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This study assessed the feasibility of using cork powder, an abundant by\u2010product of the cork industry, as a cosmetic ingredient. Key challenges were identified, and effective solutions were proposed for integrating cork powder into cosmetic products.<\/jats:p><\/jats:sec><jats:sec><jats:title>Methods<\/jats:title><jats:p>To obtain a suitable ingredient, cork powder was subjected to physical treatment. The resulting heat\u2010treated powder was further characterized for particle size, colour, moisture content, hygroscopicity, pH, oil absorption capacity and heavy metal content. The stability of cork powder, both as a stand\u2010alone ingredient and incorporated into a makeup formulation, was evaluated over 90\u2009days, and its safety was assessed in human keratinocytes and a 3D EpiSkin\u2122 model.<\/jats:p><\/jats:sec><jats:sec><jats:title>Results<\/jats:title><jats:p>Cork powder exhibited a brownish colour, low moisture content (3.03\u2009\u00b1\u20090.42%) and hygroscopic properties (9.04\u2009\u00b1\u20090.08%), along with high oil absorption capacity (206.93\u2009\u00b1\u20092.33\u2009g\/100\u2009g) and acceptable heavy metals levels, considering the intended use as cosmetic (As\u2009=\u20090.350\u2009\u00b1\u20090.020\u2009ppm; Cd\u2009=\u20090.086\u2009\u00b1\u20090.003\u2009ppm; Hg\u2009=\u20090.005\u2009\u00b1\u20090.001\u2009ppm; Pb\u2009=\u20091.420\u2009\u00b1\u20090.030\u2009ppm), which remained stable for at least 90\u2009days. The safety of the powder for skin application was also ensured up to at least 5% content. Using 2% cork powder in O\/W formulations provided a colour shade suitable for makeup foundations and remained stable over the 90\u2010day study period.<\/jats:p><\/jats:sec><jats:sec><jats:title>Conclusion<\/jats:title><jats:p>Key challenges in transforming cork by\u2010products into cosmetic ingredients include the standardization of the preparation process, batch uniformity and suitable microbiological burden. Sieving, washing, filtration and heat treatment of cork powder reduced microbial burden and improved batch uniformity. Industrial processing did not introduce contaminants, with heavy metal levels remaining below regulatory limits for cosmetic use. The treatment and storage conditions adopted preserved the physicochemical properties, and pre\u2010formulation and stability studies validated its potential as a sustainable innovative ingredient for decorative and mattifying cosmetics. Transforming by\u2010products into cosmetic ingredients is a stepwise process that must be carefully carried out to ensure optimal performance.<\/jats:p><\/jats:sec>","DOI":"10.1111\/ics.13066","type":"journal-article","created":{"date-parts":[[2025,4,11]],"date-time":"2025-04-11T06:33:44Z","timestamp":1744353224000},"page":"768-779","update-policy":"https:\/\/doi.org\/10.1002\/crossmark_policy","source":"Crossref","is-referenced-by-count":2,"title":["Overcoming challenges in the development of cosmetic formulations with agro\u2010industrial by\u2010products: The case of cork powder"],"prefix":"10.1111","volume":"47","author":[{"ORCID":"https:\/\/orcid.org\/0000-0001-5348-8431","authenticated-orcid":false,"given":"Sandra","family":"Mota","sequence":"first","affiliation":[{"name":"Associate Laboratory i4HB\u2010Institute for Health and Bioeconomy, Faculty of Pharmacy University of Porto  Porto Portugal"},{"name":"UCIBIO\u2014Applied Molecular Biosciences Unit, Department of Drug Sciences, Faculty of Pharmacy University of Porto  Porto Portugal"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Ana","family":"Torres","sequence":"additional","affiliation":[{"name":"Associate Laboratory i4HB\u2010Institute for Health and Bioeconomy, Faculty of Pharmacy University of Porto  Porto Portugal"},{"name":"UCIBIO\u2014Applied Molecular Biosciences Unit, Department of Drug Sciences, Faculty of Pharmacy University of Porto  Porto Portugal"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Paulo","family":"Silva","sequence":"additional","affiliation":[{"name":"Associate Laboratory i4HB\u2010Institute for Health and Bioeconomy, Faculty of Pharmacy University of Porto  Porto Portugal"},{"name":"UCIBIO\u2014Applied Molecular Biosciences Unit, Department of Drug Sciences, Faculty of Pharmacy University of Porto  Porto Portugal"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Joana Rocha e","family":"Silva","sequence":"additional","affiliation":[{"name":"Dimas &amp; Silva, Lda Industry  Mozelos Portugal"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-1498-048X","authenticated-orcid":false,"given":"Agostinho","family":"Almeida","sequence":"additional","affiliation":[{"name":"LAQV, REQUIMTE, Laboratory of Applied Chemistry, Department of Chemical Sciences, Faculty of Pharmacy University of Porto  Porto Portugal"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Ricardo N. 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