap plus tape and position the case in the center compartment of the cabin bag surrounded by dense clothing layers.
Sealing techniques
1) Inner seal retention: if a container still has its factory foil/film, keep it in place; if removed, press a square of cling film over the opening, screw the cap down onto the film and trim excess. 2) Cap-wrap: wrap the cap area with one layer of cling film then two turns of high-adhesion tape (medical or gaffer tape preferred) across the cap-to-body junction. 3) Pump bottles: remove pump, replace with a screw cap or install a silicone O-ring under the pump collar, then lock the pump (many pumps twist to ‘lock’ – twist until it clicks). 4) Heat-shrink bands: use pre-cut shrink bands or tamper-evident seals over the cap where available; apply with a hairdryer for a snug fit. 5) Parafilm or stretch film: for jars and small necks, stretch Parafilm around threads before capping to create a pliable inner gasket. 6) Pressure-equalisation: avoid completely filling containers to the brim; leave ~5–10% headspace to reduce pressure-driven leaks during ascent/descent.
Placement and padding strategy
1) Hard-case core: choose a rigid toiletry case with dividers and a waterproof lining; place inside the central compartment of the cabin bag, not in external pockets. 2) Surround padding: pack two layers of dense clothing (jeans, sweater) around the case top/bottom/sides; use softer garments (t-shirts) as inner buffers to prevent rubbing against caps. 3) Glass items: place glass bottles in individual padded sleeves or wrap in multiple cloth layers and position them adjacent to a board-like item (e.g., a folded notebook) to reduce torsion stress. 4) Absorbent backup: insert single-use absorbent pads or a folded microfiber cloth beneath and above containers to capture any seepage. 5) Accessibility: position the toiletry case so it can be removed without unpacking the entire bag during inspection; however, keep it inside the main compartment to avoid crushing. 6) Weight and balance: keep heavier toiletry items low and centered to maintain stable carry ergonomics and reduce pressure on caps during movement.
| Method | Materials | Leak-resistance (1–5) | Best for | Notes |
|---|---|---|---|---|
| Factory inner foil | Original seal | 5 | Screw-top bottles, jars | No extra work; keep intact where present |
| Cling film + tape | Cling film, gaffer/medical tape | 4 | Screw caps, small jars | Fast, field-ready; replace tape after long trips |
| Pump lock + O-ring | Silicone O-ring, pump-lock | 4 | Dispensing pumps | Prevents pump actuation and thread leakage |
| Heat-shrink band | Shrink bands, heat source | 5 | Retail bottles, glass | Tamper-evident and robust against pressure changes |
| Hard-shell case + padding | Rigid case, foam/dividers, absorbent pad | 5 | All container types | Best single solution for containment and impact protection |
For structured storage that helps keep cases upright and accessible within the cabin bag, consider a purpose-built pack such as best backpack for salesmen.
