A continuous line process for making a packaged cosmetic device comprising a pre-formed sheet and a coating composition in a sealed package, wherein the pre-formed sheet is produced from a sol phase composition comprising a solvent and a gelling agent having a sol-gel transition point between about the melting point of the solvent and about the boiling point of the solvent by a process comprising heating the so phase composition, forming surfaces of the sol phase composition by pressing the sol phase composition between a plurality of liners, cooling the sol phase composition into a gel phase, cutting the gel phase composition to form the pre-formed sheet.