Inside the Manufacturing of Aluminum Collapsible Tubes: From Roll to Retail

Aluminum collapsible tubes have emerged as a smart, eco-conscious solution for cosmetics, pharmaceuticals, food, and industrial applications. But have you ever wondered how these sleek, flexible tubes are made—from raw material to finished product on the shelf?

Here’s a closer look inside the end-to-end manufacturing process of aluminum collapsible tubes—where precision meets performance.

1. Raw Material: From Aluminum ingot to Tube Body

The journey begins with high-purity aluminum ingot, slugs or coils, typically composed of 99.7% pure aluminum. These are carefully selected for their durability, lightweight properties, and resistance to corrosion.

The slugs are fed into high-speed extrusion machines, where they're transformed into seamless cylindrical tubes using impact extrusion—a process that compresses the slug at high pressure, forming the base tube in a single stroke. This creates a lightweight, airtight structure without any welded seams, making it ideal for sensitive formulas.

2. Trimming, Annealing & Cleaning

Once extruded, the aluminum squeeze tubes are trimmed to the desired length. The next step is annealing, a heat-treatment process that softens the aluminum, enhancing flexibility while maintaining its structural integrity. After cooling, tubes undergo thorough washing and drying to remove any residual lubricants or particles from the manufacturing process.

3. Interior Coating: Safeguarding Product Integrity

Because aluminum is reactive with certain substances, the interior of each tube is coated with an inert, protective lacquer, often epoxy or polyester-based. This barrier prevents direct contact between the contents and the metal, ensuring product safety, extending shelf life, and maintaining formula stability.

Tubes are then oven-cured to harden the internal coating and prepare them for the next step.

4. Exterior Printing & Finishing: Branding That Speaks

At this stage, the aluminum collapsible tubes are ready to shine—literally. They’re passed through advanced offset printing machines where up to 6-8 colors can be applied with high precision. Logos, branding, product information, and design elements are printed directly onto the tube’s surface.

Finishing options like matte, gloss, metallic effects, or embossed textures are added depending on the brand’s aesthetic. A protective over-lacquer is often applied to seal the design and enhance durability.

5. Capping and Crimping: Ready to Fill

Depending on the intended use, a variety of closures—such as nozzles, screw caps, or flip-tops—are added. The open end of the tube is left unsealed to allow for filling.

After capping, each tube goes through a final quality control check to ensure the print alignment, cap fit, and dimensions meet client specifications.

6. Filling & Sealing: Final Assembly

Tubes are shipped to brands or co-packers, where the filling process begins. Contents are filled through the open end using precision machinery, ensuring accurate volumes and hygiene. Once filled, the tube end is crimped or folded to create a leak-proof seal.

The finished products are then boxed, labeled, and shipped—ready to make their way to shelves and into consumers’ hands.

Why Aluminum Collaspible Tubes Stand Out

100% recyclable without loss in quality

Lightweight and tamper-resistant

Ideal for air-sensitive or high-viscosity products

Offers a premium look and feel for high-end branding

Supports sustainability goals and cleaner packaging practices

                aluminum pharma tube

   food grade aluminum squeeze tube

  multi barrier skincare metal tube

Best Picks: Aluminum Collapsible Tubes for Wholesale Buyers

If you’re sourcing in bulk for private labels, OEM packaging, or reselling, consider these top-selling tube options:

1. Pharmaceutical-Grade Aluminum Squeeze Tubes

• Perfect for ointments, creams, and gels

• Available with tamper-evident closures

• High barrier protection and FDA-compliant coatings

2. Cosmetic-Grade Tubes with Premium Finishes

• Ideal for hand creams, eye serums, hair color, and balms

• Custom printed in glossy or matte textures

• Available in 15ml–120ml sizes with a variety of cap styles

3. Food-Grade Collapsible Tubes

• Designed for condiments, sauces, and concentrates

• Food-safe internal lacquer and crimped ends for leak-proof storage

• Lightweight and recyclable—great for eco-minded brands

4. Industrial & Multi-Purpose Tubes

• Great for adhesives, paints, lubricants, and DIY kits

• Durable and flexible with precision nozzles

• Offered in custom diameters and wall thicknesses

5. Mini Travel-Sized Tubes

• 5ml–25ml small format aluminum squeeze tubes

• Popular for samples, luxury kits, and promotional sets

• Ideal for subscription boxes or giveaways

With low MOQs and customization available (diameter, volume, print, cap type), Lisson® Group makes it easy to scale packaging for any market segment.

From Factory Floor to Consumer Hands

The manufacturing of aluminum collapsible tubes is a carefully engineered process that blends precision, hygiene, design, and sustainability. Whether used for luxury hand creams, ointments, or artisan paints, aluminum squeeze tubes deliver unmatched product protection, brand appeal, and environmental responsibility.

As consumer demand grows for packaging that performs and protects—without harming the planet—aluminum collapsible tubes are more relevant than ever.