FAQ

How are cosmetic tubes filled with product?

Tubes are almost always filled from the “tail” (the open bottom end). The tube is placed head-down into a filling machine puck. Nozzles descend into the open tail, fill the product, and then heat-sealing jaws clamp down to melt and seal the end of the tube.

What does “mono-material” mean and why is it important?

Mono-material means the entire pack—the tube sleeve, the head, and sometimes even the cap—is made from a single type of plastic resin (usually PE). This makes recycling much easier because the consumer doesn’t have to separate parts, and recyclers don’t have to process mixed materials.

Yes. The most common is “Sugarcane PE.” This is polyethylene plastic derived from sugarcane ethanol rather than fossil fuels. It has the exact same physical properties as standard PE and is recyclable in the same stream, but it has a lower carbon footprint during production.

PCR stands for Post-Consumer Recycled material. A “50% PCR tube” means half of the plastic used to make the tube came from previously recycled plastic waste (like milk jugs or water bottles). Using PCR reduces the reliance on virgin fossil fuels.

It is complicated.

Yes: Standard mono-material PE (Polyethylene) or PP (Polypropylene) tubes are technically recyclable where facilities exist.

Maybe/No: Multi-layer tubes, especially ABL (with foil) or tubes made of mixed plastics, are often rejected by standard recycling streams because the layers cannot be easily separated.

Always advise consumers to check their local municipal recycling guidelines.

This is a hybrid package. It looks like a standard tube but features a pump dispenser on the head. Inside, there is usually a pouch system or a follower piston that collapses as product is dispensed, preventing air from flowing back into the tube. This is crucial for highly sensitive, antioxidant-rich formulas.

Multi-layer tubes (whether co-extruded or laminated) are designed to protect the product. The inner layer protects the formula from the plastic, the middle layers (like EVOH or Aluminum) act as barriers to oxygen and serums to prevent degradation, and the outer layer serves as the printable surface.

ABL (Aluminum Barrier Laminate): Contains a thin layer of aluminum foil sandwiched between plastic layers. This provides the ultimate barrier against light, air, and moisture, making it ideal for sensitive formulas like toothpastes or retinol creams.

PBL (Plastic Barrier Laminate): Made entirely of plastic layers, usually using EVOH (Ethylene Vinyl Alcohol) as the barrier layer instead of metal. They are generally easier to recycle than ABL and can be made transparent.

There are two primary types used in the industry:

Extruded Plastic Tubes (Monolayer or Co-extruded): Made from a single material (usually PE) extruded into a continuous sleeve. They have a seamless look and a “memory” (they bounce back to shape after squeezing).

Laminated Tubes (ABL or PBL): Made from flat webs of multiple layers bonded together, then rolled and welded to form the tube body. They usually have a side seam.

Cosmetic tubes are popular because they are versatile, hygienic, lightweight, and durable. Unlike jars, they minimize air exposure and finger contamination, helping preserve the product’s active ingredients. They are also portable and resistant to breaking if dropped in a bathroom.

Hot stamping is a decorative process where a heated die transfers metallic foil (usually gold or silver) onto the tube surface. It is used to add premium, shiny accents to logos or text that standard ink cannot replicate.

The standard finishes are Glossy (shiny) and Matte (flat/dull). A popular premium option is Soft-Touch, a coating applied over the tube that gives it a velvety, rubberized feel.

Yes. Extruded PE tubes can be made clear (though they are often slightly hazy). PBL laminated tubes can be made highly transparent if the formula requires the consumer to see the product inside. ABL (foil) tubes cannot be transparent.

Offset Printing: The most common and economical for high volumes; best for solid colors and simple graphics.

Silkscreen Printing: Creates a thicker layer of ink, offering vibrant, opaque colors and a tactile, slightly raised feel.

Flexography: Often used for laminated tubes printing on the flat web.

Digital Printing: Ideal for small runs, prototypes, or complex photo-realistic imagery, as it doesn’t require printing plates.

The most common options include:

Flip-top caps: Convenient, one-handed usage.

Screw-on caps: Traditional, secure seal (standard or stand-up “fez” style).

Pump dispensers: For controlled dosage of thinner liquids/serums.

Specialty applicators: Built-in brush heads, cooling metal roller balls (for eyes), or slanted doe-foot tips (for lip balms).

Tubes generally have longer lead times than stock bottles or jars because they are manufactured from scratch for every order. Standard lead times range from 8 to 14 weeks after artwork approval, depending on the complexity of the design and the supplier’s current workload.

MOQs vary wildly based on the manufacturer and technology.

For fully custom-printed extruded or laminated tubes, MOQs are often high, typically starting at 10,000 to 25,000 units.

Some suppliers offer “stock tubes” (blank white or clear tubes sitting on a shelf) that can be labeled later; these may have MOQs as low as 1,000 units.

The orifice is the small hole in the head of the tube where the product comes out. The size must be matched to the product’s viscosity. A thick clay mask needs a large orifice (e.g., 5mm+), while a thin eye serum needs a tiny orifice (e.g., 1.5mm) to prevent gooey messes or uncontrollable dispensing.

Tube size is defined by two measurements:

Diameter: The width across the circular opening of the tube sleeve (e.g., 35mm, 50mm).

Length: The measurement from the tube head shoulder to the open tail end. The combination of diameter and length determines the fill volume (capacity).

Compatibility testing is essential. Aggressive ingredients (like certain essential oils, sunscreens, or acids) can attack certain plastics, causing the tube to delaminate, swell, or the product to spoil. You must send your bulk product to the tube manufacturer for accelerated stability testing before ordering production.