How are laminated tubes made

Laminated tubes are widely used in skincare, cosmetics, toothpaste, ointments, and personal care products because their multi-layered material structure combines barrier properties, flexibility, appearance, and product protection in a single package.

So, how exactly are laminated tubes manufactured?

Generally, the production of laminated tubes begins with a multi-layered composite film. Manufacturers combine different functional material layers to form a composite film based on the product formulation and packaging performance requirements. This composite film is then cut to specified dimensions, rolled and shaped into a cylindrical tube, and sealed to form the tube body.

After the tube is completed, the shoulder and nozzle are formed, and then a matching cap is installed. Finally, after printing, decoration, appearance inspection, sealing tests, and other quality inspections, it becomes the final cosmetic packaging.

Based on the different internal barrier layers, laminated tubes can be mainly divided into ABL (Aluminum Barrier Laminate) and PBL (Plastic Barrier Laminate).

ABL (Aluminum Blanc Plated) typically includes an aluminum foil barrier layer, while PBL (Polymer Blanc Plated) uses polymer-based barrier materials.

Understanding this process is crucial for cosmetic brands because composite tubes are not simply a matter of gluing several materials together. The final packaging performance actually depends on the overall fit between the material layers, tube body, shoulder, cap, printing, and sealing process.

1. What is a Laminated Tube?

A Laminated Tube is a flexible packaging container made of a multi-layered composite material.

It differs from traditional extruded tubes.

Traditional extruded tubes are typically formed into tubular structures continuously using plastic extrusion equipment. Laminated Tubes, on the other hand, are usually produced by first manufacturing a composite film, which is then processed into a cylindrical tube.

A typical composite material structure might include:

• Outer protective layer
• Printed layer
• Structural layer
• Barrier layer
• Adhesive layer
• Inner heat-sealing/contact layer

Each layer has its own function.

For example, the outer layer is primarily for protection and printing; the barrier layer reduces the impact of oxygen, moisture, or other external factors; and the inner layer comes into direct contact with the cosmetic formulation, thus requiring careful consideration of formulation compatibility.

The advantage of this multi-layered structure is that manufacturers can design different packaging structures for different product needs, rather than requiring a single material to perform all functions simultaneously.

2. Two Main Types of Laminated Cosmetic Tubes

The specific manufacturing method of composite tubes largely depends on their internal material structure.

ABL Tube

ABL stands for Aluminum Barrier Laminate, meaning an aluminum foil-barrier composite tube.

This structure contains an aluminum foil barrier layer.

Aluminum foil provides strong:

• Light blocking properties
• Oxygen barrier properties
• Moisture barrier properties

Therefore, ABL can be an option for some formulations that are sensitive to the external environment.

Common applications include:

• Skin creams
• Ointments
• High-end skincare products
• Formulations sensitive to environmental exposure

The aluminum foil layer is usually located inside the composite material, rather than in direct contact with the product.

PBL Tube

PBL stands for Plastic Barrier Laminate, meaning a plastic barrier composite tube.

It does not use aluminum foil as the main barrier layer, but achieves the corresponding barrier properties through polymer materials.

Depending on the specific structure, PBL can offer:

• Good flexibility
• Smooth appearance
• Good printability
• Plastic-based composite structure
• Various levels of barrier properties

PBL is also very common in cosmetic and personal care product packaging.

For brands, choosing between ABL and PBL should not be based on the assumption that one structure is necessarily better, but rather on a judgment that considers the actual formulation, barrier requirements, cost, appearance, and production requirements.

3. Step One: Designing the Composite Material Structure

Before formal production, the material structure of the Laminated Tube must first be determined.

This is a crucial step in the entire production process.

Because different products have different packaging requirements.

Suppliers typically need to consider:

Formulation composition
Product viscosity
Sensitivity to oxygen
Sensitivity to moisture
Sensitivity to light
Chemical compatibility
Expected shelf life
Tube flexibility
Printing requirements
Product positioning

For example, a regular skin cream and a skincare formula containing highly active ingredients do not necessarily require the exact same barrier structure.

Therefore, the production of the Laminated Tube actually begins with materials engineering, not just tube manufacturing.

4. Step Two: Producing the Composite Film

After determining the structure, the different material layers need to be combined to form a composite film.

Depending on the production technology, manufacturers can use processes such as adhesive lamination and extrusion lamination.

The main purpose of this process is to form a stable multilayer composite film while ensuring sufficient bonding strength between the different material layers.

Structurally, it can be simply understood as:

Outer layer → Printed layer → Structural layer → Barrier layer → Adhesive layer → Inner layer

However, the specific structure will vary depending on the product and the supplier's technical solutions.

The thickness and material of different layers will affect the final hose's:

• Barrier performance
• Rigidity
• Flexibility
• Appearance
• Heat-sealing performance
• Formula compatibility
• Cost

This is why two hoses that look very similar may have completely different internal structures.

5. Step Three: Printing and Surface Decoration

After the composite film is produced, printing and surface decoration can be carried out.

This is also a significant advantage for cosmetic brands using Laminated Tube.

The tube body has a relatively large printing area, capable of displaying:

• Brand Logo
• Product Name
• Efficacy Information
• Instructions for Use
• Ingredient Information
• Regulatory Requirements

Common processes include:

• Flexographic Printing
• Offset Printing
• Screen Printing
• Hot Stamping
• Matte Effect
• High Gloss Effect
• Metallic Effect

For high-end skincare brands, different surface effects can be combined to create more visually appealing packaging.

6. Step Four: Composite Film Cutting

After printing, the composite film needs to be cut according to customer requirements.

The cut dimensions must match the final hose specifications.

Key parameters include:

• Hose diameter
• Hose length  
• Finished capacity
• Shoulder dimensions
• Sealing area
• Printing position

If the cut dimensions deviate, subsequent tube manufacturing and sealing processes may be affected.

Therefore, dimensional control is a crucial quality control step in composite hose production.

7. Step Five: Forming the Hose Body

The cut composite film is then rolled into a cylindrical shape.

After the two edges of the composite film are joined together, they are sealed to form the complete hose body.

This forms the main cylindrical structure of the Laminated Tube.

The longitudinal seams must have sufficient mechanical strength and sealing performance.

A good molding process should ensure:

• The tube body maintains stable roundness;
• The seams are uniform;
• The dimensions meet requirements;
• The printed pattern is accurately positioned;
• The tube can withstand normal pressure during filling and transportation.

After completing this step, the tube body can proceed to the shoulder and nozzle molding stage.

8. Step Six: Shoulder and Nose Forming

A single tube body cannot form a complete cosmetic package.

It needs a shoulder and nozzle to connect the tube to the cap.

During production, the tube body is placed in a molding machine, where a shoulder and nozzle are formed from plastic material.

The shoulder connects the flexible tube body to the relatively rigid dispensing area.

The nozzle needs to match the final cap.

Depending on the product positioning, it can be paired with:

• Screw cap
• Flip cap
• Disc Top Cap
• Applicator Cap
• Special dispensing structure

Therefore, the shoulder and nozzle are actually a very important part of the tube customization process.

9. Step Seven: Install the Cap

After the shoulder and nozzle are formed, the corresponding cap can be installed.

The cap must match the size, thread, or snap-fit ​​structure of the nozzle.

Common options include:

• Standard screw cap
• Flip cap
• Large-mouth cap
• Applicator
• Applicator Cap
• Custom cap

The cap needs to ensure reliable sealing during transportation and storage, while also being easy for consumers to open and close.

For skincare products that require frequent daily use, the cap design directly impacts the user experience.

10. Step Eight: Sealing and Leakage Testing

After the laminated tube is completed, quality inspection is required.

Sealing and leak prevention are especially important because the tube needs to remain intact during:

• Filling
• Storage
• Transportation
• Retail
• Consumer Use

Depending on product requirements, the following may be performed:

• Tube seam inspection
• Shoulder inspection
• Cap inspection
• Pressure testing
• Leakage testing
• Dimensional inspection
• Appearance inspection

The main purpose is to promptly detect:

• Poor seams
• Incomplete seals
• Cracks
• Deformation
• Cap mismatch issues

11. Step Nine: Formulation Compatibility Testing

Even if a tube looks very appealing, it doesn't necessarily mean it's suitable for a particular cosmetic formulation.

Therefore, formulation compatibility testing is crucial when developing new products.

Testing should be conducted using the actual cosmetic formulation and the final tube structure.

Pay attention to:

• Color changes
• Odor changes
• Material expansion
• Separation
• Leakage
• Interaction between the formulation and inner layer materials
• Dispensing performance
• Long-term storage performance

For example, some formulations containing oils, solvents, acids, or highly active ingredients may interact to varying degrees with different inner layer materials.

Therefore, truly suitable cosmetic tube packaging must meet both product formulation and packaging performance requirements.

12. Why Does the Cosmetic Industry Use Laminated Tubes?

Laminated tubes are widely used in the cosmetic industry because they combine multiple properties.

Barrier Properties

The multi-layered structure can be designed with different levels of oxygen, moisture, and light barrier capabilities to meet specific needs.

Flexible Dispensing

The flexible tube body is ideal for creams, gels, and lotions.

Customizable Appearance

The tube body can be printed with high quality and has various surface decorations.

Flexible Material Structure

Different composite layer structures can be designed according to product requirements.

Lightweight

Overall packaging weight can be reduced while maintaining functionality.

Highly Customizable

Tube diameter, length, shoulder, cap, and printing can all be customized.

13. How to Choose Laminated Tubes for Different Cosmetic Products?

Different formulations have different requirements for the tube.

Face Creams

PBL or ABL can be chosen based on the formulation and barrier requirements.

Cleansing Products

Generally, the following are important considerations:

• Ease of dispensing
• Flexibility
• Formula compatibility

Sunscreen Products

Sunscreen products require careful consideration of:

• Sun protection requirements
• Formula compatibility
• Dispensing performance

For cream-based sunscreens, laminated tubes can also be an alternative packaging option to sunscreen bottles.

Hand Creams

Hand creams are generally well-suited to flexible tubes because consumers can easily control the amount of product dispensed.

Hair Care Products

High-viscosity products such as hair masks, hair creams, and styling products can also benefit from the choice of a suitable laminated tube based on their specific formulation.

14. What is the difference between a Laminated Tube and an Extruded Tube?

The two types of tubes are manufactured using different technologies.

It's important to note that it's not accurate to simply say that a Laminated Tube is always better than an Extruded Tube.

Ultimately, the selection should be based on:

Formulation + Barrier Requirements + Appearance + Cost + Filling Process + Application Scenarios

15. What should brands ask suppliers when sourcing Laminated Tubes?

If you are a cosmetics brand sourcing tubes, you shouldn't just focus on the tube's appearance and price.

It's recommended to ask the following:

1. What composite material structure is used?
2. Is it ABL or PBL?
3. What is the total material thickness?
4. What material is the barrier layer made of?
5. Which layer comes into direct contact with the cosmetics?
6. What diameters and caps are available?
7. What printing methods are supported?
8. What cap options are available?
9. Can customization be done?
10. Can samples be provided for compatibility testing?
11. What quality checks are conducted?
12. What is the MOQ and lead time?

These questions will help buyers compare different suppliers based on actual packaging performance rather than just price.

16. What kind of support can a cosmetic packaging supplier provide?

A professional cosmetic packaging supplier shouldn't just provide an empty tube.

A more complete development process should include:

Formulation → Material Structure → Tube Size → Shoulder → Cap → Printing → Testing → Mass Production

This integrated development approach reduces the risk of packaging incompatibility, material mishaps, and sealing issues later on.

Especially for B2B cosmetic brands, it is recommended to conduct complete packaging sample testing before mass production.

Summary

So, how exactly is a Laminated Tube manufactured?

Simply put, it begins with the design of a multi-layered composite material structure. Then, a composite film is produced, followed by printing, cutting, rolling, and sealing to form the tube body. Next, the shoulder and nozzle are formed, a matching cap is installed, and finally, quality testing is conducted on dimensions, appearance, sealing, leak-proofing, and formulation compatibility.

Most importantly, the production of a Laminated Tube is not simply a matter of combining several materials.

Each layer of material has its own function, and the final packaging performance depends on the compatibility of the entire packaging system.

For cosmetic brands, when choosing ABL, PBL, or other composite structures, the following factors need to be considered:

• Product formulation
• Barrier requirements
• Discharge method
• Appearance positioning
• Sustainability goals
• Cost
• Filling process
• Target market

Therefore, a truly professional Cosmetic Packaging Supplier should not just provide a finished tube, but should be involved in the entire process, from material selection and tube structure to printing, capping, filling compatibility, testing, and custom development.

This allows Laminated Tube to simultaneously achieve excellent product protection, flexible material output, visual appeal, and stable mass production, while meeting the packaging needs of modern cosmetics and personal care brands.