Aluminum Collapsible Tube Manufacturing Process

Aluminum collapsible tubes are commonly used in the packaging of products such as ointments, paints, cosmetics, pharmaceuticals, and adhesives. Their ability to be squeezed easily, along with their durability and barrier properties, makes them a preferred choice for certain products. The manufacturing process of these tubes involves several steps, ensuring they are properly formed, filled, and sealed. Below is a detailed overview of the aluminum collapsible tube manufacturing process introduced by LISSON, one of the best squeeze tube manufacturers with 11+ production bases in the south of China:

1. Raw Material Preparation

The process begins with the raw material — aluminum sheets or coils or ignot — which are sourced from suppliers. These aluminum sheets are typically made from high-quality aluminum alloys (often 1050 or 3003), which are selected for their strength, malleability, and corrosion resistance.

• Aluminum Alloy Selection: The specific alloy is chosen based on the required characteristics of the final tube, such as flexibility, strength, and resistance to oxidation.

• Sheet Preparation: The aluminum is rolled into thin sheets or coils and then cleaned to remove any oils, dust, or contaminants. This is important to ensure that the surface of the tube is free from imperfections before processing.

2. Tube Body Forming (Drawing and Shaping)

Once the aluminum sheets are prepared, they are fed into a tube-forming machine. This step involves drawing and shaping the aluminum into a tube.

• Drawing Process: The aluminum sheets are cut into flat pieces of a pre-determined length. These flat pieces are then fed into a tube-forming machine, where a punch or die draws the material into a cylindrical shape.

  • Annealing: In some cases, the aluminum is annealed (heated) to make it more malleable before drawing.

  • Tubing Formation: The flat aluminum piece is fed into a set of rollers that curl and weld the edges together, forming a tube. This process creates the basic shape of the collapsible tube.

3. Seam Welding (Tube Closure)

Once the tube body is formed, the two edges of the cylindrical aluminum tube are welded together to form a seamless tube. This welding process is crucial for ensuring that the tube is structurally sound and free of leaks.

• Welding Process: The edges of the aluminum tube are heated and pressed together, creating a solid bond. This can be done using various methods, such as high-frequency induction welding or laser welding, depending on the manufacturer.

• Quality Check: The seam is checked for any imperfections, ensuring the tube is securely sealed. A tube with a weak seam could result in leakage during filling or transport.

4. Tube Head Forming (Nozzle Shaping)

The tube is then moved to a second machine that shapes the nozzle or the opening of the tube. This step forms the tube’s "mouth" where the product will be dispensed.

• Nozzle Shaping: The tube’s open end is compressed or rolled into the desired shape, usually a small opening or a nozzle for controlled dispensing. This nozzle can be straight, or it may have a tapered or flared end, depending on the product being packaged.

• Cutting: The tube may be cut to the desired length at this stage.

5. Printing and Decoration

Once the tube is shaped, it typically undergoes a decorating or printing process to add labels, logos, or product information.

• Screen Printing or Offset Printing: Tube manufacturers use various printing techniques to apply designs. Screen printing is commonly used for single-color designs, while offset printing is used for more complex, multicolor designs.

• Lacquering/Coating: In some cases, a protective coating or lacquer is applied to the tube to improve the finish and protect the printed design from wear and tear.

• Embossing/Debossing: For a premium look, some tubes may undergo embossing (raised design) or debossing (pressed-in design) to add texture to the surface.

6. Filling and Sealing

Once the tubes are printed and decorated, they are ready for the filling and sealing process.

• Filling: The tube is loaded into a filling machine, where the product (e.g., cream, gel, ointment, paint) is dispensed into the tube. This process must be carefully controlled to ensure that the correct amount of product is added to each tube.

  • Automation: Many manufacturers use automated filling machines that use volumetric or weight-based methods to ensure consistency in product amount.

  • Sterilization: If necessary, the filling process may be done in a sterile environment to prevent contamination of sensitive products (e.g., pharmaceuticals or cosmetics).

• Sealing: After the product is added, the open end of the tube is sealed to prevent leakage.

  • Crimping: The tube's open end is crimped using a crimping machine, which presses the tube’s neck closed.

  • Heat Sealing: In some cases, the tube may undergo heat sealing to ensure an airtight closure.

7. Quality Control and Testing

Quality control is an essential step throughout the manufacturing process, and it ensures that the final product meets industry standards and customer specifications.

• Leak Testing: Tubes undergo leak tests to ensure that there are no defects in the seams or the crimped ends that would allow product leakage.

• Pressure Testing: Some tubes are pressure-tested to check for strength and durability.

• Appearance Checks: The tubes are checked for defects in printing, denting, or scratches that could affect their appearance or function.

8. Final Packaging and Distribution

Once the tubes pass all quality control tests, they are packaged for shipment. The tubes are grouped together in cartons, often in stacks or on pallets, and prepared for distribution to clients or wholesalers.

• Stacking and Cartonizing: The filled and sealed tubes are stacked neatly and placed into cardboard cartons or plastic shrink wraps for shipment.

• Labeling: The cartons are labeled with necessary shipping information before being sent to warehouses or directly to retail outlets.

Conclusion

The manufacturing of aluminum collapsible tubes involves a series of precise and highly controlled processes, from material preparation and tube forming to filling and sealing. The use of aluminum provides excellent barrier properties, ensuring the protection of sensitive products from air, moisture, and light. Additionally, the collapsible nature of these tubes allows for easy product dispensing and minimal waste, making them a popular choice for many industries. With increasing demand for eco-friendly packaging, manufacturers are also incorporating sustainable materials and processes, ensuring that these tubes meet both functional and environmental standards.