Key takeaways
- ABL and PBL tubes differ in barrier and in aluminium content.
- The shoulder is the most common failure point under pressure.
- Barrier layer choice decides how long a reactive formula survives.
A laminate tube is made from a flat multilayer film that is printed, formed into a cylinder and sealed at the shoulder. The film carries the barrier and the decoration; the shoulder carries the mechanical load. Understanding which layer does what is the difference between a tube that lasts and one that splits in a warehouse.
1. ABL and PBL
ABL tubes contain an aluminium layer, which gives an excellent barrier and a metallic look. PBL tubes are all-plastic, with an EVOH or similar barrier layer, and are lighter and more recyclable. ABL is the standard for a reactive formula and for a premium look; PBL is the standard for a mass-market product with a shorter shelf life.
2. The layer stack
A typical laminate has five layers: an outer printed film, a tie layer, the barrier layer, another tie layer and an inner sealant. The inner layer must be compatible with the formula, because it is the only layer in contact. A formula with a solvent can attack the sealant and delaminate the tube from the inside.
3. The shoulder
The shoulder is injection-moulded and welded to the tube body, and it is where most failures start. A shoulder welded at the wrong temperature leaks at the seam; a shoulder with a thin wall splits under pressure. Burst testing at 2 bar for 30 seconds is the standard check.
4. The cap and the orifice
A tube with a 6 mm orifice dispenses a cream comfortably; a 10 mm orifice dispenses too much. The cap style — flip-top, screw, nozzle — determines the dose per squeeze, which is a real driver of consumption and of repurchase. A flip-top cap on a viscous cream often clogs.
5. Barrier performance
The barrier protects against oxygen and against fragrance loss. An ABL tube extends the shelf life of a reactive formula by months compared with a single-layer polyethylene tube. A brand that downgrades to a cheaper tube without testing will discover the difference at month nine.
6. Printing
Laminate tubes are printed before forming, which allows full-surface decoration with a photographic quality. That is the main commercial advantage over a single-layer tube, which is usually decorated with a label or a screen print.
7. Recyclability
A PBL tube is easier to recycle than an ABL tube because it has no aluminium, but the mixed polymer layers still complicate it. Some markets accept tubes in store drop-off schemes; most kerbside systems do not. The claim should reflect the local system.
8. Fill and seal
Tubes are filled from the open end and sealed by a hot-jaw crimp or an ultrasonic weld. The seal must be flat and complete, and the fill weight must account for the tail. A tube sealed with a wrinkle leaks at the fold, and the leak shows up as a complaint about a sticky cap.
9. Cost and MOQ
A printed laminate tube typically requires 10,000 to 30,000 units per design for a reasonable price. A stock white tube with a label costs far less at 1,000 units. The tube is one of the few components where the decoration is the cost.
10. Compatibility testing
Fill the tube and store it at 40 degrees for twelve weeks, then check for delamination, discolouration, odour and seal integrity. Also squeeze it 100 times to check the shoulder and the cap. Most tube problems appear in the shoulder or the seal rather than in the film.
11. Where it fits
Tube formats run across the hand cream range; the structural comparison continues in the airless entry.
Reference: Tube supplier specifications and burst test records, 2025
