Why Squeeze Tube Structure Matters in Cosmetic Packaging

The structure of a cosmetic tube determines how well it can:

• Protect active ingredients

• Block oxygen and UV light

• Prevent contamination

• Maintain product viscosity over time

• Withstand repeated squeezing

• Deliver smooth, consistent dispensing

Insensitive formulas like hand creams may perform well with simpler structures. But active-rich formulas—retinols, acids, vitamin C, natural oils—may require higher barrier protection.

Companies often underestimate how much packaging affects formula performance. Even a perfectly formulated product can fail if the tube does not offer the correct protection.

What Is a Monolayer Cosmetic Tube?

A monolayer tube is made from a single layer of PE (polyethylene). It is the simplest and most affordable type of cosmetic squeeze tube.

Characteristics of Monolayer Tubes

• Typically made from LDPE, HDPE, or MDPE

• Known for flexibility and smooth squeezing

• Best for stable, non-reactive formulas

• Easy to decorate with offset printing, screen print, or labeling

Best for These Product Types

Monolayer cosmetic tubes work well for products that do not degrade easily:

• Hand creams

• Body lotions

• Cleansers

• Scrubs

• Hair conditioners

• Moisturizing creams

• Daily-use products with low sensitivity

Advantages of Monolayer Squeeze Tubes

✔ Lower cost
✔ Environmentally friendlier (easier to recycle)
✔ Soft and flexible for easy squeezing
✔ Ideal for high-volume manufacturing
✔ Works well for simple, stable formulas

Disadvantages

✘ Weak barrier protection
✘ Not ideal for formulas sensitive to air, light, or fragrance loss
✘ Shorter shelf life compared to multilayer tubes

When to Choose Monolayer Cosmetic Squeeze Tubes

Choose monolayer if your formula is stable, affordable, and not prone to oxidation.

What Is a Multilayer Cosmetic Tube?

A multilayer cosmetic tube includes multiple layers of materials—typically PE + barrier layer + PE—to protect formulas that require higher stability.

Common multilayer structures include:

• PBL (Plastic Barrier Laminate)

• ABL (Aluminum Barrier Laminate)

Each layer serves a unique purpose.

Typical Multilayer Construction

• Outer PE layer: Provides printability and aesthetics

• Barrier layer (EVOH or aluminum): Blocks oxygen, moisture, and UV

• Inner PE layer: Protects formula contact surface

Best for Sensitive Products

Multilayer squeeze tube packaging is ideal for formulas containing:

• Vitamin C

• Retinol

• AHAs/BHAs

• Benzoyl peroxide

• Natural essential oils

• CBD-based skincare

• Fragrance-rich formulas

• Whitening actives

• Sunscreens

These ingredients degrade rapidly when exposed to oxygen, light, or humidity—making barrier protection essential.

Advantages of Multilayer Tubes

✔ Excellent barrier protection
✔ Increased shelf life
✔ Better for active-rich skincare
✔ Prevents fragrance evaporation
✔ Ideal for premium custom cosmetic tube designs

Disadvantages

✘ Higher cost
✘ More complex manufacturing
✘ Slightly less flexible than monolayer
✘ Harder to recycle due to mixed materials

When to Choose Multilayer Tubes

Choose multilayer tubes when your product requires formula protection, long shelf life, and consistent performance.

Monolayer vs. Multilayer Cosmetic Tubes: A Direct Comparison

ABL laminate Tube

PBL Laminate Tube

2. Laminate Tubes (ABL & PBL)

Laminate tubes are made by rolling laminated sheets into tubes.

ABL (Aluminum Barrier Laminate Tubes)

• Contain a thin layer of aluminum

• Offer the highest oxygen/light protection

• Ideal for whitening creams, retinol, and medicated products

PBL (Plastic Barrier Laminate Tubes)

• Use EVOH instead of aluminum

• More flexible and softer

• Ideal for moisturizers, cleansers, and natural skincare

4. Aluminum Cosmetic Tubes

100% metal collapsible tubes offer:

• Superior barrier protection

• Zero oxygen penetration

• Fully recyclable

Common for ointments, hair dyes, essential balms, and medicated creams.

5. Airless Cosmetic Tubes

These combine the flexibility of a tube with airless dispensing technology. Perfect for:

• Anti-aging serums

• Vitamin-rich formulas

• Premium skincare

Prevents oxidation and contamination.

6. Cosmetic Tubes with Special Applicators

Modern tubes often incorporate built-in applicators, enhancing user experience:

• Needle nose tips – acne treatments, medicated gels

• Roller ball tubes – eye creams

• Metal tips – depuffing eye treatments

• Brush applicator tubes – concealer, BB cream

• Lip gloss squeezable tubes – food-grade for lip care

Applicators can be fully customized for branding.

Which Tube Does Your Formula Need? A Step-by-Step Decision Guide

Understanding your formula is the key to selecting the correct cosmetic tube.

Step 1: Determine Formula Sensitivity

Is the formula sensitive to oxygen, light, or heat?

• Yes → Choose multilayer (PBL, ABL, or airless tube)

• No → Monolayer is sufficient

Future Trends in Custom Cosmetic Tube Packaging

The cosmetic tube market is evolving rapidly. Top trends include:

• Mono-material recyclable tubes

• PCR and eco-resin blends

• Digital printing for small MOQs

• Airless squeeze tubes

• Functional applicators for targeted treatments

Brands that stay ahead of these trends stand out in a competitive market.

Conclusion: Monolayer or Multilayer—Which Is Right for You?

Choosing between monolayer and multilayer cosmetic tubes depends entirely on your formula. If your product is stable and doesn’t require high barrier protection, monolayer tubes offer an affordable, flexible, and eco-friendly solution. But if your formula contains active ingredients, natural oils, or requires long-term protection, multilayer tubes—especially PBL, ABL, or airless—are the best choice.