Manufacturing Process for Collapsible Tubes by Material

Collapsible tubes are widely used in industries such as cosmetics, pharmaceuticals, food packaging, and adhesives due to their ability to protect the contents while allowing easy dispensing. The manufacturing process varies based on the material used, such as aluminum, plastic, and laminate. Here's a detailed look at how collapsible tubes are made for each material.

1. Aluminum Collapsible Tubes

Materials Used:

• Aluminum slugs (small cylindrical pieces of pure aluminum)

• Protective coatings (internal liners, varnishes)

Manufacturing Process:

1. Slug Preparation: Aluminum slugs are cleaned and preheated to improve malleability.

2. Extrusion:

   • The slug is placed in a press where it is extruded (compressed) into a cylindrical tube form.

   • A single step creates the seamless body and closed base of the tube.

3. Trimming: The open end is trimmed to ensure uniform length.

4. Threading and Neck Formation:

   • The neck is formed, and threads are added using a die, allowing for the attachment of caps.

5. Internal Coating:

   • A protective liner (such as epoxy resin) is sprayed inside the tube to prevent chemical reactions between the aluminum and the contents.

6. External Decoration:

   • Tubes are printed using offset printing or screen printing, and a varnish is applied for durability.

7. Capping:

   • Caps (usually plastic) are attached, and the tubes are inspected for quality.

Applications:
Toothpaste, ointments, paints, adhesives, and cosmetics.

2. Plastic Collapsible Tubes

Materials Used:

• Polyethylene (PE), polypropylene (PP), or a combination of both

• Barrier layers (e.g., EVOH for high-barrier properties)

Manufacturing Process:

1. Extrusion:

   • Plastic pellets are melted and extruded into a tube shape (for mono-layer tubes) or a multilayer structure.

2. Blow Molding:

   • The extruded tube is placed into a mold, and air is blown inside to create the desired tube shape.

   • This process also forms the tube shoulder (the narrowed area near the cap).

3. Trimming and Sealing: The bottom of the tube is trimmed and heat-sealed.

4. Printing and Decoration:

   • Tubes are decorated with flexographic or silk-screen printing.

   • Labels or shrink sleeves can also be applied.

5. Capping:

   • Threads are molded onto the neck, and caps are attached.

   • Flip-top or screw caps are common for plastic tubes.

Applications:
Hand creams, gels, food products (e.g., sauces), and personal care products.

3. Laminate Collapsible Tubes

Materials Used:

• Multilayer laminates combining plastic (PE), aluminum, and barrier layers (EVOH or PET)

• Internal coatings for chemical compatibility

Manufacturing Process:

1. Laminating:

   • Sheets of laminate are created by combining layers of plastic, aluminum, and other materials.

   • These layers are fused together through heat and pressure.

2. Sheet Cutting and Rolling:

   • The laminate sheet is cut into strips and rolled into cylindrical shapes to form the tube body.

3. Welding:

   • The edges of the rolled laminate are heat-sealed to create a seam.

   • The seam is carefully inspected to ensure airtightness.

4. Shoulder Injection Molding:

   • The tube body is fitted with a plastic shoulder and neck, which are injection-molded and fused onto the tube.

5. Trimming and Sealing:

   • The tube's bottom is heat-sealed or crimped to make it collapsible.

6. Printing and Decoration:

   • Designs are printed on the tube before or after assembly using techniques such as flexographic printing or gravure printing.

7. Capping:

   • Caps are added to the finished tubes.

Applications:
Pharmaceutical creams, toothpastes, food products (e.g., mayonnaise), and cosmetic items.

4. Paper-Based Collapsible Tubes

Materials Used:

• Paper with a plastic or bio-based inner lining (to make it waterproof and flexible)

Manufacturing Process:

1. Paper Preparation:

   • Sheets of high-strength paper are laminated with a thin layer of bioplastic or traditional plastic.

2. Tube Formation:

   • The laminated paper is rolled into a cylindrical shape and sealed along the seam.

3. Shoulder and Neck Attachment:

   • A plastic or metal shoulder is attached to provide structure and allow cap threading.

4. Trimming and Sealing:

   • The bottom of the tube is crimped or heat-sealed for collapsibility.

5. Printing and Decoration:

   • Eco-friendly printing techniques are used to decorate the tubes.

6. Capping:

   • Caps are added, and the tubes are tested for durability.

Applications:
Eco-friendly cosmetics, lotions, and creams.

Comparison of Manufacturing Processes

Conclusion:
The manufacturing process for collapsible tubes depends heavily on the material, with each type offering unique benefits and trade-offs. As sustainability becomes a priority, laminate and paper-based tubes are gaining popularity for their reduced environmental footprint, while aluminum and plastic tubes remain dominant for high-performance and cost-effective applications.