How to Choose the Right Squeeze Tube for Your Sunscreen Formula

When it comes to packaging sunscreen, functionality and formula protection are everything. The right squeeze tube doesn't just hold your product — it enhances usability, ensures stability, and elevates your brand. Whether you're launching a mineral SPF or a lightweight daily sunscreen, choosing the right tube plays a critical role in your product's success.

Here’s a breakdown of key factors to consider when selecting the perfect squeeze tube for your sunscreen line. 

1. Choose the Right Tube Material

Sunscreen formulas, especially those with active ingredients like zinc oxide or avobenzone, require packaging that shields them from air, light, and heat. Consider these common materials:

l Plastic (PE Tubes): Cost-effective, flexible, and widely used. Suitable for most sunscreen creams and lotions.

l Laminated Tubes (ABL/PBL): Offer stronger barrier protection to prevent UV degradation and preserve formula potency.

l Eco-Friendly Options (PCR, Sugarcane-Based): Ideal for brands focusing on sustainability without compromising product safety.

✅ Tip: Look for tubes with multi-layer structures for high SPF formulas to prevent ingredient breakdown.

2. Factor in UV Protection and Barrier Needs

Sunscreen is sensitive to UV light, so your packaging should include:

l UV-resistant layers to block harmful rays and prevent active ingredient degradation.

l Airless or foil-sealed options to reduce oxygen exposure and extend shelf life.

A good tube acts as an extra layer of SPF for your SPF!

3. Size Matters — Know Your Target Use

Different consumers have different needs. Tailor your packaging size to your audience:

l 15ml–30ml: Great for travel-size, samples, or facial sunscreens.

l 50ml–75ml: Standard daily-use size, perfect for retail.

l 100ml–200ml: Ideal for family or body-use sunscreens, especially during summer or beach seasons.

Think about portability and application frequency when deciding on volume.

4. Cap & Dispenser Style: Easy Use = Repeat Use

The type of cap influences not just function but also user experience.

l Flip-Top Caps: Most common, convenient, and one-hand friendly.

l Screw Caps: Better for thicker sunscreens or if you need tighter sealing.

l Airless Pumps: Modern, precise, and ideal for high-end or dermatologist-formulated SPF lines.

l Snap Caps & Twist-Offs: Good for smaller tubes or samples.

✅ Consider: Will your customers apply it poolside? On the go? Choose convenience.

5. Surface Finish & Branding Impact

Your tube’s finish can reflect your brand identity:

l Glossy Finish: Sleek and modern; often chosen for bright summer visuals.

l Matte Finish: Elegant and soft-touch; ideal for minimalist or luxury SPF products.

l Soft-Touch Coating: Adds a premium feel and improved grip.

Combine high-quality printing (silkscreen, hot-stamping, or offset) to maximize shelf appeal.

6. Don’t Forget Regulatory Labeling Space

Sunscreen is classified as an OTC (over-the-counter) drug in many countries. That means your tube needs to accommodate:

l Drug facts panel

l Directions for use

l Warnings and SPF rating

l Manufacturing & expiration info

Make sure your chosen tube size and design leave room for required compliance labels.

7. Test Compatibility with Your Formula

Before finalizing your tube, always test compatibility between your sunscreen and the tube material. Heat and oil in the formula can sometimes weaken plastic or trigger reactions that degrade packaging.

Run stability tests under real-world conditions (sunlight, heat, long-term storage) to avoid costly mistakes later.

The Right Tube Makes All the Difference

A well-designed squeeze tube doesn’t just store sunscreen — it protects your formula, enhances brand appeal, and offers a seamless experience for your customer. From material and barrier layers to size, caps, and finishing touches, every detail counts when you're competing in the sun care market.

If you're sourcing wholesale cosmetic tubes, work with suppliers who understand the unique needs of SPF products and can provide samples and custom solutions.