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The Basics of Packaging for Cosmetics and Personal Care Products
2026-01-30
Introduction: The Diverse World of Tube Packaging
Tube packaging has become a cornerstone of modern product packaging, with applications far exceeding its traditional scope. While the cosmetics industry remains its primary beneficiary—favoring its ease of use, portability, and customizability for makeup, daily skincare, and haircare products—its applications have significantly broadened. Today, tubes are a packaging choice for industrial products (such as lubricants and sealants), food products (such as mustard and chili sauce), pharmaceutical ointments, and advanced toothpaste designs. This article provides a comprehensive overview of the basics of tube packaging, manufacturing processes, and key criteria for brand selection.
I Core Manufacturing and Structure
1. Molding Process and Materials
Tube packaging uses PE plastic, aluminum foil, and plastic film as base materials, employing processes such as co-extrusion lamination to create sheets, which are then processed into tubes. There are three main types:
Aluminum-Plastic Composite Tubes: Combining aluminum foil and plastic film, typical structures include PE/PE+EAA/AL/PE+EAA/PE. They provide excellent barrier properties for products requiring high hygiene and freshness standards, such as certain cosmetics. Technological advancements have reduced aluminum barrier layers from 40 microns to as low as 9 microns, enhancing sustainability.
All-plastic composite tubes:Made entirely of plastic, they come in two types: unbarrier-free for low-end, fast-consumption cosmetics, and barrier-resistant. Barrier-resistant all-Plastic Tubes may contain layers such as EVOH, PVDC, or oxide-coated PET, suitable for mid- to low-end products. A typical structure is PE/PE/EVOH/PE/PE.
Co-extruded plastic tubes: These are formed in one step by co-extruding different raw materials. Single-layer co-extruded tubes are used for products with high aesthetic requirements and low performance requirements (such as hand creams), while multi-layer co-extruded tubes are designed for high-end cosmetics.
2. Surface Finishes and Aesthetics
Tubes offer a variety of visual and tactile effects, including colored, transparent, frosted (matte or glossy), and pearlescent effects (standard, scattered silver, or scattered gold). A key difference lies in colored tubes (color integrated into the tube) and Printed Tubes (color applied to a typically white base tube). Printed tubes require high-quality inks to prevent cracking or peeling at folds.
3. Graphic Applications and Printing
Decoration is achieved through direct printing or the use of self-adhesive labels.
Direct Printing: Common methods include screen printing (suitable for small areas of spot color blocks, common in professional product lines) and offset printing (suitable for large areas of multiple colors, common in consumer goods products). Hot stamping (gold/silver) is also frequently used. Offset printing typically uses UV-cured inks that require strong adhesion and color stability.
Self-Adhesive Labels: Advantages in printing versatility and stability. Traditional tube printing is limited to offset or screen printing, while labels can utilize a combination of processes such as flexographic, letterpress, offset, screen printing, and hot stamping to achieve more complex and stable color reproduction.
II Structural Components and Specifications
The tube consists of three main parts: the shoulder, the body, and the tail.
Tube Body: Classified by material (aluminum-plastic, all-plastic, paper-plastic), thickness (single-layer, multi-layer), shape (round, oval, flat), and application (facial cleanser, BB cream, hand cream, etc.). Standard tube diameters range from Φ13 mm to Φ60 mm, and capacities from 3 grams to 250 grams. Note that the production process involves multiple heating stages, which can lead to shrinkage; therefore, the final dimensions are within tolerance.
Tube Tail: Sealed after filling. Tail styles include straight lines, diagonal lines, umbrella shapes, and irregular shapes. Batch numbers or dates can be printed on the tail.
Tube Caps and Accessories: Various cap types (screw caps, flip caps, flat caps, etc.) can be enhanced through electroplating, spray painting, or hot stamping. To meet evolving consumer demands, functional accessories such as massage heads, ball bearings, and rollers are increasingly integrated into the tube design.
III Key Considerations for Brands and Buyers
1
Design and Manuscript Review
Reputable suppliers assist by providing templated design area diagrams and reviewing the technical feasibility of the manuscripts, including photocell placement, color suitability, barcode orientation, and document preparation.2
Material Selection
Materials must meet relevant health and safety standards. For example, for tubing exported to the United States, the PE or PP material must comply with FDA standards (21 CFR 117.1520).3
Understanding Filling Methods
The choice between tail-fill and shoulder-fill affects tubing design. Tail-fill requires consideration of packing direction, while shoulder-fill requires the nozzle size to match the filling tip. Understanding whether the contents are for hot filling is also crucial.4
Choosing the Appropriate Tube Type
For oxygen-sensitive products (such as whitening serums) or products with volatile fragrances, five-layer co-extruded tubing (e.g., PE/bonding resin/EVOH/bonding resin/PE) is recommended. Its oxygen permeability (0.2-1.2 units) is far superior to standard single-layer PE tubing (150-300 units), significantly preserving product efficacy and fragrance.5
Price and Production Cycle
Quality and manufacturer capability significantly impact price. The standard production cycle is 15-20 days after sample confirmation. Minimum order quantity is typically 5,000 to 10,000 pieces per SKU (large manufacturers), with some smaller factories accepting 3,000 pieces. Order quantities are generally allowed ±10% deviation.