How Formula is Filled in Cosmetic Tubes?

Filling cosmetic formulas into squeeze tubes is a precise and automated process that ensures consistency, hygiene, and product integrity. The method used depends on the type of cosmetic product, the consistency of the formula, and the type of tube being used. Here's an overview of how cosmetic formulas, like lotions, hand creams, lip balms, and lip glosses, are filled into cosmetic tubes:

1. Tube Preparation

Before the formula is filled, the cosmetic tubes themselves must be prepared. This step includes:

• Cleaning and Sterilization: Tubes are cleaned and sterilized to ensure that they are free from contaminants. This is especially important for products like lotions and creams, which are more susceptible to bacterial growth.

• Tubes Are Formed and Flattened: If the tubes are not pre-formed, they are created from plastic film, aluminum, or laminate material. These materials are flattened, shaped, and sealed at one end before the filling process begins.

2. Filling Process

Once the squeeze tubes are prepared, the actual filling process takes place. This is usually done using automated machinery for high-volume production, but manual methods may also be used for smaller batches.

Filling Methods:

1. Vacuum Filling

   • How it works: A vacuum filling system uses a pump to suck the product into the tube. This method is common for liquid or semi-solid products like lotions, serums, and hand creams. The tube is held in place as the vacuum pulls the formula into it through a nozzle.

   • Why it's used: This method ensures minimal air is trapped in the cosmetic tube, reducing the risk of contamination and spoilage. It's ideal for low-viscosity products.

2. Piston Filling

   • How it works: In piston filling, a piston-driven system is used to push the product into the tube. This is common for thicker formulations like hand creams, thicker lotions, and even some lip glosses. The formula is loaded into a chamber, and the piston pushes it into the tube.

   • Why it's used: It's accurate and effective for thicker formulas that need precise filling. Piston filling is ideal for creamy, gel-like, or viscous products.

3. Gravity Filling

   • How it works: Gravity filling uses the force of gravity to fill the tube. This method is most commonly used for liquids, gels, or low-viscosity products. The product is funneled from a large container into smaller tubes through gravity-driven pipes or hoses.

   • Why it's used: It's a simple, cost-effective method for less viscous products like lotions or some lip glosses.

4. Auger Filling

   • How it works: For thicker, solid, or paste-like formulations, an auger filler is used. The auger system consists of a rotating screw mechanism that moves the product into the tube. This system is ideal for products with a dense or paste-like consistency, such as some lip balms or thick creams.

   • Why it's used: The auger ensures that thick, sticky products are accurately filled into each tube without clogging the machine.

3. Sealing the Tube

Once the formula is filled, the open end of the cosmetic squeeze tube must be sealed to ensure the product stays inside. There are several methods of sealing:

• Heat Sealing: The tube is passed through a heat-sealing machine that applies heat to the open end of the tube, bonding it to create an airtight seal.

• Ultrasonic Sealing: In some cases, high-frequency sound waves are used to seal the tube. This method is often used for aluminum tubes or certain types of laminated plastic tubes.

• Crimping: In this method, the open end of the tube is folded and crimped to form a tight seal. This is common for aluminum tubes or plastic tubes with thicker formulas.

4. Labeling and Packaging

After the cosmetic tubes are filled and sealed, they undergo additional steps before they are ready for shipment:

• Labeling: The filled tubes are often labeled with product information, branding, usage instructions, and expiration dates. This may be done manually or with automated labeling machines.

• Inspection and Quality Control: The filled tubes are inspected for defects like air bubbles, underfilling, or leakage. Some products may undergo a visual inspection or be scanned with sensors for consistency.

• Packaging: Finally, the filled and labeled tubes are packed into boxes for shipping or retail distribution. These products are often bundled into multipacks or packed individually for display.

5. Quality Control and Testing

Throughout the entire process, strict quality control checks are carried out by manufacturers to ensure that the product remains safe, effective, and free from contamination. This includes testing for fill volume accuracy, seal integrity, and ensuring the tubes are free from air bubbles or defects.

Conclusion

Filling cosmetic tubes involves precise machinery and a variety of techniques tailored to the specific type of product being packaged. Whether it's a lightweight lotion, thick hand cream, or glossy lip balm, the right filling method ensures the formula is packaged safely, effectively, and hygienically. Through automated systems, cosmetic manufacturers are able to efficiently produce large quantities of high-quality products with consistency and precision.