Comprehensive Guide to Cosmetic Tube Materials: How to Choose the Right One (2026)

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PCR plastic tubes

Selecting the right cosmetic tube material is more than just an aesthetic choice—it’s about formula protection, consumer experience, and brand values. At Xinfly Packaging, with over 20 years of manufacturing expertise, we help brands select materials that balance performance and sustainability.

Here is a deep dive into the four primary materials used in the cosmetic industry today.

1. Plastic Tubes (PE, PP & PCR)

Plastic is the most versatile and cost-effective material, ideal for high-volume consumer goods.

  • PE (Polyethylene): The standard for lotions and cleansers. Available in LDPE (soft) and HDPE (stiffer).
  • PCR (Post-Consumer Recycled): Made from recycled plastic waste. At Xinfly, we recommend 35% – 50% PCR content to maintain both structural integrity and a premium appearance.
  • Pros: Highly flexible, squeeze-friendly, and cost-efficient.
  • Best For: Cleansers, hand creams, and body lotions.

2. Laminated Tubes (ABL & PBL)

Laminated tubes are the “high-performance” choice, combining multiple layers for ultimate protection.

  • ABL (Aluminum Barrier Laminate): Contains a thin layer of aluminum. It offers a 100% barrier against light and oxygen.
  • PBL (Plastic Barrier Laminate): Uses a plastic barrier (EVOH) instead of aluminum. It allows for “invisible” side seams and full-surface printing.
  • Pros: Superior formula protection, “dead-fold” property (ABL), and high-definition printing.
  • Best For: Toothpaste, pharmaceutical creams, and high-active skincare.

3. Aluminum Tubes

Aluminum is the classic choice for “vintage” or “medical” aesthetics and offers unmatched barrier properties.

  • Pros: 100% recyclable, air-tight sealing, and distinct luxury feel.
  • Cons: Can dent easily and doesn’t return to its original shape after squeezing.
  • Best For: Luxury hand balms, hair colorants, and professional-grade ointments.

4. Sustainable Innovations (Sugarcane & Wheat Straw)

Eco-conscious brands are moving toward bio-based feedstocks.

  • Sugarcane PE: Chemically identical to traditional PE but derived from sugarcane, a renewable resource that captures CO2.
  • Wheat Straw Tubes: Incorporates natural wheat fibers, reducing plastic usage and creating a unique “natural” speckled texture.
  • Pros: Strengthens green marketing claims and reduces carbon footprint.

Cosmetic Tube Material Comparison Matrix

Material TypeBarrier StrengthFlexibilityRecyclabilityCost Level
PE (Plastic)ModerateExcellentHigh (Mono)Low
ABL (Laminated)SuperiorLowLowMedium
PBL (Laminated)HighModerateModerateMedium
AluminumSuperiorVery LowExcellentHigh
PCR PlasticModerateExcellentHighMedium

Why Material Choice Matters for Your Formula

At Jiangsu Xinfly Packaging Co., Ltd., we always conduct compatibility tests. For example:

  • Vitamin C & Retinol: Require ABL or PBL with EVOH to prevent oxidation.
  • Organic/Natural Formulas: Often suit Aluminum or Bio-PE to match brand values.
  • Industrial/High-Chemical: Require HDPE or specific COEX structures to prevent tube deformation.

Cosmetic Tube Materials – Frequently Asked Questions

Quick answers about PE, PP, aluminum, laminated (ABL/PBL), and eco options like bio-PE and PCR, plus recyclability and cost factors.

1) What are the main materials used for cosmetic tubes?
Common choices include polyethylene (PE), polypropylene (PP), aluminum, laminated composites (ABL/PBL), and eco options like sugarcane-based bio-PE and PCR plastics.
2) What is PE and why is it widely used?
PE is flexible, lightweight, cost-effective and compatible with many skincare formulas, making it a go-to for cosmetic tubes.
3) Why might a brand choose aluminum tubes?
Aluminum offers excellent light/oxygen/moisture barrier, ideal for sensitive or premium formulations.
4) What are laminated tubes (ABL / PBL)?
Multilayer constructions (e.g., PE/EVOH/Al/PE or all-plastic high-barrier PBL) that improve barrier vs single-layer plastics.
5) What eco-friendly materials are available?
Sugarcane-derived bio-PE, PCR (post-consumer recycled) plastics, and mono-material PE designs to enhance recyclability.
6) How does material choice affect recyclability?
Mono-material PE tubes are generally more recyclable than complex laminates; acceptance depends on local facilities.
7) How does formula compatibility influence material selection?
Actives/solvents may require barrier (COEX/ABL/PBL). Aluminum can react with strong acids; verify compatibility tests.
8) Can I use paper/kraft tubes instead of plastic?
Paper exteriors usually need an internal polymer lining for function; true paper-only tubes are rare.
9) Does material impact cost and design flexibility?
Yes. Single-layer PE is cost-effective; laminates, aluminum and bio/PCR options may increase cost and affect printability/tooling.
10) What trends are emerging in tube materials?
Rising use of recycled content, bio-based feedstocks, mono-material recyclability, and transparency on sourcing/lifecycle.
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Jeff Shao
Jeff – Founder & Managing Director of Xinfly Packaging

Jeff Shao is a forward-thinking entrepreneur and packaging innovator with over 20 years of experience in the cosmetic and personal-care packaging industry. As the Founder and Managing Director of Xinfly Packaging, he has transformed the company from a traditional plastic tube manufacturer into a global provider of custom, eco-friendly, and premium cosmetic tube solutions.

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