The Ultimate Guide to Cosmetic Tube Packaging: Types, Processes, and Selection Tips

In recent years, tube packaging has expanded into a wide range of industries. Industrial products like lubricants, silicone sealants, and caulks; food products such as mustard and hot sauce; pharmaceutical ointments and even toothpaste—all increasingly rely on versatile, reliable tube packaging. Within the cosmetics industry, tubes are favored for makeup, daily-use products, and hair care items due to their ease of use, portability, custom sizing, and high-quality printing options.

Cosmetic tubes are packaging containers typically made from materials like PE plastic, aluminum foil, and plastic films. These materials are formed into sheets using co-extrusion and other compounding processes, then shaped into tubes using specialized machinery. Tubes are valued for being lightweight, portable, durable, recyclable, easy to squeeze, and highly customizable in terms of manufacturing and printing.

I. Tube Manufacturing Processes

A. Aluminum-Plastic Composite Tubes
These are produced by co-extruding aluminum foil and plastic film into a sheet, which is then formed into a tube. A typical structure is PE/PE+EAA/AL/PE+EAA/PE. Such tubes offer high barrier and hygiene properties, making them ideal for cosmetics requiring enhanced preservation. The aluminum layer provides the barrier, and advancements have reduced its thickness from 40μm to as low as 9μm, improving sustainability.

B. All-Plastic Composite Tubes
Made entirely from plastic, these come in two types:

• Non-barrier all-plastic tubes: Used for low-end, fast-consumption cosmetics.

• Barrier all-plastic tubes: Often used for mid-to-low range products. They may include EVOH, PVDC, or oxide-coated PET layers for protection. A typical structure is PE/PE/EVOH/PE/PE.

C. Plastic Co-extruded Tubes
Using co-extrusion, multiple layers or types of plastic are formed together in a single step.

• Single-layer tubes: Used for products like hand cream where aesthetics outweigh functional needs.

• Multi-layer tubes: Preferred for high-end cosmetics due to superior barrier properties.

Appendix: Tube production flow diagram

II. Surface Finishing

Tubes can be produced in colored, transparent, frosted, or pearlescent (including silver or gold pearl) finishes, with options for UV coating, matte, or gloss effects. Note that matte finishes, while elegant, may show dirt more easily. Colored tubes vs. fully printed tubes can be distinguished by the tube end—white-edged ends indicate full-body printing, which requires high-quality inks to avoid cracking or peeling.

III. Printing & Decoration

Common printing methods include:

• Screen printing: Ideal for small color blocks and specialty colors. Often used in professional product lines.

• Offset printing: Suitable for large, multi-color designs. Common in daily cosmetic products.

• Hot stamping: Gold or silver foil applications.

Most tube printing uses offset lithography with UV-cured inks, ensuring strong adhesion and color stability. Print registration should be accurate within 0.2mm, with clear, legible text.

The tube body consists of the shoulder, barrel, and tail. The barrel is typically decorated via direct printing or label application. Compared to direct printing (screen or offset), self-adhesive labels allow for more diverse and stable printing effects, including flexography, gravure, and combination processes.

IV. Tube Types & Configurations

1. Tube Body

• By material: Aluminum-plastic, all-plastic, paper-plastic, high-gloss metallized tubes.

• By thickness: Single-layer, double-layer, five-layer composite.

• By shape: Round, oval, flat.

• By application: Face wash, BB cream, hand cream, hair removal cream, sunscreen, toothpaste, conditioner, hair dye, mask tubes, etc.

• Standard diameters: From Φ13 to Φ60 mm.

• Standard capacities: From 3g to 250g.

B. Tube Size & Volume Reference
Note: During production, heating processes (e.g., tube extrusion, connecting, coating, printing) may cause dimensional variation. Slight shrinkage is normal.

C. Example: Five-layer Plastic Composite Tube Structure

2. Tube Tail
Tails can be sealed after filling with various patterns: straight, diagonal, umbrella-shaped, or custom shapes. Date codes can be printed during sealing.

3. Caps & Closures

• Standard options: Screw caps (single or double-wall), flat-top, round-top, flip-top, sprayer, ultra-flat, double-cap, lipstick cap. Caps can be finished with hot stamping, coloring, spraying, or electroplating. Nozzle and lipstick caps often include an inner plug.

• Note: Most tube manufacturers produce tubes but not caps.

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4. Functional Components
To meet diverse market needs, functional elements such as massage heads, roll-ons, and rollerballs are increasingly integrated with tube packaging.

V. How to Choose the Right Cosmetic Tube

1. Design & Artwork Review
   Reputable suppliers assist with design adaptation, ensuring correct placement of eye marks, color suitability, barcode orientation, and overall print readiness.

2. Material Selection
   Materials must comply with relevant health standards (e.g., FDA 21CFR117.1520 for the US market), controlling heavy metals and fluorescent agents.

3. Filling Method
   Consider whether filling will be through the tail or nozzle. Match tube opening size to the filling equipment. Understand if hot-fill or cold-fill is required, and plan packaging orientation accordingly.

4. Tube Type Selection
   For oxygen-sensitive (e.g., whitening creams) or fragrance-sensitive products (e.g., essential oils), choose five-layer co-extruded tubes with EVOH barrier layers, which offer far superior oxygen and moisture resistance.

5. Pricing Factors
   Pricing varies by quality and manufacturer. Plate-making costs range from ¥200–300 per color. Multi-color printing, screen printing, and hot stamping are available. Screen printing offers high quality but is more expensive.

6. Production Lead Time
   Typical production takes 15–20 days after sample confirmation. Minimum order quantities are usually 5,000–10,000 units. Larger suppliers may require 10,000 units, while smaller ones may accept 3,000. Note: actual delivery quantity may vary by ±10%.