Sustainable packaging is often talked about in general terms, but the actual manufacturing process behind eco-friendly tubes is less commonly explained. Here is how PCR and Bio-PE tubes, the two sustainable materials Top Tubes offers, are actually made.
How PCR (Post-Consumer Recycled) Tubes Are Made
PCR tubes start with plastic that has already been used and discarded, most commonly HDPE and PE packaging collected through municipal recycling programs. That plastic goes through several stages before it becomes a new tube:
Collection and sorting: Used plastic is collected and sorted by resin type, since different plastics need to be processed separately to maintain material quality.
Cleaning and shredding: Sorted plastic is washed to remove labels, adhesives, and contaminants, then shredded into small flakes.
Reprocessing into pellets: The cleaned flakes are melted and reformed into small pellets, called resin, which can be handled the same way as virgin plastic resin in manufacturing.
Extrusion into tubes: The PCR resin is fed into the same extrusion process used for standard plastic tubes. It is melted, pushed through a die to form the tube shape, then cooled and cut to length. Learn more about this extrusion process in our guide on how plastic tubes are made.
Because PCR resin behaves similarly to virgin plastic once reprocessed, PCR tubes end up with the same strength, flexibility, and finish as standard PE tubes, while reducing the demand for new plastic production.
How Bio-PE Tubes Are Made
Bio-PE, or bio-based polyethylene, is chemically identical to standard polyethylene, but it starts from a renewable plant source instead of petroleum.
Growing and harvesting sugarcane: Sugarcane is grown and harvested, then processed to extract its sugar content.
Fermentation into ethanol: The sugar is fermented into bio-ethanol, the same basic process used to produce fuel-grade ethanol.
Dehydration into ethylene: The bio-ethanol is dehydrated, a chemical reaction that removes water and converts it into ethylene gas.
Polymerization into polyethylene: The ethylene molecules are linked together, or polymerized, into polyethylene resin, chemically identical to petroleum-based PE.
Extrusion into tubes: Like PCR resin, Bio-PE resin is then extruded into tubes using the same manufacturing process as standard plastic tubes.
Because Bio-PE is molecularly the same as conventional PE, it performs identically in durability, flexibility, and printability, while significantly lowering the carbon footprint associated with sourcing virgin, petroleum-based plastic.
Why the Manufacturing Process Matters
Both PCR and Bio-PE tubes go through the same extrusion process as standard plastic tubes, which is why they can be offered in the same sizes, colors, and closure options without compromising quality or requiring brands to redesign their packaging. The difference is entirely in where the raw material comes from, not how the final tube is made or how it performs on the shelf. If you’re comparing PCR and Bio-PE against other options like PBL/EVOH barrier tubes or reduced wall thickness, our sustainable tube packaging options guide covers the full range of choices.
Frequently Asked Questions
Do PCR and Bio-PE tubes perform differently than standard plastic tubes?
No. Both materials go through the same extrusion process as standard PE tubes and perform identically in strength, flexibility, and printability.
Is PCR plastic actually recycled material, or just recyclable?
PCR stands for Post-Consumer Recycled, meaning the resin is made from plastic that was already used by consumers and recycled, not just plastic that is capable of being recycled in the future.
Where does Bio-PE come from?
Bio-PE is made from ethanol derived from sugarcane, a renewable plant source, rather than from petroleum.
Does Top Tubes offer PCR and Bio-PE tubes?
Yes. Top Tubes supplies both PCR and Bio-PE tubes as part of our sustainable packaging line. Contact us to discuss materials, sizes, and MOQ for your product.