Every wax and oil is checked before use, because cosmetics must meet strict safety standards. A bad lot of wax would change how hard the stick is.
Measured waxes and oils go into heated mixers. Carnauba has a high melting point and stiffens the stick, while petrolatum and lanolin give the slick seal. Flavor, color and sunscreen go in at this stage.
The hot mixture is held under vacuum so trapped air rises out. Bubbles left in would show up as holes in the finished stick.
The batch rests while the waxes crystallize, for about 48 hours. That long rest settles its final texture.
The crystallized mass is warmed back into a liquid so it can be poured or pressed into its final shape.
Liquid balm is poured into metal molds or straight into its containers and chilled until it hardens. Lipstick makers go one step further and pass the sticks through a flame for half a second to give them a glossy skin.
Sticks are seated in twist-up tubes, while softer balms go into pots or squeeze tubes. Caps and labels go on last.